Overview of Heating

Systems
CHAPTER 4, PART 2
WATER & STEAM
DISTRIBUTION SYSTEMS
Learning Objectives:
• Understand the hydronic heating circuit and its
subcomponents.

• Calculate basic heating loads

• Explain the need for, and the methods used to achieve,

piping system balancing.

• Describe the operation and maintenance of the

components in hydronic systems.

2
 Introduction
water to distribute the heat.
Boilers are heating systems that use _____
(Boilers)

Water as a gas (Steam) Water as a Liquid (Hydronic)

- High temperatures - Lower temperatures
- Gas (steam) flows in a pipe - Needs to be pumped
without being pumped - Lower pressures
- Simpler systems
Introduction
Basic Steam System
steam
Exhaust

Heating loads
traps
Liquid
Air
steam Complex (condensate)
P100
System
LSH
Boiler
water
T100
LSL

Fuel combustion
Vent
Feed Water
Vent
Drain LSH

Condensate
Tank LSL

Deaeration
Tank
Feed Pump
City Water
Condensate
Pump

4
Introduction
Basic Hydronic System
Exhaust

Heating loads
Air
Expansion
tank
P100

LSH
Boiler
water
T100
LSL

Fuel combustion

Primary Pump
Vent
Drain

Feed Water
Deaeration
Feed Pump Tank
City Water

5
Hot Water Heating System
3. Control valves and zone valves
• Valves are required in the heating system for differ
reasons
such as:
• Balancing the flow
• Controlling the flow
• Back-flow preventer valves to prevent
contamination
• Regulating the pressure in the system etc.

Balancing Valve
Picture: armstrongfluidtechnology

Reduced Pressure Zone Backflow Preventer

Photo: zoro.com
Hot Water Heating System
4. Expansion Tanks
• An expansion tank serves one primary function in a hot water system. It
provides a means for the system water to expand, as it is heated, without
significantly increasing system pressure.

• The expansion tanks are three type:

• Bladder expansion tanks
• Diaphragm expansion tank
• Non-bladder, non-diaphragm expansion tanks
(compression Expansion Tank)

Picture: limacompany.net

Picture: achrnews.com Diaphragm Type Expansion tank piping diagram

Hot Water Heating System
Expansion Tanks

Bladder Type Expansion tank piping diagram

http://www.taylor-engineering.com
Hot Water Heating System
Air separator
Hot Water Heating System
4. Temperature Controls

• Four typical devices control the temperature in a heating system:

• Aquastat operates the boiler at a constant temperature
• Outdoor air temperature sensor, resets the boiler set point
according to the outdoor air temperature
• Outdoor cut-out device that turns off the boiler system on days that
no heating is required.
• High limit temp sensor, turns off the boiler if the temperature
exceed the safe operation limit

Aquastat

Pic source: https://highperformancehvac.com/boiler-components-aquastat-temperature-control/

Outside Air Temperature/Hot Water Temperature
Hot Water Heating System
5. Heating units/Coils/Fin tubes
• Heat exchangers that transfer the distributed heat by the
heating fluid into the space.
Hot Water Heating System
6. Thermostats
• Thermostats regulate the temperature of the heating coil/fin
tubes in space.
 Types of piping configurations

❑ Piping configurations: One Pipe, two-pipe, three-

pipe and four-pipe
The differences are based on:
• Cost of installation and maintenance
• Controls and valves required
• Means by which water is supplied to the terminals
• Consistency of the temperature of water supplied to the
terminals
• Method used to control the temperature in each room
• Both heating and cooling are being used in the same system
and at the same time

14
 High Temperature Hydronic System Layouts
The most common and basic hydronic system is the Series Loop
system.

Advantages
• Low installation cost
• Low maintenance

Typical Series Hydronic Loop

Disadvantages: Picture Courtesy of: Refrigeration and Air Conditioning Technology, 6 th Edition

• It is not possible to have individual temperature control

for each area that is being heated.
• That the first terminal units being supplied will be
warmer than the later ones. 15
Series Hydronic System
• This system has three terminal units that are designed to provide 20,000
Btu/h, 30,000 Btu/h, and 50,000 Btu/h, respectively. The water supplied by
the boiler is 180°F and that the temperature of the water returning to the
boiler is 160°F. From this information, calculate the total flow in gpm at the
pump.

Typical Series Hydronic Loop

Picture Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
Series Hydronic System
• We now know that there will be 10 gpm of water flow through the piping circuit when
the circulator is operating. Calculate the temperature of the water at the outlet of the
first terminal unit.

• So, if the temperature of the water entering the first terminal unit is 180°F, the temperature
of the water at the outlet of the first terminal unit will be 4 degrees less than that, or 176°F.
The temperature of the water at the outlet of the second terminal units can be calculated as
follows:

The water Temperature at Each Coil

Picture Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
Series Hydronic System
• Since the temperature of the water entering the second terminal unit is
176°F, the temperature at the outlet of the second terminal unit is 170°F
(176°F - 6°F). The temperature at the outlet of the third terminal:

• Since the temperature of the water entering the third terminal unit is
170°F, the temperature at the outlet of the third terminal unit is 160°F
(170°F - 10°F).

The water Temperature at Each Coil

Picture Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
Series Hydronic System
Calculating the Heat Output

• Using the formula a little differently, we can determine the output of a particular terminal
unit if we know the temperature difference across it. Consider a terminal unit that has 8
gpm of hot water flowing through it. The temperature at the inlet of the terminal unit is
180°F and the temperature at the outlet of the terminal unit is 178°F. The capacity of the
terminal unit is as follows:
Hydronic Heating – One Pipe System

• In a one-pipe hydronic system, one main loop extends around the building
and connects the outlet of the boiler (Hot Water Supply) back to the return
of the boiler (Hot Water Return).

• All the heating terminals are connected to the main loop with two Tees,
they should be specially designed for one pipe system.

One Pipe Hydronic System

Picture Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
Hydronic Heating – One Pipe System

• The proper operation of a one-pipe hydronic system relies on the proper ratios
of resistance between the terminal unit branch and the resistance to flow in the
section of pipe between the two tees.

• Lower the resistance, higher the flow.

• If 4gpm water enters the Tee, 4 gpm must
Leave the Tee.
• If the resistance in the coil is 3 time the
resistance in pipe, the flow in the coil will
be one third of the flow through the Tee. The water Temperature at Each Coil
Picture Courtesy of: Refrigeration and Air Conditioning Technology,
6th Edition

The high resistance at point B lowers the flow through that branch
Picture Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
Hydronic Heating – One Pipe System
• The following factors shall be considered when layout or
evaluating a one pipe system:

o The length of the terminal unit branch circuit

o The distance between the tees
o The size of the piping in the branch circuit
o The size of the piping between the tees
o The location of the terminal unit with respect to the main loop

Diverter Tees (Monoflo Tee)

• They are specialty Tees installed in the main loop to increase
the resistance in the main, to increase the flow in the heating
coil.

Diverter Tees Monoflo Tees

Pictures Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
Hydronic Heating – One Pipe System

A sample one-pipe system using thermostatic radiator valves

Pictures Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
 Types of piping configurations
Two-pipe Systems
• First pipe: provides the supply water
• The second pipe: sends the return water back to the boiler.
• Water in the pipes can be either warm for heating or cold for
cooling. Not simultaneously.
• The water temperatures are blended together to achieve the
desired temperature.
• All the terminals are fed with water at the same temperature.
• After the water loses part of its heat in the terminal, it flows
into the return pipe and then back to the boiler.

24
 Hydronic Heating System - Two-Pipe System

❑ Two pipe direct-return System

• The water has shorter distance

and less resistance within the
first coil.

• More water will flow through Two Pipe System Direct-Return

the coils closer to the boiler. Pictures Courtesy of: Refrigeration and Air
Conditioning Technology, 6th Edition

Balancing valve is
required to make sure
the system works
properly.

24’ T1 & 30’ T4

 Hydronic Heating System - Two-Pipe System

❑ Two pipe revers-return System

• The first coil to feed is the last coil

to return to the boilers.

• The distances and resistance for

all coils are equal. A two-pipe reverse-return piping
arrangement.
Pictures Courtesy of: Refrigeration and Air Conditioning
• This system may perform without Technology, 6th Edition

a balancing valve if all the coils are

at the same elevation.

• 31 feet distance for all the coils

Hydronic System - Two Pipe System

A Two-pipe System
27
 Two pipe cooling & heating “change over”

Pic source: https://slideplayer.com/slide/3315957/ 28

 Hydronic System Primary–Secondary Pumping

❑ The primary-secondary system includes one

primary loop which circulates the water
through the boiler and main loop.

❑ The secondary circuits have circulation

pumps to inject the water from the main
loop in to the heating coils.

❑ Diverter or Monoflo tees are not required in

Primary-secondary system with one secondary loop
primary-secondary systems.

❑ If there is no demand in the secondary loop,

the primary loop will still circulate the water
to maintain the minimum flow rate required
inside the boiler/s.

Primary-secondary system with multiple secondary loop.

Pictures Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
Hydronic System Primary–Secondary Pumping

❑ More resistance between the tees results in

more water flow through the terminal unit
connected to the tees.

❑ Less resistance between the tees results in

less water flow through the terminal unit.

Primary-secondary system with one secondary loop

Pictures Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
 Hydronic System Primary–Secondary Pumping
Sample 1
• The one-pipe system with three secondary zones providing 200,000 Btu/h of
heating to the occupied space. The boiler is operating at ∆T = 20 ⁰F.
• There are three secondary loops with the
following heating capacities:
Zone 1: 120,000 Btu/h Zone# 2 Zone# 3
Zone# 1
Zone 2: 50,000 Btu/h
Zone 3: 30,000 Btu/h
Calculate:
1. The total water flow in the
main loop and each zone.

2. Calculate the mixed water

temperature at the common
pipe downstream each zone.

3. Calculate the water

temperature returning to the
boiler if zone# 1 is closed.
Primary-secondary system with Three secondary loop.
Pictures Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
Hydronic System Primary–Secondary Pumping
Sample Question
1.1 Total water flow required in the main loop:

1.2 Calculate the 𝒈𝒑𝒎 for each zone: ❖ We assume ∆T at each zone is 20⁰F.

120,000
𝑔𝑝𝑚𝑍𝑜𝑛𝑒 1 = = 12𝑔𝑝𝑚
500 𝑋 20
50,000
𝑔𝑝𝑚𝑍𝑜𝑛𝑒 2 = = 5 𝑔𝑝𝑚
500 𝑋 20

30,000
𝑔𝑝𝑚𝑍𝑜𝑛𝑒 3 = = 3 𝑔𝑝𝑚
500 𝑋 20
2. Calculate the mixed water temperature at the common pipe downstream
each zone.
(Flow 1 X Temp. 1) + (Flow 2 X Temp. 2) = (Flow 3 X Temp Mix )
Second T after zone 1:
(12 X160) + ( 8 X 180) = (20 X Temp Mix )
Temp Mix = 168⁰F
Forth T after zone 2:
(5 X148) + ( 15 X 168) = (20 X Temp Mix )
Temp Mix = 163⁰F
Sixth T after zone 3:
(3 X143) + ( 17 X 163) = (20 X Temp Mix )
Temp Mix = 160⁰F

Primary-secondary system with Three secondary loop.

Pictures Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
3. Calculate the water temperature in the main loop if zone# 1 is closed.
(Flow 1 X Temp. 1) + (Flow 2 X Temp. 2) = (Flow 3 X Temp Mix )
Forth T after zone 2:
(5 X160) + ( 15 X 180) = (20 X Temp Mix )
Temp Mix = 175⁰F
Sixth T after zone 1:
(3 X155) + ( 17 X 175) = (20 X Temp Mix )
Temp Mix = 172⁰F

Primary-secondary system with Zone 1 Off

Pictures Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
 Hydronic System Primary–Secondary Pumping
Sample 2
• The one-pipe system with three secondary zones providing 650,000 Btu/h of
heating to the occupied space. The boiler is operating at ∆T = 20 ⁰F.
• There are three secondary loops with the
following heating capacities:
Zone 1: 200,000 Btu/h Zone# 2 Zone# 3
Zone# 1
Zone 2: 150,000 Btu/h 200,000 Btu/hr 150,000 Btu/hr 300,000 Btu/hr
Zone 3: 300,000 Btu/h
Calculate:
1. The total water flow in the
main loop and each zone.

2. Calculate the mixed water

temperature at the common
pipe downstream each zone.

3. Calculate the water

temperature returning to the
650,000 Btu/hr
boiler if zone# 1 is closed.
Primary-secondary system with Three secondary loop.
Pictures Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
Hydronic System Primary–Secondary Pumping
Sample Question
1.1 Total water flow required in the main loop:

𝒈𝒑𝒎 = 𝟔𝟓𝟎, 𝟎𝟎𝟎 ÷ (500 x 20) = 65 gpm

1.2 Calculate the 𝒈𝒑𝒎 for each zone: ❖ We assume ∆T at each zone is 20⁰F.

200,000
𝑔𝑝𝑚𝑍𝑜𝑛𝑒 1 = = 20𝑔𝑝𝑚
500 𝑋 20
150,000
𝑔𝑝𝑚𝑍𝑜𝑛𝑒 2 = = 15 𝑔𝑝𝑚
500 𝑋 20

300,000
𝑔𝑝𝑚𝑍𝑜𝑛𝑒 3 = = 30 𝑔𝑝𝑚
500 𝑋 20
2. Calculate the mixed water temperature at the common pipe downstream
each zone.
(Flow 1 X Temp. 1) + (Flow 2 X Temp. 2) = (Flow 3 X Temp Mix )
Second T after zone 1:
(45 X180) + ( 20 X 160) = (65 X Temp Mix )
Temp Mix = 174⁰F
Forth T after zone 2:
(50 X174) + ( 15 X 154) = (65 X Temp Mix )
Temp Mix = 169.4⁰F
Sixth T after zone 3:
(35 X169.4) + ( 30 X 149.4) = (65 X Temp Mix ) Zone# 1 Zone# 2 Zone# 3
Temp Mix = 160⁰F 200,000 Btu/hr 150,000 Btu/hr 300,000 Btu/hr

650,000
Btu/hr Primary-secondary system with Three secondary loop.
Pictures Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
3. Calculate the water temperature in the main loop if zone# 1 is closed.
(Flow 1 X Temp. 1) + (Flow 2 X Temp. 2) = (Flow 3 X Temp Mix )
Forth T after zone 2:
(50 X180) + ( 15 X 160) = (65 X Temp Mix )
Temp Mix = 175.4⁰F
Sixth T after zone 1:
(35 X 175.4) + ( 30 X 155.4) = (65 X Temp Mix )
Temp Mix = 168.8 ⁰F

Zone# Zone# Zone#

2 300,000 Btu/hr
1200,000 Btu/hr 150,000 Btu/hr 3

650,000 168 ⁰F
Btu/hr
Primary-secondary system with Zone 1 Off
Pictures Courtesy of: Refrigeration and Air Conditioning Technology, 6th Edition
 Types of piping configurations
Three-pipe System
• Used in buildings that have both a boiler and a chiller
• These systems are not used at the same time – they are used
at different times of year.
• For heating system :
✓ hot water supply pipe
✓ cold water supply pipe
✓ common return pipe
• When the boiler is offline and the chiller is in use, the same
pipes are used.
• Only one set of pumps is used on the common return
piping.

39
Hydronic System - Three Pipe System

Three pipe System

Pic source: www.pinterest.ca/pin/368098969516582315 40

 Types of piping configurations
Four-pipe System
• It is not uncommon for a building to require both heating
and cooling simultaneously
• An office may need to be kept at a higher temperature
than the data center, for example.
• In fact, most modern buildings require both heating and
cooling during some seasons of the year
• consists of:
✓ A hot water supply
✓ A hot water return
✓ A cold water supply
✓ A cold water return

• It is necessary to adjust the calibration of the control system

to minimize energy waste
• Any time a terminal is using both heating and cooling water,
it is usually using excess energy.
41
Hydronic System - Four Pipe System

A Four-pipe System
Hydronic System Primary–Secondary System
Mixing Valves

❑ Mixing valves are used to combine two water streams with different temperatures.

❑ Most Common Types of Mixing valves:

• 3 Way Valve: Two inlet and one outlet

• 4 Way Valve: Two inlet and two outlet

3-Way Mixing Valve

Picture Courtesy of Honeywell

4-Way Mixing Valve

Picture Courtesy of Honeywell
Hydronic System Primary–Secondary System
3-Way Mixing Valves

• The 3-way valves are ideal for mixing two stream of

water with different temperature.

• They can be manually adjusted or to be

thermostatic type.

• Ideal for tempering water at showers and

washrooms and public places.

• This will allow to have different temperatures at

different zones.

3-Way Mixing Valve

Pictures Courtesy of: Refrigeration and Air
Conditioning Technology, 6th Edition
Hydronic System Primary–Secondary System
Mixing Valves
• Four-way mixing valves allow some of the water leaving
the boiler to return to the boiler to keep the return-water
temperature high enough to prevent flue-gas condensation.
This applies for non-condensing boilers.

4-Way Valve Application

Picture Courtesy of Honeywell
4-Way Mixing Valve
Pictures Courtesy of: Refrigeration and Air
Conditioning Technology, 6th Edition
 Hydronic System Layouts

• As it is generally the case, the heating

plant is also producing the domestic
hot water.

Hot Water Plant 46

Picture Source: Water treatment program manual-Gov. of Albertac
Hydronic System Layouts

Primary/Secondary Loop System

47
Hydronic System Layouts
Temperature of the Water in the Loops
constant temperature loops:
• Loops that send heated water around the perimeter of the building and
then to heating terminals (radiators)
• temperature in perimeter loops >that of other constant temperature loops
Why? heat loss anticipated around the perimeter of the building.
variable temperature loops:
• The temperature of the water is adjusted - raised or lowered, depending on
the needs.
• Secondary loops that go into the building’s center are variable temperature
loops in which the temperature of the water is controlled locally

48
Hydronic System Layouts

Constant Temperature Perimeter Loop 49