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• LEED Certification
2
Today’s Agenda
• Why variable flow pumping started
• ASHRAE 90.1
• Differences in hydronic boiler system design
• Primary secondary vs Variable flow primary
• Condensing boiler technology review
• High mass vs low mass
• Characteristics of condensing boilers
• System comparison
• Review Primary secondary vs variable flow primary at various load conditions
• Summary
• Q&A
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Guest Presenter: Gregg Achtenhagen
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The Hydronic System
Air Elimination
Pump(s)
Heat
Generation
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Why Variable Flow Pumping Started
Primary-Secondary Pumping Arrangement
Return Supply
Secondary pumps
(variable speed)
Buffer Tank
Decoupler
Primary pump Primary pump Primary pump
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System Comparison
Primary-Secondary:
Hydraulic De-Coupler
Gp Gs Gp Gs Gp Gs
Return Supply
Primary pumps
(variable speed)
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Definitions
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Definitions
Outdoor Temperature Reset
ASHRAE 90.1
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Differences in Hydronic System Design
Traditional Boiler Limitations
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Differences in Hydronic System Design
Thermal Shock
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Differences in Hydronic System Design
Corrosion
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Condensing Boiler Technology
Different Boiler Designs
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Condensing Boiler Technology
Key Operational Criteria
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Condensing Boiler Technology
Key Operational Criteria
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Condensing Boiler Technology
Key Operational Criteria
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Condensing Boiler Technology
Low Mass Boiler Design
Advantages Disadvantages
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Condensing Boiler Technology
High Mass Boiler Design
Advantages Disadvantages
• Rugged construction • Higher first cost
• Less cycling • Heavier
• Lower thermal stress • Somewhat larger than
on the boiler low mass
• Stable temperature
control
• Minimal pump head
• Low flow or no flow
tolerant
• Compact
• Excellent efficiencies
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System Comparison
Primary-Secondary: 100% Design Load = 6000 MBH
120F 160F
300gpm
Buffer Tank
300gpm
0 gpm
100gpm 100gpm 100gpm
300gpm
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System Comparison
Variable Flow Primary: 100% Design Load = 6000 MBH
120F 160F
300gpm
300gpm
120F 120F 120F 120F
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System Comparison
100% Design Load
Primary-Secondary
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 100%
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System Comparison
Primary-Secondary: 70% Part Load = 4200 MBH
120F 160F
300gpm
90 gpm
100gpm 100gpm 100gpm
210gpm
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System Comparison
Variable Flow Primary: 70% Part Load = 4200 MBH
Hydronic piping system arrangements
120F 160F
210gpm
210gpm
120F 120F 120F 120F
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System Comparison
70% Part Load
Primary-Secondary
Boiler Inlet Temperature: 130F
Boiler Firing Rate: 75%
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Impact of Higher Inlet Temperature
On Efficiency
Primary-Secondary
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System Comparison
70% Part Load
Primary-Secondary
Boiler Inlet Temperature: 130F
Boiler Firing Rate: 75%
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System Comparison
Primary-Secondary:
50% Part Load – With Outdoor Reset = 3000 MBH
Hydronic piping system arrangements
110F 150F
200gpm
50 gpm
100gpm 100gpm 0gpm
75% FR 75% FR 0% FR
150gpm
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System Comparison
Variable Flow Primary:
50% Part Load – With Outdoor Reset = 3000 MBH
Hydronic piping system arrangements
110F 150F
150gpm
150gpm
110F 110F 110F 110F
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Inverse Efficiency Curve on Condensing Boilers
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System Comparison
Variable Flow Primary:
50% Part Load – With Outdoor Reset = 3000 MBH
Hydronic piping system arrangements
110F 150F
150gpm
150gpm
110F 110F 110F 110F
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System Comparison
50% Part Load – W/ Outdoor Reset
Primary-Secondary
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 75%
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System Comparison
50% Part Load – W/ Outdoor Reset
Primary-Secondary w/ 3 boilers operating
Boiler Inlet Temperature: 137F
Boiler Firing Rate: 55%
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System Comparison
Primary-Secondary:
33% Part Load – With Outdoor Reset = 2000 MBH
Hydronic piping system arrangements
100F 140F
200gpm
100 gpm
100gpm 100gpm 0gpm
50% FR 50% FR 0% FR
100gpm
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System Comparison
Variable Flow Primary:
33% Part Load – With Outdoor Reset = 2000 MBH
Hydronic piping system arrangements
100F 140F
100gpm
100gpm
100F 100F 100F 100F
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System Comparison
33% Part Load – W/ Outdoor Reset
Primary-Secondary
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 50%
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System Comparison
33% Part Load – W/ Outdoor Reset
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System Comparison
50% Part Load – With Outdoor Reset – Redundant Boiler
Primary-Secondary w/ 2 boilers operating
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 75%
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Summary of Energy Consumption
Hydronic piping system arrangements
Load Primary-Secondary Variable Flow Primary Savings
Return Supply
Secondary pumps
Primary pumps
(variable
(variablespeed)
speed)
Buffer Tank
Decoupler
Primary pump Primary pump Primary pump
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Primary Secondary vs Variable Flow Primary
Comparison
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Comparing the Designs
Simplicity of Variable Flow Primary
Modulating
No need for minimum flow bypass
Bypass
Flow Meter
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Comparing the Designs
Primary-Secondary with Low Mass Boilers:
Buffer Tank
45 Co.
Courtesy of Wessels
Comparing the Designs
Primary-Secondary with Low Mass Boilers:
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Comparing the Designs
Primary Secondary
Advantages Disadvantages
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Comparing the Designs
Variable Flow Primary
Advantages Disadvantages
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Keys to Efficient Hydronic System Design
• High Delta T
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Contact Us
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