Hydraulic Separation

Moving Beyond Priamry / Secondary Piping...

load! #1

load! #2

load! #3

primary! circulator

presented by: John Siegenthaler, P.E. Appropriate Designs Holland Patent, NY www.hydronicpros.com
Copyright 2012, J. Siegenthaler, all rights reserved. The contents of this le shall not be copied or transmitted in any form without written permission of the author. All diagrams shown in this le on conceptual and not intended as fully detailed installation drawings. No warranty is made as the the suitability of any drawings or data for a particular application.

parallel! primary! circuit

crossover! bridge

closely! spaced! tees balancing valves

Hydraulic Separation
Its not just about hydraulic separators...
Todays topics...
What is common piping? Whats the relationship b/w common piping & hydraulic separation? It doesnt have to be perfect What is the ideal hydronic header? Achieving hydraulic separation using low resistance heat souce Achieving hydraulic separation using closely spaced tees Achieving hydraulic separation using a buffer tank Achieving hydraulic separation using a hydraulic separator Divide & Conquer Examples of systems using hydraulic separation

What is COMMON PIPING? Its the piping components shared by two or more circuits.
common piping

circulator 2 circuit 2 circuit 1 circulator 1

The degree to which two or more operating circulators interact with each other depends on the head loss of the common piping. The lower the head loss of the common piping the less the circulators will interfere with each other.

When the head loss of the common piping is very low, there is hydraulic separation between the circuits.

When the head loss of the common piping is very low, there is hydraulic separation between the circuits.
Very little head loss occurs! in this portion of the circuits.

circulator 2 circuit 2 circuit 1 circulator 1

common piping

Very little head loss occurs! in this portion of the circuits.

circulator 2 circuit 2 circuit 1 circulator 1

common piping

circuit 1 head loss curve including ! common piping (both circulators on) circuit 1 head loss curve including ! common piping (1 circulator on)

Assume that circulator 1 is operating, but that circulator 2 is off. The lower (blue) system head loss curve in gure 2 applies to this situation. Next, assume circulator 2 is turned on, and circulator 1 continues to operate. The ow rate through the common piping increases, and so does the head loss across it. However, because of its spacious geometry, the increase in head loss across the common piping will be very slight. The system head loss curve that is now seen by circulator 1 has very slightly steepened. It is the upper, (green) curve shown in gure 2. The operating point of circuit 1 has moved very slightly to the left, and as a result, the ow rate through circuit 1 has decreased very slightly.

head loss (feet of head)

pump curve! (circulator 1)

very small change in! head loss across! common piping! when both circuits are on

0 ow rate
VERY small decrease in! circuit 1 ow rate! when circuit 2 is on ow rate in circuit 1 when BOTH circuits! are operating ow rate in circuit 1 when it is the only circuit operating

Almost Perfect Is Good Enough:

Very little head loss occurs! in this portion of the circuits.

circulator 2 circuit 2 circuit 1 circulator 1

common piping

Imagine a hypothetical situation in which the head loss across the common piping was zero, even with both circuits operating. Because NO head loss occurs across the common piping, it would be impossible for either circulator to inuence the other circulator.

This would be perfect hydraulic separation.

Fortunately, perfect hydraulic separation is not required to ensure that the ow rates through independently operated circuits remain reasonably stable.

Common piping with high ow resistance is NOT good:

common piping (with HIGH FLOW RESISTANCE)

circulator 2 circuit 2 circuit 1 circulator 1

The higher the ow resistance of the common piping, the more each circulator will inuence ow in the other circuit (e.g. the lower the hydraulic separation of the circuits.

High ow resistance common piping - something to avoid

" D % !P = ( Head ) $ ' # 144 &
head added (feet)

6 4 2 0

15
4 psi P at 0 ow

10 5 0 0 2 4 6 8 ow rate (gpm) 10

small circulator P=22 psi large circulator

P produced" by circulator" @ 0 ow = 4 psi ON ON P = 5 psi

pump curve! for small circulator

P=17psi

backseated! ow check

P= 10 psi

larger circulator

ON

ON

P=12 psi P= 5 psi P=13 psi P=16 psi

smaller circulator

P=17 psi
no ow

common piping and ! heat source have! HIGH FLOW RESISTANCE

common piping and ! heat source have! high ow resistance

Multi-zone system - using zone circulators

other zone circuits

zone circulators with spring-loaded check valves compact mod/con boiler purging! valves low ow resistance headers

high ow resistance of compact boiler creates ow bottleneck

other zone circuits

zone circulators with spring-loaded check valves

OK
low ow resistance heat source

purging! valves

NOT OK

Always keep the ow resistance of the common piping as low as possible. This provides hydraulic separation between circulators. Always provide a check valve on each zone circuit.

Divide & Conquer:

Hydraulic separation allows designers to think of an overall system as a collection of independent (hydraulically isolated) circuits.
circulator 2 circuit 2 circulator 2 circuit 2 circuit 1 common! piping circulator 1 common! piping

circuit 1 common! piping circulator 1

From the standpoint of hydraulics, each circuit can be designed as if its a stand-along circuit. More on this later...

Primary / Secondary piping - where it all began...

secondary circuit

Primary / secondary piping, using closely spaced tees, is now well known and often used in North America.

secondary! circuit load! #1

secondary! circuit load! #2

primary! circulator

Primary / secondary piping, is one way to achieve hydraulic separation between circulators.

primary! circuit! (series) load! #3 secondary! circuit

closely! spaced! tees! (typical)

But primary / secondary piping is not the ONLY way to create hydraulic separation...

Series and parallel primary/secondary systems

secondary circuit

SERIES primary loop

secondary! circuit load! #1 secondary! circuit load! #2

PARALLEL primary loop

load! #1 load! #2 load! #3

primary! circulator

primary! circulator
parallel! primary! circuit

crossover! bridge

primary! circuit! (series) load! #3 secondary! circuit

closely! spaced! tees! (typical)

closely! spaced! tees balancing valves

Both series and parallel primary/secondary systems require a primary circulator. This adds to the installed cost of the system AND adds hundreds, even thousands of dollars in operating cost over a typical system life.

An example of primary loop circulator operating cost:

Consider a system that supplies 500,000 Btu/hr at design load. Flow in the primary loop is 50 gpm with a corresponding head loss of 15 feet (6.35 psi pressure drop). Assume a wet rotor circulator with wire-to-water efciency of 25 is used as the primary circulator. The input wattage to the circulator can be estimated as follows:

0.4344 f P 0.4344 50 6.35 W= = = 552 watts 0.25 0.25

Assuming this primary circulator runs for 3000 hours per year its rst year operating cost would be:

3000 hr 552 w 1kwhr $0.10 1st year cost = = $165.60 yr 1 1000 whr kwhr

An example of primary loop circulator operating cost:

Assuming electrical cost escalates at 4% per year the total operating cost over a 20-year design life is:

(1 + i ) N 1 (1 + 0.04 )20 1 = $165.60 = $4, 931 cT = c1 i 0.04

This, combined with eliminating the multi-hundred dollar installation cost of the primary circulator obviously results in signicant savings.

Question: What is the ideal header in a hydronic system? Answer: One that splits up the ow without creating head loss Think about a copper basketball with pipes sticking out of it in all directions.

very low head loss! inside header

Wouldnt this be pretty close to an ideal header???

So why dont we build headers like this??? Instead, we approximate the ideal header by making it short & fat

very low head loss! inside header

fat
Short / fat headers are GOOD! Long / skinny headers are BAD!

short

So whats EXACTLY is a short / fat header???

max (design) ow rate

fat short
select pipe size that yields a ow velocity no higher than 2 feet per second

Hydraulic separation achieved by low ow resistance heat source & short / fat headers.

very low ow resistance! common piping!

The low ow resistance heat source maintains low ow resistance of common piping

low ow resistance heat! source

size headers for max ow velocity of 2 ft/sec

The short / fat headers hydraulically separate the distribution circulators from each other.

Hydraulic separation achieved by closely spaced tees & short / high ow ! fat headers.
resistance boiler

The short / fat headers hydraulically separate the distribution circulators from each other. The closely spaced tees hydraulically separate the heat source from the header system.

closely spaced tees size headers for max ow velocity of 2 ft/sec very low ow resistance! common piping!

Hydraulic separation achieved by closely spaced tees & short / fat headers. ouside! The short & fat header and close
sensor multiple! boiler! controller

spacing between supply and return connections results in a low pressure drop between points A and B. Each load circuit is hydraulically separated from the others.

Header should be sized for max. ow velocity of 2 feet per second

air! vent

zone circulators! (w/ check valves)

Each circuit must include a check valve. The supply temperature sensor must be downstream of the point of hydraulic separation.

closely! space! tees

supply ! temperature! sensor

The header can be vertical (as shown) or horizontal.

B
drain! valve

purge! valves "short/fat" header

Hydraulic separation achieved by buffer tank (piped as shown ) & short / fat headers.
high ow resistance boiler

boiler! circulator

The short / fat headers hydraulically separate the distribution circulators from each other.
size headers for max ow velocity of 2 ft/sec

The buffer tank hydraulically separate the heat source from the header system.

buffer! tank

very low ow resistance! common piping!

Hydraulic separation achieved by buffer tank

to / from other heating zones

wood gasication boiler

ThermoCon tank
VENT

chilled water air handlers

Hydraulic separation achieved by buffer tank

insulate all chilled water piping! to prevent condensation temperature! sensor chilled water ThermoCon tank
VENT

zoned chilled water cooling

cooling mode
reversing! valve

evaporator

condenser

purging! valves earth loop circuits

Only tanks with sprayed foam insulation should be used for chilled water storage.

Hydraulic Separation in Micro-load systems:

The small insulated tank provides: Thermal buffering Hydraulic separation Air separation and collection Sediment separation and collection
TRV TRV

outdoor! temperatue! sensor

thermostatic! radiator valves! (TRV) on each! radiator

TRV

TRV

TRV TRV

variable speed! pressure-regulated! circulator

manifold! station

indirect water heater buffer tank, also serves as hydraulic separator,! air separator, dirt separator

Hydraulic separation achieved by hydraulic separator.

The hydraulic separator hydraulically separates the heat source from the header system.
high ow ! resistance boiler

The short / fat headers hydraulically separate the distribution circulators from each other.

hydraulic separator size headers for max ow velocity of 2 ft/sec very low ow resistance! common piping!

Whats going on inside a hydraulic separator?

diameter = 1"

air vent

area = A

air bubbles can rise faster than the downward water ow

ow velocity = 4 ft/sec ow rate = 6.5 gpm ow velocity = 0.44 ft/sec ow rate = 6.5 gpm

diameter = 3" area = 9A almost zero pressure drop b/w! upper and lower connections

dirt particle drop into lower bowl

drain valve

The low vertical velocity inside the separator produces minimal pressure drop top to bottom. Thus there is very little tendency to induce ow on the load side of the separator.

What does the coalescing media do inside a hydraulic separator?

air vent

air vent upper coalescing media encourages! air bubbles to form air bubbles "ride" up the vertical laments of the coalescing media - out of the active ow zone

"STANDARD"! hydraulic ! separator

HIGH PERFORMANCE! (air & dirt removal)! hydraulic separator

lower coalescing media encourages! dirt particle to drop! out of active ow zone

drain valve

drain valve

The coalescing media creates tiny vortices that cause gas molecules (mostly oxygen and nitrogen) to form microbubbles. The media also helps microbubble merge together and rise upward out of the active ow zone.

Why companies that offer air and dirt separators also offer hydraulic separators...
air vent air vent

air vent

air vent

high performance! (microbubble)! air separator

CUT

WELD

CUT

WELD

high performance! (low velocity zone)! dirt separator

drain valve

drain valve

drain valve

drain valve

High performance hydraulic separators provide three functions:

1. hydraulic separation 2. air separation 3. dirt separation

Hydraulic! Separator

boiler circuit

distribution system

heating! load(s)

air! separator distribution system boiler circuit closely! spaced! tees sediment! strainer heating! load(s)

As the ow rates of the boiler circuit and distribution system change there are three possible scenarios:
1. Flow in the distribution system is equal to the ow in the boiler circuit.

2. Flow in the distribution system is greater than ow in the boiler circuit.

3. Flow in the distribution system is less than ow in the boiler circuit.

Each case is governed by basic thermodynamic...

Case #1: Distribution ow equals boiler ow:

f1 T1
NOTE:

f2 T2
NOTE:

f1 = f3
(always!)

f2 = f 4
(always!)

T3

f3

f4

T4

In this case only:!

T1 = T2 T3 = T4

Very little mixing occurs because the ows are balanced.

Case #2: Distribution ow is greater than boiler ow:

f1 T1
NOTE:

f2 T2
NOTE:

The mixed temperature (T2) supplied to the distribution system can be calculated with:

f1 = f3
(always!)

f2 = f 4
(always!)

( f4 f1 ) T4 + ( f1 ) T1 T2 = f4
T4
Where: f4 = ow rate returning from distribution system (gpm) f1 = ow rate entering from boiler(s) (gpm) T4 = temperature of uid returning from distribution system (F) T1 = temperature of uid entering from boiler (F)

T3

f3

f4

Mixing occurs within the hydraulic separator.

Case #3: Distribution ow is less than boiler ow:

Heat output is temporarily higher than current system load. Heat is being injected faster than the load is removing heat.
f1 T1
NOTE: NOTE:

f2 T2

The temperature returning to the boiler (T3) can be calculated with:

f1 = f3
(always!)

f2 = f 4
(always!)

( f4 f1 ) T4 + ( f1 ) T1 T2 = f4
Where: T3 = temperature of uid returned to boiler(s) (F) f1 = ow rate entering from boiler(s) (gpm) f2, f4 = ow rate of distribution system (gpm) T1 = temperature of uid entering from boiler (F) T4 = temperature of uid returning from distribution system (F)

f3 T3

f4

T4

Mixing occurs within the hydraulic separator.

Sizing of Hydraulic Separators: Hydraulic separators must be properly sized to provide proper hydraulic, air, and dirt separation. Excessively high ow rates will impede these functions. The size of a hydraulic separator refers to the nominal piping size of the 4 side connections (not the diameter of the vertical barrel). The piping connecting to the distribution side of the Hydro Separator should be sized for a ow of 4 feet per second or less under maximum ow rate conditions.
union connections ange connections

Pipe size of hydraulic separator Max flow rate (GPM)

1.25 1.5

2.5

11

18

26

40

80

124

247

485

Typical European concepts for multiple mod/con installation:

Typical European concepts for multiple mod/con installation:

Boiler manifold with integral hydraulic separator (courtesy Sinus North America).

Form tting insulation is supplied with all manifolds. Flexible piping connects each boiler to low manifold. (Boilers have integral circulators and check valves.) Notice that two additional boilers can be added to the front side of lower manifold.

Here's what the real products look like

How about 8 mod/cons with integral hydraulic separator (courtesy Sinus North America).

Think of the output per unit of mechanical room oor area Each boiler can be independently serviced . Flexible piping connects each boiler to low manifold. (Boilers have integral circulators and check valves.)

Example of Hydro Separator Installation in New System: Magna Steel Corporation - Connecticut

Photos courtesy of Peter Gasperini - Northeast Radiant

Example of Hydro Separator Installation in Old System: Because hydraulic separators remove sediment fromsystems theyre ideal for applications where new boilers are retrot to old distribution systems.

Example of Hydro Separator Installation in Old System:

Because hydraulic separators remove sediment from systems theyre ideal for applications where new boilers are retrot to old distribution systems.

multiple! boiler! controller

outdoor! temperature! sensor

supply! temp.! sensor

hydraulic! separator

from existing system

sediment capture! and removal

A hydraulic separator is a great way to interface a new mod/con boiler to a older steam conversion system.

WHY?

existing cast-iron radiators (converted from steam) mod/con boiler! w/ compact heat exchanger vent

supply! temperature! sensor

ECM! pressure! regulated! circulator

hydraulic! separator existing piping

Dirt separation is especially important in older systems with iron components.

The will allow the ow rate in the earth loop to be different than the ow rate through the heat pump array - more on this later...

to / from! other heat pumps

zone! valve

heating mode

Hydraulic Separators will likely become a key component in multiple ground source heat pump applications.

reversing! valve

evaporator

variable-speed! pressure-regulated! circulator

balancing! valve

water-to-water! heat pump

geothermal manifolds hydro! separator

purging! valves earth loop circuits

purge

uid feeder

condenser

Hydraulic Separators will likely become a key component in multiple ground source heat pump applications.
heating mode
compressor

chilled water air handlers

reversing! valve

AB
evaporator condenser

A B 12D

A AB B

compressor

circulator! w/ check

reversing! valve

AB
evaporator condenser

A B 12D

A AB B

TXV

heating mode

compressor

circulator! w/ check

reversing! valve

3-way! diverter! valve

AB A B 12D

size all header piping for maximum ow velocity of 2 ft/sec to provide hydraulic separation

evaporator

condenser

A AB B

TXV

temperature! sensor geothermal manifolds hydro! separator chilled water buffer tank purging! valves earth loop circuits purge

variable-speed! pressure-regulated! circulator

xed speed! or! variable-speed! circulator

water-to-water! heat pump

3-way! diverter! valve

insulate all chilled water piping! to prevent condensation

TXV

insulate all chilled water piping! to prevent condensation

circulator! w/ check

heating mode

to / from other heating zones

temperature! sensor uid feeder! (optional)

variable-speed! pressure-regulated! circulator

VENT

warm water buffer tank

Divide & Conquer:

Hydraulic separation allows designers to think of an overall system as a collection of independent (hydraulically isolated) circuits.
circulator 2 circuit 2 circulator 2 circuit 2 circuit 1 common! piping circulator 1 common! piping

circuit 1 common! piping circulator 1

From the standpoint of hydraulics, each circuit can be designed as if its a stand-along circuit.

Divide & Conquer:

Simplifying system analysis Preventing ow interference

panel radiator

TRV

thermostatic radiator valves! on each panel radiator

TRV TRV

Divide & Conquer:

TRV

This portion of system lled with 40% solution of inhibited propylene glycol

! brazed plate SS! heat exchanger

TRV TRV

3/4" copper

manifold G! (garage)

P8

30 psi! PRV

strap-on! aquastat! contacts! close at 100F! open at 50F to / from other! radiators These panel radiators are representative! of second oor heating distribution system! exact size and number of panels may vary,! but all are supplied with 1/2" PEX-AL-PEX tubing, and controlled by individual thermstatic radiator valves.

P&TRV

supply sensor 356 injection mixing controller swing! check

ll/purge

variable speed! pressure regulated! circulator! set for Pc

P7

HW 12D CW
1.25" copper 1.25" copper tank acqustat

12D
1" copper 12- circuit manifold distribution system using PEX or PEX-AL-PEX tubing 3/4" fast ll piping

P1
3/4" copper

12D
2" air separator

12D

P6

MRHL

12D

PRV

LWCO

3/4" cold water supply

2" copper brass unions! (typical) 2" copper balancing! valve cast-iron sectional boiler! with oil burner

balancing! valve

12D

! indirect water heater

3/4" copper

oor! drain

3/4" copper

12D

3/4" copper

3/4" copper

3/4" copper

3/4" copper

3/4" copper

3/4" copper

3/4" copper

3/4" copper

1" copper

1" copper

purging! valves

3/4" copper

manifold A

manifold C

How does the water know where to go???

manifold B

manifold D

manifold E

manifold F

manifold H (2nd oor)

manifold I (2nd oor)

3/4" copper

1" copper

1" copper

1" copper

1" copper

In a complex system like this...

2" copper supply! and return headers! keep as short as possible

all three injection pumps! equipped with internal! check valves

3/4" copper

3/4" copper

return temperature! sensor for 356! mixing controllers

P3

outdoor! sensor 356 injection mixing controller

outdoor! sensor

P5

356 injection mixing controller

closely spaced tees

P2

1.25" copper

12D

! mix supply! sensor

closely spaced tees

P4

1.25" copper

12D variable speed! pressure regulated! circulator! set for Pc

! mix supply! sensor

zone valves

Webstone! purging! valves

TRV

TRV TRV

Divide & Conquer:

P8

TRV TRV TRV

Hydraulic separation allows designers to think of an overall system as a collection of independent (hydraulically isolated) circuits. In this system, hydraulic separation was achieved using short / fat header in combination with low ow resistance heat source.

P7 P1

P6

low ow resistance heat source! + short / fat headers

cast-iron sectional boiler

P3

P5

P2

P4

manifold H (2nd oor)

manifold I (2nd oor)

You nd it: Where is the hydraulic separation in this system?

chilled water air handlers

DHW

P&TRV

insulate all chilled water piping! to prevent condensation

electric! heating! element

heating is off
to / from other heating zones

water heater

cooling mode

reversing! valve

temperature! chilled sensor water

variable-speed! pressure-regulated! circulator

evaporator TXV

condenser

buffer tank

VENT

geothermal manifolds

purging! valves earth loop circuits

You nd it: Where is the hydraulic separation in this system?

indoor unit

OUTSIDE

INSIDE

thermostatic tempering valve

make-up! water & supllemental! expansion tank

! outdoor unit

indiret water heater with auxiliary electric element

motorized diverter valve closely! spaced! tees variable speed! pressure regulated! circulators

low ow resistance headers ow setter zone valve

purge! valve

air handler w/ drip pan

low temperature space heating chilled water cooling

Hydraulic Separators now available in North America

Calef

Spirotherm

Bell & Gossett

Sinus North America

Precision Hydronic Products

Taco

Thank you for attending...

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