FloCon™ Commissioning ModulesFan coil and chilled beam headers

Patent No. GB2 376 066B

www.savmodules.com

FloCon Commissioning Module Concept2

Valve Module

2-6 Fan Coils per module

Recommend 15m to furthest terminal

Max module inlet size - 32mm

Max pipe feed to terminal units - 20mm

Flexible Multi-layer Pipe

Flexible Multi-layer Pipe

FloCon MODULE DESIGN - MANIFOLD IS COMMON FLUSHING BYPASS

4 Fan Coils need only 2 branch tees (just 6 joints in all) “Manifold & multilayer pipe more cost efficient to install” (See BSRIA costing sheets)

4 Fan Coils = 8 branch tees (24 joints) - Copper pipe in 3 meter lengths

Multi-layer pipe supplied in

up to 200 metre coils

Simple multi-layer

pipe installation

Joint-less continuous pipe runs from

FloCon module to fan coil

BSRIA FLUSHING &CLEANING GUIDEAG1/2001

In traditional systems, using copper pipe, the valves must be close to the fan coils to allow full flushing of

the pipe work. Once you employ flexible, multi-layer, plastic coated metal pipe where no flushing is needed,

all valves can be centralized. This allows off-site assembly, swift commissioning and effortless maintenance.

TRADITIONAL DESIGN - FLUSHING BYPASS LOCAL TO FAN COIL

FLUSHING PATH

FLUSHING PATH

Largebodiedstrainer

Flowmanifold

Returnmanifold

Flushing by-pass and airvent

Large Bodied Strainer

Centralized Flushing, Back Flushing, Venting & Balancing

Insulated and Vapour Sealed Box

THE BIG 3

FULL OFF-SITE ASSEMBLY AND TESTINGUNDER STRICT QUALITY CONTROL

COMPACT BOX IS VAPOUR SEALED TO PREVENT CONDENSATION

As BSRIA Guide AG1/2001:

- Remove CM strainer baskets

- flush/chemical clean steel pipes

- final fill with treated water

- replace CM strainer baskets

- vent all CMs.

FLUSHING THROUGH MAIN BRANCH

BACK FLUSHING THROUGH TERMINAL BRANCH

TERMINAL BRANCH AIR PURGE

3FloCon Commissioning Module Features

Start

Finish

Step 1

Step 2

Step 3

Step 4

Step 4

Start

Step 1

Step 2

Finish

Step 3

Traditional CommissioningExtremely laborious - decentralized valves at remote terminal units mean much use of stepladders!

Step 1: Flush Pipework up to Fan Coil Step 2: Vent Fan Coils Step 3: Back-Flush Fan Coils Step 4: Proportional Flow Balance

Step 1: Flush Valve Module Step 2: Vent, Back-Flush & Flow Balancing can be performed at one visit. Step 3: Balance modules against each other

4 Commissioning

As BSRIA Guide AG1/2001

As BSRIA Guide AG1/2001: Remove CM strainer baskets,flush/chemical clean steel pipes,

final fill with treated water, replace CM strainer baskets, vent all CMs.

FloCon Commissioning ModulesGrouping makes life so much easier.

ADDING A FAN COIL

1. Drain Branch

2. Cut into pipework

3. Run new pipework

out to Fan Coil

4. Re-balance flow rates

to all Fan Coils

on branch

1. Position new Fan

Coil unit

2. Run new flexible pipes

from module

3. Re-balance module

balancing valves

With Valve ModulesWith Traditional Layout

MOVING A FAN COIL

With Valve ModulesWith Traditional Layout

1. Drain Branch / Move

terminal unit

2. Remove Valves and

pipework back to mains

3. Refill branch pipework

4. Re-balance flow rates to

all Fan Coils

1. Move terminal unit

2. Extend or re-route

pipework

3. Re-balance valves

in module

5Change and Churn

Control valves must be sized against main branch DPCV pressure

Control valves can be sized against local valve module DPCV with typical ΔP2 of 0.2 - 0.7 bar.

PRACTICAL DESIGN GUIDE FOR VARIABLE VOLUME PUMPING SYSTEMS

is available upon request. Call us on 020 8941 4153

or visit www.savmodules.com

DIFFERENTIAL PRESSURE CONTROL VALVE MODULE WITH ZONE VALVE

DPCV MODULE WITH INDIVIDUAL TERMINAL UNIT CONTROL VALVES

6 Variable Speed Pumping Systems

Energy saving is a critical issue in the design of modern buildings and variable-speed pumps offer significant

potential for energy savings. However, designers face the challenge of utilising the undoubted energy saving

potential of variable speed pumps, without losing the energy efficiency of modulating control. BSRIA and CIBSE

recommend a minimum Valve Authority of 0.3 to ensure acceptable modulation control.

The objective of good regulation control is to minimize the difference between the actual and set point

temperature to improve energy efficiency and comfort control.

Traditional Layout

FloCon Commissioning Modules

7Technical Data

2 pv Type - VZL2 DPCV - AVP-F

Flow Capacities - Max. Working Temperature: 95oC Max. Working Pressure: 10bar

Commissioning Sets

10

100

1000

0.01 0.1 1

Flow Rate (kg/s)

16mm

di

20mm

di

26mm

di

200

300

400

500

50

0.2 0.3 0.4 0.5 0.6 0.70.02 0.90.03 0.04 0.05 0.06 0.08

14mm

di

Pre

ss

ure

Dro

p (

Pa

/m)

Nom. Size Flow Range (l/s) Maximum balancing kv kvspressure (kPa)

15 LL 0.014 – 0.028 54200 Q2 0.473 0.47315 ML 0.028 – 0.055 54200 Q2 0.825 0.97615 SL 0.055 – 0.095 54200 Q2 0.85 1.79915 SS 0.095 – 0.12 2366 Q2 1.911 1.799

20 0.12 – 0.29 1250 Q2 4.427 4.05725 0.21 – 0.54 1203 Q2 7.648 7.45232 0.46 – 1.12 284 Q2 16.56 16.628

Equations: �P(Pa) = ���2/2 or �P(kPa) = (Qx36/kv)2 Where Q = flow kg/s, � = density kg/m3, � = velocity m/s

Terminal Unit Flow Equation: Q=kW/(4.2*�t) where Q = flow in l/s, kW = Term. Unit duty in kW, �t = difference between Flow & Return temperatures in oC

NB: Pressure

losses are for

straight pipe

Pipe Pressure Losses - Outer Diameter

Inlet Pipe Sizemm (OD)

Maximum Flow(l/s)

15 0.12

20 0.29

26 0.54

32 1.12

Terminal Pipe Sizes Maximum Flow(l/s)mm (Outer Diameter) mm (Internal Diameter)

14 10 0.04

16 12 0.08

20 16 0.16

26 20 0.28

Note: Manifold ports

can be adapted to

receive different pipe

sizes. Hence a mixture

of sub-circuit sizes from

the same manifold

is possible.

2 port valve

mm kvs mm kvs

15 0.25 15 1.60

15 0.40 15 2.50

15 0.63 20 2.50

15 1.00 20 4.00

DPCV

DN mm kvs DN mm kvs

15 1.60 20 6.30

15 2.50 25 8.00

15 4.00 32 10.00

UK Customer Support CentreSAV, Scandia House, 131 Armfield Close, West Molesey, Surrey KT8 2JR

Tel: +44 (0)20 8941 4153 Telefax: +44 (0)20 8783 1132 Email: info@savmodules.com Web: www.savmodules.com

30 St Mary Axe

Albion Riverside Luxury Apartments BskyB Head Office

Harvey Nichols London Stock Exchange

“The SAV solution offers better more accurate control of differential pressure and easier,

faster commissioning - a sixth of every floor at 30 St Mary Axe, could be

balanced and finely tuned from a single point.”

Dave Gatwood, Project Manager, Hills Mechanical

“SAV FloCon Modules fitted with DPCV's allow us to commission one module at a time if

necessary. Variable speed systems are simple to commission in this way and phased

occupancy of the building is made easier. Adjustment of pump speed according to

measured readings satisfies our responsibility under the Part 'L' regulations. Measurement

of pressure drop and flow become highly predictable, so we can now truly commission

the system instead of simply measuring flow rates.”

Duncan Selby, Comdronic Ltd

“The benefits at the commissioning stage have been remarkable.

There were zero problems in a 125,000 ft2 building! Our commissioning

engineers describe the Modules as “a dream to work with” and all

their figures were within the design set margins.”

Stuart Bareham - Waterman Building Services

“The installation was highly successful, resulting in an overall time saving compared

to a traditional system. We are now proposing the Commissioning Module

solution on a number of new projects we are now involved with.”

JS Key, Contracts Manager, Balfour Kilpatrick Limited

FloCon Commissioning Module Installations - Fan Coils and Chilled Beams