HOTWATER HEATING

PI-AI{SERVICE
D.E.Darby, R. Borg . .

9735
85:04 R00.08

Hotwaterheating(hydronic heating) is a popularand effective methodof heatingagricultural buildings. There have been greattechnological advancesin hydronic heating controls and products sincethis bulletin was first done in 1984.This leafletgivesdesignand installation guidelines for bothfloorand spaceheatingsystems. Hotwatercan be usedfor manyheatingapplications in farmstructures, including: . Spaceheatingof livestock buildings, usually with blacksteel pipe,finned-tubeconvectorsor hot water unitheaters.Hog,dairy,and poultrybuildings lend themselves well to this. . Floorheating of shops,whichcommonly supplies all of the heatingneeds. . Localized floorheatin hog barns,suchas in baby pig creepsand sleeping areasof growerhog pens. . Heatedfloorbroilerchickenhouses. . Otherspecialized floorheating, suchas in honey housesor processing rooms. . Greenhouse heating, usually withfinned-tube convectors or unit heatersto give the greaterheating capacity thesebuildings require. Hotwateris the obvious choicefor floorheating.In addition,hot water space heatingoffersseveral advantages for confinementlivestock buildings: . Heatingseveralareasfrom one centralboiler is easy, with zonecontrolof each. . Problems with dust,cloggedair filters,and the fire hazardsof dust in ductsand furnacesare avoided. . lt is compatible with ventilation systems;desirable air flow patternscan be reinforcedby correctlocationof the heatingunits,and furnacebackdrafting due to ventilation fan suctionis.avoided by puttingthe boiler in a separate room. . lt is usuallymoreetficient and has a loweroperating cost than forcedair.

Floorheatis placedin the optimumlocation whereit is mosteffectively utilized. Hotwatercan be the principle heatsourcefor ducted air systems for heating, ventilation and air conditioning, suchas officesin largefarm building complexes. lt is easyto cleanand maintain.

The initialcost of a hot water systemis often higherthan that of othertypes,particularly when usedfor smaller one-room buildings.For largebuildings with several heating zones,hot wateris usuallymoreeconomical. The systemshouldbe designed for eachbuilding, and alternatives evaluatedto makean objectivecomparison. HEATING SYSTEMS The basichot waterheatingsystem,as illustrated in Figure 1, consists of the following components: . hot waterheateror boiler. . circulating pump, . expansion tank, . distribution piping, . radiators in the spaceto be heated;blackironor steelpipe,finned-tube convectors, unitheatersor pipes, under-floor . controls, gauges, valves, temperature and pressure air bleeding valve,pressure reliefvalve,and pressure regulator. LAYOUT: The sequence of equipment and circuitdesign (illustrated in Figure t) is important to get optimum flow, with minimumproblems balancing the system.The pump shouldbe on the outletside of the boiler, and closeto the expansion tank,as this is the pointof leastpressure changein the system.

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CANADA

The Canada Plan Service prepares leatlets showing how to construct modern farm buildingsn livestock housing systems, storage and equipment for Canadian agriculture. Permission is given to copy this leaflet. You may contact PLANSERVICE the Canada Plan Service through your provincial agriculture department or on the internet at wwwcps.gov.on.ca-

HEATING UNITS: Several typesof heaterscan be used, ranging from a smallresidential heaterto large commercial boilers.Domestic hot waterheaters will satisfyrequirements up to 12 kW (40,000BTU/h),They are cheapto installbutwill not lastas long as a boiler.A pump,expansion circulating tank,and controlsmustbe added. Commercialwater boilers are recommended for larger systems.Theseare designed for highoutputand higher flow rates,and will provide the best long-term performance. Mostare eithergas or oil-fired. Though Coal or wood{iredboilersare also available. theseare lessconvenient and havehigher emissions, they may be moreeconomical in somesituations.Be surethat with safetyand functional suchboilersare fullyequipped controls(seethe sectionon controls). Boilersare classilied by threecategories: . Typeof fuel- gas,oil or solidfuel. - sectional . Physical structure or tubetype,'\uet'or "dry"based. . Heatexchanger material- copper, steel,cast iron or combination alloy. . Typeof heatexchanger, condensing or non-condensing.
1 .B o i l e r gauge 2. Temperature 3. Backfloworeventer 4. Make-upwater 5. Drain valve 6. Pressure regulator 7. Expansion tank 8. Air separator or purger 9. Hightemp.supplyline 10.Return line 11.Primary circulator 12.Secondary circulator

Non-condensing boilers are mostcommon.Theyare so namedbecause the watervapourcomponent of the products is totallyexhausted of combustion withthe flue gas. Theseboilersgenerally shouldnot operatewith waterjackettemperatures below58'C (135"F)because this resultsin partialcondensing of the watervapour whichleadsto corrosion and earlyfailure. In condensing boilers, the watervapourfractionis condensed in the heatexchanger, capturing the extra energyof vaporization, resulting in higherefficiency typically 95% ratherthan 80 85"/o. EachGigajoule (millionBTU)of naturalgas produces about40 L (9 gal) of watervapour.To perform effectively, theseboilersrequire lowerreturnwatertemperatures, as well as non-corroding and specially designed secondary heatexchangers. EFFICIENCIES: efficiency, Combustion the inpuVoutput ratioon the nameplate, is onlyone component in the overallsystemperformance. Otherfactorsaffecting efficiency are the cycleefficiency and seasonal performance. Simplystated,an oversized boilerthat cyclesfrequently is lessefficient than one exactlysizedto the heatingneed. Also,a boilersystemthat requires high heatfor coldweather, but operates at fractional loadthe other9 months,is lessefficient thanthe nameplate rating.Table 1 showstypicalefficiency ratings for boilers.
H i g ht e m p . l i n e Low temo.line

13. Fanforcedunit heater (underair inlets) 14. Pipe radiators 15. Low tempfloor heat 16. Injection valve 17. Balancing valve(globetype) 18.Zonevalve(if required) 19. Floorsensors(groupof 4) 20. Roomair sensors 21. "Smart'controloanel 22.Flue and drafthood

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Figure 1: Schematicof aTypical Hot Water HeatingSystem

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Methods for achieving bettercycleand seasonal efficiencies are: factorof 1. Do not oversize the boiler;an oversize 15 - 20o/o is recommended. 2. Usea modulating controlboilerthat adjuststhe flameto suitthe heatingload. 3. Use an "outdoor resetcontroller," a systemthat adjusts boilertemperature relative to outdoorconditions. Table 1: Typical BoilerCycleand Seasonal Efficiencies.
7" Run Time 100 80 60 4 20 10 Cycle Efficiency % of Steady States 100 97 95 92 85 60 Oversize Above Design Load 1.0 1.5 2.0 2.5 3.0 Seasonal Efficiency *
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RADIATORS: Theseare the elements that transfer the hot water'sheatto the room. Blacksteelpipe,finned-tube plateradiators, convectors, and fan{orcedhot waterunit heatersare the maintypes. Figure 2 showssometypes andtheirapplication. Black steelprpe; Mostcommonly usedin livestock buildings, it is easyto clean,leastaffected by dust,and not easilydamaged.Barepipemay be morecostlyand require morelabour to install thanfinned-tube convectors it is largerand morepipeis required,Galvanized because pipeshouldnot be usedsincethe galvanizing restricts heattransfer. Blacksteelpipe is usuallymountedunderair inletsor on wall brackets.Piperadiators shouldbe mounted at least one pipe diameter fromthe wall to permitfree air Heatoutputfor baresteelpipe,and the length circulation. of pipeneededcan be determined fromTable 2. Livestock roomsusuallyhavefrom one to four loopsof pipe. Table 2: HeatOutputFromBareSteelPipe, (Wm or BTu/h.ft'z)?'
Nominal Pipe Size mm 38 tn, 1.5

70 60 50 45 4

- Basedon boilersteady state efficiencyof 84% run time, would Example:a boilerof 80olo efficiency, operatingal 4oo/o have a cycle efiiciencyof 0.92 x 80 = 73.6%.

The boiler should be in a separate mechanical room,At a to avoidbackbarn,it shouldhavean outsideentrance causedby ventilation fans. This roommust draftproblems ventsfor combustion air supplyfrom havethe required outdoors.This varieswiththe fuel,the type of heaterand in accordance withthe applicable building construction installation code. CONTROLS:Hot waterheatingsystemsshouldhave: high-limit watertemperatu re shut-off ; o low-lim it watertemperature start-up; a high-limit safetyswitch; a low-water-vol ume safetyshut-off ; o pressure reliefvalveon the heateroutlet(located whereit willnotcauseinjuryif it should blow); modulating reset controland/oroutsidetemperature (optional); flow switch(forsometypes).
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Pipeto-airTemperature 'C ("F) Difference

txf 35 .+c) 55 75 (65) (8s) (100) ( 1 1 7 ) (135)

Pipe Volume

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1.32

gal/ft

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W

72 70 92 75

'|00 94
125 100

127 118 158 121

154 142 191 '145

181 166 223 174

0.016
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Notes: 1. Datais from Feddes et al, University of AB, 1988,in a simulated hog barn environment. 2. C = ceilingmounted; W = wall mounted 3. Referto Figure2 for typicalapplicationdetail. 4. Dustyconditionsreducevalues by up to 5 - 8%. will increasevalues 10 - 15olo. 5. Forcedconvection 6. Pipe volume is used to estimatesystem fluid volume required. 7. 1.0Wm = 1.04BTU/h.ft, whichis practically equal.

1. Fan-forced hot waterunit heater 2. Finnedtube convector with optional meshguard 3. Delta plate-tubeconvector 4. Baresteelheatingpipe (wallor ceilingmounted) 5. Recirculation duct 6. Baffledair inlet Figure 2: Radiators

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Example:What lengthof 2 in.steelpipe is required to input30 kW (102,000 BTU/h)of heatto a hog barn maintained at 15'C (60'F),if the average hotwater pipeis ceiling is 80'C (175'F); temperature mounted? Answer:The temperature difference is 80 - 15"C= 65'Ci fromthe table,reada heatoutputof 190Wm for 2 in. pipe. Pipelength required is 30,000 W * 190Wm = 160 m (525ft). Fourlines(two loops)wouldbe typical. Finned-tube convectots:These havefour to five times capacity the heattransfer of bare pipe. Outputvarieswith fin sizeand spacing, so consult manufacturer's design data. Theyare particularly suitable for smallroomsor greenhouses wherethe lengthof bare pipe may be excessive. Whereless heat is required, shortsections of convector can be spacedalonga wall. The maindrawbacks to finned-tube systemsare that they performance), collect dust(reducing require frequent and can easily cleaning be damaged. Theyare not recommended for dustylivestock buildings. Plate-type radiators: Theseare a combination of fins and platefinsto the pipe. barepipeby addingflat or triangular Theseofferthe advantage of highoutputand ruggedness withlessdustproblem thanfin-tubing. Hot waterunitheaters:Theseare excellent for small livestock rooms, shops, milkhouses, and similar areas wherea concentrated heatsourceis desired.They can withventilation also be incorporated ductsor othertypes of air circulation systems.In dustybuildings, these radiators shouldbe inspected and cleanedregularly to maintain heating effectiveness. SYSTEMDESIGN Hereis a summaryof systemdesign,followed by details on someof the maincomponents. 1. Sizethe heater unitto meetthe requirement of the (suchas floor building or the particular application heat). 2. Selectthe appropriate sizeor lengthof radiator based for each room, on the heat required 3. Layout the systemon a plan. pumpcapacity 4. Determine the circulating to matchthe heater sizeor the individual circuit requirements. - expansion 5. ldentify the required equipment tank, controls, valves, etc. THE HEATER:The building's SIZING supplementary heatingrequirement can be calculated fromthe insulation levelof the building, ventilation rate,livestock heatoutput, outdoortemperature and otherfactors.Livestock housing givegeneralguidelines. references Thesevalues,usually per animal,are reliable in termsof heatrequired for most Also see the floorheatsectionfor designing situations, floorsystems,

A heatingunitshouldbe selectedby its net or output rating, not its input.Inputis important for gas supply, flue sizingand combustion air supply.Both ratingsare listed on the unit'snameplate. Notethat the high-altitude rating is usedfor elevations higherthan 600 m (2000ft). Add 15 - 2Oo/o as a safetyfactor. WATERFLOWRATE:Waterflow and temperature must be adequate to provide the desiredheatoutputand to allowfor a temperature dropthroughthe system. Heat outputof pipeconvectors and unitheatersdependson waterand air temperatures. Mostsystemsare designed for 85 - 95"C (185- 200'F) water. Lowerwater temperatures requirelargerradiators or longerheating pipes,cost more,and are lessefficient.
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watergivesup its heatin the radiator, Circulating and regainsit at the boiler.The flow rateshouldbe sufficient nhan nhiet to keepthistemperature changewithinacceptable limits; the higher the flowrate, the lower thischange.This change should normally be 10 - 14'C (18- 25"F)for spaceheating, and lessthan 10'C for floorheating to maintain uniform floortemperatures. Flowrate,temperature change,and heatoutputare related by the following equation: 14.33 Q T'-To

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Where: F = flowrate,Umin (GPM) Q = energyexchange by the water,kW (BTU/h) T,- To= temperature changeof waterfrom inletto outletof 'C ('F). the boileror radiator, T in'Fl Q in MBTU/h, lF =2.0 O(T,-T) for F in USGPM, Example:Whatflow rateis required for a 60 kW (205 MBTU/h) systemto maintain the watertemperature change at 1O'C(18'F)? F = 14.33O(Ti - T") = 14.33x 60/10 = 86 Umin (22.7GPM). lmperial: (2x205/18= 22.8GPM)

is usually usedin equipment specifications. " TheUSgallon - gallon 1x 0.264 Makesurethat the linesize is adequate to carrythisflow, basedon the lengthof each loop,flow in each loop,and pressure losscharacteristics of the pipe. For blacksteel pipe,the pipesizeselected for heatoutputis usually largerthan neededto handlethe flow Longrunsor small pipesizesshouldbe checked for pressure lossusing pressure program. losstables or a computer

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pumpthat provides the desired flow Selecta circulating lossfor the entiresystem. Pressure rateat the pressure lossshouldnot exceed60 kPa (20 ft of head)for most systems.lt is a good ideato havea sparepumpon hand,

EXPANSION TANK:Waterexpands about4o/o ds it heats fromroomtemperature Thisis to nearboiling. accommodated by the expansion tank. The expansion in the tank is alsothe pointof leastchangein pressure system. The pumpshould always be located immediately Thermometers and pressuregauges: Theseare handy afterthe expansion tank for bestperformance. for balancing the system;besides thermometers on the returnand supplyside of the boiler, and a system pressure gauge, gauges for the correct the equipment supplier tankfor the in-line Consult otherpermanent are not system.To selectan expansion tank,the volumeof water required. In somesituations it maybe desirable to read hasto be calculated. in the entiresystem Tanksizewill fluidtemperatures for secondary loopsor floorheating. of the systemvolume.Table 2 gives usuallybe about1Oo/" pipeas an aid in computing the capacity of standard the Expansion and contraction; Takechangesin pipelength pipesupports systemvolume.To this,add the waterin the heateritself. intoaccount whenchoosing and planning the layout.Provide sleeves or adequate clearance where pipespassthrough OTHERCONSIDERATIONS wallsor floors.Pipesupports should allowfor this movement. It is beyond the scopeof this leafletto provide a complete manualon hot waterheat,butthe following are someof Allowfor expansion at the end of a longpipe lineor loop that shouldbe considered. The serviceof the details by stopping shortof the end wall. Fora 100'Cchange in heating experienced contractors or equipment suppliers temperature, steelexpands 0.12%in length; mostrigid plastics in assuring is valuable thatthe rightcomponents are in expand 5 to 10 timesas muchas steel. place. Systemand equipment suppliers all have computer assisted designservices to optimize the Pressure regulatorand backflowpreventer: Requiredon of thesesystems. designand performance the watersupplyconnection.Mostsystemswork best pressure undera moderate of about125kPa(20 psi)for Automatictemperature controland zone control: These bettercirculation and to avoidvapourlocks. controlled flow regulators or valves thermostatically regulate the hot watercircuitin each roomor zone,and MAINTENANCE for that room. The are actuated by the thermostat Maintenance is criticalto efficient andtrouble{ree pumpusually performance runscontinually, circulating andthe valves of hydronic heatingsystems.Hereare the open or closeas required.Alternatively, the pumpcan be mostimportant considerations: or aquastat, 1. Pumpsand mixingvalvesshouldbe exercised startedby thermostat as one or morezones at least callfor heat. Variable speedpumps,whichregulate the oncea monthduringthe off-season to prevent seizure flow as required, are excellent for someapplications. anddeterioration. 2. Pumps should be oiledregularly as required. Valvesshouldisolateand controlall zonesor circuits. 3. Thefluepassages and combustion chamber should Install valves withunions or flanged connections on both be cleaned on an annualbasisandthe burner checked or otherequipment thatmayneed andcorrect sidesof the pump, to ensure efficient combustion. servicing, so it can be removed for repairs.Manual 4. Checksystempressure whichshouldbe maintained at (use globe valves) required valves are usually to balance about125kPa(20 psi).Toohigha pressure cancause installations, for systemshut fromthe pressure reliefvalve,too low causes the systemin multi-zoned blow-off fails. Selecta valveof down,or if a thermostatic controller cavitation in pumpsor indicates a leak, the required capacity to matchthe flow rate. 5. Conventional boilers shouldnol operatebelow60'C (140'F)to avoidfluegasfromcondensing. if heatinglines Draining and venting:Bothare facilitated 6. Checkfor areasof reduced heatoutputfromfloor slopeuniformly to one end (or one point).Install drain heating;this couldindicate air beingtrapped, a kinkin failure. cocksat the low pointsand air ventsat the highpoints. the pipe,or control for simple 7. Hydronic One of each may be all that is required systemsshouldbe maintained at about pH 9 - 10,and testedannually for effectiveness systems, othersmay requireseveral. of protection. corrosion inhibitor and antifreeze Heatingf/urds;Qualityof the heating fluid is the lifeblood 8. Sludgecan form in presence of glycoland available heating fluidsare waterand pipefor signsof sludge of the system.Commercially oxygen. Inspect growth; recommended; theycontain corrosion inhibitors formation if necessary to and microbial the performance maintain long-term of systemsand system should be flushed and purged.
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components. lf wateris used,it shouldbe demineralized or softwater,with corrosion inhibitors, added. Hardness causesscalebuild-up whichis harmfulto the system. For glycolsolution freezeprotection use an ethylene specially formulated for hot waterheatingsystems.Do not use automotive antifreeze. Checkthe fluidsolution everyyear, andadd inhibitor if needed.Mostchemical suppliers orovide thisservice.

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Heatoutputfrom a floorslabto roomair can be Twoor morewatertemperatures may be required in calculated by this equation: livestock barns.Floorheat requires waterat 40 - 45'C _ 6 1. -- '2'0(T'-T")' "'121 ( 1 o o -1 1 0 ' F ) , w h i l e s p a c e h e a r ti n g e q uireswaterat88'C where: (190'F).Thereare severaloptions: . Usetwo separate systems.This may be bestfor large Q = heattransfer Wlmz(Wlm2 x 0.32= BTU/h.ff) 'C multi-room buildings. = pha tron floor temperature, I . Use a thermostatic oC mixingvalveto blendhot water T, = air temperature, -^ intothe floorcircuit to maintain the desired lQ=2.12 (l - T")forT in'F and Q in BTU/h.ft'?l temperature nhiet o mong muon . Use an injection controlloopfor the lowtemperature r__ _t Fora floorat 30'C and air of 20oC,heatoutputwouldbe ^;_: circuit.This is the latestand most reliable'^-'-:'Iecnnology 12.0x 10'c = lzowlm2 (38 BTU/h.ft2). heat Greater for multi-circuit systems. outputfromthe floorsystemis obtained as air temperature drops' Forexample, at 12'C air to 30'C floor, The firstmethodallowsfor the completely independent (7o BTu/h'ft'z)' flux is 216 W/m2 This is a nice operation of eachsystem(e.g. if space -r--- heatiifi; J;; '--"' " *.T" serf-regurating feature froor heat. of downfor the summer).-'-' t ieu hoa pumpfor The lasttwo methodsuse a separate circulating the floorheating circuit.Thesesystemshavethe most flexibility, bestcontrolstrategies, and leastproblems with flow balancing.Consultsuppliers of thesesystems for installation details. FLOORHEATING

TWO.TEM PERATU RESYSTEMS

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Floorheatingis accomplished by circulating hotwater throughlinesof plasticpipe placedin the reinforced gia floor. Floorheat is usedin farm shoosand in concrete livestock housing for creepor weanerpig areas. Figure 5 illustrates a typicalshopfloorheatinginstallation, Figure 6 showsdetailsfor a hog barnfloor. The following is a guideto heatinglevels for various farmapplications, Application Shopfloors Officeor Utility Babypig creeps Weanerpigs Growerpigs

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INJECTION MIXING

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1. Boiler 2 . Primary circuit, 85"C 3. Low temp.loop,44'C 4. Motorized injection valve 5 . 4-waymixingvalve 6. Balancing valve(globetype) 7. Thermal trap,15"min. (pumps) 8 . Circulators

FloorTemp

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HeatOutput Wm'z(BTU/h.fF)
100- 130(32- 45) 90 - 110(30 - 35) 100- 125(32- 40\ 90 - 110(28- 35) 80 - 105 (25 - 32)

24 - 30 (75 - 86) 24 - 28 (75 - 82) 28 - 32 (82 - 90) 24 - 28 (75 - 82) 22 - 25 (72 - 77\

MIXINGVALVE SYSTEM

Figure 3: Methods of Achieving Multi-temperature Zones.

DESIGN Floorsystems are designed usingthe sameprinciples for spaceheating.Mostof the equipment outlined is the pump, same;heater or boiler, circulating expansion tank, valvesand controls. Heattransferred fromthe concrete floorto the building depends on bothfloorand the air temperature. Heatinput to the floorwill dependon the inletwatertemperature, pipespacing and waterflow,if the heatingunit has enoughcapacity to keepup to the floor heatloss.

Waterflow and pumpcapacity are calculated as outlined (equationl earlier change of 5 - 8'C ), usinga temperature (9 15'F),depending on the uniformity required. Flow tnh pressure through eachloop,for checking dropand sizingong valves, is the totalflow dividedby the numberof loops. The flow rateshouldusuallybe higherthanfor spaceheat to keepthe temperature moreuniform,

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The headersystemmay be of steelpipe,copperor rigid plastic, withT-fittings for attaching the floorlines.The headershouldbe sizedfor the totalwaterflow in the system.Valvesare recommended on eachfloorlineto balance or controlllow; one on the supply and another on the returnare best in case one loopspringsa leak. 6-

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Watertemperaturetor floorheatingis muchlowerthan for spaceheating. Water temperature willbe 10 - 15'C (18 - 25'F) warmerthan the floorslab. Floortemperature is bestcontrolled by the wateror slabtemperature, rather than by startingor stopping the flow. Controlof small sections, suchas in babypig creeps,may be more preciseand adjustable if injection or mixingvalves watertemperature regulate whilemaintaining fullflowto eachsection, Twocontrolstrategies applyto heatedfloors:1) set floor for occupant slabtemperature comfort, typicalof piggery floors, and someotherapplications, or 2) provide variable heatoutputaccording to the roomthermostat, the typicalmodefor floorheatedhouses.Forthe special caseof a farm shop,it is desirable to increase heatoutput roomtemperature, to maintain butat the sametimethe slabtemperature shouldnot exceed30'C (85'F) for floorwater comfort.This can be done by limiting temperature in conjunction with in-slab sensors. It is oftenusefulto knowthe floortemperature. An covered with a smallslabof foam ordinary thermometer, in contact withthe floorcan measure insulation, temperature directly.Moderncontrolsystemsuse for temperature sensing for bothcontroland thermistors readout. Piping:Modernhydronic floorsystemsuse cross-linked polyethylene (PEX)pipe. lt is available with or withoutan piping is highly oxygen barrier. Oxygen-limiting for systemsof ironor steel. Special recommended proprietary connectors are also used. Floorheatmayrequire longruns. Pipesizeand loop length should matchtheflowand pumphead. For assistance in complexsituations, obtaintechnical loss. Otherwise, checking flow and pressure the pipesize: following is a safeguidefor minimum Pipe Size mm (inch) 12 (1t2) 15 (5/8) 20 (3/4) Allowable Loop Length m (ft) - 275) 60 - 80 (2OO 90 - 120 (300- 400) 120- 150(400- 500)

The layoutof the floorcircuitis critical to achieving the mostuniform temperature. configurations Several can be used,butthe mosteffective is reverse counter-flow loop, wherethe returnlinedoubles backalongthe supply lineto (Figure average out the slabtemperature 5). Forthe case of multiple floorloops,it is important to havethe system properly balanced. The layoutin Figure 5 achieves this by making all loopsequalin length. PEXpiping hasgreatstrength and ductility; it thusdoes notfaildueto normal floorcracking. Wherefloorlines jointsor otherfloor breaks,run the line in crossexpansion pipeto provide a 300 mm (12")longsleeve of larger the necessary roomto stretch. Pressure test all linesbefore is placed. the concrete Floordesign;Whenconcrete curesit shrinks, which causescracks.Reinforcing is required to reduce cracking to smallhairline cracks.Tocontrol cracking, the recommended cross-section areaof reinforcing steelis 0.15to 0.20"/o of the cross-section areaof the floorslab. Forexample, 10 m rebar at 400 mm (16")spacing in a gage 140mm (5.5") flooris 0.18%steel,Equivalent heavy wire meshcan alsobe used. Reinforcing can benefit any floor,butlessis neededif controljoints are partof the for largefloors. design

for higherflowswherea small Use shorterlengths longer wheregreater temperature dropis desired; changeis practical. temperature lnstallation: Pipespacingis not critical, since can be adjusted as required.As a guide, temperatures usea spacing of 150- 250 mm (6 - 10') for smallareas likepensor creeps, and 250 - 300 mm (10 - 12")for large areasand for thickerfloors,like in farm shops. Closer pipespacing reduces the flowper linewhichmayhelp lossis a concern. wherepressure -7

1. 2. 3. 4. 5. 6. 7. 8. 9.

Reinforced concrete floor Floorheatinglines Reinforcing steelor mesh granular fill,'150 mm Compacted Vapourbanier(if @ not used) Foundation wall (optional) insulation Under-floor perimeter foundation Exterior insulation Sensorlocation for heatcontrol

4: InstallationDetailfor Floor

Floorheatingpipe shouldbe placednearthe centreof is most the reinforced concrete slab. Reinforcement just aboveslab centre,Thoughmost effective placethe steelfirst,the idealis to placethe contractors waterlinesjust belowthe reinforcing. Use of pipesupport tracksor clipsare highlyrecommended for precisepipe placement.Floorheatmatsof small-diameter plasticpipe are effective for specialarea applications. -

underfullyheatedfloors,suchas in farm Insulation perimeter cost-effective. However, shops,is marginally insulation is important. Insulating under foundation the floorswill improve heatedportions of livestock comfort and heatdistribution. FLOORHEATFOR FARMSHOPS floorsare popular for farm shops. Heatedconcrete Design the systemlollowing the guidelines outlined previously. For shops,floorheat is moreexpensive than systems; however, mostpeopleprefer mostotherheating mostsuitedto the ownerwho makesa it. lt is probably greatdealof use of the shopduringwinter. advantages: Floorheathas several . Warmfloorsdry quickly. . Snowand ice meltfasterfrom vehicles. . Heatingis very uniformand recovery rapid. . Floorhas highthermalmass,thus retainsheatfor a longtime.

It also has somedisadvantages: . Relatively highcostcompared with othermethods. . Systemcan be damagedif the floorcracksbadly. . Not suitable for occasional use. . By itself, 20oCroom the floormay not maintain temperature during the coldest weather. for a shop is 25 - 30"C The bestfloortemperature (75 - 85'F);warmer floorsare uncomfortable, and cooler in keeping warm. As onesare lesseffective the building notedearlier, for a floorat 30'C and air temperature of (38 BTu/h.ft'z). lf the 20'C, heatoutputis about 12OWlm2 building coolsto 15'C,the heatfluxwillincrease. lt is recommended to designfor 140Wm'z(45BTU/h.ft'?) and sizethe systemslightlylargerto accountfor system losses. This heatoutputwill keepa reasonably well-insulated shop at 12 - 15"C but does not haveextracapacity for reserveheat. lt is also possible to get by with a smaller heatingunit,downto about100Wm2 (30 BTU/h.ff),if coolerfloorsare acceptable.

5 - Loops@ 300 ft each,5/8" PEX pipeat 12"spacing. flow and balace. Eachloop (follow the arrows)is "reverse counter- flou/'foroptimum Figure 5: Floor Heatfor Farm Shop

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PlanViqr
1. Creep area (front creeps) 2. Slattedfloor 3. Concretefloor 4. Balancingvalve (globe-type) 5. Primaryloopfrom boiler 6. Thermostat controller 7. Injectionvalve 8. Secondarylow-temploops and circulator 9. Manualshut-otf 10. Floor sensors,group of 4 typical 11. Sleeveat floor 12. Floorcircuit 13. Reinforcing 14. Rigidinsulation (optional)

Figure6. Hog Barn FloorHeatingInstallation

FLOORHEATING LIVESTOCK Applythe sameinstallation and designprinciples used with otherfloorheatsystems.Injection mixing,coupled with solid state controlsystemsare ideallyadaptedto whereseveral situations floorsections are heatedfrom one system. Mostaccurate floortemperature regulation is obtained by usingin-floor sensors.A bankof four is recommended. The simplest methodis to supplyall floorareaswith the samewaterat about45"C. The babypig creepareas,if insulated, will be 2 - 5"C warmerthanthe weanerfloors. -9-

Thisworks,butthe weanerfloormay still be warmerthan desired.The valveto that floorcircuitcouldbe closed downto regulatetemperature. Figure 6 illustrates a typicalfarrowing barn systemand somemethods of installation and control.For operating heatedfloorbarns,it is desirable to knowfloor temperature to be sureequipment is workingand as a guidefor makingadjustments. Insulating underand besidecreepfloorswillconcentrate the heat,improving the babypigs'comfort withoutoverheating the sow. For largeheatedpen areasinsulation is less important.There shouldbe no floorheatunderthe sow.

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Design example: Design a floorheating system for a shop9.6m by 15m (32x 50 ft), (Figure 5). Floor areainside thefoundation is about 9 m x 14m = 126mr(1350 ftr). 1. Calculate system sizebased on 140Wm2heat input(45BTU/h.tF): = 18000Wor18kW. 140Wm2 x 130m2 a unit of 20 24 kW (70- 80,000 Select BTU/h). 2. Determine flowratefor a temperature change of 8"C (15'F)across thesystem, using equation 1: F = 14.33 A/(T,_TJ
Q = 18kW T, -T"=g"C

v du:Thiet ke he thong si san cho ca hang 9,6m nhan 15m (32x50ft),(hnh 5).Dien tch ben trong nen mong khoang 9mx14m=126m2(1350 ft2) 1.Tnh tai si he thong da vao nhiet si au vao Cho :140W/m2 (45BTU/h.ft2): 140W/m2 x 130m2=18000W=18kw. Chon bo 20 en 24 Kw (70,000-80,000BTU/h) 2.Xac nh lu lng chenh lech nhiet o 8 o C (15 o F) ngang qua he thong nay,s dung cong thc 1: F=14.33Q/(Ti-To)=14.33x18/8=32L/min (8.5GPM) 3.Xac nh ng knh ong si trong san nen mong Khoang cach gia 2 ong gan nhat trong 1 loop 300 mm((12"): chieu dai ong sap x 130m2/0.3=430m (1450ft). 5 loop moi loop ong dai khoang 90m (300ft) ,r# Theo bang trang 7 chng nay ta co: ng knh ong 15mm (5/8") la u. Lu lng nc cua moi loop =32/5=6.4 L/min; 4.Xac nh ong gop nhiet: Theo bieu o 3 trang 3-22 sach piping design vi Lu lng 35L/min th Ong gop ng knh 25mm la u. 5.c tnh the tch cua he thong si 430m cua ong san 15mm x0.18 L/m=80 (L) 2m ong gop ng knh 25mm x 0.5L/m=1 (L) The tch noi hi c tnh=10 (L) Tong cong=90 L(25gal) 6.Dung tch bnh gian n: Yeu cau dung tch bnh dan n toi thieu la 5% cua tong the tch cua he thong=5%x90L=5l (1.3gal);ta co bnh gian n vi dung tch gian n hoan toan la 5 L toi thieu. Chu y:Mat ap vi lu lng 1.7L/min suot ong loop dai 90m (300 ft)ch ra vao khoang 40 kpa (14 ft) ; 4 loops 115m (375 ft) yeu cau lu lng cot ap cao hn la 60kpa (21 ft), ma la ng bien cho vai bm.

F = 14.33 x 1U8= 32 Umin(8.5GPM) 3. At 300mm(12')spacing, is thepipelength 130m70.3m = 430m (1450 approximately ft). Try5 loopsof about90 m (300ft) long,thus15mm(5/8') pipewill beadequate. = Water flowin eachloop= 3215 mm(1 in)pipeis adequate. 6.4Umin;25 4. Sizethe header for a flowof 35 Umin; system 25 mm(1 in) pipeis adequate. 5. Estimate thevolume of thesystem. 430m of 15mmfloorpipex 0.18Um = 80 L 2m ot25mmheader x0.5 Um = 1 L = 10.0L (estimated) Boiler unitvolume Total= 90 L (25gal) Minimum expansion required is 5%of capacity 90 L = 5 L (1.3gal);obtain an expansion tankwithat least5 L netexpansion capacity. Note: a check on headlossat a llowof 1.7Uminthrough a 90 m (300ft) loopindicates about40 kPa(14ft);4 loops flowandgreater of 115m (375ft) wouldrequire higher headof 60 kPa(21ft),whichis marginal for somepumps. Ad<nowledgements: Thisrevised edition of Leaflet 9735wasdeveloped in withseveral hydronics consultation andplumbing industry representatives. Thetechnical assistance of PolyTech Products of Calgary is particularly appreciated.

-10-

tOW TEMPERATURE HOT WATERSYSTEMS

B R I E F R E S U M EO F S Y S T E MC O M P O N E N T S BOILER - Produces steam or hot water by burning fuel. CONVERTOR - Transmits heac from one medium to another, such as from steam to water. CIRCULATING PUMP - Creates Pressure difference to circulate water. COMPRESSIONTANK - Accommodateswater volume fluctuations due to system temperature changes. Prevents dangerous build-up of system pressuf,es. HEAT EXCHANGE UNIT - Transfers heat from one system water to air, such as coil, convector, unit heater, radiant panel, and finned radiation. PIPING - Distributes water proportionately to all heating units.
THERMOMETER

APPLICATION ENGINEERING

BALANCING COCK - Proportions water flow in various parts of the system to get proper ousput from heating units. SHUTOFF VALVE - Hand valve which shuts off water to a heating unit, and allows replacement or servicing without draining the system. A balancing cock may serve as a temporary shutoff valve. CONTROL VALVE - Regulaces flow to heat exchange unit in response to controller signal. It thereby controls temperature, pressure, or flow. CHECK VALVE - Permits water flow in one direction only. Prevents undesirable backflow, and/or short circuiting. THERMOMETER - Provides visual temperaturecheck of system. May be used as aid in balancing.

3o /
PIPING

fir,<*,ag 4,[. : {.: .

COMPRESSION TANK

CONTROL VALVE

CHECK VALVE

'".::":::K
CEILING PANEL\

A.C.UNIT

B A L A N C I N GC O C K

FIGURE I

(fig'rre AND BOILERACCESSORIES 2) BOILER

RELIEF VALVE - Opens automatically when boiler pressure becomes dangerously high. FLOW-CHECK VALVE -WeigLted check valve which permits water to flow only when the pump is operating and prevents gravity circulation. DIP TUBE - Eliminates air entering supply mains. FILL VALVE - Automatically adds makeup water to the system. TEMPERATURE AND PRESSURE GAUGE - Shows temperature and pressure at the boiler.
TEMPERATURE PRESSUREGAUGE
PRESSURE RELIEF

CHECK VALVE

r-+I

RETURN

{.r'lXlu"I'
,t. I

ORAIN VALVE

D,
.I /

. SKtlKIE, rILr1{0ts THE PllWERS REGUTATtlR CtlMPAl{Y

CONTROL SYSTEMS SINCE I891
PRINTEO IN U.S.A.

OFFICES IN PRINCIPAL CITIES IN U.S.A. AND CANAOA

NOVEMBER, I965

APPLICATION ENGINEERING AE.T3 PAGE 2

THE POWERS REGULATOR COTIPANY

CENTRIFUGAL PUMPS
Pump performance can best be determined by studying published pump characteristic curves. A pump curve stated in terms of feer head vs. GPM is a general statement within broad viscosity limitations of pump capacity, regardless of the water remperature pumped. A pump curve is general because of the limits used. Feet head on a pump curve meaos usable pump energy input; ft. lb pressure energy added per lb. of water pumped. The pump raises each lb. of warer pumped to a height srated by che curve as feet head. Figure l illustrates two different characreristic curves.
.FLAT" CHARACT

size can be selected. This is done from a series of pump curves to find out which curve will best suit rhe operation poinr. Oversizing the pump usually leads to more problems than undersizing.

COMPRESSION TANK
tanks provide a space in the system for system water to expand and contract as it heats and cools, and also prevent extreme pressure changes. Sizing is based on sysrem volume and temperature change. There are two types of compression tanks: the open and the closed. Open tanks are open ro the atmosphere by a vent pipe. These tanks are located at the highest point in the system, usually 3 feet higher than other parts. Systems with an open tank are limited to about 180F because of boiling problems. Consequently, Compression

g o
ltl I

F lrl lr.l

CUT.OFF POINTS

o =
f (L

..STEEP''

FLOIY(GPM) FIGURE 3 Pumps with flat characteristics are preferred on automatically controlled hot water systems. They provide the least system pressure change and greatest system flow change as individual valves close. But since systempressure drop can lead to excessive velocities, and pump overloading, it is ertremely important that the pump be sized correctly. Pumps with steep characteristics are a poor choice for valve controlled systems. System pressure changes cause fluctuations in flow, and this pressure change adversely affects valve performance..

they are not in popular use today. The closed tank contains a trapped air pocket and is usually located iust above the boiler. It does not have the limitations of the open tank.

The location of the tank and pump determines system pressures during pump operarion. Figure 4 illustrates two possibilities. The "point of no pressure change" in the piping syslem is the location of the compression The trapped air in the tank follors tank. the gas laws, and pump operation Dressure. does not change tank

ARRANGEMENT 2

ARRANGEMENT I

Theendof the pump curve is called "the cutoff point". Operation to the right of this point may lead to cavitation, limit the discharge capacity, and overload the pump motor. A non-overloading pump-motor combination means that the motor is large enough so thar it will not overload as flow increases, unless the "cutoff point" is passed.

The "no delivery head" is the pressure developed by This is the pressure the pump when there is no flow. across the control valve when closed, provided it is the only valve in the system. Cenuifugal pumps will not develop dangerous pressures with no delivery, but will heat up and should not be operated at this condition. After the full flow system resistance is calculated and the necessary flow and pressure determined, the pump

(PUMP NOT

SYSTEM PRESSURE IPUMP OPERATINGI

\__ __ _

FIGURE 4

_.

LTHWSYSTETS

APPLICATIOX ENGINEERING AE.I3 P A G E3 mix -- the supply water ro the second unit is a mixture of supply water to the first plus return water from the first. Unit valve control is becer than in the series-loop system. The conuol valve should be line size-

In arrangemenr 1, rhe,rank is located at the pump dis_ charge. Since the pump discharge pressure cannot change with the tank in this location, the pump suction pressure must change. Therefore the system operates below rhe original {ill pressure and may operare below atmospheric pressure depending upon pump.size. The resulr is unst4ble circulation with the possibility of air being sucked into the system air vents. In arrangement 2, the tank is located at rhe pump in_ let. This is the preferred arrangement. Vhen the pump operares, the discharge rises by the amounr of the pump head. The pump suction pressure remains constanr and equal to the initial fill pressure.

FITTINGS

PIPING SYSTEMS: ONE-PIPE SYSTEMS There are several hor water piping sysrems. The one pipe system is commonlyknown as the .,series loop" and the "single pipe". SERIES LOOP (Figure 5) In each loop of this piping system, all of the water flows through each heating unit. Limitations are: 1- Last unit in a series (3) hal to be larger to give an equal heat output.
2. Units cannot be controlled individually by one control valve -- as rhrorrling one unit in a loop will throttle all units in the loop. If there are many loops or zones, eaih zone can be controlled by a valve satisfactorily. This valve should be line size. TWO.PIPE SYSTEMS

FIGURE 6

Two-pipe systems are classified as ,,direct retum,, and "reverse return". Conrollability is usually better than the one pipe systems and two-pipe sysrems are generally larger.

DIRECT

RETURN (Figure 7) This system is inherently unbalanced, since unit one has the shortest supply and rerwn, and unit three the longest. Unit one receives more flow than its share, and unit three less flow. The cost of balancing this system usually exceeds savings in pipe installation over the reversed retrun system.

LOOP

2
BALANCING COCK

F I G U R E7

FIGURE 5 SINGLE PIPE (Figure 6) In this system, all of the water does not go through each unit as in the series loop, but a special fitting diverts a portion of water through each unit. The temperature drop after each unit is the same as in the series-loop, since the supply water and return water REVERSE RETURN (Figure 8) In this system, the first unit supplied is the lasr to be returned. The path through any circuit is the same length and has the same resistance as any other. The system is inherently in balance and is the easiest ro control. It also stays in balance as flow changes in any part of the system.

APPLICATION ENGINEERING

AE.I3

P A G E4

THE POWERS REGULATOR COMPANY

1. Make certain system is srabilized and under heat load.

?

Open balancing Take

cocks.

3.

meterata

a temperature reading with a surface pyrospot on the pipe just before the balancing cock. Use a data sheet to record temperatures. record supply temperature.

4.

Also

5. Calculate and record the temperarure drop through each loop. FIGURE 8 6. Calculate the average temperature drop. 7. Throttle loops with a remperatute drop less aaerage -open loops with a temperature more than average. than drop

SYSTEMBALANCING(Fieure9)
Systems are usually designed for a specific identical when the water temperature drop through all loops. is identical, system is in each loop the drop through drop is too small, flow If the temperature the balance. great. Vith a high water is too temperature drop, of the flow is too small.

8. Allow system to stabilize, steps.

then repeat the above

It will usually take three uials to get the sysrem ro where all loop temperature drops are essentially the same. As balancing progresses, mark the cock positions and at the final balanced position.

Proper balance insures: l. That all system components receive their share of heating water according to design. This is extremely important in systems where conrols cannot compensate for poor balance. 2. Low visits. technique is recommended for balancing a series loop system. The example in figure ! shows three loops -- but the procedure would be the same for any number of loops. Tr,e following fuel consumption, and fewer maintenance

COCK 45o rotation of motion away from the full openpositioncauses very little reduction in the amount of flow, Most of the throttling occurs during the 4io The first rotation toward the fully closed position.

BALANCING

Vhen the plug is rotated, loosen the locking nut and tap the plug slightly to release the grip of the taper.

SYSTEM DESIGN
LOOP 2 LOOP I Design of hot water system consists of: 1. Selection and laying out suitable piping. 2. Selectingby proper size and performance,componenr parts, such as pumps, heating units, boiler, valves and controls.

I LT J
I
PUMP +

-1

9 FIGURE

LTHW SYSTEMS

APPLICATIONENGINEERING PAGE 5 AE.I3

HOT WATER CONTROL SYSTEM

METHODS OF CONTROL
Any heating system is designed for optimum conditions of outside temperature, indoor temperature, wind velocity and building construction. At conditions less than optimum, controls will be required to maintain desired room and system temperatures. The heating output of a unit may be controlled or more of the following methods: MODULATING VATER by one WATER TEMPERATURE - This can be done for an entire system, zone, or heating unit with a Powers Mastrol System. See figure 4, RESETTING For the entire system or zone, an outdoor thermostat resets the supply water temperafure according rc the chart shown in figure 3. Control is maintained because the heat outpui of the various heat exchange units more nearly approximates the load. For the heating unit itself, a three-way water mix valve provides a variable water temperature by mixing supply water with system return water. See figure 4.

FLOV - This is done by varying the amount of water supplied by a two-way throtSee tling valve or a three-way water mix valve. figures I and 2.

TWO-WAY THROTTLIXG VALVE

THREE.WAY M I X I N GV A L V E

HEATING UNIT

I FIGURE

FIGURE 2
WATER TEMPERATURE RESET AT OESIGNTEMPERATURE OF -'OF

FACE AND BYPASS CONTROL - This is for water to air coils. Heat transfer to the air stream, is proportional to che amount of air padsing through the coil face. This is controlled by an automatic face-bypass damper. A conuol valve is employed to stoP water flow after the face damper is fully closed. CONTROL-Variation COIL WATER TEMPERATURE of coil water temperature can be obtained by adding a secondary pump in the coil circuit. Constant flow is maintained through coil. A three-way .-lyater mix controls coil water temperature by mixing hot vater as required.

o_

u 250
l

ffzm . U
I F

. 2 2 0sYs' E M

ff 150
F

\
I

.
I I f

> 100

OUTSIDE TEMP.

2oo'' J',1.,,

I , \

-10010m304050s
oursrDE TEMPERtruae (or)

3 FIGURE

REMOTE BULB THERM.

SUBMASTER THERMOSTAT

-100 To 650 OUTSIDE AIR

PUMP CUTOUT SET FOR 7OOO.A. BREAK @15 PSI MAKE @ 14 PSI

FLOWRITE MIXIMG VALVE

HOT WATER BOILER

RETURN 1 FIGURE

APPLICATION ENGINEERING PAGE 6 AE-I3

THE POWERS REGULATOR COIIPANY

COIL OF }VATER SELECTION

x
l F @ I

2?OF INTERING

WATER

L
c o

The heat output of a water to air coil is not linearly related to flow. As the water flow is reduced, a greater temperature drop of the water occurs, maintaining a Figure 5 shows the high output of heat transfer. typical heat capacity of. a coil vs. flow. If the coil is designed for a large water temperature becomes more drop, the output flow characteristic See figure 6. For example, when water flow linear. to a 20F drop coil is reduced from L00% to 50%, there is only a 15% reduction in heat output, while with a 50F drop coil, the reduction is 35% in outPut.

o
F

=
L

o
F

E c

(.)
lo '20 40 70 30 50 60 PERCENTOF FULL FLOW eo 90 roo

5 FIGURE

We recommend coils with design s'ater temperature This coil requires a smaller drops exceeding 40F. flow of water to give the same heat output as a low Consequently, smaller pump temperature drop coil. andpipes are required, and pumping costs are lowered. The air temperature rise for a coil should be limited - 50F for good control. If a rise of 80F is .o 19 A premay be provided. needed, two or more coils heat system of outside air is shown in figure 7 using This system is limited since the first two coils. coil must be sized to prevent possible freezing in the This means a 50F extreme temperatures of say -10F. rise. In mild weather, say 30F, the discharge would be l0 + 50 = 80F, causing overheating. Ve recommend the system shown in figure 8 which employs a face-bypass control of the preheat coil. The outside thermostat will open coil valve at temperatures below 40F, while the discharge thermostat will position the face-bypass to maintain 55F for necessary ventilation Further reheating is added in the air handcooling. ling unit or zone ducts to satisfy room conditions. A freeze detection thermostat with coiled bulb is recommended on leaving side of heating coil to insure fan and outside damper shut-down in case of svstem failure,

F. f 0F f

o
F lrl

bR

% FLow 6 FIGURE

DIRECT ACTING REMOTE

DIRECT ACTING REMOTE BULB THERMOSTAT

CONTROL VALVE

ELECTRO-PNEUMAT IC VA LVE (WIRE TO FAN MOTOR}

FREEZE = DETECTTON I . .I T HERMOSTAT

(WIRE TO FAN STARTER)

ELECTROPNEUMATIC VALVE (WIRETO FAN MOTOR}

FREEZE C TS IO NT .D HE ET RE M O TA

FIGURE 7

FIGURE 8

LTHWSYSTEMS

APPLICATION ENGINEERING AE.I3 PAGE7 Once the design pressure drop and GPM are known, select the proper size valve from valve tables. Control valves for single pipe systems with diverting fittings should be the same as the pipe size. Since these systems are designed specifically with low pressure drop diverting fittings, any additional pressure drop at the control valve will affect system capacity.

CONTROL VALVE SELECTION

There arehotwater control valves for throttlhg, mixing, or diverting. For besr conrrol, select the valve for: 1. Use 2. Size 3. Flow Characteristic The valve should meet system static pressure, differential pressure, and temperature requirements for best service and long life. The valve must be sized with a reasonable pressrue &op so that water flow is determined ar rhe valve. If this is not done, pressure drop across rhe valve increases on valve closure. This causes a corresponding increase io water velocity through the valve (pressure &op varies as the square of warer velocity) hence, little water volume change until the valve actually closes. Figure p shows flow-lifr curves for a linear valve with various perceotages of design pressure drop. Note the improved characterisric as pressure drop approaches 100% of system pressure drop at full flow.

For more information on valve sizing, see Powers Form AE-l "A p p I i c a t i o n and SizingFlowrite Valves". There are three basic flow characteristics that can be designed into a valve. The type of acrion desired determines the valve choice for a particular control appliciation. See figure 10.

100

100 = o

J lt

bR

=
ll

9
FOR LINEAR VALVES

ts

% L|Fr
IO FIGURE

1. The srnall

quick

opening

valve

gives

F I G U R9 E Minimum pressure drops recommendedare: 1. Withaninletpressure less than 20 psig -&op of 5 psi.

lift and is used primarily control applications.

large flow with in two-position

2. In the linear valve, the opening and flow are related in direct proportion.

pressure
3. For the equal percentage valve each equal increment of opening increases the flow by an equal percentage over the previous value.

2. Vith an inlet pressure gre^ter than 20 psig -pressure drop equal to 25% of inler pressure, but not over 15 psi. 3. In sizing water mix valves, the pressure drop is the difference between the lower of the inlet oressures and the outlet pressure,

The equal percentage valve offers the best conrol since its characteristic combined with the coil characteristic gives coil output which is nearly linear with respect to valve lift. See figure 11.

_j
APPLICATION ENGINEERING

THE POWERS REGULATOR COMPANY

AE.I3

P A G E8

VALVE
CHARACTERISTIC

VALVE-COIL CHARACTERISTIC

l F

CHARrcTERISTIC
GPM

o
CONTROL OCCURS OVER ENTIRE RANGE

f, F

CLOSED

POStTtON F I G U RIE I

OPEN

CLOSED

POSITION

OPEN

SUPPLY

CHARACTERISTICS ul E

Li
D I F F E R E N T I A LP R E S S U R E REGULATOR

l o an ul

tr

0-

FLOW FIGURE 12

RETURN
15 FIGURE

RETURN

THE EXAMPLES 1 3T H R O U G H 1 5E M P L O Y A V.PORT O RD O U B L E S E A TV A L V E .

PRESSURE CONTROL
CONTROL VALVE Figure 12 illustrates a sloping pump characteristic D I F F E R E N T I A L curve- Without pressure control of the system, pressure PRESSURE will rise when control valves throttle water flow. This REGULATOR ttA" ttBtt causes a shift of system curve from and to increases the pressure drop across the valves -atfecting control adversely. SUPPLY PUMP FIGURE I3 Itisdesirable to maintain the system pressureconstant, and most pressure variation is caused by water flow change. A "bypass" around the pump or piping sysrem can be used. [. A pressure bypass can be used around the pump, providing the pump chosen .has a steep "head" curve. See figure 13.

limiting

To prevent motor overload, caution should be taken in the flow when the valve is full open.

CONTROL VALVE

2. Apressure reducing valve is recommended when the See fijure 14. pump curve is "flat". l. A system bypass valve can be employed at the end of a system or zone. Care should be taken in sizirg supply and retum main to insure adequate This can apply to either "flar" pressure control. or "steep" head pump curves. See figure 15.

FIGURE l,f

LTHWSYSTEMS

APPLICATION ENGINEERING AE.I3 PAGE 9

CIRCUITS AND PUMPS ZONING- USEOF SECONDARY

ZONESUPPLY ZONE RETURN ZONE PUMP Z O N EM I X I N G VALVE

3
ZONE BYPASS LOOP BALANCING

cocK

Y SUPPLY HOT WATERSOURCE

+>--\

P R I M A R YR E T U R N --<P R I M A R YP U M P

FIGURE I6 (zone circuits) are Primary and secondary circuits water is distributed a single from primarily used where point to several buildings, or in large buildings which require zoning. Figure 16 shows a suggested method of piping this system. Note that: 1. The zone system is taken off from a bypass loop (l-2-)-4) which is connected between the primary supply and retqrn mains. 2. The zone take-off tees.(2 and 3) are as close together as possible to equalize the pressures from This minimizes the effect the primary circuit. these pressures will have on operation. 3. The total rate pass loop plus how much water The balancing of flow from 1 to 4 through the bythe zone is constant regardless of is diverted through the zone circuit. cock allows enough water to pass

water temperature. This temperagure is conaolled by the zone mixing valve which mixes hot supply water wirh zone return water. 6. The primary circuit flow is independent of zone Since flow through each zone bycircuit flows. pass (from point one to point four) is constant, the sum of these is also constant. Therefore, the flow in the primary circuit is always constanr as long as the primary pump is running. This is a very desirable feature.

AIR VENTING
Air and gasses enter a hot water system (1) during filling and makeup, (2) by chemical action, and (3) by automatic air vents located where the system is at sub-atmospheric pressure. Trapped air can reduce or stop water flow, and can cause reduced heat output and possible freeze-up. Air collects at high points and separates from water at To remove air the highest and slowest movhg point. from a hot water system: 1. Use a dip tube or similar device at boiler.

to satisfy the maximum zone design load. 4. At full load, all of the zone water goes from point two through the zone circuit and back to point three. None goes directly from two to three. 5. Flow through the zone circuit depends solely upon the operation of the zone pump. Changes in heating demands are met by a changing zone supply

APPLICATIONENGINEERING

(continued) AIR VENTING

2. Vent air through automatic air vent placed at high Vent system at least twice points of system. during heating season. l. If system is subject to a vacuum, do not use auto' matic air vents. Particularly check a system with compression tank on supply side of pump. 2. Proper venting and balancing of the system. 3. Continuous pump circulation temperature drops below 40F. when outdoor

A pump with starters that automatically power failure.

reset after

PROTECTION COILFREEZE
Hot water'coils in sub-freezing air streams will freeze if water flow is restricted, stopped, or somehow apTo prevent freeze' proaches freezing temperatures. design and precaucions: control up, provide these 1. Automatic closingof outside air damper and opening of coil valve on fan shutdown, or when the coil water temperatlue or coil discharge air temperature approaches 32F.

In severe applications, provide face-bypass control Control valve in addition to coil valve control. closes after bypass opens, except an outside air thermostat causes valve to remain open when outside air temperatrue is below freezing, To prevent overheating when coil valve is opeo, reset water Refer temperature according to zone temperature. to figure 8 section II.

6.

Use of a secondary coil circuit and separate coil pump for contiouous flow through large coils.

F O R F U R T H E R I N F O R M A T I O N C O N T A C T Y O U R N E A R E S TP O W E R SR E P R E S E N T A T I V E

. SKllKIE, IHEPOWERS rrult0ls REGUTATI|R CtlMPA}IY

DIFFERENTIAT PRESSURE CONTROT

Applicotion Eng. Form

AE-25
Augusi,l97l

POWERS
INTRODUCTION
Hydronic systems should be designed for minimum pressure variations to assure control stability and system balance. Primary consideration should be given to: 1. Provide minimum required flow thru refrigeration machines to avoid danger of freeze-up, reduce the rate of tube fouling and scale buildup, and maintain a more constant load on machine. 2. Minimize pressure drop variation valve to assure adequate reduction disc positions and minimize high for stable control and longer valve across control in flow for all fluid velocity life. DIFFERENTIAL PRESSURE CONTROL METHODS Vorioble Speed Pumping Variable speed pumping has the advantage of reducing pump'horsepower (operating costs) as flow is decreased. The design pump head can also be reduced if necessary. Pump speed is controlled by a differential pressure controller sensing pressure drop across a rypical coil and valve (figure 1). As the valves close, pressure drop across the supply and return mains increase. DP-1 detects this and slows down the pump sufficiently to reduce pressure differential to its set point value. Pump speed is reduced through a fluid coupling (actuated by damper motor) or electrical transducer (135 ohm proportionalpressure controller). Vhen used on chilled water applications care should be taken to keep the pump from going below suggested chiller minimum flow rate.

3. Optimizing pump power requiremenrs ro reduce operating costs. Maximum flow is often required for cooling mode or only at maximum load. 4. Differential pressure adjustment to match sysrem requirements. This is particularly important on systems designed for expansion (having oversized pumps).

System design considerations for minimizing variations in pressure may be achieved through the use of (1.) 3-way valve controlled coils (2.) uncontrolled coils (unit heaters, etc.) (3.) face bypass damper (4.) primary-secondary pumping coils controlled (J.) hot watertemperature reset (6.) flat head pumps (7.) differential pressure control.

Pressure Reducing Volve A valve placed at the pump discharge and controlled by DP-l as shown in figure 2 will give essentially the same control as variable speed pumping. When coil valves close, the pressure differential across them increases and DP-1 will close choke valve V-1 which absorbs the increased system pressure drop. The valve must be sized for at least 25% of the system drop and capable of withstanding high pressure differentials. The VF 597DS Flowrite valve is suit-

CONTROLLER

F I G U R E I - V A R I A B L E S P E E D P U M PC O N T R O L

F I G U R E2 - P R E S S U R E REDUCING VALVE CONTROL

P O W E RR SE G U L A T O C S K 0 K l E ,l L L l N 0 l S 6 0 0 7 5 RO M P A NY GENERAL A N DF A C T 0 R Y : 0FFICES
O F F I C E S I N P R I N C I P A LC I T I E S , U . S . A . A N D C A N A D A S A L E SA N D E N G I N E E R I N G

Applicotion Eng. Form

RSREGULATOR COMPANY
AE-25 Pose 2

DIFFERENTIAL CONTROL METHODS

SYPASS VALVE

70

60 FEET.. HEAD 40

30

BYPASS FIGURE 3A - PUMP CONTROL

20

l0

Pressure Reducing Volve (Cont'd.) See application drawing able for this application. A-2632" If flow can be reduced below 25% of design, two parallel piped valves should be operated in seq

38 FIGURE W I T HP U M PB Y P A S S CONTROL CURVES ANDPUMP SYSTEM VALVES EO C O N T R O L H I F TO F P R E S S U RT I L L U S T R A T I NS G

Pump Byposs Control Pump bypass control is the least desirable of all differential pressure conuol methods. It does not reduce pump horsepower nor can differential pressure set point be adjusted more than !5%. Figtres 3A and 38 show what happens when DP-l and V-l maintain Closing control valves constant pump differential. (Y-2) at the cooling coils result in decreased system flow and increased pump differential pressure. For example at75%flow thepump head has increased from 75 to 80 ft. DP-l senses the increased pump differential and opens bypass valve V-1 far enough to let pump differential return to set point (75 tt.). Setpoint differential across the pump only occurs at full flow. Therefore, regardless of flow thru cooling coils, DP-l and V-1 maintain constant pump discharge. CONTROL VALVE PRESPUMP DIFFERENTIAL= SURE DROP +HEAT EXCHANGER PRESSURE DROP + COIL PRESSURE + PIPING PRESSURE DROP For the system shown in figure 3A, as coil valves

close, pump head remains constant and the pressure decreases in coils, chiller, and piping. Therefore, the control valve differential will rise.

A second type of pump bypass control is shown in figore 4. DP-l and V-l attempt to maintain a constant pressure drop across the control valves and cooling coils. As control valves begin to.close the pressure drop from A to B increases and DP-l opens bypass valve V-1.

how a decrease in DP-l set Figure 5 illustrates point or poor selection of sensing point in figure 4 could cause pump to overload and/or cavitate. To achieve correct pressure drop at 75% flow, the pump head must be reduced from 75 ft. to 52 ft. which is beyond the pump cut-off point.

The bypass valve should be sized for pump head (L00% drop) at design flow. Maximum adjustability is obtained when using a steep crrve Pump.

DI F F E RENTIA L _ WATER PRESSURE CONTROLS SYSTEMS

A p p l i c o t i o nE n g . F o r m AE-25 Pose 3

BYPASS

N.C

'r-r

CONTROL

I
I
FIGURE4-PUMPBYPASS

COOLING cotL

% DEsIGN FLOW

F I G U R E 5 - P U M PA N D S Y S T E M CURVES CONTROL W I T H P U M PB Y P A S S P U M PO V E R L O A D ILLUSTRATING

System Byposs Control The system shown in figure 64' and 6B maintains constant flow in part of the hydronic circuit. The system sections having constant flow will maintain constant pressure drop regardless of the flow thru

chilled water coils. Differential pressure is being sensed across two points where full flow occurs, therefore pump flow rate, discharge head, and power consumption will remain constant regardless of flow thru the cooling coils.

PUMP HEAD REMAINs

60

;;;;50 40
cooLtilG cotL

30
AYPASSVALVE MAINTAINS M I N I M U MO F 2 0 F T . S Y 5 T E M P I P I N GD R O P

70

t0 0 r00

FIGURE 6A SYSTEM B Y P A S S- V - I L O C A T E DT O M A I N T A I NC O N s T A N T2 0 F T , I N C I R C U I TA B C D E

F I G U R E5 8 BYPASS VALVE SYSTEM

Applicotion Eng. Form

DIFFERENTIAL - WATER SYSTEMS CONTROLS PRESSURE

AE-25

4 Pose

DIF FERENTIAL CONTROL METHODS BypossControl(Cont'd.) System

The system bypass valve V-l should be located as far down stream as possible. This will keep a larger part of the system pressure drop constant and will mean less change in pressure drop actoss the conBypass trol valves as flow thru the coils'varies. valve V-l should be sized for a pressure drop at full system flow egral to pump head minus drop in bypass loop piping. Moving the bypass to the end of the supply main (figure 7) will give a more uniform drop across V-2. Vhen all coil control valves are fully closed design flow will go thru the full length of the supply main and thru bypass figure 6. The supply and return mains must be run full size their entire length. Such mains often rule out this method of differential pressure control, because of their high cost. Three-Woy Volves A three-way mixing valve at each coil as in figure 8 eliminates need for a differential pressure control. Almost constant pump flow and head is maintained regardless of control valve position. Vhen all valves are in mid position, half the water will flow thru the coils and half thru the coil bypass. The pressure drop across the coils will be one-fourth of what it was at full flow, however pressure drop across the coils is usually a relatively small part of the total system drop and has negligible effect on control valve pressure drop. Total flow will remain almost constant and therefore pressure drop thru mains and chiller will not change significantly. Mixing valves represent an excellent method of differential pressure control but extra cost is incurred from additional valve piping and slightly more expensive control valve. As an economic measure smaller valves located near the pump may be of the two-way type. Three-way valves farther from the pump maintain full flow thru most of the system.

FIGURE 7 - E N DO F M A I NB Y P A S S

BYPASS CONTROL FIGURE 8 - THREE.WAY

C o n t r o l d e u i c e s a r e c o m b i n e d , o m a k e d s y s t e m . E a c b c o n t r o l d e u i c e i s m e c b a n i c a l i n n d r u ? ea n d d l l m e c b a n i c a l components must be regulatly seruiced to optimize tbeir operation, All Pouets brancb ollices ollet seruice conttacts thdt uill insure yoa contintoas, trouble-lree systen perlotndnce, For Fartber Inlormation Contact Your Nearest Powers Retresentdtiue

TfiIPOWERS
\n 3;;;::li::rffTo"n'
PRINTED IN U.S.A.

Y t
,

i
CONTROL AND
A p p l i c o r i o nB u l l e t i n

PROTECTION O F P R E H E A TC O I L S

AB-184
August,1970

POWERS
INTRODUCTION This aPplication bulletin lists and erplain's recommendationsfor ccintrol and prorection of sream and water preheat coils. The control of preheat coils is critical because the system mdst be designed to sufficieotly hear the incoming air to prevent coil freeze rF. Yet, the system must also provide control ro prevenr overheating rhe conditioned area. This problem and others often found in preheat coil control are disculsed in this bulletin.

STEAM PREHEAT COIL Simple System Simple control of a steam coil can be accomplished with a temperature cootroller and valve control of the coil as shown in figure 1.

-i lr
tl

STEAM+

Note: For 100% O.A. Applications it is re commended tbat th ermos tat sapply be connected to EP aalue utben freeze detection tbetmostat is usid, Tbis minimizes nu.isance tripping,

.altJsPE+

FAf.l STARTER

Vhen the unit fan starts, EP-l is energized to pass air pressure to M-l whictr opens outside air damper. Valve V-l is throttled by temperature controller T-1 to maintain 55F remperarure of air stream leaving the coil. Operation of freeze detection thetmostat (T-2) is explained in Preheat Coil Accessories Section. Since both coil and valve must be sized latge enough to heat the entering air from lowest design outside temperature (which might be minus 20F), the valve is practically closed with outside air temperature in 20 to 30F range. Wirh rhe valve near closed, the system is likely to cycle. The condensate from this small cyclic cooled below freezing by the cold outdoor air. flow of steam could readily be

Outside Air Thermostat for Protection One method to prevent coil freezeup is to provide full steam flow through the coil whenever outside air is at below freezing temperature. This is done by employing an outside air thermostar (T-3) as shown in figure 2.

60076 P O W E RR SE G U L A T OC R O I , I P A N-Y G E N E R A L : K O K I E I, L L I N O I S 0 F F I C E SA N D F A C T O R YS A N D C A N A D A P R I N C I P A L U . S . A . C I T I E S , E N G I N E E R I O N F G F I C E I S N SALES AND

A p p l i c o t i o nB u l l e t i n

RSREGULATOR COMPANY
AB-184 Pose2

-l
-l I I

I
For L00% O.A. Applications it is te co mmende d t bat t hermo s t at sapply be connected to EP ualue uben freeze detection tbemostctt is ased. Tbis minimizes nuisance tipping.

T-2
STM.

OUTSIDE AIR

55F

WIRE TO FAI\I STARTER

I
L )

EP-I With outside air warmer than 15F, valve V-1 is throttled by temperature controller T-1 to maintain 55F temperature of air stream leaving the coiL Vhen outside air temperature drops below 35F, positive acting thermostat T-l opens V-l to supply full capacity of preheat coil. T-2 is freeze detection thermostat, Careful sizing of the preheat coil and valve is very important. The remperature rise should not exceed lOF when entering air is J5F, otherwise overheating of thi space is likely to occur. If more than a 10F rise is needed, then multiple coils should be used as shown in next figue' Frc. z Two Coils These Sequenced with Outside Air Temperature of the air to the conditioned area as shown in figure 3,

can be used to reduce

overheating

- -- -r !-; -:--1T-l p,i ! s-tg

T-2

l{irc

to {rn

T-Z controls V-l and V-2 in sequence to maintain desired discharge air temperature. When outside air temperature fails below 40F, positive acting ther'mostat T-i opens V-l on first preheat coil. T-J is a freeze detection rhermostar.

FIG.3

A p p l i c o t i o nB u l l e t i n

CONTROL A N D P R O T E C T I OO NF P R E H E A T COILS
AB-lg4 poge 3

Face and Bypass Coil Control For best preheat coil conuol,. Powers recommendsface and bypass dampers conrolled by a discharge thetmostar as shown in figure 4.

o.A. 35F

..+

FAgE

6uo

1---

Face and bypass dampers ate controlled by thermostat T-l whose remote bulb is in the discharge of the dampers. As the discharge remperature increases, T-l gradually increases the branch pressure to fully close the face damper and fully open the bypass at l0 psig, and with further tise closes valve at 1l psig. On a decrease in discharge temperature, T-1 gradually reduces btanch pressure to allovr more air to flow through coil to wide open position at 3 psig, Bypass, which is interconnected, is closed at 3 psig. Outside air thermostat T-2 opens V-l upon dtop in fresh air below 40F, regardless of T-1 pressure. T-3 is freeze detection thermostat. FIG. 4

Minimum Fresh Air Preheat Coil

With mixed air systems, the racio of outside air to re$rn air is varied to maintain the desired duct temperature. A minimum fresh air damper is included to provide a minimum amount of fresh air for ventilation whenever the fan is energized. A preheat coil is included to heat the minimum fresh air as shown in figure 5. System is often designed so 25% of the outside air flows through the coil when both fresh air dampers are full open.
WIRETO FAN STARTER

T-t D.A, 6 PS|/!F

4)_

1 I I

F|
Pst/.Ff

I
I

I
_l

Note: Prebeat Coil must baue no rnore than a jOF Temp. rise or T-7 must be sequenced uitb mixed air controller,

L_

--r-

R.A.

G.N.o I

Vhen the circulating fan is turned on, EP-l, is energized to pass 15 psig supply pressure to open minimum fresh air damper and to T-2 which positions maximum fresh air and return air dampers to maintain 55F mixed ait temperature. Vhen outdoor tempetature is below 35F, T-1 opens V-l.to prevent freezeup of the preheat coil. As outdoor tempetature rises above 3JF, V-l is closed. T-l is freeze detection thermostat. FIG.5

A p p l i c o t i o nB u l l e t i n

REGULATOR COMPANY
AB-184 P o g e4

HOT VATER PREHEAT COIL Since constant flow through a coil is necessary to prevent freezeup, a three-s'ay mixing valve and a circulating pump are required for each hot water preheat coil. The coil pump is required in addition to the main circulating pump as shown in figure 6.

v-l

c-l
I

H . W "S U P . H.W.RET.

OUTSIOE AIR W I R ET O FAN STARTER ,,//

-qrf
-

t-y

I -J

EP-I

Temperature controller T-1 throttles three-way mixing valve V-l to control temperature of air leaving the coil, The flow of water through the coil is constant and temperature of rhe water is varied to satisfy the heating demand. T-2 is freeze detection thermostat. FIG.6

PREHEAT COIL VITH ANTIFREEZE SOLUTION Coil freezeupcan be preventedby using an ^ntifleeze solution such as ethylene glycol (Prestone) for the heating medium. A heat exchangerheats the glycol solution as shown in figure 7.

-t
r I

-O U T S I D E
AIR

W I R ET O F A N STARTER _/,,

17

.t-t

--

I I
I

STEAM

HEAT EXCHANGER PUMP TRAP

T-1 controls temperature of the air stream leaving the coil by varying the stream to the heat exchanger through V-l. Add freeze detection thermostat if downstream coils must be protected. FIG,7

A p p l i c o t i o nB u l l e t i n

CONTROL A N D P R O T E C T I OO NF P R E H E A T COILS
AB-184 Pose5

PREHEAT COIL ACCESSORIES Freeze Detection Thermosta! A f.reeze detection thermostat.is a necessary safery device on preheat coils. The freeze detection thermostat is locared so as to sense the lowest temperature of air leaving the coil and is wired to stop air circulating fan and close outside air damper. It may also be used to sound an alarm or flash a lighc when freezeup conditions are reached. This will enable maintenance personnel to take corrective action. Steam Trap The steam rrap musr be located at least 12 inches below the coil to provide a head of water to operate trap and must be sized large enough to handle the condensate. See figure 8.

r-VACUUM BREAKER

TRAP

CONDENSATE I RETURN V
FIG. 8

Vacuum Breaker An induced vacuum in a steam coil can prevent drainage of condensate which could risult in coil freezeup. Induced vacuum occurs when valve closes and steam in the coil cools and condenses. Vacuum breakers must be included to allow air flow into the coil to relieve any vacuum and allow the condensate to drain.

AIR STRATIFICATION Air suatification is air flowing through the duct in temperature layers instead of as a constant temperature sueam. Stratificarion is a serious problem and should be reduced as muih as possible since it results in erroneous temperature measurement.

colL
FIN

colL TUBE
AIR STREAVI r COLD LAYER

FIG.9

The air immediately leaving the coil is stratified since the air which flows directly over the tubes is much hotter This phenomenon has been know to cause false alarms rhan the air which flows between the tubes (see figure !). by the freeze detection thermosrat responding to the small, cold air layer. This can be remedied by moving the rhermosrat a sufficienr distance from the coil where the air stream is of a more uniform mixture.

A p p l i c o t i o nB u l l e r i n

A N D P R O T E C T I OO CONTROL NF P R E H E A T COILS
AB-184 P o s e6

Air stratification can often be reduced sufficiently by the proper design of an air conditioning system. In some cases, baffles may have to be added to mix the air stream. One method to reduce sratificaition is to position the coil so rhe tubes are perpendicular to the axis of the damper blades. See figure 10.

DAMPER

BLADES

COLD AIR STREAM DAMPER WITH VERTICAL BLADE - TUBES

INCORRECT _ COIL TUBES PARALLEL TO DAMPER BLADES

CORRECT - COIL TUBES PERPENDICULAR TO DAMPER BLADES

Ftc. 10

In face and bypass coil conuol, the bypass air should flow above the coil so when the sueams join together, the bypass air which is colder and therefore heavier, will fall into the warmer stream and cause mixing (see figure 11).
-INCORRECTSTRATIFICATTON

-CORRECTBETTER MIXING

OUTSIDE AIR

WARM LAYER

- COLD

LAYER FIG. 11-FACE AND BYPASS COIL SYSTEM

In mixed air systems, the outside air which is colder above the return air as shown in figure 12.
-INCORRECTSTRATIFICATION

and therefore

heavier,

should

be introduced

to the system

-CORRECTBETTER MIXING

RETURN AIR (WARM)+

WARM LAYR COLD

LAY

ouTslDE AtR (COLD)+

OUTSIDE AIR (COLD)+

RETURN AtR (WARM!-

ARM AIR

FIG.I2-MIXED AIR SYSTEM

For Furtber

Inlormation

Contdct

Your Nearest

Pouers

Reqresentttiue

Company P o w e r sR e g u l a t o r S k o k i e .l l l i n o i s 6 0 0 7 6

POWERS
PRINTEO IN U.S.A.