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 ID: 783829
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Slide1
SureFlow
Presented by: Ron Porter LEED APIEC Oklahoma City
Copyright 2012
Slide2Topics
Fan Coil Basics Traditional System Design SureFlow Hydronics
SureFlow Unit Design SureFlow Applications
Slide3This
Is A Fan CoilFan + Coil = Fan CoilRoom Air Conditioner
Slide4Moves air through a coil with:
Chilled WaterHot WaterElectric HeatR410a
Let’s focus on the water systems…
How Do They Work ?
Slide5FCU
Chiller
FCU
FCU
FCU
Central Pump Pushes Water Through Piping to Supply Each Fan Coil
Standard
Water Pressure
Differential System
Slide6How Do We Size The Main Pump ?
Slide7Central Pump Horsepower = __
Head x GPM__ 3960 x Efficiency
Slide8FCU
Chiller
FCU
FCU
FCU
Calculate All Circuits
Pump Sizing Based On Highest Pressure Drop Circuit
Slide9FCU
Chiller
FCU
FCU
FCU
Water Always Takes The Path Of Least Resistance
How Do We Know The Fan Coils Will Operate As Advertised ?
Slide10FCU
Chiller
FCU
FCU
FCU
Water Pipe Has Resistance To Water Flow
Pipe and Riser Diameters ?
Slide11Continuity : Water In = Water Out (GPM Per Minute)
Velocity : Speed of Travel (Feet Per Second)
D1
D2
Vel1
Vel2
Area1
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
Slide12Pressure drop is defined as:
The difference in pressure between any two points on a piece of equipment.
D1
D2
Vel1
Vel2
Area1
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
Slide13Coil Pressure
Drop =Cost of OperationDetermined from several parameters-
Unit sizeCoil rowsCoil 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
Slide14Valve Pressure Drop
:Resistance to water flowBased on water volume through the valve at
Full Open
Calculated using
Cv
Rating Number
PdFt
= ( GPM / ( 0.658 x
Cv
))^2
Slide15Typical 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
Slide16Full-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
Slide17Slide18Erie 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
Slide19Erie 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
Slide20Erie 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
Slide21FCU
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
Slide22Boiler
FCU
FCU
FCU
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 Head
60 PSI
Δ
25 PSI
Typical
of 20
Units
Slide23Boiler
FCU
FCU
FCU
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 Head
60 PSI
Δ
25 PSI
Units & Valves
@ 3.0 GPM
Require
4.0 PSI Diff
Excessive Flow
Low Flow
Slide24Boiler
FCU
FCU
FCU
FCU
Cartridge Valves For Automatic Balancing
Supply
Return
Slide25Hays 2517
Automatic Balancing Valve2-80 PSID range up to 5.5 GPM+/- 10% Accuracy
Slide26Valve Will Add Resistance As Required For Specified Water GPM
Slide27Analyze Combined Unit And Valve Package Pressure Drop
@ GPM = 3.0Ball Valve PdFt = 0.1Hays Valve
PdFt = 4.6Coil PdFt = 5.9
Erie Valve
PdFt
= 3.3
Ball Valve
PdFt
= 0.1
Total PdFt = 14
÷ 2.33
= 6.0 PSI Diff
FCU
Slide28Boiler
FCU
FCU
FCU
FCU
80 PSI
70 PSI
Full Load
Pump
60 GPM
60 Ft Head
VFD
Δ
P
Δ
10 PSI
Full-Load Variable Frequency Drive
Slide29Boiler
FCU
FCU
OFF
FCU
80 PSI
70 PSI
Part Load
Pump
45 GPM
VFD
Δ
P
Δ
10 PSI
Part-Load Variable Frequency Drive
Slide30Boiler
FCU
FCU
FCU
FCU
80 PSI
70 PSI
Full Load Pump
60 GPM
60 Ft Head
VFD
Δ
P
Δ
10 PSI
Direct Return System
Slide31Chiller
Reverse Return –
Balancing is reduced, therefore the need for balancing valves is reduced, but only if all coils
have identical
Δ
P and system pressure differential always equals coil required
Δ
P.
VFD
Δ
P
FCU
FCU
FCU
FCU
Slide32Chiller / Boiler Equipment Plant
Pumps Create Water Pressure DifferentialPipes Running To and From Each UnitValves – 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
Slide33System Complexity Issues
There Must Be A Better Way
Slide34Primary Circuit Water Flow
Integrated Circulator
Cycles on Thermostat Demand
2008 ASHRAE Handbook
HVAC Systems and Equipment
Chapter 12.
Thermostat
OFF
Slide35Cool Air
Cool AirCool Air
Cool Air
Primary Circuit Water Flow
2008 ASHRAE Handbook
HVAC Systems and Equipment
Chapter 12.
Thermostat
ON
Slide36Primary Circuit Water Flow
2008 ASHRAE Handbook
HVAC Systems and Equipment
Chapter 12.
Thermostat
OFF
Slide37Slide38Slide39Average 40% Less Piping
Fewer Pipe Hangers
Less Insulation
Massachusetts College of Pharmacy and Health Sciences
Worcester, Massachusetts
Slide40Reduced
Core DrillingFewer Joints = Fewer LeaksContractor Savings
Westin
Cupples
Station
St. Louis, Missouri
Slide41Westin
Cupples
StationSt. Louis, Missouri
Slide42CPF SureFlow Unit
What Happened To The Zone Valves and Flow Control Valves ?
Slide43Circulator – 1/40 HP
30+ Years In ProductionMillions In UseQuiet OperationChilled Water CERTIFIEDWet Rotor Cartridge DesignInternal Flow Check Valve
200 PSI RatingCycles On-Off (Thermostat Controlled)Low Energy Consumer – 65 Watts
Slide44Slide45Slide46Two Pipe Cooling
With Only One Installed Pipe
Chiller
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
Water Circulation Rate ≈ 3 GPM per Ton
Pump Head & Energy Reduced
Slide47Chiller
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
Boiler
Two Pipe Cooling & Heating “Change Over”
With One Installed Pipe
Slide482-Pipe Cooling and Heating Changeover With Only One Installed Pipe
Massachusetts College of Pharmacy and Health Sciences
Worcester, Massachusetts
Slide49Four Pipe Heat & Cool
With Only Two Installed Pipes
Chiller
FAN
COIL
Boiler
FAN
COIL
FAN
COIL
FAN
COIL
Slide50What Happens To The Water Temperature ?
Will It Control Humidity ?
Challenges:
Slide5142ºF
46.6ºF
46.6ºF
48.6ºF
44.4ºF
Chiller
Off
52.1ºF
Water Temperature Changes As BTUs Are Injected Into The SureFlow Loop
1 Ton
13177t 9954s
1 Ton
12052t 9519s
1 Ton
14424t 10448s
1 Ton
Slide52Cooling Loop Water
Pipe SizeDesign Guide
Type 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 @ 8
Δ
T
2.7
5.3
8.3
17.7
28.3
42.3
Tons @ 10
Δ
T
3.3
6.7
10.4
22.1
35.4
52.9
Slide53Pipe 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 @ 20
Δ
T
80
160
250
530
850
1270
MBH @ 25
Δ
T
100
200
312
662
1062
1587
Design Guide
Type L Copper
Heating Loop
Water
Pipe Size
Slide548 Degree Loop Delta-T = 3 GPM per Ton
Cooling Loop Water Temperature
Slide5510 Tons Peak x 3 GPM per Ton = 30 GPM
1-1/2” L Copper @ 30GPM = 5.43 fps = 7.55 ftpd/100ft2” L Copper Pipe @ 30GPM = 3.14 fps = 2.02 ftpd/100ft
Peak Load Analysis Sample
Slide567.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio
Solar
Block
vs
Peak Load Analysis
Slide57With 42F Supply, 3 GPM Per Ton, 75% Ratio
Max Actual Water Temperature = 48F
BLOCK LOAD RATIO
Design For Diversity
Slide58With 42F Supply, 3 GPM Per Ton, 75% Ratio
Max Actual Water Temperature = 48F
Design For Diversity
SOME UNITS ARE NOT RUNNING
ARE SOME UNITS OVER SIZED ?
Slide59SureFlow Allows Adjustment Of The Design
For OccupancySchool Classroom vs. Common areas
Hotel RoomsOffices
Usage patterns, time of day
Slide60SureFlow Allows Modification Of The Design
For Run Time and Fan SpeedActual hours of operation with full water flow
Good water flow rate results in excellent humidity controlTake full advantage of controls capabilities
Always recommend automatic fan speed reduction for extended run-time on coil
Slide61Circulators Only Consume Power When Running
Local Circulators Controlled by Room ThermostatsSystem Strategy: Demand Controlled PumpingThe Building Hydronic System Becomes An
Energy Management System
Horsepower Savings
LEED 2009-NC Credit EAc1
Optimize Energy Performance
Up To 19 Points Available
Slide62Complex 2-way
valve package =
32 solder
joints
SureFlow valve package
=
16 solder joints
Installation and Maintenance Savings
Slide63Primary
Pump
Common Load
Secondary
Pump
Chiller
- Or -
Heat Exchanger
Compound Primary-Secondary Pumping
Slide64Building 1 of X
Building 2 of X
Central Plant
Campus Chilled Water
Slide65Balance Valves
3 Way Control Valve
Load
Replace Your Original Existing 2-pipe FCU….
CW Supply
CW Return
Slide66…. With a New SureFlow Unit and
Have 4-Pipe Performance With Two Pipes
Existing Pipes
Heating
Coil
Cooling
Coil
CW Supply
/Return
HW Supply
/Return
Slide671839 US Tariff Building – General Post Office
Owner: US Department of Interior – Park ServiceLease: Kimpton Hotel & Restaurant Group
232 Rooms – AAA 4 DiamondOpened Summer 2002
SureFlow Fan Coils
Hotel Monaco
Washington DC
Case Study
Slide68Fernando Garcia, P.E.
Vice PresidentCTA Consulting Engineers Inc.Rockville, MD(301) 637-0058
Slide69Chicago Blackstone Renaissance Hotel
636 South Michigan332 RoomsRestoration 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 3
rd
-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.
Slide70The Nines, The Luxury Collection, Starwood Hotels
Top 9 Floors - 331 Guest Rooms
Portland’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
Slide71Elysian / Waldorf Astoria
60 Stories on East Walton Street in the Gold Coast52 Private Residences
188 Room Waldorf Astoria Hotel
Constructed 2006-2010
Renamed Waldorf Astoria Chicago February 1, 2012
AAA Five Diamond
TripAdvisor.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 R
ent
:
$16,000/mo
nth
3-Bed, 3.5-Bath, 3,747 Sq Ft
Slide7212,000
Units over
12
Years
Slide73Cool Air
Cool AirCool Air
Cool Air
Average 40% Less Piping
Installed Cost Savings $$$
Pump Energy Savings For Owner $$$
Reliable Operation
Occupant Comfort
LEED Credit Opportunities
4 – Pipe Performance With 2 Installed Pipes
Low Maintenance
Easy To Design
Slide74www.fancoil.comwww.iec-okc.com
Slide75Application:
SureFlow75
Slide76FCU
Delta
P
VFD
Chiller
DDC
FCU
FCU
FCU
Part Load Pump Controls
Standard Piping Method
76
Slide77System Design Issues
Chiller / Boiler Equipment PlantPumps Create Water Pressure Differential
Pipes Running To and From Each UnitValves – 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
Slide78Primary Circuit Water Flow
Integrated Circulator
Cycles on Thermostat Demand
Thermostat
OFF
78
Slide7979
Slide80SureFlow
Average 40% Less Piping
Less Core Drills on RenovationContractor Savings
80
Slide8130+ Years In Production
Millions In UseQuiet OperationChilled 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
Slide82Two 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
Slide83Two Pipe Heat & Cool
With Only One Installed Pipe
Chiller
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
Boiler
83
Slide8442ºF
46.6ºF
46.6ºF
48.6ºF
44.4ºF
Chiller
Off
52.1ºF
Central Pump Is NOT Responsible For Pressure Drop Of Coil Or Valve Packages
1 Ton
13177t 9954s
1 Ton
12052t 9519s
1 Ton
14424t 10448s
1 Ton
SureFlow System Pumping
84
Slide857.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio
Solar Exposure
Block
vs
Peak Load Analysis
85
Slide861839 US Tariff Building – General Post Office
Owner: US Department of Interior – Park ServiceLease: Kimpton Hotel & Restaurant Group
232 Rooms – AAA 4 DiamondOpened Summer 2002
SureFlow
Fan Coils
Hotel Monaco
Washington DC
SureFlow
Installation - Case Study
86
Slide87Application:
SureFlow87
Slide88Standard Piping Method
Chiller
FCU
FCU
FCU
FCU
88
Slide89FCU
Chiller
FCU
FCU
FCU
Primary-Secondary Pumping
Standard Piping Method
89
Slide90FCU
Delta
P
VFD
Chiller
DDC
FCU
FCU
FCU
Part Load Pump Controls
Standard Piping Method
90
Slide91System Design Issues
Chiller / Boiler Equipment PlantPumps Create Water Pressure Differential
Pipes Running To and From Each UnitValves – 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
Slide92Primary Circuit Water Flow
Integrated Circulator
Cycles on Thermostat Demand
Thermostat
OFF
92
Slide93Cool Air
Cool AirCool Air
Cool Air
Primary Circuit Water Flow
Integrated Circulator
Cycles on Thermostat Demand
Thermostat
ON
93
Slide94Design 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
Slide9595
Slide96SureFlow
Average 40% Less Piping
Less Core Drills on RenovationContractor Savings
96
Slide9730+ Years In Production
Millions In UseQuiet OperationChilled 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
Slide98Two 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
Slide99Two Pipe Heat & Cool
With Only One Installed Pipe
Chiller
FAN
COIL
FAN
COIL
FAN
COIL
FAN
COIL
Boiler
99
Slide100Four Pipe Heat & Cool
With Only Two Installed Pipes
Chiller
FAN
COIL
Boiler
FAN
COIL
FAN
COIL
FAN
COIL
100
Slide10142ºF
46.6ºF
46.6ºF
48.6ºF
44.4ºF
Chiller
Off
52.1ºF
Central Pump Is NOT Responsible For Pressure Drop Of Coil Or Valve Packages
1 Ton
13177t 9954s
1 Ton
12052t 9519s
1 Ton
14424t 10448s
1 Ton
SureFlow System Pumping
101
Slide102Coil Pressure Drop is Redesigned to Match Circulator Pump Curve
102
Slide1038 Degree Loop Delta-T = 3 GPM per Ton
Cooling Loop Water Temperature
103
Slide10410 Tons Peak x 3 GPM per Ton = 30 GPM
1-1/2” L Copper @ 30GPM = 5.43 fps = 7.55 ftpd/100ft2” L Copper Pipe @ 30GPM = 3.14 fps = 2.02 ftpd/100ftSureFlow Peak Load Design
104
Slide1057.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio
Solar Exposure
Block
vs
Peak Load Analysis
105
Slide106With 42F Supply, 3 GPM Per Ton, 75% Ratio
Max Actual Water Temperature = 48F
BLOCK LOAD RATIO
Design For Diversity
106
Slide107With 44F Supply, 3 GPM Per Ton, 75% Ratio
Max Actual Water Temperature = 50F
BLOCK LOAD RATIO
Warmer Supply Temperature?
107
Slide10810,000 Units over 10 Years
108
Slide1091839 US Tariff Building – General Post Office
Owner: US Department of Interior – Park ServiceLease: Kimpton Hotel & Restaurant Group
232 Rooms – AAA 4 DiamondOpened Summer 2002
SureFlow
Fan Coils
Hotel Monaco
Washington DC
SureFlow
Installation - Case Study
109
Slide110Fernando Garcia, P.E.
Vice PresidentCTA Consulting Engineers Inc.Rockville, MD
(301) 637-0058
110
Slide111Chicago Blackstone Renaissance Hotel
636 South Michigan332 RoomsRestoration 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 3
rd
-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
Slide112Portland, Oregon
The Nines HotelPart of The Luxury Collection, Starwood Hotels & Resorts
Top 9 Floors - 331 RoomsLower 5 floors is Macy’s
Redevelopment of 1909
Meier & Frank Department Store
National Register of Historic Places
Opened October 16, 2008
LEED Silver
112
Slide113New Orleans Monaco Hotel
250 UnitsHistoric 1926 Masonic Temple Lodge June 2001 Conversion to a 4-Star Luxury HotelKimpton Sold to Dimension Development Co.
Reopened 2007 as the Hilton Saint Charles
Humidity Kept Under Control
113
Slide114Cool Air
Cool AirCool Air
Cool Air
Average 40% Less Piping
Installed Cost Savings $$$
Pump Energy Savings For Owner $$$
Reliable Operation
Occupant Comfort
LEED Credit Opportunities
4 – Pipe Performance With 2 Installed Pipes
Low Maintenance
Easy To Design
114
Slide115www.fancoil.comwww.iec-okc.com
115