http://kb.eng-software.

com/display/ESKB/Reverse+Return+Systems

Q. What is a "Reverse Return" System?

A. A reverse return system is a type of closed loop system in which the return header is connected
to the most hydraulically remote load, as shown in Figure 1. Compared to the direct return system in
Figure 2 in which the return header is connected to the load closest to the pump, the reverse return
system distributes the flows and pressures more evenly across the system, making it more
inherently balanced.

Figure 1: Reverse return closed loop system.

 Figure 2: Direct return closed loop system.

The inherent balance of the reverse return system can be shown when modeled in PIPE-FLO and
the systems are calculated. Let's first look at the pressure and flow distributions in the direct return
system. Figure 3 shows the direct return system with no controls on the loads and the pump sized
for 450 gpm (designed for 150 gpm through each identical load).

Figure 3: Direct return system calculated. Pump sized for 450 gpm.

The inlet pressure to each load decreases the farther the load is from the pump discharge, and the
outlet pressure of each load decreases the closer the load is to the pump suction. This creates a
larger differential pressure at Load 1 and a decreasing differential pressure across each load the
farther the branch is from the supply pump. This differential pressure profile causes the flow rate to
decrease from 155.9 gpm at Load 1 to 145.9 gpm at Load 3, a 10 gpm (or 6.4%) variation from
minimum to maximum flow rate. The pressures and flow rates are summarized in Table 1 below.

Figure 4 shows the calculations for an identical system with the exception of an additional length of
piping on the return header to create a reverse return system.

Figure 4: Calculated reverse return system. Pump sized for 450 gpm.

Just as with the direct return system, the inlet pressures to each load decreases the farther the load
is from the pump. However, with the return header connected to Load 3, the outlet pressures
decrease from Load 1 to Load 3 (opposite of the direct return system). This causes a smaller
variation in the differential pressures across each load in the system. The inherent balance of this
reverse return system produces a flow rate variation of 4.4 gpm, or just 2.9%.Table 2 summarizes
the pressure and flow distribution in the reverse return system.

There are a couple of additional points to note about the calculated results for the two systems.
Because the reverse return system requires an additional length of pipe at least the length of the
return header, there is additional head loss that must be overcome by the head of the pump. This
 requires the total head of the pump in the reverse return system to be higher than the direct return
system (147.9 ft vs. 129.7 ft in this example). Along with the added capital cost of the extra piping,
the increased pump head results in higher operating cost, and may require a larger pump and motor
to meet the demands of the system. Also, the increased pump head results in higher discharge
pressures, which may affect the selection of pipe material or schedule and the capital costs of the
piping.

The benefits of having an inherently balanced system may out-weigh the additional costs that may
be incurred. Depending on the need for exact control of flow for each load, it may be possible to
design the system without costly flow control valves and eliminate the associated controllers, wiring,
pneumatic tubing, and other support instrumentation. An in-depth cost analysis should be done to
determine the best solution for any given application.

Two-Pipe Return Systems: Direct vs. Reverse

Leave a reply

by Marie of Flo-Pac, LLC

http://blog.jacksonsystems.com/two-pipe-return-systems-direct-vs-reverse/

A two-pipe direct return system and a two-pipe reverse return system are similar in function and require the
same parts (such as piping and balancing valves), but there are a few key differences in the way the return
piping and the terminals are laid out. Each system has advantages and disadvantages.
How Does a Two-Pipe System Work?

A two-pipe water heating system is centered on two main pipes: one to deliver water (the supply) and one to
return the water to the boiler (the return). In addition to the two mains, each terminal connected to the main
will also have supply and return pipes. Unlike one-pipe systems, the mains of a two-pipe system will provide
water thats a consistent temperature to each terminal so this setup can be used for water systems in large or
small buildings.

Direct Return

In a two-pipe direct return system, the return piping takes the water back to the pump by the shortest possible
path. Since the main piping is the most difficult and expensive piping to install, this has the advantage of
keeping the mains shorter. A direct return system also routes terminals so that their locations on the supply and
return pipes correspond; that is, the first terminal on the supply is the first on the return, and the last on the
supply is the last on the return. A direct return system requires less main piping, but because flow will be
uneven (favoring the front terminals), the system will require manual or automatic balancing valves.

Reverse Return

A reverse return system is routed to be the opposite of a direct return: the first terminal in the supply is the last
terminal on the main and vice-versa. This is possible because the return is set up to be the same length as the
supply, and it often runs in a circle around the building. A reverse return system means that supplies and
returns are the same length throughout the water system, making for a more even water flow to all terminals.
However, unless the system is designed to be self-balancing, balancing valves will still be necessary to ensure
consistent water flow.

You might also like:

Balancing Your Water System without Automatic Balancing Valves

Troubleshooting Your Balancing Valves When Your Systems Water Flow is Too Low or Too High
 Why Choose a Manual Balancing Valve Over a Circuit Setter?

The Advantages and Disadvantages of a One-Pipe Main HVAC

System
http://energy-and-industry.blogspot.com.tr/2011/10/advantages-and-disadvantages-of-one.html

A one-pipe main water system offers a few advantages over a two-pipe return system, but its only
suitable for a few unique cases. Where two-pipe systems utilize two main pipes a supply to deliver
water and a return to bring it back to the pump a one-pipe main uses one main pipe that stretches
around in a loop. Rather than connect each terminals supply and return line to the corresponding
supply or return main, each terminals supply and return is connected to the main.

The one-pipe main system allows for each terminal to be controlled separately by installing the right
valves. Unlike a two-pipe system, the terminal can be shut off or flow can be decreased without needing
to disrupt the entire circuit. Also, if the installers use a pipe of a consistent size around the system plus a
circulator, it wont require balancing valves or control valves. Even control valve suppliers admit that a
one-pipe main system uses up to 40% fewer pipes and valves.

The system is not suitable for all purposes, however. If there are more than a few terminals, the water
temperature may not be even throughout the entire system the terminals furthest from the pump and
boiler will be colder. A two-pipe system may be necessary for larger applications requiring even heating.

Balancing Your Water System without

Automatic Balancing Valves
Leave a reply

By Marie of Flo-Pac, LLC

Automatic balancing valves offer an excellent way to balance a water system without resorting to
setting the system manually. Its important in any HVAC system to achieve and maintain hydronic
balance in order to ensure proper air temperature control in the building.

However, if your system does not feature automatic balancing valves, you will need to configure the
balance manually. This is not a difficult task with the right knowledge and tools.

Balancing Your System: The Basic Procedure

A hydronic system is in balance when the flow throughout the entire system corresponds to the flow
rate specifications recommended for it. Most experts prefer to balance a water system using direct
flow measurements, as it avoids the mistakes usually associated with using pressure drops or
temperature changes.
1. Set controls so that the coils are receiving full flow.
2. Adjust the pressure reducing valve, or PRV, so that the system maintains a minimum of 5psi of
additional pressure at the highest terminal. Pressure throughout the rest of the system should be
put on the normal setting.
3. Open all manual valves fully and balance the system proportionally.
4. Balance is adequate when water measures within 10% of the flow specifications for the design. If
the system does not come to within 10%, you can adjust the impeller diameter.
If your system utilizes three-way valves, you may need to take additional steps to ensure proper
balance. Balancing valve and control valve suppliers recommend closing off water flow through the
bypass while water flows through the coil, then doing the opposite (closing off water to the coil while
water flows through the bypass). Full flow gpm should be the same through both the bypass and the
coil.

http://www.grundfos.com/service/encyclopedia-search/one-pipe-system.html

There are two basic categories of pipe systems: one-pipe and two- pipe systems. In a one-
pipe heating system all radiators are connected to the same pipe, which acts as both flow
pipe and return pipe. This means that the temperature decreases along the pipe. For this
reason, the radiators along the pipe line should increase in size correspondingly to provide
the same heat output.
One-pipe system with vertical distribution
The water is distributed from above from the horizontal distribution pipe. A single air vent is sufficient at
the top.
Since there is only one pipeline to the radiators, the system is visually more acceptable. This is an
advantage in a system where the pipes are exposed.

One-pipe system with horizontal distribution

A one-pipe system where the water is piped horizontally is to be preferred in situations where it is
undesirable to have a vertical pipe up through the rooms.
Such a system is more difficult to vent, so all radiators need to have an air vent screw.

Theres more than one way to pump a chiller or boiler system. In fact, there are five
common approaches, and all but one includes some variation of our topic of late --
primary secondary pumping.

Variable Primary Pumping

Contemporary systems that do not utilize primary secondary pumping are typically
known as variable primary systems. In this simple design, there is only one set of
pumps (chiller or boiler pumps) creating flow for the entire system. As you can see in
Figure 1, there is still a common pipe between the chiller pumps and the system
distribution, but there are no secondary pumps. A control valve is installed in the
common pipe. By throttling this valve, we create a pressure drop through the
common pipe, which forces more water into the distribution piping. The control valve
is the only means of control in this type of system.

Pros/Cons: Generally speaking, variable primary systems can have lower first-cost,
but pumping operating costs can increase because of the wasted horsepower that is
associated with throttling a control valve. Variable primary on chilled water systems
allows for delta-T compensation if you can over-pump a chiller. Control sequences
can be difficult to master and such systems are not as easily expanded to meet
growing or changing demands as systems with secondary pumps.

Figure 1

Primary Secondary Pumping

The next step up is a simple primary secondary system something weve been
talking about extensively over the last several weeks. In Figure 2 you can see all the
basic building blocks of virtually any type of primary secondary
configuration. Constant speed pumps drive the flow through the primary (chiller or
boiler) loop. A separate secondary pump delivers variable flow to the secondary loop
and two-way valves are applied to control flow through each zone.

Pros/Cons: This simple design typically has a low first cost and good flexibility. It
also decreases the complexity of the chiller or boiler staging and control by
eliminating on/off valves and min/max flow requirements. However, efficiency is
limited because the zone nearest to the primary loop is susceptible to over-
pressurization.

Figure 2
Primary-Secondary-Tertiary Pumping

In a primary-secondary-tertiary system (Figure 3), things start to get a bit more

complicated, but the principles are all the same. The common pipe (whether it is
between the primary loop and the secondary loop, or the secondary loop and the
tertiary loop) acts as the decoupler, so flows act independently of one another and
there is extra degree of thermal isolation.

Pros/Cons: Primary-Secondary-Tertiary systems have long been applied to large

campus-type installations with long pipe runs. They give the designer the flexibility
to separate far-off zones so that the secondary pumps neednt bear such high head loss
burdens. They offer excellent design flexibility because flow to each zone is
independent, thus primary-secondary-tertiary pumping is a good option for systems
with diverse load patterns. First costs are higher given the extra pumps and two way
valves, but when properly designed primary-secondary-tertiary pumping offers
significantly lower operating cost. Such systems are also easily expandable because
additions will not impact the flow or balance of existing pumps.

Figure 3
Primary-Secondary-Tertiary Hybrid

Primary-secondary-tertiary designs may also be hybridized, meaning you dont have

to put a tertiary loop on every zone. Rather, you can isolate a high head loss zone
with a tertiary pump while continuing to efficiently serve nearby zones with the
secondary pumps. Figure 4 shows a primary-secondary-tertiary hybrid design.

Pros/Cons: This approach offers all the efficiency and flexibility of a standard
primary-secondary-tertiary, but does eliminate some of the extra equipment costs.

Figure 4

Primary-Secondary Zone

Finally, there is the primary-secondary- zone approach. In a primary-secondary zone

design, separate pumps serve each individual zone; there is not a dedicated secondary
loop pump. As you can see in Figure 5, there is no common pipe between the
individual zones, therefore a change to one zone willimpact flow through the other
zones. For that reason, this is not the best choice for a system that is likely to face
future expansion or renovation, as changes in existing loads might require resizing of
all pumps.

This type of design has the potential for high energy savings, but with certain caveats,
including slow reaction time to changes in system demand. Because the pumps are in
parallel, special attention must the paid to the selection and performance curves must
be compatible. Also, under certain load conditions, the return pressure may be higher
than the supply pressure, which could create problems with the primary loop
equipment.
Pros/Cons: The main advantage to this piping arrangement is significantly lower
system pressures, and reduced horsepower. Controllability, however, is a challenge
because there is no decoupling between zones. Expanding the system could also be
quite costly.

Figure 5

Primary/Secondary, Chiller Pumps, Boiler Pumps, HVAC Pumping, Variable Primary, Pumping, Primary
Secondary Tertiary, Hybrid Pumping Design,Zone Pumping

Marshall Seymore A year ago

I notice that there is no discussion of a Variable Primary/Variable Secondary (VPF-

VSF) chilled water system.

A VPF-VSF chilled water system can:

Maintain chilled water flow through the decoupler piping at or near zero by producing
only the chilled water required by the distribution demand.

Load chillers to 100% if required.

Maintain the distribution design chilled water temperature at all times.

See ASHRAE Journal October 2014 article "Simplified Chiller Sequencing."

http://uwf.edu/media/university-of-west-florida/offices/facilities-development--
operations/docsues/!ASHRAE-Journal---October-2014-Simplified-Chiller-
Sequencing.pdf
The article discusses an approach for sequencing multiple chillers and controlling the
primary pump speed with only four temperature sensors used to analyze temperatures
entering and leaving the decoupler piping connections.
JMP 2 years ago

Thanks for the comment Rob and always good to here of new things. Here are a
couple of thoughts: We would still want the air separator on the suction side so we
have the hottest water at the lowest pressure. Keep in mind the pump contribution to
the temperature increase from the pump might also be spread out over the system (due
to friction loss). Another consideration also would be raising the inlet pressure to the
chiller by having the secondary pumps in this location (remember the point of no
pressure change is the expansion tank). You need to make sure you do not run the risk
of exceeding the pressure rating of the chiller. Thanks for the input!
Rob Rettew 2 years ago

One of the alternate arrangements I've done in primary-scondary piping is to put the
secondary pumps in the return back to the chillers instead of in the supply leading out
to the loads. The advantage of this is some energy savings. This savings will come
from the fact that the chillers now have the opportunity to remove the pumping energy
so that the water out of the chiller goes straight to the loads. In other words, you don't
have to consider the temperature rise in the water due to the pumping energy of the
secondary pumps so that if you want, as an example, 45 degrees F at your loads, you
can get that right out of the chiller instead of pushing the chiller down to say 43.5 (or
so) degrees F to get 45 degrees F at your loads. I did this on a project in Charlotte and
it worked great! The TAB guys were a little confused but admitted that it worked fine
by their measurements.
Hassan 2 years ago

Can someone suggest where to install air seperator, make up water connection,
expansion tank, chemical dosing feeder in the given chilled water circuits. Thanks

All About Hydronic Multiple Boiler Systems

While Climatic Control Company does not, at this time, actually design hydronic systems; we do deal with the control
systems and the people that service and design them. Having knowledge of good hydronic design principles can come
in very handy when repairing or upgrading a hydronic system. You can speak intelligently about a system, enabling
you to solve a problem or problems.
Lets consider a typical hydronic multiple boiler, primary/secondary system, as found in many small to medium
size commercial buildings such as hospitals, churches, nursing homes, office buildings, even large residences. These
systems consist of three major parts:

1. The boilers; heat generators

2. Primary loop; a heat transport system
3. Radiators; heat distributors

Boilers
Boilers are sized for worst-case conditions. If the heat loss calculations are correct, a boiler will run continuously
at design day conditions. Design day conditions will probably be reached on only two, maybe three days a year. If
the boiler runs continuously on more than just the design days, it will be very inefficient. It makes no sense to have
one big boiler generate its maximum output on warmer than design days.
To overcome this problem, gas-fired boilers are available with modulated firing rates, even small residential boilers
as small as 45,000 BTU/Hr input. They are very expensive, and should the boiler fail and need repair, no heat is
available until the boiler is fixed. This could be a disastrous situation if the repair takes too long. The building could
freeze up, resulting in broken plumbing, loss of income, etc.
By splitting the load between two or three boilers, piped in primary/secondary systems, we have built in a stand-
by feature, and still generate just the amount of heat needed to match the buildings heat loss at any given moment. The
chances of all the boilers needing repair on the same day are extremely remote. Comfort, economy, and peace of
mind are attained.
By splitting the load, we recognize that not every day is the coldest day of the year. On an average winter day,
probably one boiler can heat the building. Chances are it will run longer than a single, large boiler. By splitting the
load, we recognize that not every day is the coldest day of the year. On an average winter day, probably one boiler
can heat the building. Chances are it will run longer than a single large boiler, improving overall operating efficiency,
thereby reducing fuel usage. As the weather gets colder, the second boiler will come on, but only on the really frigid
days. In addition, by piping the boilers in a primary/secondary system, no water will flow through an off boiler, reducing
heat losses through the stack and boiler jacket of the off boiler. Its as if the off boiler were valved off from the rest of
the system, even though it isnt.
Small commercial buildings that can utilize these systems abound: churches, schools, convenience stores, etc.,
even large residences, will benefit from these systems.
The load can be split to use more than two boilers. However, in buildings where the design load is 1,000,000
BTU/Hr or less, the economic return using three or more boilers is so small it doesnt justify the extra installed
expense. (Over a million BTUs three boilers may return the extra expense, but seldom would four boilers. Careful
calculations to figure the payback on systems of four or more boilers should be made. Since, in this Info-Tec, we are
dealing with buildings in the 400,000 to 1,000,000 BTU/Hr range, we will concentrate on two boiler systems, the most
economical to install and operate.)
 Multiple boiler primary/secondary systems are comparatively small in size. They can be easily installed in
buildings during remodeling or in new construction. They are easy to pipe. Usually two (even three) boilers will fit in
the same space an old cast-iron or steel tube boiler occupied. Labor costs will be decreased in handling smaller, lower
weight boilers. Small boilers will fit through most doors, making them perfect for retrofit jobs.
The boilers in a primary/secondary system are the heat generators. They inject heat into the primary flow
system, but the boilers themselves are on a secondary loop. Consequently, one need only to size the boilers circulator
and piping to meet each boilers needs only. By using the primary/secondary system, the circulator will usually be an
off-the-shelf in-line pump, and the boiler piping will be much smaller than needed for one large boiler.
Figure 1 is a rule of thumb chart for a typical boiler. The 25F is based on using 25F as the system temperature
drop, or put another way, 25F is the temperature rise through the boiler. It is always best to check the actual boiler
manufacturers specifications, but for illustrative purposes, Figure 1 is typical.

Figure 1.
Figure 2 shows the basic primary/secondary system.
Note: Always keep the boiler supply and return lines about six inches apart where they connect to the
primary loop. Never more than a foot apart! (See Info-Tec No. 36). Piped that way, no water will
flow through the off boiler when its pump is not running.

Note: Always pump down into the boiler with its secondary pump, away from the common primary piping.
Figure 2.
Regardless of how many boilers are used, use only one connection to the primary loop for the compression
tank. If the system is big enough for multiple compression tanks, manifold the tanks together, but still only connect at
one single point in the primary loop.
The compression tank is the point of no pressure change in a closed hydronic system. Its the one place a
circulators differential pressure cant affect. If you pump away from the compression tank, the pump will add its
pressure differential to the systems fill pressure. If you pump toward the tank, the pump will remove its pressure
differential from the fill pressure. Air is always in the systems water, and if the pump drops the system pressure, the
air comes out of solution and forms bubbles (think of a bottle of soda, when you open the cap the drop in pressure
releases the dissolved Carbon Dioxide).
Note: To avoid air problems always pump away from the compression tank!

Thats another reason to always have the secondary boiler circulating pumps pump away from the primary
loop. The secondary pumps use the primary loop as their compression tank. Also, always bring feed water into the
point the compression tank connects to the system. Its the only place in the system where the pressure cant
change due to the circulators. Therefore, the feed valve will get a true reading of whats going on in the system.
Primary Loop
Now, lets look at that primary loop. The primary loop is the transportation system for the heat. It carries the
heat from the boilers to the radiators.
When zone circulators draw heat out of the primary loop, the boilers turn on and put heat back into the primary
loop. In this way, the primary loop acts as an extension of the boilers.
The primary loop circulator is run continuously during the heating season. The circulator needs to be sized only
for the flow and head-loss for this loop. You usually end up with an off-the-shelf, in-line pump. There is usually very
little resistance to flow in a primary loop, since there are no boilers or radiators in the loop.
With commercial single boilers, single pump systems, you almost always need a single large base-mounted
pump. These types of pumps are expensive to buy and install. They must be mounted on heavy concrete bases,
grouted in, and take up valuable floor space. In primary/secondary systems, you work with small, inexpensive, in-line
circulators.
To size the primary loop circulator a rule of thumb can be used. It is: One gallon per minute of primary flow
will transport 12,500 BTU/Hr to the system. (This is based on 25F temperature drop.)
Lets begin an example using a building with a calculated heating load of 500,000 BTU/Hr. Well split the load
using two 250,000 BTU/Hr output rated boilers.
 To get the flow rate for the primary circulator, divide 12,500 BTU/Hr into the total load of 500,000 BTU/Hr:

To get the proper copper pipe size for the 40 GPM flow rate; Figure 3 can be used. Figure 3 is based on industry
accepted flow rates for the sizes shown.

Figure 3.
Now we need to know the head-loss. Another rule of thumb:
For every 100 feet of primary-loop piping, allow six feet of pump head.
In our example, lets say our primary loop measures 300 feet. Based on the flow rates in Figure 3, we find we
will need a circulator that can pump 40 GPM at an 18-foot head.
Once you know the flow rate and head loss, its a simple matter to select a pump from manufacturers catalogs.
Radiators
The radiators, and their secondary piping loop become the final part of our system. Look at Figure 2 again. Note
the two closely installed tees (about six inches apart) and the circulator pumping out of the primary loop. The secondary
radiation piping should be sized to match the flow rate needed for each zone.
For sizing radiation zones, we have another rule of thumb.
Figure 4 is based on the same 25F T weve used throughout our example. If a zone was sized to use a
baseboard to put 15,000 BTU/Hr into the zone, you select 1/2" nom (5/8 OD) copper tube, tee off the primary, keeping
the tees about six inches apart, and install a secondary circulator pumping away from the tee. When a zone thermostat
calls for heat, the circulator is turned on. The zone circulators will almost always be small ones, such as the B & G
SLC, since this pump sees only the flow rate and P through the secondary loop.
Figure 4.
Figure 5 shows how to handle a radiant panel heat zone, mixed with baseboard zones that require lower
temperature water than the baseboard zones. A three-way valve is piped on the primary loop side of the circulator to
keep the flow stable through the radiant panel. The three-way valve need only be a manual valve, adjusted to maintain
the desired radiant loop water temperature. Its the simplest, least expensive way to handle this loop. (Once properly
adjusted, it is a good idea to remove the handle of the three-way valve to prevent unauthorized personnel from changing
the adjustment.) Once again, the circulator goes on and off in response to a room thermostat.

Figure 5.
The multiple boiler primary/secondary system is beautifully simple:
Boilers inject heat into the primary loop. This heat is orbited in the loop and extracted as needed into the zones
where people are.
The small zone circulators used are as inexpensive as zone valves, and using the primary/secondary system
results in a relatively small, inexpensive, in-line primary pump too.
One need not employ an expensive hydronic engineer to design a system. The rules of thumb work
well. Overall, these systems are less expensive to design, install, and operate than a single large boiler system with
zone valves. These systems result in customer comfort and the peace of mind that comes with multiple boilers. An
example will best illustrate how all this comes together. Our example is even going to include a Climatic Control
Company designed control system.
Our example building is a commercial building with nine baseboard radiators and zones. Heat loss calculations
are:
Three zones at 18,000 BTU/Hr each = 54,000 BTU/Hr
Four zones at 48,000 BTU/Hr each = 92,000 BTU/Hr
One zone at 70,000 BTU/Hr each = 70,000 BTU/Hr
One zone at 80,000 BTU/Hr = 80,000 BTU/Hr
Total load = 396,000 BTU/Hr
Boiler Selection:
The total load will be split between two boilers, each rated at 200,000 BTU/Hr output. 25 F is to be used for
figuring the system T. From the boiler manufacturers catalog, we find that a 250,000 BTU/Hr input boiler is rated
200,000 BTU/Hr output, requires 16 GPM, and is equipped with an SLC B & G circulating pump. The supply and return
lines from the boilers to where they tee into the primary loop could be 1-1/4" or 1-1/2" copper pipe, its a close call. If
those lines are short (and they should be) 1-1/4" is okay. If, for some reason, the piping from the primary loop to the
boilers begins to approach a total of 80 feet or more, 1-1/2" pipe should be used. (Supply and return lengths are added
together to get a total length.)
Now, lets deal with the primary loop:

Using Figure 3, we find the primary loop will be 2" copper pipe. Lets say our primary loop measures 360
feet. Using our rule of thumb that for every 100 feet of primary loop we allow 6 feet of pump head, we find well need
a pump that can pump 32 GPM at a 22 ft. head. (6 x 3.6 = 21.6 round off to 22). Looking at the B & G catalog, we find
that the in line 60 - 13 will fit our need. A PD37 will also work, but is more expensive.
The piping for the 9 zones is sized using Figure 4.
Three 18,000 BTU zones 1/2" copper pipe
Four 48,000 BTU zones 3/4" copper pipe
One zone at 70,000 BTU, and one zone at 80,000 BTU 1" copper pipe
(Note: Those of you familiar with friction loss and flow rates through residential 3/4" baseboard will see that the large
zones would require commercial baseboard with 1-1/4" pipe. But, we are not dealing with baseboard sizing in this Info-
Tec.)
The hydronics of our hydronic system have now been done. But the hydronics are only half the system. The
other half is a control system.
For maximum comfort and economy, the control system should utilize all the features of the system, and yet be
affordable. Climatic Control Company is an expert at designing and supplying these control systems.
As you will see, enhancements can be added to the basic control system.
The boilers used in these systems are usually sold as packaged boilers. That is; they come complete with limit
controls, circulator, gas train, etc. One needs only to supply power to the boiler and a contact closure to make the
boiler operable. One thing to watch for on these packaged boilers is how the circulator is wired to
operate. Some manufacturers will wire the circulator to run all the time. Re-wire these boilers so the circulator
will run only when the boiler fires. A relay may be required.
Each zone has a thermostat that simply turns on and off the zone circulating pump. Since it is much easier and
cheaper to run low voltage wiring instead of line voltage wires, a pump relay will be needed. This relay can be of many
different configurations, but theHoneywell RA89A is a popular pump relay that incorporates all the necessary
features. It has a built-in transformer, for our low voltage circuit, comes in a NEMA 1 case, and is UL approved. The
10.2 amps at 120VAC contact rating are more than enough to handle the small zone circulators being used. Installed
cost is low. Always consider installed cost, not just the item cost. See Figure 6.
Figure 6.
We need to have hot water available at all times in the primary loop so when a zone calls for heat, response is
immediate. There should be no lag to bring the supply water to temperature. But it is not necessary to maintain the
supply water temperature at design temperature at all times. Remember, the design water temperature is only needed
on the few coldest days. It would be fuelish to maintain, say 180F supply water all winter.
The A350R reset controller is the solution. It is designed to raise or lower the temperature of the supply water
based on outside temperature. Because of the A350Rs many adjustment features, the supply water temperature can
be matched to the heat-loss characteristics of the building. Add-on stage modules can be plugged into the A350R, as
can a power module.
In our example building by using the A350RN-1, S350AA-1, and Y350R-1, we would have a very inexpensive,
but completely adequate efficient control system. The total control materials list would be:
Nine: Low Voltage Zone Thermostats
Nine: RA89A Pump Relays
One: A350RN-1 Reset Controller
One: S350AA-1 Stage Module
One: Y350R-1 Power Module

One: WEL11A-601R Well
The A350R includes both the supply water sensor and outdoor sensor. The outdoor air sensor comes with an
outdoor enclosure, even wire nuts and a conduit connector! Only a well for the supply water sensor needs to be added.
Figure 7 would be the wiring diagram for boilers with their own power supply.
Figure 7.
System Enhancements
As stated, this control system will work, is efficient, and is certainly low cost, but by adding some enhancements,
the system can be made more efficient and even easier to install. Most often, these options are very useful.
The first add-on to our basic system should be lead/lag. As it stands now, boiler one will always be the first boiler
to come on line on a call for heat. Boiler one will probably get 80 to 90 percent more run time than boiler two.
This unequal wear and tear results in more maintenance and a shortened life span for boiler one. The lead/lag
add-on will even out the on times of the boiler, just like rotating the tires on your car, resulting in longer life and
consequently less cost. Equalizing the boilers run times will save money.
Another useful add-on is the D350 digital temperature display. It can be used as a tool for setting up the A350R
at installation time. When the D350 display is plugged into the left side of an A350R it will continuously display the
outside sensor temperature. When the button on the front of the D350 is pressed, the supply water sensor temperature
will be displayed. The D350 plugged into the left side of the A350R is the most used position. (The D350 can be
plugged into the right side of the A350R. It will then continuously display the supply sensor temperature, and pressing
the button will display the supply setpoint.)
Weve now added to our materials list a D350AA-1, an ARA-24-ACA Diversified duplexer, and a PF083A-E base
for the ARA.
Climatic Control Company can custom-build a panel. All the controls will be mounted, wired, tested, and placed
in one good-looking, convenient enclosure. The installer only has to mount the enclosure and bring a few wires to it to
complete an installation. While the cost of this panel will be more than the cost of just the parts, the contractors installed
cost will be less than if he were to field mount and wire the system. Climatic Control Company even includes computer
generated wiring diagrams!
Extras, such as pilot lights to show which boilers are on, add nice touches that customers come to appreciate,
and can be helpful in trouble shooting if something should fail in the future.
Figure 8 shows the completed Climatic Control Company diagram for just such a panel.
Figure 8.
Adding another staging module and changing the duplexer into a triplexer will allow one to control a three-boiler
system.
On many of these systems, a stand-by primary pump will be installed, such as in hospitals, nursing homes,
schools, anywhere it is crucial that heat be maintained at all times. The stand-by pump is to automatically come on
line if the primary pump fails.
This feature can easily be incorporated into our panel. First, remember that the primary loop pump runs all the
time during the heating season. Therefore, there is no need for automatic lead/lag. That leaves two ways to configure
a stand-by pump arrangement, as far as the controls are concerned.
One way is to have the stand-by pump (pump 2) automatically come on when the lead pump (pump 1) fails, but
pump 1 will always be the lead pump. This is illustrated in Figure 9.
 Figure 9.
Well call this stand-by pump, auto on, no lead change.
The devices needed to construct this type of circuit are shown in Figure 9.
An explanation of how the circuit works will help us understand it. The on/off switch gives manual control to turn
pump 1 on for the heating season, off for summer. When the switch is turned on, current flows through the closed
contacts of 1R3 and 2R3, energizing pump 1. At the same time, the one-minute time delay is energized. This delay is
to give pump 1 time to build pressure, moving contacts of the P74FA-5 differential pressure control to break R to
B. After a one-minute delay (delay timing is adjustable to be able to match any systems response timing), relay R1 is
energized making contact 1R1. Nothing more happens.
Should pump 1 fail, the P74FA-5 will sense the loss of differential pressure and make R to B, energizing relay
R2. Contacts 1R2 will close, energizing R3. Contacts 1R3 and 2R3 will switch, energizing pump 2, and opening the
circuits to pump 1. Contact 3R3 is also closed, latching the circuit to R3 to keep it energized. Pump 2 rebuilds pressure
and the P74s R to B contact is once again broken.
Relay R2 is de-energized, opening contacts 1R2, but R3 remains latched through its contact 3R3, keeping the
circuits to pump 2 closed and pump 2 on. As long as the on/off switch remains closed, pump 2 will run. Pump 1 can
now be repaired or replaced. The circuit will be only reset when the on/off switch is opened, and, of course, if there is
a total loss of power. Note that when powered, pump 1 will always be the lead pump. Pump 2 will only run when pump
1 fails to maintain the necessary differential pressure.
The circuitry can be improved, for very little extra cost, to be able to select which pump will be the primary pump.
Figure 10 shows the addition of a 3-position selector switch in lieu of the on/off switch. The rest of the circuits are
the same as Figure 9, as is the sequence of operation, except now the lead pump can be manually selected. This
manual selection of the lead pump can be done once each season, once a month, whatever an operator decides. This
way, run time on each pump can be equalized, resulting in prolonged life of the pumps.
Figure 10.
Indicating pilot lights can be easily added to show whether pump 1 / pump 2 is on or off or both.
Closed loop pressure

In a Chilled water system, how do you calculate your head? ( what are the different types of head)
- The building is 150 meters high. Does that go in for the head caluclation?

Another question, if the pump is switched off, system full of water, what would be the reading on the gauge
before and after the pump.
bimr (Civil/Environmental)28 Apr 15 16:09

If the pump was switched off, the pressure readings on either side of the pump would be the static head of
150 meters..
LittleInch (Petroleum)28 Apr 15 16:32

In a closed loop system the static pressure at the lowest point in the system must be at least equal to the
static head of the fluid (water) at the highest point, in your case 150m. However to avoid cavitation and air
bubbles forming, the system is usually pressured to a bit more so that the highest point the pressure is
always > 0 barg, often 1-2 barg. This increase the static head at the lowest point.

The differential head of the pump though, regardless of where it is located, is the head required to pump the
water around the system at the flow rate required through the elements required (AHU, chiller etc). Often the
pump on large building is located at the top to reduce the pressure rating of the pump and its seals. The
height of building is irrelevant to this calcualtion as the height issue cancels each other out.

bimr (Civil/Environmental)28 Apr 15 19:05

Correction to my post. If the pump was switched off, the pressure reading on the discharge side of the pump
would be the static pressure head created by the difference between the elevations of the uppermost pipe
(assume that it is on the roof) and the pump plus any residual pressure that was put into the closed loop by
the pump. The pressure on the inlet side would be more or less the same since it is a closed loop.

moeg (Mechanical)

While calculating the pump head in a closed loop chilled water system, you consider
1) the height of the building, in our case the 150 m, as static pressure.
2) dynamic head, the system losses (chillers,thus...etc)

Assume the longest route with all its fitting losses is 10 bar, and building height is 150 m, so 15 bar head.
Total pump head is 25 Bar?

Please correct this information for me if it is wrong.

bimr (Civil/Environmental)28 Apr 15 19:30

It is 10 Bar.

The term pump head however, has nothing to do with height. It is a term that is used that is the pumps
ability to overcome the friction that is created when fluid flows through a pipe. Once a system is filled with
fluid the pump merely has to overcome this friction. An easy way to think about it is that as water goes up
one side of the loop, it also comes down the other side of the loop. The two cancel each other out.
nabeel3 (Mechanical)16 May 15 12:27

In a closed loop system,like in a chilled water circuit the height of the building is irrelevant because the work
done(Pressure) by the pump in lifting the water column is gained when the water column falls by the same
height. So the +ve and - ve pressure cancels each other. Hence consider only the dynamic pressure head
only. i.e The pressure that the pump has to develop to circulate the fluid overcoming the friction loss and
fitting pressure loss. Also consider the pressure loss in the most remote AHU or FCU. That will give the Head
required by the Pump.
Closed loop pressure
If a pump pumps water to a heat exchanger at a certain height, say, 20 m is the head required indeed
lower for a closed loop system than an open loop system? The link below says so, but I wanted to verify.
Assume pipe friction losses are the same in both cases. Can one really take credit for the static head
developing a pressure at pump suction in a closed loop system? It makes sense from the basics but
intuitively I wasn't sure.

So the link is to a pdf. It is correct. So long as the pump inlet pipe is full of water it will provide pump inlet
pressure that will cancel the head at the pump outlet. The pump presents a pressure difference that only
needs to overcome head loss due to flow.

o expand on what Baluncore said, you'll recover your static head loss (that is, the 20 m of head the
discharge must overcome is, when the system is full of water, recovered as suction head). In a true
closed loop, the pump is serving to overcome only the line losses due to friction and pressure drops over
valves, fittings, and equipment (like heat exchangers). However, with heat exchangers it is often difficult
to have a true closed loop system as the heat exchanger becomes less and less effective as the cooling
water heats up. You can't circulate the same volume of water continually, or else your heat exchanger will
lose it's ability to cool. You'll need to employ a method of cooling the water after it leaves the exchanger,
which typically means opening up that closed loop. I've done this before in a semi-closed system, where
my pump passed water through a heat exchanger and into an elevated holding tank where cold makeup
water was being introduced. The water mixed, cooled, and was sent back down via gravity to feed the
pump. Very little static head allowance was required for that pump.

Reference https://www.physicsforums.com/threads/pump-head-requirement-closed-vs-open-loop.753612/