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HVAC Pump Handbook

James B. Rishel, P.E. Systecon Inc.

West Chester, Ohio

New York San Francisco Washington, D.C. Auckland Bogota Caracas Lisbon London Madrid Mexico City Milan

Montreal New Delhi San Juan Singapore Sydney Tokyo Toronto

b

v

Contents

Preface xv

Part 1 The Basic Tools

Chapter 1. Digital Electronics and HVAC Pumps

Introduction Computer-Aided Calculation of HVAC Loads and Pipe Friction Pressure-Gradient Diagrams Speed and Accuracy of Electronic Design of Water Systems Databasing Electronic Communication Electronic Design of the Piping and Accessories Electronic Selection of HVAC Equipment Electronic Control of HVAC Water Systems Electronics and HVAC Pumps Electronics and Variable-Speed Pumps Electronic Commissioning Purpose of This Book Bibliography

Chapter 2. Physical Data for HVAC System Design

lntroduction Standard Operating Conditions Thermal Equivalents Water Data Glycol-Based Heat-Transfer Fluid (HTF) Solutions Steam Data Areas and Volumes of Pipe and Tanks Electrical Data Efficiency Evaluation of HVAC Water Systems Additional Reading Bibliography

vii

viii Contents

Chapter 3. Piping System Friction

Mgximum Velocity in Pipe Pipe and Fitting Specifications Steel Pipe Friction Analysis Steel and Cast Iron Pipe Fittings Thermoplastic Pipe Glycol Solutions Pressure-Gradient Diagrams Piping Network Analyses Summary Bibliography

Part 2 HVAC Pumps and Their Performance

Chapter 4. Basics of Pump Design

lntroduction Centrifugal Pump lmpeller Design General Performance of a Centrifugal Pump Sizing Centrifugal Pumps Specific Speed of a Pump Critical Speed of a Pump Minimum Speed for a Variable-Speed Pump Minimum Flow for HVAC Pumps Two Types of Centrifugal Pumps for HVAC Service Open or Closed lmpellers General Pump Design Information Bibliography

Chapter 5. Physical Description of HVAC Pumps

lntroduction Physical Description of HVAC Pumps Two Basic Types of Centrifugal Pumps Positive-Displacement Pumps Regenerative Turbine Pumps Pump Construction Mechanical Devices for Pumps Bibliography

Chapter 6. HVAC Pump Performance

6.1 lntroduction 6.2 Pump Head-Capacity Curves 6.3 SeriesIParallel Operation of Centrifugal Pumps 6.4 Affinity Laws of Pumps 6.5 Pump Suction Limitations 6.6 Internal Forces on Pumps

Contents ix

6.7 Pumping Energy 6.8 Sources of Pump Information 6.9 Summary 6.10 Bibliography

Chapter 7. Pump Drivers and Variable-Speed Drives

7.1 lntroduction 7.2 Electric Motors

7.3 Variable-Speed Drives for Electric Motors

7.4 Steam Turbine Drives for HVAC Pumps 7.5 Engine-Driven Pumps 7.6 Summary 7.7 Bibliography

Part 3 The HVAC World

Chapter 8. The Use of Water in HVAC Systems

Efficiency of Operation Efficient Use of Water in HVAC Systems Hot and Chilled Water Systems Energy Comparison of the Three Systems Categorization of HVAC Water Systems Suggested Design Rules Eliminating Energy Waste During Commissioning Bibliography

Chapter 9. Configuring an HVAC Water System

lntroduction Selection of Temperature Differential Modeling a Water System for System Head and Area Static Pressure Three Zone of HVAC Water Systems Piping Configurations Location of Expansion Tanks Elimination of Air in HVAC Systems Control of Return Water Temperature Bibliography

Chapter 10. Basics of Pump Application for HVAC Systems

10.1 lntroduction 10.2 Point of Selection 10.3 Number of Pumps 10.4 Mixing Constant- and Variable-Speed Pumps 10.5 Efficiency of a Pumping System 10.6 Wire-to-Water Efficiency Indication

X Contents

10.7 Pump Control 10.8 Effects of Water Systems on Pump Performance 10.9 Bibliography

Part 4 Pumps for Open HVAC Cooling Systems

Chapter 11. Cooling Tower Pumps

lntroduction Water Flow Conditions for Cooling Towers Cooling Tower Piping Location of Cooling Tower Pumps Selection and Operation of Condenser Pumps Special Condenser Water Circuits Understanding Legionnaires' Disease Summary Bibliography

Chapter 12. Pumps for Process Cooling

12.1 Introduction 12.2 Liquid Cooling 12.3 Energy Recovery 12.4 Gas Stream Cooling 12.5 Bibliography

Chapter 13. Pumping Open Thermal Storage Tanks

lntroduction Cool Thermal Storage Types of Cool Water Storage Systems Chilled Water Storage Open Ice Storage Systems Eutectic Salt Systems Decision as to the Type of Energy Storage System Basics of Pump Application to Open Energy Storage Tanks Types of Pumps for Thermal Storage Operating Pumps on Thermal Storage Systems Hot Water Storage Summary Bibliography

Part 5 Pumps for Closed HVAC Cooling Systems

Chapter 14. Chillers and Their Pumps

14.1 lntroduction 14.2 Rating of Chillers 14.3 Chiller Energy Consumption

Contents xi

14.4 Circuiting Chilled Water to Chillers 14.5 Operating and Sequencing Chillers 14.6 Preferentially Loading Chillers 14.7 Fuel-Fired Absorption Chillers

14.8 Connecting Primary Pumps to Chillers 14.9 Connecting Multiple Chiller Plants 14.10 Bibliography

Chapter

Chapter

16.1 16.2 16.3 16.4 16.5 16.6 16.7 16.8 16.9 16.1 0

15. Chilled Water Distribution Systems

lntroduction Primary Systems Primary-Secondary Systems Primary-Secondary-Tertiary Pumping Systems Distributed Pumping Consensus Bibliography

16. Closed Condenser Water Systems

lntroduction Reasons for Closed Condenser Systems Types of Closed Condenser Systems Heat-Recovery Condenser Systems Uses of Heat Reclaimed from Chillers Condensing-Type Boiler Improves Heat Recovery Pumping Aspects of Heat Recovery Storage of Hot Water Summation Bibliography

Chapter 17. Pumps for Closed Energy Storage Systems

17.1 lntroduction 17.2 Pressure Tanks for Energy Storage 17.3 Closed Energy Storage Systems with Open Tanks 17.4 Circuiting Internal Ice Melt Systems 17.5 Pumping Internal Ice Melt Systems 17.6 Bibliography

Chapter 18. Pumps for District Cooling and Heating

18.1 lntroduction 18.2 Model System for District Cooling 18.3 Calculating Central Energy Plant Static Pressure 18.4 Primary-Secondary Pumping System Analysis 18.5 Distributed Pumping System 18.6 Differential Temperature 18.7 Building Connections

xii Contents

18.8 District Heating 18.9 Conclusions 18.10 Bibliography

Part 6 Pumps for HVAC Hot Water Systems

Chapter 19. Steam and Hot Water Boilers

lntroduction Classification of Boilers Types of Boilers by Materials of Construction Types of Boilers, Condensing, or Noncondensing Rating of Boilers Computing Boiler Water Flow Connecting Pumps to Boilers Reset of Boiler Temperature versus Zone Reset Boiler Controls Bibliography

Chapter 20. Low-Temperature Hot Water Heating Systems

20.1 lntroduction 20.2 Classification of Hot Water Systems 20.3 Sources of Heat for Hot Water Systems 20.4 Uses of Hot Water in HVAC Systems 20.5 Distribution of Low-Temperature Hot Water 20.6 Hot Water Design and Differential Temperatures 20.7 Bibliography

Chapter 21. Pumps for Medium- and High-Temperature Hot Water Systems

21.1 lntroduction 21.2 Calculation of Water Flow 21.3 Calculation of Pump Head 21.4 Medium- and High-Temperature Water Generators 21.5 Distribution of Medium- and High-Temperature Water 21.6 Pumps for Medium- and High-Temperature Water Systems 21.7 Bibliography

Chapter 22. Condensate, Boiler Feed, and Deaerator Systems

22.1 lntroduction 22.2 Review of Steam Systems 22.3 Low-Pressure Steam Systems 22.4 High-Pressure Steam Systems 22.5 Steam Boilers 22.6 Condensate Systems for Steam Boilers 22.7 Design and Selection of Boiler Feed Pumps

Contents xiii

22.8 Number of Boiler Feed Pumps

22.9 Condensate Transfer Pumps for Deaerators

22.10 Summary

part 7 Installing and Operating HVAC Pumps

Chapter 23. Instrumentation for HVAC Pumping Systems

Introduction Transmitters Indicators Controllers Control Wiring Control Valves Summation Bibliography

Chapter 24. Testing HVAC Centrifugal Pumps

lntroduction Objective Types of Tests Testing Procedures Field Testing of Pumps Test lnstrumentation Test Reports and Records Summation Bibliography

Chapter 25. Installing HVAC Pumps and Pumping Systems

lntroduction Preinstallation Procedures Pump and Pumping System Bases Connecting Piping to Pumps Electrical Provisions for Pumps Alignment of Pumps and Motors Initial Operation of Pumps Summation Bibliography

Chapter 26. Factory-Assembled Pumping Systems

26.1 lntroduction 26.2 Types of Factory-Assembled Pumping Systems 26.3 Advantages of Factory-Assembled HVAC Pumping Systems 26.4 Components of a Factory-Assembled Pumping System 26.5 Testing Pumping Systems 26.6 Summation

xiv Contents

Chapter 27. Operating HVAC Pumps

lntroduction Checking for Efficient Selection of HVAC Pumps Constant- or Variable-Speed Pumps Proper Selection and Operation of Variable-Speed Pumps Control Signals for Speed Control Sequencing and Alteration Summary Bibliography

Chapter 28. Maintaining HVAC Pumps

28.1 lntroduction 28.2 Maintaining the Pumping Equipment at High Efficiency 28.3 Checking the Pump Itself 28.4 Checking the Pump Installation 28.5 Checking the Electrical Conduit and Piping lnstallation 28.6 Maintenance Observations and Scheduling 28.7 Summation

Chapter 29. Retrofitting Existing HVAC Water Systems

29.1 lntroduction 29.2 System Evaluation 29.3 Evaluation of Existing Procedures 29.4 System Configuration Modification 29.5 Summation

Chapter 30. Summary of HVAC Energy Evaluations

30.1 Review of Efficiencies 30.2 System Efficiencies 30.3 Purpose of Efficiencies 30.4 Sustained System and Equipment Efficiencies 30.5 Summary

Appendix A. Abbreviations

Appendix B. Terms and Nomenclature

Appendix C. Glossary of Equations

Appendix D. Conversion of English Units to SI

Index 521

Abbreviations, 491 Absolute viscosity of water, 17 Absolute pressure, 15 Absorption chillers, fuel fired, 308 Additional reading, 30 Adding variable speed to existing sys-

tems, 483 Affinity laws of pumps, 109, 110, 111

proper use, 210 Air elimination, 199

equipment, 21,22 Air entrainment, 115

effect on pump capacity, 116 Air release from water, 21 Air solubility in water, 20 Air vents, 95 Alternation of Pumps, 465 Ambient air, 14

temperature, maximum, 14 American National Standards Institute

(ANSI), 36 American Society of Heating,

Refrigeration, and Air-Conditioning Engineers (ASHRAE), 14,31,33,62

Design Study RP-450,35 American Society of Mechanical

Engineers (ASME), 26 Amereican Society for Testing and

Materials (ASTM), 36 Analog signals, 419 APEC, Inc. computer programs, 3 , 4 APEC outputs for piping, 5 Areas and volumes of pipe and tanks, 27,

28 Atmospheric pressure, 15

variation with altitude, 15

Autotransformer starters, 132 Axial flow type pumps, 79,88,89 Axial thrust, 119, 120

~ ~ C n e t @ , 9 Backpressure control valves, 281 Balancing valves, 96 Bernoulli theorem, 38,46,63 Best efficiency control, 227 Best Efficiency Point, 75, 101

parabolic path, 106 Boiler:

codes, 26 controls, 383 efficiency vs. inlet water temperature,

380 efficiency, 30 feed systems, 407 feed pump NPSH, 412 feed pumps, design and selection, 410 feed pump head, 412 feed pump capacity in GPM, 411 high-low control, 383 minimum flow, 382 modulating control, 384 on-off control, 383 pump location, 382 rating, 380 temperature reset vs. zone reset, 383 types, condensing or non-condensing,

379 types, by construction, 378 water flow in GPM, 381

Boilers, hot water and steam, 377 Brake Horsepower, 16

522 Index

British thermal unit, 16 Bypass starters, 147 Bypass coil pump for laminar flow, 176 Bypassing:

in pumps, 93 around chillers, 300

CD-ROM discs, 9 Cameron Hydraulic Data, 52,53,54,56 Campus type chilled water systems, 337 Can pump, 91 Carry-out, 73 Casing rings, 92, 93 Cast iron pipe fitting ratings, 37 Categorization of water systems, 177 Cavitation, 19, 112, 118 Central energy plant static pressures, 364 Centrifugal pump:

classification, 82 configurations, 74 design, 73 parts, 92,93 performance, 99-125 pressure-temperature limitations, 94 types, 78 (See also Pumps)

Centrifugal force, 74 Changing constant volume to variable

volume, 482 Changing pumped coil systems to vari-

able volume. 319.483 , ,

Changing constant speed to variable speed, 482

Chemical attack on variable frequency drives, 145

Chilled water: distribution, 317-338 flow, GPM, 182

Chilled water plant total energy con- sumption, 295

Chilled water storage, 273 system configuration, 274, 275

Chillers: and their pumps, 291-316 bypass location, 296-300 capacity in GPM, 292 chilled water circuiting, 296 energy, effects of piping on, 300 energy consumption, 293,294,295

with equalized piping, 300,307 with preferential piping, 300,307

fuel fired, absorption, 308

Chillers (Cont.): KW per ton, 300,304, 306 loading preferentially, 305 multiple chiller plants, 313, 314 piping, correct and incorrect, 298,

299 preferential loading, 305 primary pumps for, 308 rating of, 292 sequencing, 303

by bypass flow, 305 by chiller power input, 305 by leaving temperature, 305 by system flow, 303 unsatisfactory methods, 305

Churn, 73 Circulator pumps, 86 Clean power, variable frequency drives, '

141 Close couple pumps, 84, 85 Closed condenser systems, 339-351

with heat recovery, 343 Closed energy storage systems, 353-359

with open tanks, 355 Coefficient of performance, 293 Coil connections, l70

proper use of coil pumps, 176 flow testing, 179

Colebrook equation, 47 Commissioning HVAC systems, 10 Computer aided drafting (CAD), 3 Computer aided calculation of HVAC

loads, 3 Computer aided calculation of pipe fric-

tion, 3 Condensate systems, 401-413

boiler feed systems, 405, 407 deaerators, 408 discharge pressure, 401,405 transfer pumps, 413

Condenser pumps: constant speed, 254 selection and operation, 253 variable speed, 255

Condenser water circuits, 253-256 closed systems, 339-351 for absorption chillers, 255 for water source heat pumps, 342 heat reclaiming circuits, 344 uses of reclaimed heat, 344

Condensing type boilers, 379,380 improve heat recovery, 347

Connecting multiple chiller plants, 313

Index 523

Control valves: sizing, 169 three-way valves, 172 two-way connections, 171

Control of existing pumps, 477 Control wiring, 427 Control valves, 427

location, 281 Controllers, 426 Converting to distributed pumping, @/4 Cooling towers, 243-263

avoiding ice, 257 free cooling, 258-260 heat rejection, 245,262 legionnaire's disease, 261 piping, 246 plume abatement, 258 water flow conditions, 245

Cooling tower pumps, 243-263

/ pump location, 248 flow in GPM, 24,245

Corrosion, 75 Cost of pumping energy, 33 Coupling guards, 96 Critical speed of a pump, 77 Cross-over bridges, 161 Cyclone separator for pumps, 95

Darcy Weisbach equation, 46 use of, 52

Databasing, 8 Dead band, 418 Deaerators, 408 Design rules, 177, 178 Deviation, 418 Dserential pressure transmitters, 232-238

communication, 238 location, 233-235

Diffuser, 74 Digital control systems, 3 Digital electronics, 3, 10 Digital signals, 418 Diminished use of mechanical controls, 3 Direct free cooling, 258 Direct return systems, 197 Distributed pumping, 38, 329-337

for a hospital, 329 for a large airport, 337 fora a small college campus, 337 for a three building system, 332 with variable chiller flow, 333 with water temperature reset, 336

Distribution of water in a HVAC system, 8 District heating and cooling, 361-374

building connections, 370 central plant static pressures, 364 distributed pumping, 367 differential temperature, 370 with grid type systems, 364

Diversity, 7 Double volute pumps, 74 Double suction pumps, 87, 88 Dry bulb temperatures, 14 Dusty process dangers to electronics, 14 Dynamometer type head-capacity curves,

421,422 Dynamometer test, 100

Eductors, 301 Efficiency evaluations of HVAC systems,

30 Efficiency of a pumping system, 30,

218-222 Efficiency of operation, 461463 Efficent use of water in HVAC systems,

166 Efficient selection of pumps, 204 Eighteen pulse, variable frequency drives,

141 Electric motor:

currents, 132 efficiency, 134-135 performance curves, 131 voltages, 24 (See also Motors)

Electric power, 27,28 Electrical data, 27 Electronic control advent, 11 Electronic control of water systems, 9 Electronic commissioning, 10 Electronic communication, 8 Electronic design of piping, 8 Electronic design, speed and accuracy, 7 Electronic instrumentation, 10 Electronic selection of HVAC equipment, 9 Electronics and HVAC pumps, 9, 10 Electronics and variable speed pumps, 10 Emergency backup of pumps, 228 Encapsulated ice systems, 278 Energy:

calculations for balance valves, 163-165

consumers, l 6 1 consumption by pumps, 123

524 Index

Energy (Cont.): consumption of water distribution, 159,

160,167 comparison of three systems, 174 effect on chillers and boilers, 164

efficiency ratio, 293 generation, 167 inefficient use, 156 lost to mechanical flow control devices,

161,162 storage tank location, 274 transportation of, 167 use in HVAC systems, 167,168 useful, 156 waste during commissioning, 178

Engine driven pumps, 150 Enthalpy of water, 27 Equation solution by computer, 7 Equations, glossary, 503 Equivalent fuel per KW, 166 Erosion, 75 Ethylene glycol properties, 22 Eutectic salt energy storage systems, 279 Evaluation of existing procedures, 478 Evaluation of existing pumps and motors,

476 Evaluation of existing systems, 473 External ice storage systems, 279 Expansion tank location, 199

Fabrication of pipe fittings, 61 Factory assembled pumping systems,

445459 advantages, 451454 chilled and hot water, 445448 components, 454 control centers, 458 condenser water, 450 primary pumping, 446 secondary pumping system, 447 steam heated systems, 449451 types, 445 with expansion tank and air separator,

448 with vertical, double suction pumps, 449 with complete houses, 457

Family of pump curves, 72 Feet of Head Formula, 71 First cost vs. operating cost, 33,34 Flow meters, 419

accuracy, 420 calibration, 421

Flow meters (Cont.): electronic type, 420 head loss type, 419 installation, 422 magnetic type, 422 propeller type, 420 selection, 422

Flow of water in steel pipes, 39-45 Four pipe systems, 199 Frame or bracket, 85 Free cooling, 258-261

direct, 258 indirect, 260 refrigerant migration, 260

Gauge pressure, 15 Glycol-bases heat-transfer fluids, 22, 63

freezing points of, 25 pump flow equation, 22 specific heat of, 22,26 specific gravity of, 24 viscosity of, 23

Good piping design, 33

Hardy Cross method, 68 Harmonic distortion, 30, 142, 143 Harmonics and variable speed drives, 142 Head-capacity curves, 99, 100, 103,104

constant speed pumps, 71,72,100 dynamometer, 105 family of, 72 high specific speed, 101,102 rising characteristic, 101 series-parallel, 107 steep vs. flat, 105 variable speed pumps, 100,105

Heat release from variable speed drives, 144

Heat exchangers: multiple temperatures, 390 with three-way temperature control

valve, 389 with variable speed pump, 387

Heat generation in equipment rooms, 15 Heating Boiler Code, 26 Heating and cooling coils, 169-175 Henry's law, 21 High pressure steam systems, 403 High temperature water systems, 395-400

pumps for, 399 water flow, 396

- -

Index 525

Hot water storage, 28

water boilers)

differential temperatures, 393 distributed pumping, 392 low temperature, 385 primary systems, 392 sources of heat, 386 temperature reset, 394

Hot water distribution, 385-394 Hot water system flow, GPM, 182,396 HVAC load calculation, 183-184 HVAC pumps:

classification, 82 description, 81 installation, 437444 performance, 99-125

HVAC system standards, 13 configuration, 181 three zones of, 195

Hydraulic gradient, 6, 34,43,54 Hydraulic Institute, 3945,47,49,50, 52

Engineering Data Book, 54 Hydrogen sulphide danger to electronics, 14 Hydrostatic testing of pumps, 430

Ice storage systems, 277 Ice harvesters, 277 Ice in cooling towers, 257 IEEE standards, 127,142 Impeller design, 73, 74

enclosed, 89 internal passages, 75 propeller, 90 semi-open, 89 slots, 74 trimming, 105, 209, 210

In line pumps, 85 Inboard bearing, 93 Indicators, 426 Indirect free cooling, 258,259 Indoor air quality, 15 Inefficient use of energy, 156 Installing pumps and pumping systems,

437-444 Institute of Electrical and Electronic

Engineers, 31 Instrumentation for HVAC systems,

417428 Instruments:

accuracy, 417

Instruments (Cont. ): dead band, 418 deviation, 418 overshoot, 418 process, 418 repeatability, 419 response time, 418 set point, 419 span, 419

Internal pump forces, 119 Internal ice melt system pumping, 356,

358

K factors for pipe fittings, 54-59 Kilowatts per to efficiency, 30 Kinematic viscosity, 17 Kwlper ton for chiller plants, 295

Laminar flow in coils, 169 Legionnaires disease, 261 Level transmitters, 425 Load range for a water system, 166 Low pressure steam systems, 377 Low temperature hot water heating sys-

tems, 385-394

Maintenance of HVAC pumps, 467471 checking pump itself, 469 observations, 470

Manual petcock, 95 Manual transition for drives, 148 Maximum distance of transmitters from

pump control, 238 Maximum temperature of variable fre-

quency drives, 145 Maximum water velocities, 35

designer's responsibility, 36 Mechanical devices disappearing, 9 Mechanical flow device energy consump-

tion, 161 Mechanical devices for pumps, 95 Mechanical seals, 94 Medium and high temperature water sys-

tesm, 395-400 distribution, 399 pump head, 397 pumps for, 399 water flow, 396

Minimum speed for HVAC pumps, 77 Minimum flow for HVAC pumps, 78

526 index

Mixed flow pumps, 88 Mixing constant and variable speed

pumps, 213 Moody diagram, 47,49 Motors, electric:

code letters, 130 construction, 135 derating factors, 128 enclosures, 135, 136 efficiency, 134, 135 output horsepower, 133 synchronous speed, 129 speed, 129 sizing for HVAC pumps, 136 currents, 131, 132 output ratings, 129 testing, IEEE, 134 torque and horsepower, 131,132

Multi-stage pumps, 88, 89 Multi-pulse circuits, 141 Multiple duty valves, 96

NEMAinduction motor designs, 127 Net Positive Suction Head Available

(NPSHA), 19, 113 formula, 113, 114, 115 pump pressure gradient, 114

Net Positive Suction Head Required (NPSHR), 97,99

Non-uniformly loaded buildings, 187 Number of variable and constant speed

pumps in parallel operation, 217 Number of pumps operating, 212

On-line data services, 9, 11 Open or closed impellers, 79 Open energy storage systems, 277

backpressure valves for, 281 energy recovery, 282

turbine pumps, 283 Open type HVAC systems, 241 Open thermal storage tanks, 271 Operating pressures, 15 Operation of HVAC pumps, 461466 Output horsepower (Water horsepower),

121 Owning cost of piping, 35

Parallel pump operation, 108 Part winding starters, 133

Physical data for HVAC system design, l3 Pipe friction analysis, 33

formulas, 46 network analyses, 68 tables, 3945

Pipe velocities, maximum, 33,34,35 Pipe fittings:

specifications, 36 fabrication, 60, 61 friction losses, 54

bushings, 55 couplings, 55 elbows, 55, 56 equation for, 54 reducing fittings, 56

cast iron, 59 steel, 58

sudden enlargements, 55 tapered fittings, 57,58 tees, 56 unacceptable fittings, 59 unions, 55

Piping configurations, 195, 198 direct return, 197 four pipe systems, 199 open systems, 198 reverse return, 196 two pipe systems, 198 three pipe systems, 198

Piping system friction, 33-68 effect on pump selection, 33

Plastic pipe, 61 (See also Thermoplastic pipe)

Point of selection for pumps, 204 Positive displacement pumps, 91,99 Power Boiler Code, 26 Power Factor, 134 Power factor correction equipment, 30 Pressure gradient diagrams, 6,63-67 Pressure relief valves, 239 Pressure reducing valves, 157 Pressure and differential pressure trans-

mitters, 414 Pressure-temperature limitations for

pumps, 94 Primary pumps, 308-310

location, 311-312 Primary/secondary pumping, 323

multiple zone, 324 zone pumping, 325-327

Primarylsecondaryltertiary pumping, 328 Primary systems, 318

small type, 320

Index 527

Primary systems (Cont.): variable volume type, 320

existing chillers, 320 digitally controlled chillers, 321

with relief valve, 319 wire-to-water efficiency for, 323

Primary resistor starters, 133 Primarylsecondary zone pumping, 325 Priming means, 97 Process (Instrumentation), 418 Process cooling, 265-270

energy recovery, 270 gas streams, 270 liquids, 265

Propeller pumps, 88 Proportional-Integral-Derivative control,

419 Proportional-Integral control, 419 Pump duty, 73 Pumping systems:

efficiency of, 217 factory assembled, 445 losses, 191, 192 wire-to-water efficiency, 218-222

Pumps, centrifugal: alignment, 443 alternation, 228, 465 and field piping, 440 application basics for open tank sys-

tems, 203 bases, 437

seismic restraints, 440 bowl, 74,89 brake horsepower, 122 constant speed with variable speed,

213,216 construction, 92 control centers, 58 control, 225 design basics, 71 drivers and drives, 127-151 duty, 73 electrical connections, 442 emergency backup, 228 energy, 121 expansion provisions, 441 fitting arrangement, 441 fitting sizes, 440 for thermal storage, 359 general design information, 80 head-capacity curves, 72, 91, 100 horsepower, 122 houses, 456

Pumps, centrifugal (Cont.): impellers, 74 initial operation, 443 information sources, 124 internal forces, 119 installation, 437 K W formula, 181 maintenance, 467 materials, 92, 93 motor power, 122, 123 number of, 212 packing, 94 parts, 92 performance, 99 point of selection, 204

constant speed, 205 variable speed, 208

power, KW, 122 pressure-temperature limitations, 94 radial thrusts, 120 relief valves, 239 rotation check, 444 safety controls, 443 series-parallel, 106, 107 sequencing, 226 special speeds, 208,209 speed control, 229

communication from remote sensors, 236

sensors, 230,231 location, 233-235 wire sizes, 238

suction limitations, 112 test for priming, 432 test types, 430 testing in the field, 433 tests for head-capacity, 105 tests for NPSH required, 432 types, 78

Purpose of book, 10 PWM variable speed drives, 138,140

Reduced voltage starting, 132 Reducing fittings, 55 Reducing bushings and couplings, 55,56 Refrigeration migration, 260 Regenerative turbine pumps, 91,99 Remote cooling tower sumps, 240 Repeatability, 419 Response time, 418 Retrofitting existing HVAC systems,

473-485

528 Index

Return water temperature, 183 Return water temperature control, 200

valves, 201,202 Reverse return systems, 197 Reynolds Number, 47,49,50 Rotor assembly, 87 Roughness parameter, 47

Seismic restraints, 440 Series pump operation, 107 Self priming pumps, 86 Sequencing pumps, 464 Seriesiparallel operation of pumps, 107 Set point, 419 Shut off head, 73 S1 units, 517 Simplicity of system design, 9 Six pulse, variable frequency drive, 138 Sizing centrifugal pumps, 76 Solid state starters, 133 Solubility of air in water, 20 Spacing of pumps, 125 Span, 419 Special pump speeds, 208 Specific speed of a pump, 76 Specific weights of water, 18, 19,20 Specific heat of pure water, 397 Standard air conditions, 14 Standard operating conditions, 13, 14 Static head, 38

loss for open tank systems, 283 Static pressure, 194, 195 Steam turbine drives, 150 Steam and hot water boilers, 377-384

boiler water flow, 381 boiler controls, 383 classification, 377 connections to pumps, 382 condensing, 379 rating boilers, 380 reset of water temperature, 383 types of boilers, 378,379

Steam data, 25,27 Steam systems, 401 Steam turbine driven pumps, 127 Steel and cast iron pipe fittings, 36,37 Steel pipe:

flow of water in, 3 9 4 5 maximum capacities, 35 friction analysis, 38

Steep vs. flat pump curves, 106 Strainers, 95

Submergence for turbine pumps, 118, l l g Sudden enlargements, 55 Suggested design rules for HVAC water

systems, 177 Summary of HVAC energy calculations,

487-490 Sumps, 249,252 Surfactants, 33 Synchronous speed motors, 128 System efficiency, 30,487

calculation of, 157-160 System friction, 33 System pressure, 38

energy recovery, 228,283 System head areas, 187, 189,190

for a campus, 190 System head curves:

components, 184 coordinates, 187 generation, 185

Tank connection losses, 55 Tapered pipe fittings, 55,56,58 Temperature differential selection, 182 Temperature transmitters, 425 Terms and nomenclature, 495 Test instrumentation, 433

calibration intervals, 434 installation, 434

Test reports and records, 434 Testing of HVAC pumps, 429-435

factory assembled systems, 459 field testing, 433 hydrostatic, 430 NPSHR, 432 performance, 430 priming, 432 types, 430

Testing procedures, 433 Thermal storage:

pumps for, 286 (See also ice and water systems)

Thermal equivalents, 16 Thermodynamic properties of steam, 25 Thermoplastic pipe, 61, 62

design factors, 62 Three zones of a water system, 168 Three pipe systems, 198 Three way coil valve systems, 169, 170 Time saving of factory assembled pump-

ing systems, 452 Torque and horsepower, 131

Index 529

Total head of a system, 38 Total owning cost of piping, 34, 35 Transmitters, 419 Trimming pump impellers, 210, 212 Turbine pumps, 88 Turbulent flow, 49 Twelve pulse variable frequency drives,

141 Two pipe systems, 198 Two way valve system with circulator,

171 Two-way coil control valves, 171 Typical wire-to-water eff~ciencies, 225

Uniform Building Code, 13, 440 Uniform system head curve formula, 185 University of Kentucky pipe friction net-

working, 68 Use of energy, 156 Uses of heat reclaimed from chillers, 156

Vacuum pumps, 404 Valves:

friction losses, 57 location in open storage systems, 281 multiple duty valves, 60

Vapor pressures of water, 18,19,20 Variable speed drive types, 137,138 Variable speed pumping, 11, 100, 105,

208,218,220,224,225,230-238 Variable frequency drives, 10

advantages, 144 application, l44

cleanliness, 145 chemical attack, 145 location, 145 maximum temperature, 145

as reduced voltage starting, 133 bypass starters, 147 certification, 147 clean power, 141 enclosures, 146, 149 harmonics in, 142 instrumentation, 149 multi-pulse circuits, 141 ventilation, 145-146, 149

Variable speed drives: control, 225, 228 history, 137

Variable speed drives (Cont.): types, 138

Variable chiller flow with distributed pumping, 333

Variable speed pumps, 11 Variable speed pumping control centers,

146,458 Vector diagram for a centrifugal pump,

73,74 Velocity head, 6, 7, 38,39,43, 63, 105 Ventilation air quality, 14 Vertically mounted, end suction pumps,

85,86 Vertically mounted, double suction

pumps, 88 Viscosity equivalents, 17 Viscosity of water, 17 Voltage imbalance factors, 128 Voltages, standard 50 and 60 HZ, 29 Volumes of pipes and tanks, 27 Volute type pumps, 79, 83, 84

close coupled, 84 flexible coupled, 74 in-line, 85 multistage, 86 self priming, 86 vertically mounted, 85

Vortexing, 115, 117, 118

Water data, 16 Water horsepower, 121 Water temperature standards, 16 Water source heat pumps for central

plants, 344 Water source heat pumps, terminal type,

343 Water system modeling, 183 Watt transmitters, 425 Wet bulb temperatures, 14 Wet pits, 252 Williams and Hazen equation, 46,47

use of, 52 values of "C" for, 53

Wire-to-water efficiency, 30, 218-222 control, 228 indication, 222 instrumentation, 224 typical efficiencies, 219, 225

Wye delta starters, 133