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SureFlow
Presented by:
Ron Porter LEED AP
IEC Oklahoma City
Copyright 2012
Topics
• Fan Coil Basics• Traditional System Design• SureFlow Hydronics• SureFlow Unit Design• SureFlow Applications
This Is A Fan Coil
Fan + Coil = Fan CoilRoom Air Conditioner
Moves air through a coil with:
Chilled WaterHot WaterElectric HeatR410a
Let’s focus on the water systems…
How Do They Work ?
FCU
ChillerChiller
FCUFCUFCU
Central Pump Pushes Water Through Piping to Supply Each Fan Coil
Standard Water Pressure Differential System
How Do We Size The Main Pump ?
Central Pump Horsepower = __Head x GPM__
3960 x Efficiency
FCU
ChillerChiller
FCUFCUFCU
Calculate All Circuits
Pump Sizing Based On Highest Pressure Drop Circuit
FCU
ChillerChiller
FCUFCUFCU
Water Always Takes The Path Of Least Resistance
How Do We Know The Fan Coils Will Operate As Advertised ?
FCU
ChillerChiller
FCUFCUFCU
Water Pipe Has Resistance To Water Flow
Pipe and Riser Diameters ?
Continuity : Water In = Water Out (GPM Per Minute)
Velocity : Speed of Travel (Feet Per Second)
D1 D2
Vel1 Vel2Area1 Area2
Flow In “Q” Flow Out “Q”
Flow In “Q” = 10 GPM
D1= 1 Inch “L” Copper
Vel1 = 3.9 Ft Per Second
Flow Out “Q” = 10 GPM
D2= 2 Inches “L” Copper
Vel2 = 1.05 Ft Per Second
Pressure drop is defined as:
The difference in pressure between any two points
on a piece of equipment.
D1D2
Vel1 Vel2Area1 Area2
Flow In “Q” Flow Out “Q”
Flow In “Q” = 10 GPM
D1= 1 Inch “L” Copper
Vel1 = 3.9 Ft Per Second
PD1 = 6.71 Ft per 100 Ft
Flow Out “Q” = 10 GPM
D2= 2 Inches “L” Copper
Vel2 = 1.05 Ft Per Second
PD2 = 0.29 Ft per 100 Ft
PD1 PD2
Coil Pressure Drop =Cost of Operation
Determined from several parameters-• Unit size• Coil rows• Coil circuits• GPM• Tube water velocity• Water temperature
Use IEC Rating Program to determine pressure drop through
the coil at actual operating conditions
Example
@ 3.0 GPM
Coil PdFt = 5.9
Valve Pressure Drop:
• Resistance to water flow
• Based on water volume through the valve at
Full Open
• Calculated using Cv Rating Number
• PdFt = ( GPM / ( 0.658 x Cv ))^2
Typical Ball Valve Pressure Drop:
• PdFt = ( GPM / ( 0.658 x Cv ))^2
• Ball valve Cv = 5.84 (1/2 inch)• GPM = 3• PdFt = (3 / (0.658 x 5.84))^2
• PdFt = 0.61
Full-Port Ball Valve Pressure Drop:
• PdFt = ( GPM / ( 0.658 x Cv ))^2
• Ball valve Cv = 14.2 (1/2 inch B&K # 107-503T)• GPM = 3• PdFt = (3 / (0.658 x 14.2))^2
• PdFt = 0.10
Erie Valve Pressure Drop:
• PdFt = ( GPM / ( 0.658 x Cv ))^2
• Cv = 3.5 (1/2 inch VT2213)
• GPM = 3
• PdFt = (3 / (0.658 x 3.5))^2
• PdFt = 1.7
VT2213
3.5 Cv (7/16” Port)
25 PSI Close-Off
Erie Valve Pressure Drop:
• PdFt = ( GPM / ( 0.658 x Cv ))^2
• Cv = 2.5 (1/2 inch VT2212)
• GPM = 3
• PdFt = (3 / (0.658 x 2.5))^2
• PdFt = 3.3
VT2212
2.5 Cv (5/16” Port)
40 PSI Close-Off
Erie Valve Pressure Drop:
• PdFt = ( GPM / ( 0.658 x Cv ))^2
• Cv = 1.0 (1/2 inch VT2211)
• GPM = 3
• PdFt = (3 / (0.658 x 1.0))^2
• PdFt = 20.8
VT2211
1.0 Cv
60 PSI Close-Off
FCU
Analyze Combined Unit And Valve Package Pressure Drop
@ GPM = 3.0
Ball Valve PdFt = 0.1
Coil PdFt = 5.9
Erie Valve PdFt = 3.3
Ball Valve PdFt = 0.1
Total PdFt = 9.4
÷ 2.33
= 4.0 PSI Diff
Total Value Required For Proper Fan Coil Operation
BoilerBoiler
FCUFCUFCU
Will This Design Operate Properly ?
Supply
Return
80 PSI
Δ 10 PSI
70 PSI 65 PSI
85 PSI
Δ 20 PSI
Units &
Valves
@ 3.0 GPM
Require
4.0 PSI Diff Pump
60 GPM
60 Ft Head60 PSI
Δ 25 PSI
Typical of 20 Units
BoilerBoiler
FCUFCUFCU
Water Balancing Is Required
Supply
Return
5 PSI
Δ 1 PSI
4 PSI 70 PSI
80 PSI
Δ 10 PSI
Pump
60 GPM
60 Ft Head60 PSI
Δ 25 PSI
Units &
Valves
@ 3.0 GPM
Require
4.0 PSI Diff
Excessive FlowLow Flow
BoilerBoilerFCUFCUFCUFCU
Cartridge Valves For Automatic Balancing
Supply
Return
Hays 2517 Automatic Balancing Valve
2-80 PSID range up to 5.5 GPM
+/- 10% Accuracy
Valve Will Add Resistance As Required For Specified Water GPM
Analyze Combined Unit And Valve Package Pressure Drop
@ GPM = 3.0
Ball Valve PdFt = 0.1
Hays Valve PdFt = 4.6
Coil PdFt = 5.9
Erie Valve PdFt = 3.3
Ball Valve PdFt = 0.1
Total PdFt = 14
÷ 2.33
= 6.0 PSI Diff
FCU
BoilerBoilerFCUFCUFCUFCU
80 PSI
70 PSI
Full Load
Pump
60 GPM
60 Ft Head
VFD
ΔP
Δ 10 PSI
Full-Load Variable Frequency Drive
BoilerBoilerFCUFCUOFFFCU
80 PSI
70 PSI
Part Load
Pump
45 GPM
VFD
ΔP
Δ 10 PSI
Part-Load Variable Frequency Drive
BoilerBoilerFCUFCUFCUFCU
80 PSI
70 PSI
Full Load
Pump
60 GPM
60 Ft Head
VFD
ΔP
Δ 10 PSI
Direct Return System
ChillerChiller
Reverse Return –Balancing is reduced, therefore the need for balancing valves is reduced, but only if all coils have identical ΔP and system
pressure differential always equals coil required ΔP.
VFD
ΔP
FCU FCU FCU FCU
Chiller / Boiler Equipment Plant Pumps Create Water Pressure Differential Pipes Running To and From Each Unit Valves – On/Off or Modulating Balancing Valves – Flow Regulators Strainers Pressure Relief Valves Variable Speed Drives on Pumps Controls, DDC, Building Energy Management System Installation Labor – vs. – 2/Pipe – vs. – 4/Pipe Test & Balance Maintenance
System Design Issues
System Complexity Issues
There Must Be A Better
Way
Primary Circuit Water Flow
Integrated CirculatorCycles on Thermostat
Demand
2008 ASHRAE Handbook HVAC Systems and Equipment
Chapter 12.
ThermostatOFF
Cool AirCool AirCool AirCool Air
Primary Circuit Water Flow
2008 ASHRAE Handbook HVAC Systems and Equipment
Chapter 12.
ThermostatON
Primary Circuit Water Flow
2008 ASHRAE Handbook HVAC Systems and Equipment
Chapter 12.
ThermostatOFF
• Average 40% Less Piping
• Fewer Pipe Hangers
• Less Insulation
Massachusetts College of Pharmacy and Health Sciences
Worcester, Massachusetts
• Reduced Core Drilling
• Fewer Joints = Fewer Leaks
• Contractor Savings
Westin Cupples StationSt. Louis, Missouri
Westin Cupples StationSt. Louis, Missouri
CPF SureFlow Unit
What Happened To The Zone Valves
and Flow Control Valves ?
Circulator – 1/40 HP• 30+ Years In Production
• Millions In Use
• Quiet Operation
• Chilled Water CERTIFIED
• Wet Rotor Cartridge Design
• Internal Flow Check Valve
• 200 PSI Rating
• Cycles On-Off (Thermostat Controlled)
• Low Energy Consumer – 65 Watts
Two Pipe CoolingWith Only One Installed Pipe
Chiller
FANCOIL
FANCOIL
FANCOIL
FANCOIL
Water Circulation Rate ≈ 3 GPM per TonPump Head & Energy Reduced
Chiller
FANCOIL
FANCOIL
FANCOIL
FANCOIL
Boiler
Two Pipe Cooling & Heating “Change Over”
With One Installed Pipe
2-Pipe Cooling and Heating Changeover With Only One Installed Pipe
Massachusetts College of Pharmacy and Health Sciences
Worcester, Massachusetts
Four Pipe Heat & CoolWith Only Two Installed Pipes
Chiller
FANCOIL
Boiler
FANCOIL
FANCOIL
FANCOIL
1. What Happens To The Water Temperature ?
2. Will It Control Humidity ?
Challenges:
42ºF 46.6ºF46.6ºF 48.6ºF
44.4ºF
Chiller
Off
52.1ºF
Water Temperature Changes As BTUs Are Injected Into The SureFlow Loop
1 Ton13177t 9954s
1 Ton
12052t 9519s
1 Ton
14424t 10448s
1 Ton
Cooling Loop Water Pipe Size
Design GuideType L Copper
Pipe Size 1” 1-1/4 1-1/2 2 2-1/2 3
GPM 8 16 25 53 85 127
FPS Vel 3.13 4.1 4.53 5.54 5.74 6.01
PdFt / 100Ft 4.53 5.66 5.46 5.58 4.57 4
Tons @ 8ΔT 2.7 5.3 8.3 17.7 28.3 42.3
Tons @ 10ΔT 3.3 6.7 10.4 22.1 35.4 52.9
Pipe Size 1” 1-1/4 1-1/2 2 2-1/2 3
GPM 8 16 25 53 85 127
FPS Vel 3.13 4.1 4.53 5.54 5.74 6.01
PdFt / 100Ft 4.53 5.66 5.46 5.58 4.57 4
MBH @ 20ΔT 80 160 250 530 850 1270
MBH @ 25ΔT 100 200 312 662 1062 1587
Design GuideType L Copper
Heating Loop Water Pipe Size
8 Degree Loop Delta-T = 3 GPM per Ton
Cooling Loop Water Temperature
10 Tons Peak x 3 GPM per Ton = 30 GPM1-1/2” L Copper @ 30GPM = 5.43 fps = 7.55 ftpd/100ft
2” L Copper Pipe @ 30GPM = 3.14 fps = 2.02 ftpd/100ft
Peak Load Analysis Sample
7.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio
Block vs Peak Load Analysis
With 42F Supply, 3 GPM Per Ton, 75% RatioMax Actual Water Temperature = 48F
BLOCK LOAD RATIO
Design For Diversity
With 42F Supply, 3 GPM Per Ton, 75% RatioMax Actual Water Temperature = 48F
Design For Diversity
SOME UNITS
ARE NOT RUNNING
ARE SOME UNITS OVER
SIZED ?
SureFlow Allows Adjustment Of The Design For Occupancy
– School Classroom vs. Common areas– Hotel Rooms– Offices– Usage patterns, time of day
SureFlow Allows Modification Of The Design For Run Time and Fan Speed
– Actual hours of operation with full water flow
– Good water flow rate results in excellent humidity control
– Take full advantage of controls capabilities
– Always recommend automatic fan speed reduction for extended run-time on coil
Circulators Only Consume Power When Running
Local Circulators Controlled by Room Thermostats
System Strategy: Demand Controlled Pumping
The Building Hydronic System Becomes An Energy Management System
Horsepower Savings
LEED 2009-NC Credit EAc1Optimize Energy Performance
Up To 19 Points Available
Complex 2-way valve package
= 32 solder joints
SureFlow valve package
= 16 solder joints
Installation and Maintenance Savings
Primary Pump
Common Load
Secondary Pump
Chiller - Or -Heat
Exchanger
Compound Primary-Secondary Pumping
Building 1 of X Building 2 of X
Central Plant
Campus Chilled Water
Balance Valves
3 Way Control Valve
Load
Replace Your Original Existing 2-pipe FCU….
CW Supply
CW Return
…. With a New SureFlow Unit and Have 4-Pipe Performance With Two Pipes
Existing Pipes
HeatingCoil
HeatingCoil
CoolingCoil
CoolingCoil
CW Supply/Return
HW Supply/Return
1839 US Tariff Building – General Post Office
Owner: US Department of Interior – Park Service
Lease: Kimpton Hotel & Restaurant Group
232 Rooms – AAA 4 Diamond
Opened Summer 2002
SureFlow Fan CoilsHotel MonacoWashington DC
Case Study
Fernando Garcia, P.E.Vice PresidentCTA Consulting Engineers Inc.Rockville, MD(301) 637-0058
Chicago Blackstone Renaissance Hotel
636 South Michigan332 Rooms
Restoration of 1908 HotelOpened Fall 2007
1920: Location of the famous “Smoke Filled Rooms” where Warren G. Harding was chosen as the Republican nominee for President.
1940: Franklin Delano Roosevelt’s 3rd-term Democratic Nomination was forged here.
1944: Harry S. Truman stayed here when he received Vice Presidential Nomination.
1952: Dwight D. Eisenhower stayed here during first Republican ballot.
The Nines, The Luxury Collection, Starwood Hotels
Top 9 Floors - 331 Guest RoomsPortland’s First 5-Star Hotel
Lower 5 Floors is Macys Dept Store
Redevelopment of 1909 Meier & Frank Department Store
National Register of Historic Places
Opened Oct 2008 LEED Silver
Portland, Oregon
Elysian / Waldorf Astoria
60 Stories on East Walton Street in the Gold Coast52 Private Residences
188 Room Waldorf Astoria Hotel
Constructed 2006-2010Renamed Waldorf Astoria Chicago February 1, 2012
AAA Five DiamondTripAdvisor.com Ranked # 1 Hotel in USA
Conde Nast Traveler Ranked Best Hotel in USA
Chicago
As of Feb 1, 2012:
Hotel rates: start at $395
Condo Sales up to $8 Million
Condo Rent: $16,000/month 3-Bed, 3.5-Bath, 3,747 Sq Ft
12,000 Units over 12 Years
Cool AirCool AirCool AirCool Air
Average 40% Less Piping
Installed Cost Savings $$$
Pump Energy Savings For Owner $$$
Reliable Operation
Occupant Comfort
LEED Credit Opportunities4 – Pipe
Performance With 2 Installed Pipes
Low Maintenance
Easy To Design
Application:SureFlow
75
FCU
ChillerChiller
FCUFCUFCU
Part Load Pump Controls
Standard Piping Method
76
System Design Issues
• Chiller / Boiler Equipment Plant• Pumps Create Water Pressure Differential• Pipes Running To and From Each Unit• Valves – On/Off or Modulating• Balancing Valves – Flow Regulators• Strainers• Pressure Relief Valves• Variable Speed Drives on Pumps• Controls, DDC, Building Energy Management System• Installation Labor – vs. – 2/Pipe – vs. – 4/Pipe• Test & Balance • Maintenance
77
Primary
Circuit Water
Flow
Integrated Circulator
Cycles on Thermostat
Demand
Thermostat
OFF
78
79
SureFlow
Average 40%
Less Piping
Less Core
Drills on
Renovation
Contractor
Savings
80
• 30+ Years In Production
• Millions In Use
• Quiet Operation
• Chilled Water CERTIFIED
• Wet Rotor Cartridge Design
• Internal Flow Check Valve
• 200 PSI Rating
• Cycles On-Off (Thermostat
Controlled)
• Low Energy Consumer – 65 Watts
SureFlow Circulator – 1/40 HP
81
Two Pipe Cooling
With Only One Installed Pipe
Chiller
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
82
Two Pipe Heat & Cool
With Only One Installed Pipe
Chiller
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
Boiler
83
42ºF 46.6ºF46.6ºF 48.6ºF
44.4ºF
Chiller
Off
52.1ºF
Central Pump Is NOT Responsible For Pressure Drop Of Coil Or Valve Packages
1 Ton13177t 9954s
1 Ton
12052t 9519s
1 Ton
14424t 10448s
1 Ton
SureFlow System Pumping
84
7.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio
Block vs Peak Load Analysis
85
1839 US Tariff Building –
General Post Office
Owner: US Department of
Interior – Park Service
Lease: Kimpton Hotel &
Restaurant Group
232 Rooms – AAA 4
Diamond
Opened Summer 2002
SureFlow Fan Coils
Hotel MonacoWashington DC
SureFlow Installation - Case Study
86
Application:SureFlow
87
Standard Piping Method
ChillerChiller
FCUFCUFCUFCU
88
FCU
ChillerChiller
FCUFCUFCU
Primary-Secondary Pumping
Standard Piping Method
89
FCU
ChillerChiller
FCUFCUFCU
Part Load Pump Controls
Standard Piping Method
90
System Design Issues
• Chiller / Boiler Equipment Plant• Pumps Create Water Pressure Differential• Pipes Running To and From Each Unit• Valves – On/Off or Modulating• Balancing Valves – Flow Regulators• Strainers• Pressure Relief Valves• Variable Speed Drives on Pumps• Controls, DDC, Building Energy Management System• Installation Labor – vs. – 2/Pipe – vs. – 4/Pipe• Test & Balance • Maintenance
91
Primary
Circuit Water
Flow
Integrated Circulator
Cycles on Thermostat
Demand
Thermostat
OFF
92
Cool AirCool AirCool AirCool Air
Primary
Circuit Water
Flow
Integrated Circulator
Cycles on Thermostat
Demand
Thermostat
ON
93
Design Considerations: Piping Circuits - Diverting
Series
One-pipe diverting series circuits – “when coupled with
compound pumping systems, series circuits can be
applied to multiple control zones on larger commercial
or institutional systems.”
2008 ASHRAE Handbook
HVAC Systems and Equipment
Chapter 12.94
95
SureFlow
Average 40%
Less Piping
Less Core
Drills on
Renovation
Contractor
Savings
96
• 30+ Years In Production
• Millions In Use
• Quiet Operation
• Chilled Water CERTIFIED
• Wet Rotor Cartridge Design
• Internal Flow Check Valve
• 200 PSI Rating
• Cycles On-Off (Thermostat
Controlled)
• Low Energy Consumer – 65 Watts
SureFlow Circulator – 1/40 HP
97
Two Pipe Cooling
With Only One Installed Pipe
Chiller
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
98
Two Pipe Heat & Cool
With Only One Installed Pipe
Chiller
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
Boiler
99
Four Pipe Heat & Cool
With Only Two Installed Pipes
Chiller
FAN
COIL
Boiler
FAN
COIL
FAN
COIL
FAN
COIL
100
42ºF 46.6ºF46.6ºF 48.6ºF
44.4ºF
Chiller
Off
52.1ºF
Central Pump Is NOT Responsible For Pressure Drop Of Coil Or Valve Packages
1 Ton13177t 9954s
1 Ton
12052t 9519s
1 Ton
14424t 10448s
1 Ton
SureFlow System Pumping
101
Coil Pressure Drop is Redesigned to Match
Circulator Pump Curve
102
8 Degree Loop Delta-T = 3 GPM per Ton
Cooling Loop Water Temperature
103
10 Tons Peak x 3 GPM per Ton = 30 GPM1-1/2” L Copper @ 30GPM = 5.43 fps = 7.55 ftpd/100ft
2” L Copper Pipe @ 30GPM = 3.14 fps = 2.02 ftpd/100ft
SureFlow Peak Load Design
104
7.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio
Block vs Peak Load Analysis
105
With 42F Supply, 3 GPM Per Ton, 75% RatioMax Actual Water Temperature = 48F
BLOCK LOAD RATIO
Design For Diversity
106
With 44F Supply, 3 GPM Per Ton, 75% RatioMax Actual Water Temperature = 50F
BLOCK LOAD RATIO
Warmer Supply Temperature?
107
10,000 Units over 10 Years
108
1839 US Tariff Building –
General Post Office
Owner: US Department of
Interior – Park Service
Lease: Kimpton Hotel &
Restaurant Group
232 Rooms – AAA 4
Diamond
Opened Summer 2002
SureFlow Fan Coils
Hotel MonacoWashington DC
SureFlow Installation - Case Study
109
Fernando Garcia, P.E.
Vice President
CTA Consulting Engineers Inc.
Rockville, MD
(301) 637-0058
110
Chicago Blackstone Renaissance Hotel
636 South Michigan332 Rooms
Restoration of 1908 HotelOpened Fall 2007
Location of the famous “Smoke Filled
Rooms” where Warren G. Harding
was chosen as the Republican
nominee for President in June 1920.
Franklin Delano Roosevelt’s 3rd-term
Democratic Nomination was forged
in 1940.
Harry S. Truman stayed when he
received 1944 Vice Presidential
Nomination.
Dwight D. Eisenhower stayed during
first Republican ballot in 1952. 111
Portland, OregonThe Nines Hotel
Part of The Luxury Collection, Starwood Hotels & ResortsTop 9 Floors - 331 Rooms
Lower 5 floors is Macy’s
Redevelopment of 1909 Meier & Frank Department Store
National Register of Historic Places
Opened October 16, 2008LEED Silver
112
New Orleans Monaco Hotel
250 Units
Historic 1926 Masonic Temple Lodge
June 2001 Conversion to a 4-Star Luxury
Hotel
Kimpton Sold to Dimension Development Co.
Reopened 2007 as the Hilton Saint
Charles
Humidity Kept Under Control
113
Cool AirCool AirCool AirCool Air
Average
40% Less
Piping
Installed Cost
Savings $$$
Pump
Energy
Savings For
Owner $$$
Reliable
Operation
Occupant
Comfort
LEED Credit
Opportunitie
s
4 – Pipe
Performance
With 2 Installed
Pipes
Low
Maintenance
Easy To
Design
114