05-02-TDP Carrier - Water Piping and Pump

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DISTRIBUTION
SYSTEMS
Water Piping
and .
·-
Pumps
Te.c hnical Development Program

T~chnical Development Programs (TDP) are modules o.f technical training on HVAC theory,.
system design, equipment selection and application topics. They are .target.ed at engineers and
designers who wish to develop their knowledge in this field to effectively design, specify, sell or
apply HVAC equipment in commercial applications.
Although TDP topics have been developed as stand-alone modules, there are logical group-
ings of topics. The modules within each group begin at an introduct01y level and progress to
advanced levels. The breadth of this offering allows for customization into a complete HVAC
curriculum·- from a complete HVAC design course at an introductory-level or to an advanced-
level design course. Advanced-level modules assume prerequisite knowledge and do not review
basic concepts .
. Introduction to HVAC .
Psychrometries
Equipment
Systems
Controls
Applications
. ' .
Water piping and pumping is a fundamentals topic of HVAC design. The correct layout, se-
lection and sizing of the piping system and associated hydronic components is required to
properly deliver chilled and hot water as required to maintain comfort conditions. Piping connec-
tions at various equipment are covered, along with piping arrangements for chilled water systems.
Pump basics,_pipe sizing, and a pump selection example complete the TDP.
© 2005 Carrier Corporation. All rights reserved.

The information in this manual is offered as a general guide for the use of industry and consulting engineers in designing systems.
Judgment is required for application of this information to specific installations and design applications. Carrier is not responsible for
any us~s made of this information and assumes no responsibility for the performance or desirability of any resulting system design.
The information in this publication is subject to change without notice. No part of this publication may be reproduced or transmitted in
any form or by any means, electronic or mechanical, for any purpose, without the express written permission of Carrier Corporation.
Printed in Syr.acuse, NY
,_
CAR~IER CORPORATION
Carrie~t'arkway
Syracuse, N'f 13221, U.S.A.
Table of Contents
Introduction ...................................................................................................................................... 1
Types of Piping Systems ..........................................................................................................·....... 1
Closed-Loop (Evaporator) ........................................................................................................... 1
Open-Loop (Co·nde·nser) .............................................................................................................. 2
Once-Thru .................................................................................................................................... 2
Water Distribtltion Systems ............................................................................................................. 3
1-Pipe Systems ............................................................................................................................. 3
2-Pipe Systems ....................................................................................................... ...................... 4
3-Pipe Systems ............................................................................................................................. 5
4-Pipe Systems ............................................................................................................................. 6
Direct and Reverse Return Systetns ................................................................................................. 7
Direct Return ................................................................................................................................ 7
Reverse Return ............................................................................................................................. 8
Water Piping Components and Accessories .................................................................................... 8
Pipe Materials .............................................................................................................................. 9
Joints ............................................................................................................................................ 9
Fitti11gs ....................................................................................................................................... 10
Valves ........................................................................................................................................ 11
Hydronic System Components .................................................................................................. 16
Strainers ................................................................................................................................. 16
Expansion Tanks .................................................................................................................... 16
Air Separators ........................................................................................................................ 18
Air Vents ................................................................................................................................ 18
Thermometers, Gauges, Pete's Plugs ..................................................................................... 19
Pipe Hangars and Anchors .................................................... ,................................................ 19
Volu1ne Tank:s ........................................................................................................................ 20
Typical Piping Details at Equipment ................................................................. ............................ 21
Chillers ....................................................................................................................................... 21
AHU Coil or Fan Coil ................................................................................................................ 22
Pumps .............................................................. ~ .......................................................................... 22
Systen1 Piping Arrangements ........................................................................................................ 23
Parallel and Series Chiller Evaporators ..................................................................................... 23
Single Water-Cooled Chiller Loop ............................................................................................ 24
Multiple \Vater-Cooled Chiller Loop with Dedicated Pumps .................................................... 24
Multiple \Vater-Cooled Chillers with Manifolded Pmnps ......................................................... 25
Primary-Secondary Chilled Water System ................................................................................ 25
Prhnary-Only, Variable-Flow Chilled Water System ................................................................ 26
Chiller Head Pressure Control ................................................................................................... 27
Head Pressure Control Piping Methods with Diverting Valve .............................................. 28
Head Pressure Control Piping Method with VFD or Modulating Valve ............................... 29
Pump Basics and Types of Pumps ................................................................................................. 29
Pu111p Curve ...................................................................,. ........................................................... 32
Selectio11................................................................................................................. ·.................... 35
Centrifugal Pump Types ............................................................................................................ 36
Pipe Sizing and Pump Selection Example ..................................................................................... 37
Step 1: Determine Water Velocity in Piping ............................................................................. 37
Step 2: Determining Piping Friction Losses ............................................................................. 37
Step 3: Gather Job Specific Component Pressure Drops and Design Data .............................. 3 8
Step 4: Review the Highest Pressure Drop Circuit and Calculate Water Flows ........................ 39
Step 5: Size the Pipe; Find the Friction Rate/ 100 ft ..................................................................40
Step 6: Find the Longest Circuit Pressure Drop ....................................................................... .41
Step 7: Sum All the Pressure Drops for Pump Selection ......................................................... .42
Step 8: Size the Chilled Water Loop ........................................................................................ .43
Step 9: Check Evaporator Loop Volume ................................................................................. .45
Piping System Calculator Tool .................................................................................................. 46
Summary ........................................................................................................................................ 46
Work Session ............................. .................................................................................................... 4 7
Appendix ...................... .................................................................................................................. 49
References .................. ................................................................................................................ 49
Charts and Tables .................. ..................................................................................................... 49
Chart 1 - Friction Loss for Closed Loop ........ ....................................................................... 50
Chart 2 - Friction Loss for Open Loop .................................................................................. 51
Chart 3 -Friction Loss for Closed and Open Copper Tubing System .................................. 52
Table 4 - Physical Properties of Steel Pipe ........................................................................... 53
Table 5 -Friction Loss of Valves in Equivalent Length of Straight Pipe ............................. 54
Table 6- Friction Loss of Pipe Fittings in Equivalent Feet of Straight Pipe ........................ 55
Table 7- Special Fitting Losses in Equivalent Feet of Straight Pipe .................................... 56
Table 8 - Control Valves and Strainer Losses in Equivalent Feet of Straight Pipe ............... 57
Work Session Answers .............................................................................................................. 58
_ _ __ __ _ _.WATER PIPING AND PUMPS
Introduction
In this TDP module we will cover major topics associated with chilled water piping, and to a
limited extent, hot water piping. We will discuss the three types of piping systems and the four
basic piping distribution designs used to supply and return water to HVAC hydronic equipment.
There are important components and accessories that are required to complete a water piping
system. These include valves, tanks, and air eliminators. We will examine these system compo-
nents and define their role in the total hydronic system.
After examining some typical piping hook-ups to commercial HVAC equipment, we will
diagram and discuss popular piping arrangements, such as primary secondaty and primary vari-
able flow. We will then discuss a popular pipe-sizing tool from a noted pump manufacturer that
streamlines the sizing process. We will also examine types of water pumps used in HVAC sys-
tems and their characteristics and applications.
Upon completion of this TDP, the reader should feel comfortable identifying, selecting, and
applying the major components of water piping systems.
Types ofPiping Systems

Before piping design can be discussed in detail, you must first have an understanding of the
three basic types of piping systems: closed-loop, open-loop, and once-thru.
Closed-Loop (Evaporator)
In a closed-loop piping system,
-
Chiller,..-_ _P_,_ip-"'-in""'g- -- ----"_.;.....,.------,
the water is contained within a closed ... ~....., k
piping system, or loop, through which ~rrA~ [3 ~~nsion
it circulates. While there may be some :r~-
nominal contact with the air depend- •
L__ ~ •
Two-Way ~'/4. ·
j
:-.V..
ing on the type of tank used, the ~Pump _ 55° F ..: Valve L-.1:hr.ee-Way.J
system is considered closed to the Valve
environment. Typically, closed-loop Includes:
systems are chemically treated to con- • A chiller and!or a boiler
• Coils that produce cooling or heating
trol corrosion, scale, slime, and algae
• Two or three-way valves to control the coils
within the piping but their chemical
• Piping and pump to circulate water
treatment requirements typically are
• An expansion tank (insignificant water contact with air)
not as extensive as an open-loop.
Figure 1
Example ofa Closed-Loop Piping System
Distribution Systerns
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Open-Loop (Condenser)
In an open-loop piping system,

Water-Cooled
the water is in constant contact with Condenser
the air and the system is therefore 94 to ss• F
open to the atmosphere. A typical ex-
ample of an open-loop system is a 3 gpm/ton!
recirculating condenser water system ' Condenser
with a cooling tower where the water ~~~ter ~J_mf>~, _ ~-"o,-~--'"'' .§~5~_F. .... ..
is circulated through the cooling • The water-cooled condenser is typically part of a water-cooled chiller
tower, sprayed over the tower media or water-cooled package unit
smface, collected into the tower basin, • A cooling tower rejects the condenser heat to the atmosphere
circu1ated through the condenser, and • Flow rates and temperatures are industry standards for North America
• Piping and pumps circulate water
then sent back through the cooling
• Water is reused and exposed to the ambient conditions
tower. in the cooling tower
Figure 2
Example ofan Open-Loop Recirculating System
Once-Thru
In this type of system, water passes through the system once and is then discharged. An ex-
ample of a once-thru system would be a chiller with river water piped into its water-cooled
condenser. The rejected heat from the
r
Once-Thru condenser is introduced back into the
Optional J>l['l river, which is not always acceptable
Valve J
from an environmental perspective.

Source of Water to In general, once-thru systems that use
water (river) waste or "city" water are not allowed because
source
they use excessive amounts of water.
Pump
• Much less common due to environmental concerns

• Water is sent to waste or returned back to source
• Large consumption of water
• Source example: river, lake , we ll
Figure 3
Example of a Once-Thru System
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WATER PIPING AND PUMPS
Water Distribution Systems

There are four main types of water distribution systems. They arc defined by the number of
pipes used in the system- 1-pipe, 2-pipe, 3-pipe, and 4-pipe. While lhis TOP will discuss primar-
ily chilled water and condenser water system piping system design, it is imponamto understand
the evolution from 1-pipe into the 01her three systems, all of which arc used for heating as well as
cooling.
1-Pipe Systems
A 1-pipc water distribution system is a system that has a one main pipe looping around the
bui lding and then retuming.
1-Pipe System Uses
Typical
Heating-Only
Matn Piping LO:)p System
This pipe is both lhe supply and St.rpply and Return
return main. Its size is constant (1 sizo11vooghoU1)
throughoul, and all o f the water in -..._sys;em

Pump
the system flows through it feeding
one or more zone heating terminals. Figure 4
A small amount of water is 1-Pip<: Oistributio11 Sysrem
induced to leave the main at each
riser by the usc of a special flow fining used on 1-pipe systems, sometimes referred to as a
•·monoflow" lining. These finings create a pressure drop in the main equal to or greater than the
pressure drop through the riser, nmout, zone tem1inal unit, and return piping.
Con1rol of flow rate to the zone tenninal unils in a !-pipe system is often difficuh to achieve.
The pressure drop from lhe point where wmer leaves the main to where it returns is small and
small changes in resistance in this line rcsull in large changes in flow rate. As a resull, many J.
pipe systems avoid flow rate conlrol at the zone terminals and achieve capacity COtllrol by regu-
lating airflow over the zone lenninals instead.
Some advantages of the 1-pipe system include the simple
His101y of1-Pipe Systems
design of the system that requires one pipe size. This sim-
-- plicity of design leads to easy installation and low installed
cost.
However. )-pipe systems have severn! tli<ntlvanrages.
The pumping head is generally higher than that in other sys-
tc;ns because of the resistances occuning in series. That
means the pump and pump enCJ'&'Y is larger than olhcr distri·
but ion systems of comparable size.
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The change in water temperature as the water moves through the system (the water gets
colder after each successive terminal because of mixing) creates the possible need of larger units
at the end of the main, which will complicate the selection of the zone terminal units and add cost
due to oversized units near the end. Also, at part load, the end unit may be over or under capacity.
In order to keep the pressure loss through the unit coils low, the water velocity through the
coils must be kept low. This results in coils with large tube diameter, a greater number of tubes in
parallel, or larger coils than used with other distribution systems. Therefore, a physical space and
terminal cost penalty exist when a 1-pipe system is used.
The 1-pipe system is poorly suited to chilled water distribution for several reasons. The water
quantity used in chilled-water systems is usually considerably higher than that used for heating
because the unit coils work on smaller temperature differentials in the cooling mode than in the
heating mode. In order to economically accommodate higher flow rate, zone terminals used for
chilled water would need to be redesigned so they are not prohibitively large, expensive, or
space-consummg.
2-Pipe Systems
The 2-pipe water distribution system is used with both heating and cooling equipment con-
taining water coils. It is equally useful for room fan coil units and medium or large central air
handlers using combination hot water and chilled water coils. The 2-pipe system can be used to
distribute either hot or cold water, or alternate between the two. The same piping is used for both
heating and cooling so there must be a definite outdoor temperature, which is called the "change-
over temperature," or some other in-
dicator of building load, at which Summer Mode
point the hot water in the piping is
replaced by the chilled water and vice
versa.
Some 2-pipe fan coil units are
equipped with electric heat in addition
to the heating capability of the hot
water coil. This "touch up" electric
Piping
heat can be used if heating is required
for a fan coil but the system is still not
changed over to the heating mode.
Figure 5
2-Pipe Reverse Return Distribution System
There are two forms of 2-pipe water distribution systems in common use: 2-pipe direct return
and 2-pipe reverse return. Direct and reverse return will be covered later.
In a 1-pipe system, the supply and return main is the same pipe. The quantity of water flow-
ing through the main is approximately constant and the main is built of one diameter pipe
throughout its length. On the other hand, in the 2-pipe system, the supply and return mains are
separate pipes and water leaving the supply main goes into the return main. As water leaves the
GD.
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supply main and goes through the terminal units, the quantity of water flowing in the main is re-
duced, so the pipe diameter can be reduced. The opposite is true for the return main, which starts
out small at the furthest terminal and has to be increased in size as water enters it.
Advantages of 2-pipe systems include the fact that a higher friction loss can be taken in both
the piping and the zone tenninal units and still have a total pumping head lower than that in the
same size 1-pipe system because the zone tem1inals are in parallel water circuits, not series. Also,
it is easier to balance the flow to each unit in this system than in the 1-pipe system, assuming
branch balancing valves are installed in the piping as the system is installed. Another advantage
of 2-pipe systems is that the water temperature entering each zone terminal will be the same in
temperature because the return water from each terminal unit does not mix with the supply water
in the supply main.
However, the installed cost is greater than that for a 1-pipe
system. In systems of the same size, even though the average
pipe diameter in the 2-pipe system is smaller than that in the 1-
pipe system, the extra pipe and greater number of fittings means
that this system will have a greater first cost. Like the 1-pipe
system, the 2-pipe system distributes only a common tempera-
ture fluid to the zone terminals. Because the system cannot
deliver hot water or chilled
water simultaneously to the
coils, it must be in either the
heating or cooling mode. To change over from heating to
cooling, the water in the mains must be completely circulated
through the chiller and back to the unit before any cooling is
available at the zones. Changeover takes time. It is not practi-
cal to plan to change over frequently. Seasonal changeover is
the most common method u sed. Two-pipe supplemental heat-
ing systems are also quite common, both for separate
perimeter heating and zone reheat at the terminals.
3-Pipe Systems
The 3-pipe water distribution sys- Distributes hot and cold water simultaneously
tem has two supply mains feeding
each zone terminal, one for chilled
water and one for hot water, and a
common return main. The chilled wa-
ter supply and hot water supply lines
are sized according to normal stan-
dards and the return is sized to handle
Special 3-pipe
the maximum flow rate (which is the Water Control
cooling flow rate). As with 2-pipe
systems, the return main can be either
direct return or reverse return configu-
ration.
Figure 6
..
3-Pipe Distribution System
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Because of the two supply mains to each zone terminal, there is always hot and cold water
present at the entrance to the zone coil ready to be used when needed. This gives any fan coil or
air handler supplied by the 3-pipe water distribution system the ability to heat or cool at any time.
No changeover from summer to winter cycle is
needed in the 3-pipe system.
However, the operating cost of this system can
become prohibitively high because of the mixing of
hot and cold return water. It is important to be famil-
iar with 3-pipe systems because they have been
installed in existing buildings and are still in use.
4-Pipe Systems
The 4-pipe water distribution system is actually two, 2-pipe systems in parallel; each system
consisting of its own supply and return main. One system is always distributing chilled water to
the units and returning it to the chiller. The other is distributing hot water to the units and return-
ing the water to the boiler. Unlike the
3-pipe system, there is no mixing of hot Distributes hot and cold water simultaneously
and cold water. By using two separate
coils in each zone terminal unit, or one '7
coil with a separate cooling and heating
circuit, the heating and cooling systems
are completely separated. The chilled
water flows through a cooling coil and
the hot water flows through a separate
heating coil. At no point are the two
circuits connected. In a 4-pipe water
distribution system, each terminal unit
can become a separate zone of control,
with its own thermostat. Both hot and Figure 7
cold water are available to all units at
one time. 4-Pipe Distribution System
Four-pipe distribution systems are actually two 2-pipe systems in parallel. This system offers
both hot and chilled water to all zones simultaneously, enabling the system to meet cooling and
heating loads whenever and wherever they occur. There is no need for seasonal or more frequent
changeover. The hot and chilled water circuits are completely separate and the two water streams
are never mixed. The design methods, valves, and controls are similar to 2-pipe and 3-pipe sys-
tems.
A 4-pipe system with a fossil fuel-fired boiler can deliver a competitive or lower operating
cost than some 2-pipe systems with "touch-up" electric heat built into the unit. That is because
the electric heaters in the 2-pipe unit must sometimes operate more often than is expected and
electric resistance heat is expensive, and the heaters may require a larger building electric service.
This operation occurs prior to the entire system changeover to heating. Fossil fuel rates typically
offer an advantage to electric rates.
~ Distribution Systems
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WATER PIPING ~ND PUMPS
However, 4-pipe systems have a higher installed price than 2-pipe and most 3-pipe systems.
The extra pipe and valves at the zone terminals tend to make the 4-pipe system the most costly in
terms of installed cost. Four-pipe systems also require terminal units with dual coils or a 2-circuit
coil, which costs more. Also, there are four pipes to run throughout the building, which takes
more time and consumes more space for piping than the other systems.
For commercial buildings, the choice comes down to 2-pipe versus 4-pipe designs. The com-
fort and control advantage of 4-pipe over 2-pipe must be weighed against the higher installed cost
of the 4-pipe system. Where the building configuration and layout of spaces may require long
periods of both heating and cooling simultaneously, and occupant comfort is a requirement, 4-
pipe makes the most sense. When the building lends itself to a seasonal changeover without large
compromises in comfort, 2-pipe is suitable.
Direct and Reverse Return Systems

Closed-loop systems can be further classified as direct return or reverse return.
Direct Return
The direct return system allows piping to be run in the most direct path to optimize piping
costs. The disadvantage is that the flow at each fan coil unit or air handler usually needs to be
balanced using a balancing valve. The
length of the water circuit through the I, ~nit-: 1] ~ 1, Unn-~ ij I. ~nn~ ~ l]nn-~. ~
supply and return piping to each fan
coil or air handler is different in direct Supply
Return •
.. vo PC l)D ~-~z ;Yr:J
return piping. Fan coils close to the y
Balancing Valves
pump receive greater flow rate than
• Water enters Unit-1 from supply
those further away unless balancing is
accomplished. • Water leaves Unit-1 and returns directly to source
• The first unit supplied is the first returned
Open-loop systems such as the
• Unequal circuit pressure drops result
condenser water system discussed
earlier with a cooling tower are al- • Circuit pressure drop through
Unit-1 < Unit-2 < Unit-3 < Unit-4 < Unit-S
ways direct return since individual
terminals don't exist and balancing is • Balancing valves are a necessity
relatively simple. Figure 8
Direct Return Horizontal System Layout
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_\li.ATER PIPING AND PUMPS - -------------
Reverse Return
The reverse return system is piped so that the length of the water circuit through the supply
and return piping to each fan coil or air handler is essentially the same. Therefore, pressure drops
are basically equal. Buildings such as
hotels with multiple identical fan coil 1, Unit-1 ~ ( unit-2] i, Unit-3] [ unit-4]
units with identical flows are excel-
lent candidates for reverse return Supply
systems. Return
Reverse return has greater pipe • Return header flow is same direction as supply flow
lengths and cost. However, the cost
• Water leaves Unit-1 and goes all the way around in
of adding a balancing valve for each returning to source
fan coil using a direct return system
• The first unit supplied is the last returned
could offset the additional costs of
the added reverse return piping. • Circuit pressure drop through
Unit-1 =Unit-2 =Unit-3 =Unit-4 =Unit-5
If the individual fan coil or air- • Balancing valves may be eliminated
handling unit water pressure drops
are not reasonably close to each Figure 9
other, engineers will often specify Reverse Return Horizontal System Layout
balancing valves anyway, regardless
of the piping arrangement.
Water Piping Components and Accessories

There are many, varied, components that make up all water, and air-water systems. Pipe, fit-
tings, valves, strainers, pumps, chillers, air-handling units, cooling towers, expansion tanks, air
separators, Pete's plugs, thermometers, gauges, air vents, pipe supports, and possibly a volume
tank are all included. Following are descriptions of hydronic components that are used in chilled
water piping systems.
~)
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-'-"-'-'
ATER PIPING AND PUN1 P$_
Pipe Materials
Typically the piping used in an HVAC system is either schedule 40 black steel welded or cut-
grooved pipe, or lighter gauge rolled-groove steel pipe for sizes 2-1/2-in. diameter and above.
Type L copper or threaded schedule 40 black steel pipe is normally used for 2-in. diameter and
smaller. In some closed-loop water
source heat pump applications, sched- Typical Materials:
ule 40 PVC piping has been used ~ 2 %-in. Schedule 40 black steel
where local codes and inspectors ~ 2- in. Schedule 40 black steel or Type L copper
permit. If PVC is used on the exterior
of a building it should be protected
from the elements with insulation so
that the piping does not deteriorate
from extended exposure.
Figure 10
Materials Used for Water Piping
Joints
Steel pipe is offered with weld, Beveled Edge to J
mechanical groove or threaded connec- Accept Weld
tions. Copper pipe is offered with
solder or mechanical rolled-groove
connections. PVC pipe is offered with Thread
solvent or mechanical grooved connec- Joint
tions.
Female
Thread
J
Weld-joint pipe has beveled ends
so that when two pieces are butted to-
Figure 11
gether they fmm a groove for welding.
Weld and Threaded Joint
Female The threaded joint design has

Connection
Fitting male tapered threads at the end of the
pipe that screw into the female thread
of a fitting.
Capillary
Space 'd)\ Solder (sweat) joints and solvent
(exaggerated) \
joints are formed by one end that slips
inside the other; solder or glue is used
to seal the joint.
Figure 12
Sweat or Solvent Joint
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__W.AJEJs..ElE IN G ANQ_p U_l'y1 PS_____________________________
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Mechanical groove joints have

Coupling a groove that is cut or rolled into
Clamp the end of the pipe and fitting. The
joint is then completed with a me-
chanical coupling that locks into the
grooves. Each coupling has a rub-
ber gasket that seals the joint.
Figure 13
Mechanical {Groove) Joint
Actual photo courtesy ofVictaulic Company
Fittings
Numerous fittings are available such as 90 and 45-degree elbows, tees, concentric reducers,
eccentric reducers, flanges, etc. Fittings that allow for the least pressure drop, best routing and
proper drainage should be used. The friction loss that best represents the type of fittings for a spe-
cific project (standard radius el-
bow versus long radius elbow for
instance) can be most easily found
in the Fitting Equivalent Length
Pressure Drop Charts in the Ap-
pendix When Calculating total 45° Elbow goo Short Radius Elbow Saddle Tee Cap
system pressure drop.
Equivalent lengths for un-
usual fittings not covered in the
Tables will have to be determined
by consulting with the manufac- Concentric Tee Flange
Reducer
turer.
Figure 14
Example of Various Pipe Weld Fittings
... )
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Valves
Many types of valves are available in the HVAC industry. Each type of valve has certain
characteristics that make it better for certain applications such as shutoff, balancing, control (also
refen-ed to as "throttling"), or one-
way flow. Some valves are suitable Used on larger
for multiple applications. A brief de- pipe sizes (2Y2 in.
scription of the different types of and larger)
valves and their applications are listed

below. Used for shutoff and
throttling duty
Butterfly valves are generally Good for
frequent
found on larger sized systems and are Threaded operation
used for shutoff duty, throttling duty lug applications
and where there is frequent operation.
isc
They have good flow control (linear low cost, low
relationship between percent open and pressure drop
percent of full flow through the
valve), low cost, high capacity and Figure 15
low pressure drop. They typically
Butterfly Valves, Lug Pattern
have bigger valves and are used on
pipe sizes 2 Y2-in. and larger. Lug-pattern will either through-bolt between two flanges, or be se-
cured at the end of a pipe section, while a wafer-pattern is a more economical style that just sits
between the bolted flanges without its own lugs.
Gate valves, also known as "stop valves," are designed for shutoff duty. When the valve is in
the wide-open position, the gate is completely out of the fluid stream, thus providing straight
through flow and a very low pressure
drop. Gate valves should not be used
Handwheel
for throttling. They are not designed
for this type of service and conse-
Gate valves are quently it is difficult to control fluid
also known as flow with any degree of accuracy.
stop valves Vibration and chattering of the disc
occurs when the valve is used for
Not used for throttling, resulting in damage to the
throttling duty seating surface. The flow rate an-ows
in the figure indicate that a gate
valve can be installed without regard
to direction of flow within the pipe;
they can seat in either direction. The
globe valves shown next need to seat
against the flow, which is why there
is only one flow direction arrow on
Figure 16
the figure.
Gate Valve
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_WATER PIPING At-J D PUMP$______ - ------ - - - -- -
Globe, angle, and "Y" valves are of the same Handwheel

basic design and are designed primarily for throt-
tling (balancing) duty. The angle or Y-pattern
valve is recommended for full flow service since
it has a substantially lower pressure drop at this
condition than the globe valve. Another advantage
of the angle valve is that it can be located to re-
place an elbow, thus eliminating one fitting. Plug
-.__.'"'7,-- Body Seat Ring
Figure 17
Globe Valve
Handwheel
Angle valves
can replace an
elbow fitting Globe, angle and Y valves can be opened or
closed substantially faster than a gate valve be-
This is the same cause of the shorter lift of the disc. When valves
basic design as a
globe valve
are to be operated frequently, the globe design
provides the more convenient operation. The seat-
Seat ing surfaces of the globe, angle or Y valves are
subject to less wear and the plug and seat are easy
to replace compared to the gate valve discussed
previously.
Figure 18
Angle Globe Valve
Figure 19
Y-Globe Valve
~{ ~ Distribution Systems
Turn to the Experts..- - -- -- - - - - -- - -- -- ------------··- - - - ----·--·-- · ------- ··------------
12
- - - - - - - - - - - - - - - - - - - - - - - · - - --- WATER£Jfl NG__ANQ_P!,J_M_E_~
Plug valves, also called plug

cocks, are primarily used for balanc-
Plug valves are
ing flow rates in systems not subject
used for balancing
duty on smaller to frequent flow changes. They come
Flow
flow applications Opening with cylindrical or tapered plugs that
are usually lubricated to reduce gall-
Waterflow -+ ing, turning torque, and face leakage.
Plug valves have approximately the
same loss as a gate valve when in the
fully open position. ·when partially
closed for balancing, this line loss
increases substantially. For large
Figure 20 flow rate applications, a globe or but-
Plug Valve terfly will be used instead of a plug
valve. Their sizes are limited to
smaller applications because of cost.
• Low cost
• High capacity
Ball valves are used for full • Low leakage
open/closed service, with limited re- • Tight sealing
quirement for precise control. They
are best suited for quick-open linear
control. Their advantage is low cost, ; : Waterflow
high capacity, low leakage, and tight
sealing.
Figure 21
Ball Valve
Horizontal use or Check valves prevent the flow of

vertical upward flow water in the reverse direction. There
use only are two basic designs of check valves,
the swing check and the lift check.
Body The swing check valve may be used
in a horizontal line or in a vertical line
if flow is upward. The flow through
the S\\ring check is in a straight line
and without restriction at the seat.
Swing checks are generally used rn
combination with gate valves.
Figure 22
Swing Check Valve
(~
Distributhm Syst.erns
- - - ------ ------------------- - -- - - - - - - - - - Tum to the ExpertS.
13
_w_ATE RJ?lP IN G AN I2_P UM F?.S..___________________________________________ ________________
The lift check operates in a man-

ner similar to that of a globe valve
and, like the globe valve, its flow is
restricted. The disc is seated by back-
flow or by gravity when there is no
flow, and is free to rise and fall, de-
pending on the pressure under it. The
lift check should only be installed in
horizontal piping and usually is used
...
Waterflow
in combination with globe, angle and
Yvalves.
Figure 23
Lifi Check Valve
Control Valves: 3-Way and 2-Way
Control valves can be 2-position (open or closed), 2-way modulating (modulates to vary flow
through the coil and system), or 3-way modulating (modulates flow through the coil by bypassing
water back to the return thereby maintaining a nearly constant flow through the system). Three-
way valves are used for hot and cold water flow control on chillers, boilers, air coils, and most all
HVAC hydronic tmits where temperature control is necessary.
Three-way mixing valves have two inlets and one outlet. Three-way diverting valves have
one inlet and two outlets. Mixing valves are typically used to vary the flow through a load (such
as a chilled or hot water coil). Divert-
ing valves are used to direct the flow
+ - Valve Actuator - - .
one way or another and are useful in
applications like 2-pipe changeover or
in bypass applications.
Three-way valves are used in
many applications such as flow rate
1
variation, temperature variation, and
primary-secondary pumping systems
in both 2-pipe and 4-pipe systems.
l
3-Way Diverting
t
3-Way Mixing
2 outlets 1 inlet 2 inlets 1 outlet
Two-way modulating valves are
used for variable flow through heating
and cooling coils. They throttle the 2-Way Modulating
flow for part-load control instead of
bypassing the flow around the coil. Figure 24
Control Valve Types
...,
Tum to the Expert$: _ _ __ ______ _ _ _ _ __
14
Circuit Setters™ are valves that
allow for preset balancing as in direct Circuit SettersTM allow
return system. The manufacturer's for pre-set balancing of
application information should be waterflow
used when using circuit setters in a
design.
The Circuit Setter™ balance
valve is designed specifically for pre-
set proportional system balance. This
valve assures optimum system flow
balance at minimum operating horse-
power. A Circuit Setter™ is a popular
three-function valve providing flow
Figure 25
balance, flow metering, and shutoff.
Circuit Setter
Photo courtesy ofBell & Gossett
A Triple Duty Valve™ is often Triple Duty ValveTM

on pump discharge
used on the discharge of the pump to
replace an individual shut off valve,
balancing valve and check valve.
Triple duty valves are used to save
cost of material and labor.
Determining which valve to use Combines shut-off,
is a matter of choice, based on the balancing, and check
valve into one
application and cost.
assembly
Figure 26
Triple Duty Valve
Photo courtesy of Bell & Gossett
Relative Valve Comparison Chart $

Swing Wafer Lug
Size BaiP Gate2 Globe2
Check1 Butterfly3 Butterfly3
~ 6 40 50 40 - -
% 6 30 50 40 - -
1 15 50 75 60 - -
2 40 100 215 150 100 120
3 210 310 1100 500 120 140
4 250 600 1300 - 140 160
6 375 1000 2500 - 220 260
Notes:
1. All sizes threaded bronze body
2. Sizes Y, to 2-in. threaded bronze body; sizes 3 to 6-in. threaded iron body
3. All sizes cast iron body
Figure 27
Comparison of Valve Costs
CBD!>
.Turn to the Experts.
15
Hydronic System Components

Strainers
The typical strainer used in the HVAC industry is a "Y" strainer. The strainer (minimum 20
mesh) is used to prevent construction debris from entering the equipment during initial startup
and to catch any small debris that may
be circulating through the system dur- Waterflow
ing normal operation or servicing.
Strainers are normally installed on the
inlet side of a chiller as well as the
suction side of a pump. In some rare
cases, strainers are also installed at the
inlet of chilled water coils.
Strainers are
most important
in open loop
systems
Figure 28
"Y" Strainer
Photo courtesy of Fle.xicraft Industries
Systems with large quantities of debris may use a "basket" strainer in lieu of a "Y" strainer.
The basket strainer has two baskets and a transfer valve that allows flow to be changed from one
basket to the other. This allows for one basket to be cleaned while the other is in use. A basket
strainer is expensive and is used sometimes for extra straining of condenser water systems on wa-
ter-cooled chillers.
Expansion Tanks
Temperature changes cause the water to expand or contract within a closed-loop system. As
the temperature increases, the water occupies a larger volume of space. An expansion tank is
sized to handle the excess water that is a result of temperature change and water expansion and
should be part of every closed-loop system, chilled water, condenser water, or hot water. Expan-
sion tanks are not required in open systems like a cooling tower water loop.
An expansion tank also provides a make-up location
for automatic replacement of water to the system that has
been lost due to various reasons such as, leakage through
pump glands or servicing. Expansion tanks are available as
an open tank, or a closed type tank. A diaphragm tank is a
closed tank with an internal diaphragm that separates the
water and air and is in the closed tank category. The open
tank is just that, a tank that is open to the atmosphere.
-- ~ ~ Distribution Systems
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16
-
The variation of water volume caused by temperature changes can be calculated by determin-
ing the total water volume in the system and then multiplying the volume by the change in
specific volume of water between the highest and lowest temperatures expected.
Bladder tanks are another type of closed tank and cost

more per gallon than diaphragm tanks, but bladder tanks
have a larger "acceptance volume" (the actual amount of
water the tank can hold) than diaphragm; so for the par-
ticular application, the cost difference can be negligible.
The liner (bladder) is replaceable, whereas the mem-
brane for the diaphragm tank is not. The diaphragm
membrane can be a wear point due to expan-
sion/contraction. Bladder tanks have an acceptance
volume of approximately 95 percent, which means if the
system expansion were calculated to be 200 gallons, the
actual tank size required would be approximately 210 gal-
lons.
To size an expansion tank you will
~ Charging Valve
need to know the total gallons of water
in the system, temperature of the water
when the system is filled, average
maximum operating temperature of
• Very Popular
the water, minimum operating pres- Lifting Ring
sure, and the maximum operating • Most Cost
Effective
pressure which is typically chosen at
10 percent below the relief valve set-
ting. Elevation differences between the
tank, pumps, relief valves, and top of Drain (Not Show n)
the system may also be considered.
For maximum pump protection, Figure 29
the tank should be located on the suc-
tion side of the pumps, usually the Diaphragm Type Expansion Tank
Photo courtesy ofBell & Gossell
point of no pressure change (where a
gauge would read 0 psig). Consulting
with your local tank vendor for advice on the best location is advised in critical situations. A
wrong location may result in pump cavitation or the need for excess residual system pressure.
Dis~ribution Systems
17
(- -)
_ __ __ _ _ _ _ _ Turn to the ExpertS.
Air Separators
Inlet - +
Tangential Stainless Steel
flow-thru design Air Collector Tube
- + o utlet
NPT. Grooved
Vessel Shell or Flanged
(3 times the Connections
nominal inlet/outlet
pipe diameter)
Figure 30
Air Separator
Air Vents
Manual or
Automatic
Air Vent
tr
r JQ Service Valve
Locate at high points

Typical Locations:
• Risers
• Coils
• Terminals
Figure 31
Air Vent Piping
.. " • Distribution Systems

Turn to the Experts.-- ---------------------··--·--------------- - -------- - - - - - - - - -·- - - - -
18
Thermometers, Gauges, Pete's Plugs
It is recommended that thennometers, sensors, and gauges be mounted at the inlet and outlet
of each major piece of equipment. Major pieces of equipment are chillers, boilers, air handler
coils, cooling towers, thermal storage tanks, and pumps.
Pete's plugs are small fittings with a rubber seal that can be used to read temperature or pres-
sure with an insertion type thermometer or pressure gauge. They can be used in lieu of fixed
location thermometers and gauges and
are typically installed at small air- (D Pete's Plugs:
handling units, fan coil units, water ~ Te, ture and Pressure Ports
source heat pumps, etc. Pressures are
used to verify flow through heat ex-
changers and temperatures are used to
measure equipment performance. It is I~
very important that gauges or Pete's Locate thermometers f•• ~ · t@
~-
and gauges • \ ,. c •• ,
plugs are located immediately up- " f f " .\;>:~1
at inlets and outlets · . ~ ~·
stream and downstream of each piece of equipment
of equipment's connection stub-out
but prior to any valves. If mounted t1
after the valve the pressme reading

would include the pressure loss Figure 32
through the valve, this would give an
inaccurate reading. Typ ical Thermometers, Pete 's Plugs, and Gauges
Gauges and thermometer photos courtesy of Weiss Instruments, Inc.
Pipe Hangars and Anchors
All piping should be supported with hangers that can withstand the combined weight of pipe,
pipe fittings, valves, fluid in the pipe, and the insulation. They must also be capable of keeping
the pipe in proper alignment when
necessary. Where extreme expansion Recommended Support Spacing for Schedule 40 Pipe
or contraction exists, roller-type Nominal Pipe Size Distance Between Supports
hangers and saddles should be used. (in.) (ft)
The pipe supports must have a o/.-1Y4 8
smooth, flat bearing surface, free from 1~ - 2~ 10
burrs or other sharp projections that
3 - 3% 12
would wear or cut the pipe.
4- 6 14
The controlling factor in the spac-
ing of supports for horizontal piping is
8- 12 I 16
14 -24 20
the deflection of piping due to its own
weight, weight of the fluid, piping Figure 33
accessories, and the insulation. The Recommended Support Spacing for Schedule 40 Pipe
table lists the recommended support
spacing for Schedule 40 steel pipe,
using the listed conditions with water as a fluid. The support spacing for copper tubing is given in
the next table, which also includes the weight of the tubing filled with water, fittings, accessories
and insulation.
---- -- ------
19
- --
..
- - -- -Turn to the ExpertS:
_VV_AT_I;R PIPING AND PUMPS
In the vertical direction, on a tall building, i.e. 20-stories, the risers might be anchored on the
5th floor and on the 15th floor with an expansion device located at the 1Oth floor. This arrange-
ment allows the riser to expand in both di-
Recommended Support Spacing for Copper Tubing
rections from the 5th and 15th floor,
resulting in less pipe travel at headers, Tube OD Distance Between Supports
whether they are located at the top or bottom (in.) (ft)
of the building or in both locations. Smaller
5/8 6
buildings, i.e. 5-stories, risers are anchored
but once. Usually this is done near the 7/8- 1 1/8 8
header, allowing the riser to grow in one 1 3/8-2 1/8 10
direction only, either up or down depending 2 5/8- 5 1/8 12
on the header location. 6 1/8- 8 1/8 14
Figure 34
Recommended Support Spacing for Copper Tubes
Horizontal expansion is usually taken up in

the many direction changes that occur in a normal
layout. When long straight runs occur, proper an-
choring is required, as are guides and either
expansion devices or pipe loops to allow proper movement of the pipe as it goes through its tem-
perature range. Detailed presentations on this topic are available in the Carrier System Design
Manual, Part 3, and the ASHRA.E Handbook-HVAC Systems and Equipment.
Volume Tanks
An important factor in piping design in-

volves having enough volume of chilled water Rule of thumb for chilled-water systems:
in the piping system to assure stable operation
of the chiller. Loop volume is the amount of -3 gallons per ton of chiller for
fluid in the cooler, piping, cooling coils and Suggested volume normal air-conditioning duty
optional storage tank that remains in circula- tank designs
tion at all times. If the loop volume is too - 6 to 10 gallons per ton of chiller for
process duty or low ambient unit
small, fluctuations in the loading will affect
•
operation
the chiller much more quickly and result in
greater compressor cycling with resulting
chilled water temperature swings. All chiller
manufacturers require a minimum loop vol- Figure 35
ume for proper operation of their chillers to Volume Tank Requirements
prevent rapid changes in water temperature
and sh01t cycling of the compressor. In effect, adequate loop volume acts as a "flywheel" so that
the chiller does not cycle too quickly. To minimize cycling, the minimum loop volume should be
at least three gallons per nominal ton capacity at the design point for normal comf01t cooling duty
applications. For process and loads that operate under variable flow conditions; the minimum
should be from six to ten gallons per ton. Applications that operate under low ambient tempera-
tures or use brine typically also require six to ten gallons per nominal ton. All recommendations
are manufacturer dependent.
(< 8; 0
~ ~ Distribution Systems
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20
---·----------··--·---·-------------------------------------- WAI.E R PIPING AN Q_E.UM.P.~.
A method to increase the loop volume is the addition of a volume tank connected to the
chilled water system.
For example, suppose a chiller installation with a 200-ton chiller was connected to a system
calculated to have a loop volume of 400 gallons. The recommended minimum loop volume
would be:
(200 nominal tons) * (3 gallons/nominal ton) = 600 gallons
If the loop volume were 400 gallons and the minimum required loop volume 600 gallons, a
volume tank holding a minimum of 200 gallons would be required.
Typical Piping Details at Equipment

Now that we have a basic understanding of piping systems and valves, let's take a look at
some typical piping details at various pieces of equipment.
Chillers
The installer should mount the valves high, when the piping permits, to allow for removal of
piping in order to service the equipment.
Locating thermometers in
Supply Return
vertical piping helps avoid dam-
r
age that could result from
mounting them on a horizontal
section of pipe.
Locate gauges close to the
equipment so that the condenser
and cooler pressure drops can be
measured and flow verified.
All of these devices must be
accessible. The thermometers and
gauges must be at an elevation
and angle so they can be read.
Figure 36
Typical Water-Cooled Chiller Piping Details,
Two-Pass Evaporator And Condenser Shown.
Distribution Systems (8Jt> .

·-------------··-·--·--···--·--------·-·-------·-·-·····-··-··-····--··--·-····-···-··- ·····--···--·-········-··- - -·- - ------- --- Tum to the Experts.
21
AHU Coil or Fan Coil
For coil piping, where unit discharge conditions are critical, a good recommendation is to use
a separate balancing valve so flow can be set and then the valve locked in place. Having a valve
on each side of the control valve also allows for control valve servicing.
Mount the valves high and install flanges or unions on the entering and leaving coil connec-
tions to allow for removal of piping to
service equipment. Return
.---Shutoff Valve
Locate Pete's Plugs as close to the Control Valve (2-Position On/Off,
coil as possible so pressure can be 2-Way Modulating or
3-Way Mixing)
measured and flow verified. r Balancing Valve
Coil control valves can be 2-

position, 2-way modulating, or 3-way
modulating. Multi-row coils should
always be piped for counterflow and
per the manufacturer's recommenda-
tions. This means the water moves
through the coil opposite the direction
of airflow. This maximizes heat trans-
fer. For a complete discussion on Figure 37
counterflow, refer to TDP-614, Coils:
Direct Expansion, Chilled Water, and Typical Hot or Chilled Water Coil Piping Detail
Heating.
Pumps
A concentric reducer is recommended at the pump discharge to allow for smooth flow.
Return (Suction)
- Shut-Off Valve
- Check Valve
Shut-Off Valve - Balancing Valve

or Multi-Purpose Valve
An eccentric reducer is recom-
mended at the pmnp suction to
prevent air pockets in the suction line Long Radius
entering the pump. Elbow
L___._ L...r-~+-----L...L--~Ht~...
The check valve prevents reverse
flow through the pump. Shutoff
valves are provided to isolate the Minimum of 5 pipe diameters
for end suction pumps
pump for servicing.
Figure 38
Pump Piping Detail
·- ~ ~ Distribution Systems
Turn to the Experts.----------- ------------------------------·--------------------------------------- -
22
WATER PIPIN_G _hND__EUMP~
A separate balancing valve is used so that flow can be set and then the valve locked in place.
A single combination valve with a memory stop can be used in lieu of having a shutoff valve and
balancing valve on the pump discharge, though it should be mounted downstream of the check
valve.
Gauges or Pete's plugs should be located as close to the pump as possible so pressure can be
measured and flow verified.
A suction diffuser (combination of a strainer and straightening vanes) can also be used at the
inlet of the pump. A suction diffuser replaces the valve, strainer, and 90-degree elbow since these
items are part of the diffuser. Suction diffusers are used when space limitations do not allow for a
minimum of five pipe diameters on the suction side of end-suction pumps. They may also be used
to save material and labor cost.
System Piping Arrangements

The figures that accompany the description of each piping arrangement do not show all pos-
sible system variations. The diagrams that are shown are to help you understand some of the basic
variations of chilled water and condenser water systems.
Parallel and Series Chiller Evaporators
Where chiller capacities greater than can be supplied by a single chiller are required, or where
stand-by capability is desired, chillers may be installed in parallel. Units may be of the same or
different sizes. Usually, equally sized
chillers are utilized to accomplish Parallel- (Typically 18° F drop or less)
commonality of parts and maintain
simplicity. If unequal sized chillers
are used, cooler flow rates must be
balanced to ensure proper flow to
each chiller. Software is available
from the chiller manufacturer that
automatically stages multiple chillers
of equal or unequal size.
Where a large temperature drop
(greater than 18° F) is desired, chillers
may have to be installed in series. Use
of reduced pass configuration may be
required to keep waterside pressure Figure 39
drop at an acceptable level. Parallel and Series Chiller Piping
One-pass evaporators shown .
_ _ __
...
~ ..
-------------··--·--~---------·--···-··----··--·----------------------------------·--------·---Turn to
23
the Experts.
JLY..AIJ;R PIPING AND PUMP!;?_______________ _
Single Water-Cooled Chiller Loop

Shown is a single chiller sys-
tem. It is impmtant to maintain
minimum chilled water loop vol-
umes as discussed previously as a
single chiller system is often
where a loop volume deficiency
can exist.
Note that the chilled-water
pump pushes water through the
Condenser Chilled
chiller then out to the coils. The Water Pump Water Pump
heat energy from the pump will
be cooled in the chiller evapora- Figure 40
tor before being recirculated to Single Water-Cooled Chiller System Piping,
the coils. Two-pass evaporator and condenser show11.
Multiple Water-Cooled Chiller Loop with Dedicated Pumps

In this parallel chiller scheme,
there is a dedicated pump for each
cooling tower cell and chiller.
When chilled water pumps are
piped as shown, each chiller is
interlocked to its respective
pump. The operation of an indi-
vidual chiller is dependent on the
operation of its pumps and tower
fan.
t----~M
Condenser
Water Pump
Figure 41
Multiple Water-Cooled Chillers, Dedicated Pumps
Two pass evaporator and condensers shown.
"
..
(
" " Distribution Systems
Iurn to the Experts·- - --··--·---·-·-----------------------------------------------
24
Multiple Water-Cooled Chillers with Manifolded Pumps
When chilled water pumps are manifolded as shown, a condition will exist when one chiller
is off and the other is running where Air Handling Units
there would be flow through the off
chiller. To eliminate this problem, a 2-
position isolation valve must be added
to shutoff flow when the chiller is de-
energized. The advantage of this ar-
rangement is that either pump can
operate with either chiller. A third
pump could even be added as a
standby if so desired.
Chiller
Figure 42
Multiple Water-Cooled Chillers, Manifolded Pumps,
Two-pass evaporators and condensers shown.
Primary-Secondary Chilled Water System
In a primary-secondary system, Production Loop (primary)

each parallel-piped chiller in the pri-
mmy loop starts/stops with its
dedicated pump. Flow for each chiller Alternate
Bypass
in the primary loop is maintained by Une
water circulating through the chillers minimum
chiller
and back through the bypass which flow
acts as a hydraulic decoupler line, or

• Secondary pumping station
"bridge." Water can flow in either
- One pump active, the other standby Qead-lag)
direction within the bridge depending - Pumps are VFD-equipped if all coils are 2-way
on which flow is greater at any one - Matches secondary flow to coil loads
point in time, the primaty flow or the • Hydraulic decoupler maintains constant primary flow
secondary flow.
Figure 43
Primwy -Secondary Piping System,
One-Pass Evaporators Shown.
Distribut1on Systems
..)
.Turn to the ExpertS.
25
When the primary flow exceeds secondary flow, water flows from discharge to suction in the
bridge. When the secondary flow exceeds primary flow, water flows from suction to discharge in
the bridge.
Usually, variable-speed drives are used on the secondaty pumps to match secondary pump
flow to coil load flow demand. These pumps are the large, high-head pumps serving the entire
system. When VFDS are used, two-way control valves are used on the coils on the load side of
the system. The pump station is often a lead-lag pump arrangement with only one pump operating
at any one point in time. This provides standby and ability to equalize pump operating hours.
Check valves are needed for each secondaty pump to prevent water circulating backward through
the idle secondary pump. Many designers like to place a 3-way control valve with a bypass on
one of the coils to be used as a safety valve for low flow just in case the VFD control fails.
As the two-way coil control valves close off, less water is pumped through the secondary cir-
cuit and the secondary loop pressure rises. This would normally mean that the primary pumps
would be starved for water if there wasn't a bypass line. However, the flow not needed by the
secondaty pumps moves from discharge to suction through the bridge and returns to the primary
pumps thereby insuring a constant primary loop flow to the active chiller(s).
During startup conditions, the coil control valves might all go wide open and the secondary
pump will pump more than the design flow provided by the primary loop. If this happens, water
flows the opposite way in the bridge line. The extra water not needed by the primary loop passes
from bottom to top in the bridge and back to the secondary pump.
The hydraulic decoupler (bridge) line is typically sized for the flow rate required by the larg-
est chiller and should not exceed a pressure drop of 1.5 ft wg. It should be a minimum of 3-5 pipe
diameters long. For simplicity, the bypass line is often sized the same size as the main supply and
return lines, provided it does not exceed the stated criteria for pressure loss.
Primary-Only, Variable-Flow Chilled Water System

Primary-only, variable-
flow systems take advan-
tage of the ability to
modulate the flow through
the chiller evaporator and
eliminate the need for two
sets of pumps (primary
and secondary) and instead
use a single set of pumps
equipped with VFDs.
Variable flow systems
have become more popular Variable Speed
Primary Pumps
on primary- secondary
systems since there are Figure 44
fewer pumps to buy so
Primwy -On/y Variable-Flow System,
floor space is saved, along One-Pass Evaporators Shown.
with first cost.
<
« &> ~ .
Turn to the &:perts. ~-----------------------------~-----------------
26
----·- ···-··------- ·-----------·----------- ------ -- ·-------------------WPiT!;_BJ:JEl~.-~--Ab!QE1!.M.P_$..
Two-way control valves are used on the coils and a

bridge line is still used and is sized for the minimum
flow rate through the largest chiller. A control valve
(traditionally controlled by a precision flow meter) is
used in the bridge to ensure that the minimum flow
rate always returns to the operating chiller(s).
It is important to understand, however, that there
are still limitations on the amount of flow variability.
Specifically, the manufacturer's recommended chilled
water flow range must still be respected as well as the
rate of change of flow. As a rule of thumb, the mini-
mum evaporator flow rate should not fall below approxi-
mately 40 percent to prevent laminar flow. This means that
flow may be modulated from 100 percent down to 40 per-
cent, resulting in energy savings as the pump energy is
related to speed by the cube of the ratio of speeds. The
DDC controls must also limit the rate of flow change to
adhere to manufacturer's recommendations. The chiller
manufacturer should be contacted for specific chiller ap-
plication guidelines when designing a primary-only
variable flow system. For specific recommendations on
variable flow through evaporators, refer to TDP-622, Air-
Cooled Chillers, and TDP-623, Water-Cooled Chillers.
Since a primary variable system is inherently more complicated than the traditional primary-
secondary system, the operating staff must be trained specifically on how to maintain and operate
the variable flow arrangement.
If the installation is in a remote area, or a fail-safe design is required, it is probably better to
use a traditional primary-secondary system.
If a primary-only, variable flow system is used, an accurate measurement of the return flow
rate is essential to stable, reliable operation. This means a precision flow meter is necessary.
Chiller Head Pressure Control
Overnight cooling of the tower and condenser water loop can produce temperatures below
55° F upon start-up. Chillers are designed to operate at condenser water temperatures 55° F and
above. Consequently, a bypass is required to maintain an acceptable water temperature so that the
chiller will not shut down upon startup.
Dl..,.!>r'"-l ~t; ...,,,., ~::oH~~t~.}·..~·'~

Q;ll':S.,:. :i il:)'x.,.;s ~t\J C( oi:.~ _2 ·~ )L.~.:,(:ij~"'-"' ' "'
~ . ® ,....
- - ----..-·-·-------------- --·--------------------------- -····----··---·----- -- --------·------·---·-------- ------ --·-- ·------- I lli'n t o the Experts.
27
WATER PIPING AND.__!.P~U~M.!..!CP
~S ~------------
Head Pressure Control Piping Methods with Diverting Valve
There are three piping configurations that can be used to control the condensing pressure and
temperature in the water-cooled chiller condenser when used on a recirculating cooling tower
loop. The first two methods utilize a
diverting valve. The third method util-
izes either a modulating valve or a Method 1
VFD to vary the flow rate in the con-
denser.
Method one locates the condenser Water-Cooled Chiller
water pump "outside" the bypass line
such that flow rate will be constant
through the cooling tower regardless
of diverting valve position. In this
scheme, during periods where head
pressure control may be required,
Condenser
such as morning start up, the chiller Water Pump
condenser will experience lower flow.
These lower flow rates can used to Figure 45
maintain acceptable condensing pres- Chiller Head Pressure Control with 100% Tower Flow
sures. Two-pass condenser shown.
Tower manufacturers typically prefer control schemes that maintain constant tower flow so
that the fill in the tower can be fully wetted during operation. That way predictable heat transfer
in the tower is assured. Reduced flows in the condenser can result in increased fouling in the
tubes over time.
Method t\vo locates the condenser water pump "inside" the bypass line such that flow rate
will be constant through the chiller condenser regardless of diverting valve position. In this
scheme, during periods where head
pressure control may be required, the
cooling tower will experience a re- Method 2
duction m flow. The chiller
manufacturer recommends this
scheme, because full flow IS mam-
tained in the condenser. Water-Cooled Chiller
Condenser
Water Pump
Figure 46
Chiller Head Pressure Control with 100% Condenser Flow,
Two-pass condenser shown.
"= .
~ Distribution Systerns
lum to the Experts·----·--·----------------- - - ----- --------·---- - - - - --------· -----..:.·------
28
- ---------------·- - --·- ---------------- W8I_I;.B_PI PING AN_Q_P.U MP..S..
Head Pressure Control Piping Method with VFD or Modulating Valve
Method three uses a modulating valve to vary the flow in the condenser. The reduced flow
rate through the condenser results in less heat transfer and the saturated condensing temperature
stabilizes. The flow through the con-
denser water pump and cooling tower
also varies as the system head varies Method 3
due to the change in valve position.
The valve will modulate with the
variation in water temperature to
maintain the desired saturated con- Water-Cooled Chiller
densing temperature. In this design,
the condenser pump will "ride the
curve" because the condenser flow
will vary. A VFD can also be used to
control the flow directly from a head
pressure control signal from the
chiller. This method varies the flow Condenser
Water Pump
through both the condenser and cool-
ing tower and is not as common as the Figure 47
other two methods using diverting Chiller Head Pressure Control Using VFD or Modulating Valve
valves. Two-pass condenser shown.
Pump Basics and Types of Pumps

After the piping system has been laid out, and the total pressure loss, or head, for the pumps
is calculated, the selection of pumps can be made. However, a basic understanding of pump ter-
minology is required. In this TDP module we will concentrate on centrifugal pump designs which
are the most common types used in comfort air conditioning.
Capacity
Capacity is the amount of liquid that can be pumped, given in terms of gallons per minute
(gpm).
-
.. , " ~
-----···---·······- -----·---------------·-······--------------··· ··......·----··--- - - - - - - - - - - - - - · - -Turn to the Experts.
29
_W~"(ER PIPING AN~D'-'P--'U
=:M
_,_,_P :::<__ __ _ _______ _ __ _ _ __
,__S
Head
Head (hd) is an energy unit that is
usually expressed in feet of the liquid
being pumped. In a closed system, ~u
friction is the only loss or head that
the pump has to overcome. The height
0s
of water on the suction side of the
Closed System (evaporator) Open System (condenser)
pump is always exactly equal to the • Suction head is Hs • Discharge head = Hd
height of the discharge side piping. In • Discharge head is Hd • Unbalanced head = Hu
open systems this is not true, there is Hs =Hd • Suction head =(Hd - Hu)
• Pump must overcome friction • Pump overcomes friction
always a difference in head between losses plus Hu
loss of the piping circuit only
the suction side and discharge side of
the pump. In a cooling tower for in- Figure 48
stance, the height between the water Pumping Head Examples
level in the basin and the exit from the
distribution nozzles at the top of the tower represents the unbalanced head that must be overcome
by the pump. If the distribution system consists of spray nozzles that require a specific pressure to
force water through the nozzles, this pressure must be added to the static head also. The total head
of the pump will consist of the following: pipe friction loss, valves including control valves, ac-
cessories, equipment such as coolers, condensers coils, air separators, etc., and any unbalanced
head.
If you have a high-rise building, the static head can impose significant pressure on the system
components. Example - A 50-story building with 12-ft between floors would be 600 ft. high.
Since 2.31 ft. equals 1 psi, the pressure on the components at the lowest level would be 600
ft./2.3 1 ft!psi = 260 psi. The system components at the lowest elevation must be designed for this
pressure. In this example, the chiller "waterboxes" would have to be constructed to accommodate
260 psi. If the cooling tower was on the roof, the condenser waterboxes would have to be 300 psi
rated as well. If the cooling tower was ground-mounted, the condenser waterbox could be stan-
dard construction.
Discharge H ead
Discharge head is the head at the pump discharge, made up of the static head at the pump out-
let, any positive static pressure in the discharge side of the system, discharge pipe friction loss,
and any equipment pressure drop. A pump discharge pressure gauge would indicate total dis-
charge head.
Suction Head
Suction head is the head indicated on a pressure gauge at the pump suction. In a closed-loop
system it would be the remaining discharge pressure after subtracting all the piping friction, and
the valve and equipment losses. In an open-loop system, suction head includes static head (or
lift), entrance loss and friction head in the suction piping, and any positive pressure existing on
the suction side. With a closed-loop system in operation, a pressure gauge at the pump suction
would indicate a positive suction head. On an open-loop system the gauge would read negative if
the pump was above the fluid source being pumped.
Liquid Horsepower
Liquid horsepower is obtained by the formula, gpm * hd * sp gr + 3960 (for standard water sp
gr = 1.0), where 3960 converts the equation units into horsepower (33,000 ft * lb per minute, di-
vided by 8.33 lb per gallon).
(~
30
Brake Horsepower
Brake horsepower (bhp) is the power required to drive the pump and equals the liquid horse-
power divided by the overall efficiency of the pump.
Net Positive Suction Head
Net positive suction head (NPSH)
is equal to the pressure drop in ft wg
of the liquid from the suction flange Di~~~·~R
to the point inside the impeller where
·-··~-"~
.
A minimum positive pressure
pressure starts to rise. NPSH available (P) Pressure¢ c : (P) at the pump suction flange
at the pump suction for the actual ap- at Suction ~ 1 • is required to prevent
plication must always be greater than Flange--- - /~-~, ; cavitation, which is the
the NPSH required for the pump used. ====!.· ~ formation of vapor bubbles.
Failure to do so would allow fluid Impeller Eye

vaporization within the pump (cavita-
tion). Cavitation can cause impeller Figure 49
failure, shaft failure and/or seal fail- Net Positive Suction Head at Pump Inlet
ures. To check the available NPSH at
the pump suction flange in a given
system, use the following formula:
NPSH = 2.3I(Pa -Pvp)+(Hs -HI)

If using a fluid other than water use the following for-
mula:
2.3I 1P - P ) (
NPSH = \ a vp + H s - H 1 )
spgr
Where:
NPSH net positive suction head
2.31 = conversion factor to change 1 psi to pressure head in ft of water
pa atmospheric pressure (absolute pressure, psia)
pvp = vapor pressure corresponding to water temperature at the pump suction. For wa-
ter returning from a cooling tower at 85° F it is 0.59648, for 86° F water it is
0.61585.
Hs elevation head, static head (ft) above or below the pump suction. (If above, posi-
tive static head; if below, negative static head, sometimes termed suction lift.)
H1 = friction head (ft), loss in suction line. Must include entrance loss and pressure
drop through valves and fittings.
sp gr specific gravity of the fluid being pumped
@+ ® ~
" ·-----------·--------------·--------------------·-- - - - · - - - -Turn to the Experts.
31
.YJ.AIEB_PI PI NG_A~D _EV ME_s___________________________________________ ____
Figure 50 shows a cross-section

of a typical pump. This figure is of a
centrifugal inline pump, which gets its
name from the straight inlet and dis-
charge water flow. Other centrifugal
pump designs will be discussed later Motor
in the TDP Module. The figure shows
six components of a typical pump: the
motor, coupler, bearings, pump shaft,
mechanical seal, and the impeller.
The motor is typically an open-
drip proof type provided by the pump Figure 50
manufacturer and selected specifically Typical Pump Cross-Section
for the head and flows required.
A coupler mechanism is provided to attach the pump shaft to the motor assembly.
Specifically designed bearings are utilized to provide constant circulation of oil over all bear-
ing surfaces.
The pump shaft serves the purpose of transmitting the motor torque to the impeller.
A mechanical seal is required to prevent water from entering the motor and bearing com-
partment
The impeller moves the water through the pump assembly. It is selected specifically for the
flow and head required for the application.
Pump Curve
The optimal pump curve for an • Characterized by the slope of the
pump curve
air-conditioning application is shown - Flat or st.zep
here. The very steep curve is not de- VeryAatl • Aat pump curve
sirable for HVAC duty because it can -----------
,..---...... - Head varies slightly as flow changes
lead to surging at low flow rates. The tv '", ---... - More appr~eable on closed systems
where variable flow may be used
very flat curve can be an issue be-
cause large flow rate changes occur
.
¢'
' \
\
{chilled water circult)
• Steep pump curve
\ - Head Y2ries significanlly as flew
with small changes in the head. Very Steep_/\ Good changes
for - More appfiCable in open circuits
Important items to understand IWAC (tower) where high head vlith constant
flow may exist
about pumps are: Capacity- gpm _ .
1. Varying the speed - proportion- Figure 51

ally raises or lowers the head
Pump Curve Examples
and capacity. The whole head
curve shifts up or down.
2. Varying the impeller diameter - proportionally raises or lowers the head and capacity. The
whole head curve shifts up or down. Increasing the impeller size raises the head and capac-
ity.
3. Varying the impeller diameter - proportionally varies the capacity.
«a
Turn to the ExpertS:---- - - - - --- - - - -- - -------- - ··- -------
-- -- ---------
32
__________________________ YI/ATE R PIPING AN Q_p_l)._[yl£_$._
4. Varying the pitch and number of vanes within the impeller changes the shape of the head
capacity curve.
5. Varying the impeller and vane designs produce variations in head-capacity relationships.
Narrow impellers with larger impeller-to-eye diameter ratios develop a larger head. Wide
impellers with low diameter ratios are used for low heads and large flows.
Changes in speed and impeller diameters are reflected in pump performance as follows:
2 3
1 = gpm 1
_rp_7_n_1 or-in--"1p:._e_l_le_r_d_ia_.-=- = ( head1 J = (bhp 1 J
rpm 2 impeller dia. 2 gpm 2 head 2 bhp 2
A given pump operates along its

own head-capacity curve. It is a cen-
trifugal device just like a fan. At full ...
capacity flow, the operating point j ............... £9<]1
falls at the crossing of the pump ,,/''@ Full Flow
head-capacity curve and the system ~
head curve (Point 1). If the pressure --g ~@--,- Pipe
drop increases the system curve and ~ Friction
Head
-----------------:.:c::l
the operating point moves up the
head-capacity curve (Point 2, reduced
water flow) . If a greater flow is de-
sired, the pressure drop must be
reduced and the operating point
would move down the curve (Point Capacity - gpm ---..
3) or the pump could be speeded up, Figure 52
or the impeller size increased which
would move the head capacity curve Pump and System Curve Intersection
upvvard (Point 4). These performance
characteristics are just like a fan in a duct system.
If the system head is overestimated and the pump is selected with a high head-capacity curve,
unfortunate results may occur. The pump will operate on its head-capacity curve to produce an
increased flow at decreased head and
increased horsepower demand (Point
1). The system head should always be
Pump Head-
Capacity/ I
-~
calculated without undue safety fac- Curve
I
tors or as close as practical to the tme t
r----!...-.-- I
values to eliminate possible waste of ;;:::: I
horsepower or possible overloading of u<tl

pump motor with an unvalved system. I<1.>
-- --
If not sized properly, the balancing '\Actual bhp _.
valve on the pump discharge may \
have to be throttled or the impeller -----~~db~
size decreased to achieve the desired
flow. This is especially true when Capacity- gpm -
evaluating system head on a system
designed with parallel or senes Figure 53
pumps.
Overestimating Pump Head
«<B) 0
.•
···-·--·-·--·---------·--·-·-·····----------------------------·------------·-------------Turn to the Experts.
33
Parallel Pumps
Parallel pump operation is most common in HVAC and results in multiple gpm capacities
against a common head. Example: Two pumps selected at 120 gpm at 50ft of head will produce
240 gpm at 50 ft of head. Parallel pump application is for systems requiring high capacity with a
relatively low head or for systems where a number of small pumps handle the load with one or
more pumps shutting do·wn as required. The pumps should have matched characteristics and the
motor should have ample power to
avoid overloading when operated sin-
gly.
Parallel
Pump
( Curve
gpm 1
gpm
• Two identical pumps in parallel
• Resulting gpm doubles
• Plot result to obtain parallel pump curve
Figure 54
Parallel Pump Characteristics
Series Pumps
Identical series pumps are used if
very high head is required as the flow
rate is the same as for each individual
pump, but the head is additive. A sin-
gle higher rpm pump (i.e. 3500 rpm)
could be selected, but the redundancy
value of dual pumps would be lost.
gpm
• Two identical pumps in series
• Resulting head doubles
• Plot result to obtain series pump curve
Figure 55
Series Pump Characteristics
Turn to the ExpertS.--- - - - - --
34
- - -·- - - -- - · - - ----------·-------·-····-·-----yvATER PIPING_6NQ..E.lJ MPS.
Variable Sp eed Pumping

Variable speed pumping is very common. A pump with a VFD operates much like a fan with
a VFD. A differential pressure sensor located near the end-of-run in the piping system sends a
signal to the VFD to slow down the
pump rpm if pressure in the piping is
rising, or increase the rpm if the pres-
sure is falling from set point. The
pump moves its rpm along the sys- o:=
tern curve resulting in variations in -o
flow rate. flJ
:c W here: bhp =brake horsepower
Energy savings are excellent at Capacity - gpm 1000" ~

reduced flow rates as the bhp follows • As control valves modulate, the differential pressure across supply and
return lines rises sending signal to VFD to modulate pump speed
the cube ratio of the rpm.
• Operating point moves along system curve to new rpm line
3 (points A- B - C)
rpm • According to the pump affinity laws the energy savings
* - -2
bhp 2 = bhp1
(rpm1 J is a cubed function of the ratio of the pump speeds
Figure 56
Variable Speed Pumping Characteristics
Selection
Pumps should be selected based on design, size, service, and performance. In terms of per-
formance, a pump should be selected to provide the required flow rate at the design head while
trying tO achieve the }OW- HEAD (Feet)
Pump Series: 1510
Version 3.0.3
Pump catalogs, with pump f:11"

125-
performance curves, allow
10.875'
the proper pump to be se- 100- ·
lected. Most prunp
'
'-· '
manufacturers also have 75-
. ).
1
software programs that can :Fs..-,- 15tH'- ~

--r-;; ' '
select the optimal pump for 50-
- -~-~
'-
your application. The fol- -"f== ~ 7 llPSHr
25-
lowing is an example of a
pump selection from a 0
manufacturer's program. 0 4ll0 800 1,200 1,600
Capacity(GPM)
Suction Size= & " Min Imp Dia = 9" Design Capaeity=1000.() GPM
Discharge Size = S" M ax Imp Oia "'11 " Design Head "'100.0 Feet
Cut Oia = 10.375" Motor Size =<ro HP
Figure 57
Typical Centrifugal Pump Selection Screen Capture
Courtesy ofBelt & Gossett
Distribution Systerns
-·-·..·--- ·-·-·----------·------·-··------·-·--·-----·------·-------·--·----- - - -- - -Turn to the Experts.
GD
35
Centrifugal Pump Types
There are several types of centrifugal pumps used in the HVAC industry, such as inline,
close-coupled, end suction, vertical split case, and horizontal split case. Which type of pump to
use is determined by the flow rate and head requirements, available space, serviceability and cost.
The Pump Type Comparison chart below shows the ranking of each type of pump for each cate-
gory.
Vertical
Figure 58
Types of Centrifugal Pumps
Photos cou11esy of Bell & Gossett
-·
Pump .. Flow& Head Space -: : Ease of
Cost :
I _ Typ~- ..
--. _C~pabil!~ _-_ "• ~equjred~ Servic~
In Line Least1
I 200 gpm @ 55 ft Least1 Poor 5
Close-
2 2,300 gpm @ 400 ft 2 4
Coupled I
End I
3 4,000 gpm @ 500 ft 3 1
Suction
Vertical
Split Case
4 9,000 gpm @400ft 4 2 I
Horizontal
Highest 5 40,000 gpm @ 600ft Most5 Good 3
Split Case
Figure 59
Pumv Tvne Conwarison
4D>
Turn to the Experts.--
36
-·-- ---------------- WATER PIPING ANQ_PU_MPS
Pipe Sizing and Pump Selection Example

Steps 1-7 use a condenser water piping loop as the example system. Step 8 is for sizing the
chilled-water piping loop. Once the piping system with all pipe routing, piping accessories, and
equipment has been drawn and the flow rate for each piece of equipment has been determined, it
becomes necessary to size the piping. Sizing of the piping will allow the total resistance (head) in
the system to be determined so the pumps can be selected.
Step 1: Determine Water Velocity in Piping
Pipe size is limited by velocity based on noise and pipe erosion considerations. Both sound
and erosion increase as the velocity increases. The table below gives recommended velocity lim-
its, which are based on experience and
Recommended Water Velocities
are designed to give good balance be-
tween pipe size and system life. Service Velocity Range (fps)
Pump discharge 8 to 12
Pump suction 4 to 7
Drain line 4 to 7
Header 4 to 15
Mains and Riser 3 to 10
Branches and Runouts 5 to 10
City water 3 to 07
Figure 60
Recommended Water Velocities
The header pipe is close to the pump and carries fluid to the mains and risers. Mains (hori-
zontal) and risers (vertical) distribute the fluid to the various areas of the building where branches
and runouts feed the water flow to the air terminals, fan coils, baseboard, etc.
Step 2: Determining Piping Friction Losses

Friction Loss rate for pipe can be found by using Charts 1, 2 and 3, which are found in the
Appendix. Charts 1 and 2 are normally used for larger size steel pipes, 2:_2 12-in., and Chart 3 is
usually for smaller pipes, ~2-in., where copper tubing is commonly used.
Chati 1 applies to new, smooth, clean, standard weight, steel pipe and can be used to deter-
mine the friction loss rate in a closed-loop piping system, such as a chilled water or hot water re-
circulating system.
Chart 2 applies to standard weight steel pipe that has been subject to scaling. This chart can
be used to determine the friction loss rate in an open re-circulating piping system such as a con-
denser water system with cooling tower.
Chart 3 is used to determine the friction loss in copper tubing, which can be expected to stay
clean throughout its normal life. Chilled or hot water systems that use copper piping would be
sized with this chart.
Each chart gives the friction loss or head in feet of water per 100 ft of straight pipe.
(«a>
_ _ _ _ _ _ _ _ _ _ _ _ Turn to the &-pertS.
37
Table 4 is the physical properties of steel pipe. This is helpful for inside areas, pipe and water
weights.
Friction loss in valves and fittings can be determined by using equivalent length Tables 5, 6,
7 and 8.
The equivalent length tables were derived using the published manufacturer's Cv values. This
was done to simplify and streamline the process for determining the friction loss in valves and
fittings.
All friction losses are in equivalent length (feet) of
straight pipe.
Step 3: Gather Job Specific Component

Pressure Drops and Design Data
Given:
100- ton cooling load
Entering chilled water temperature (54° F)
Leaving chilled water temperature (44° F)
Entering condenser water temperature (85° F)
Leaving condenser water temperature (95° F)
AHU-1 , 45- ton load
AHU-2, 55- ton load
Chiller 30 Series Cooler PO 12.4 ft wg
Equipment selections should be
Condenser PO 11.0 ft wg
done to determine the pressure drop
through each piece of equipment. This AHU-1 39 Series Clg. Coil PO 9.9 ft wg
can be done by using the manufac- AH U-2 39 Series Clg. Coil PO 13.4 ft wg
turer's computerized selection 6.5 ft wg
Tower From Vendor Unbalanced head
program or published data.
Required Nozzle Pressure 12.5 ft wg
Air Separator From Vendor From Vender PO 1.3 ft wg
Figure 61
Equipment Selection
~: ~ Distribution Systems
Turn to the Experts.·----- - -- -- - - -- - ----------------..·-------------- -------------·- - -·------- --- -
38
_ _____ __,W
~A.TER PIPING AND PUMPS
Step 4: Review the Highest Pressure Drop Circuit and Calculate Water Flows
Cooling tower details usually do not show the exact exit point of the water from the distribu-
tion nozzles or the exact water height in the basin. We need to determine the unbalanced head. It
doesn't have to be exact; in fact, ifyoujust use the water inlet height minus the outlet height, you
will b e close enough. For our example, we have a nozzle pressure drop of 12.5 feet and a height
of 6.5 feet for a total tower pressure
drop of 19 ft wg. Condenser Loop
You should contact the cooling
tower manufacturer for the pressure
drop of the cooling tower selected. 5• 37'
Most cooling tower electronic selec-
tion programs will show this
information. If this information is not 28 '
available, an approximation of 15 ft
wg will be close enough in most
cases.
The condenser flow rate can nor-
mally be obtained from the actual
chiller selection. For our example, we Figure 62
will use 3 gpm/ton, which is the ARl
Sizing the Condenser Water Piping
standard condenser flow rate.
The chilled water flow rate can be obtained from the actual chiller selection that was based on
tons and water ilt or it can be calculated based on the following formula:
tons * 12,000 Btuh I ton .
gpm = , or more srmp1y,
11t * 60 min/ hr * 8.33/b I gal* sp gr * sp ht
gpm =tons * 24 + ilt

100 * 24 + 10 = 240 gpm
So we will use 300 gpm for the
condenser flow rate and 240 gpm for
the chilled water flow in the cooler
(evaporator).
---·--·-·- - · - - - · - - - - - - - --
48
- - - -Turn to the ExpertS:
39
Step 5: Size the Pipe; Find the Friction Rate/100ft
First, let's size the open-loop system (condenser water system) using Chart 2 to determine the
piping friction losses.
Referring to Chart 2 in the Appendix, we find that 300 gpm intersects a 4-in. line size at 8.3 ft
per second velocity and 10.0 ft of friction loss per 100 ft of pipe. Since w e also have two pumps
that handle 50 percent of the s
flow, we must determine the
line size at the pumps. Refer-
ring to Chart 2, we find that
150 gpm intersects a 3-in. line
size at 6.9 ft per second veloc-
ity and 9.3 ft of friction loss per
100 ft of pipe.
The 300 gpm sections of
pipe will be 4-in. size, and the
150 gpm sections of pipe will 1112
be 3-in. size.
These sizes are within the
recommended water velocity
Figure 63
and pressure drop per 100 ft
recommendations. Sizing the Open-Loop Condenser Water Piping Using Chart 2
48
Turn to the ExpertS:-- -- - - -- -·-- ------------ ----- ------ ---·
40
Step 6: Find the Longest Circuit Pressure Drop
Next let's add up the lengths of straight pipe in each size from the example. We will start at
the pump suction and go in the direc-
tion of water flow around the loop.
Condenser Loop
(Note: When two pieces of equipment Find longest circuit pressure drop
are piped in parallel, only the circuit by adding all fittings and pipe lengths
with the highest pressure drop should
5' 37'
be used in the head calculation.) i+--.500 gpm
3-in. straight pipe (at pump #2) = 5 + Water-Cooled Chiller

10 + 10 + 5 =30ft 28' Located on
ground floor
4-in. straight pipe= 5 + 5 + 5 + 10 +
37 + 3 + 5 + 28 + 5 =103ft
This circuit is represented by C-H I

H
Next let's list the valves and the Figure 64
elbows and any other accessories in
Example Condenser Water Loop
the loop in terms o f their straight pipe
equivalent lengths.
3-in. equivalent lengths (ft)

Pipe (from above) = 30
Std. ells (qty of 2 at 7.67 ft each) (Table 6) = 15
Butterfly Valves (qty of 3@ 11.51 ft each) (Table 5) = 35
Lift Check Valve (qty of 1 @ 14.06 ft) (Table 5) = 14
Strainer (qty of 1 at 42ft) (Table 8) = 42
Total = 136ft

Pipe (from above) = 103
Std. ells (qty of 7 at 10.07 ft each) (Table 6) = 70
Tees (qty of 2 at 6.71 ft each) (Table 5) = 14
Butterfly valves (qty of 4 at 15.1 ft each) (Table 5) = 30
Control valve, butterfly (qty of 1 at 16ft) (Table 8) = 16
Total = 233ft
DistrH:mHon Systems
-------- ------------~------------------
cm&t>
__ Tum to the ExpertS:
41
Step 7: Sum All the Pressure Drops for Pump Selection
Total Friction Loss = Equivalent ft * loss/100 ft Head on Condenser Water Pump (ft)
For 3-in. pipe, 136 equiv. ft * 9.3 ft 1100 Friction head 36.0
For4-in. pipe, 233 equiv. ft * 10.0 ft /100 Unbalanced head 6.5
Total= 12.65 + 23.3 = 35.95 ft wg (round off to Pressure drop through condenser 11 .0
36ft wg pressure drop)
Pressure drop through nozzles 12.5
Enclosed is the actual pump curve for the
Total head across pump 66.0
condenser water pump based on 150 gpm each
at 66ft wg of head.
HEAD (feet)
Pump Series: 1 51 o
66 ft
Suct ion Si:ze ,. 2.5 •· M in lnw Dia • 1 •· Design Ca1>atity ;JQO.O CPM !Single Pump =150.01
Dis ch.uge Size • 2 " M.lx IIlli) Di.l a 9.5 " De s ign lle ad =G,.O f e et
Cut Oia ; 8.375 •· Motor Size =5 tiP
Figure 66
Example Condenser Water Pump Selection - Parallel Pumps, Single Pump Pe1formance
Screen capture courtesy ofBell & Gossett
HEAD(Feet) Err.
.. Pump Selie$: 1510
1 00·
r-H--- I l ; _j_
1ms~r
80.
I
i
I
i
I
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I
I I
I I
I l
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~±CJ=
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a.3m--;- ~I
75"rr --ft'' '7'. , l I
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60. ''-' I
. ! ""-..• i I I
I f
I I
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I .L'\1
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A. I
'
;-.. !
...... , I
i
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40
fi ' J.
•--r--r:-t:
I
~~-
I
V:l.
'......:"
_j_.
-H+
I I
l! PK
i
-i- r-
' / I II 1/ I !
I H I
! I . I I
r-r-!
!--i.:': i li!T" I
+T-1-r Ci'i ·-r
20. I I I
' ' ! '
+ Power I A
j ::;;r1
I
H-I
+F'~s~~I I
i I
I
I
'
' +
0 I ---:f .l I ! ! I ! I .J
0 100 300
200 400 500 600
Capacity (GPM)
Suction Size = 2.5 •• Min Imp Oia = 1" Design Capacity =300.0 GPM
Dis charge Size -= 2 .. Max Imp Oia = 9.5" Design Head =66.0 Feet
Cut Dia • 8.375 " Motor Size =5 HP
The Power and Eff. curves s h own are forthe cut dia. impeller.
Figure 65
Example Condenser Water Pump Selection - Parallel Pumps, Pe1jormance ofBoth Pumps
..
Screen capture courtesy ofBell & Gossett
: ~
Tum to the Experts·- - -- --- -------- -- -- ------------- ----------------------------- -··
42
_________________________VY_ATEB PIPING AND PUMJ:S
Step 8: Size the Chilled Water Loop

The closed-loop system (chilled water system) should be sized using Chart 1 to determine the
piping friction losses.
Referring to Chart 1, we find that 240 gpm intersects a 4-in. line size at 6.3 fps velocity and
3.4 ft of friction loss per 100 ft of pipe. Since we also have two pumps that handle 50 percent of
the flow, we must determine the line
size at the pumps. Referring to Chart 1,
we find that 120 gpm intersects a 3-in.
line size at 5.5 fps velocity and 3.5-ft of
friction loss per 100 ft of pipe.
Figure 67
Sizing the Chilled Water Piping Using Chart I
The two air-handling units are piped in parallel so we must use the one that has the highest
pressure drop when the piping and AHU pressure drops are summed. Since AHU-2 has the long-
est length of piping and the coil pressure drop is higher we will use the piping to AHU-2 in our
calculation. Referring to Chart 1, (55 tons * 24-;- 10 = 132 gpm) we find that 132 gpm intersects
the 3-in. line size at 6.0 fps velocity and 4.0-ft of friction per 100 ft of pipe (not shown in the
text). Notice the water flow in this circuit is clockwise with the pump pushing water through the
chillers. The longest path of water flow starts at point C, goes through the chiller, up to AHU-2,
back down through the air separator, to point Nand then through pump number 3.
Air Handling
Chilled Water Loop Units
AHU-2
132 gpm __ _
l".;:....-_:':
Water-Cooled
Chiller
Figure 68
Find longest p ressure drop circuit and calculate water flow_
_ _ __
4lilt.>
_ _ _ _ _ _ Turn to the ExpertS:
43
_\f:l8_TER PIPING AND PUMJ:_§________________ _
Straight pipe from the example:

3-in. pipe@ pump #3 = 10 + 10 + 5 = 25ft
3-in. pipe@ AHU #2 = 12 + 5 + 5 + 12 = 34ft
4-in.pipe(C-N) = 10+5+5+20+15+17+5+2+1+ 1+ 1 =82ft
3-in. equivalent lengths@ pump (ft)

pipe (from above) = 25
Std. Ells (qty. of 1 @ 7.67 ft) (Table 6) = 8
Butterfly Valves (qty. of 3 @ 11 .51 ft each) (Table 5) = 35
Lift Check Valve (qty. of 1 @ 14.06 ft) (Table 5) = 14
Strainer (qty. of 1 @42ft) (Table 8) = 42
Total = 124ft
3-in. equivalent lengths @ AHU #2 (ft)

Std. Ells (qty. of 2 @ 7.67 ft each) (Table 6) = 15
Tees (qty. of 1 @ 5. 11 ft) (Table 6) = 5
Butterfly Valves (qty. of 3@ 11 .51 ft each) (Table 5) = 35
Control Valve, butterfly (qty. of 1 @ 11 ft) (Table 8) = _11
Total = 100ft

Ells (qty. of 7 @ 10.07 ft each) (Table 6) = 70
Tees (qty. of 4@ 6.71 ft each) (Table 6) = 27
Butterfly Valves (qty. of 2@ 15.1 ft each) (Table 5) = 30
Total = 209ft
Total Friction Loss= Equivalent ft *loss/100ft of pipe

For (3-in. pipe@ pump, 124 equiv ft * 3.5 /100) + (3-in. pipe @ AHU #2, 100 equiv. ft * 4 /100)
+ (4-in. pipe, 209 equiv. ft * 3.4 11 00)
Total = 4.22 + 4.0 + 7.32 = 15.54 ft wg
(~
Turn to the Experts: _____ Distribution Systems
44
------------··------------·--·-··--·----··---------·----·-·------VY..8J~B__E1PJJ:~K~_AN D P WM f:.S
Total Head on Chilled Water Pump (Jt wg):

Friction Head = 15.5
Pressure drop through Cooler = 12.4
Pressure drop through Air Separator = 1.3
Pressure drop through AHU #2 = 13.4
Total Head across Pump = 42.6 ft wg
The chilled water pumps would be based on two pumps of 120 gpm each at 42.6-ft of pres-
sure drop and would be selected like the condenser with the pump manufacturer's selection
software. Actual selections are not shown in this example.
At this point, we can add a safety factor of 10 percent because the actual piping installed may
not match the initial design. If the system head is slightly oversized the balancing valve at the
pump discharge can be used to impose a false head and balance the flow accordingly. If the sys-
tem head is oversized to a point where the balancing valve at the pump discharge throttles away
too much head then the pump impeller should
be "trimmed." When an impeller is trimmed,
it is physically reduced in size slightly by ma-
chining down the blades. This accomplishes a
desired reduction in its capabilities.
We now have all the data to do a system
volume check and see if a volume tank is nec-
essary for the chilled water system.
Step 9: Check Evaporator Loop Volume

Required volume mle of thumb for this chiller is approximately 3 gallons per nominal ton.
Some chiller loop applications may require higher than 3 gallons per ton, such as process cooling
for instance. Some manufacturers do not establish minimum loop volume in terms of gallons per
installed ton of chiller. For instance there may be a recommendation that the cooler loop volume
be large enough such that it takes at least 4 minutes for the flow to completely move through the
entire system. So instead of gallons per ton in that instance, take the gpm flow rate through the
chiller and multiply it times 4. That would then be the required minimum loop volume. Always
check with the chiller manufacturer for their latest recommendations.
3 gallons per nominal ton * 100 nominal tons = 300 gallons
Therefore, the system must have a water volume of 300 gallons.
4-in. pipe, 82-ft* 5.51 lbs/ft of water (from Table 4 in the appendix)= 452 lbs of water= 54
gallons (water weighs 8.33 lbs/gal)
3-in. pipe, 94ft* 3.20 lbs/ft of water= 301 lbs ofwater = 36 gallons
Note: 94 ft of pipe represents all of the 3-in. pipe, not just the pipe used in the head calculation.
Cooler barrel holds 22.6 gallons (from manufacturer's chiller product catalog)
The AHU coil volume should not be taken into consideration since the coil has a 3-way valve
and could be bypassed.
(~
.Turn to the ExpertS:
45
Total number of gallons in the system= 54+ 36 + 22.6 = 112.6 gallons.

This system needs a volume tank.
300 gallons required- 112.6 gallons actual= 187.4 gallon volume tank
Piping System Calculator Tool
Shown here is a picture of a well-known pipe sizing

and calculator from a major manufacturer of hydronic
pumps and accessories. This tool combines the features
of the pipe sizing charts into an easy-to-use pre-
packaged calculator that many designers and contrac-
tors utilize for everyday piping design tasks. The
instructions are written right on the calculator.
Some of the functions the calculator perform are:
1. temperature difference and capacity
2. friction loss and velocity
3. pipe length and pressure drop
4. system curve calculation Figure 69
The same pipe sizes :from our example problem for System Syzer® Calculator
Photo courtesy ofBell & Gossett
this TDP could have been found on the calculator.
Summary
In this TDP we covered the major topics dealing with water piping. The basic piping systems
of closed, open, and once-thm configuration were diagramed.
The four water distribution systems were analyzed and advantages and disadvantages were
discussed.
Direct-return and reverse-return options were also covered in detail.
Major piping components, accessories, and typical equipment connection diagrams were pre-
sented, along with primary-secondary and variable-primary flow piping designs.
Pump basics and the various types and designs of water pumps were presented, along with a
pump comparison summary chart to assist in proper selection.
Finally, a pipe sizing example allowed us to use conventional equivalent length charts and ta-
bles to size system piping. An industry hand-held calculator was introduced that could also be
utilized instead of the manual charts and tables .
..
46
WATER PIPING AND PUMP~.
Work Session
1. A chilled water system is alan _ _ _ __ loop system.
2. A condenser water system with a cooling tower is alan _ _ _ _ _ loop system.
3. Name 4 types ofvalves that can be used for flow control duty?
1.
2.
3.
4.
4. What are the 3 types of valves that can be used for shutoff duty?
1.
2.
3.
5. vVhat is the price and equivalent pressure drop in feet for a butterfly, globe, gate and ball
valve of 6-in. size?
Valve Price Pressure Drop (ft)

Butterfly
Globe
Gate
Ball
6. What determines the need for a volume tank in a closed-loop system?
Distribution Systems ~
Turn to the ExpertS:
47
_WATERPIPING AND PUMPS
7. Sketch a typical piping detail for a pump. Label accessories and note their functions.
8. Should the pump be pushing or pulling water through the chiller evaporator and condenser?
9. In a closed-loop system with a flow of 300 gpm, what size chilled water line should be used?
What is the water velocity? What is the friction loss in ft of
water/1 00 ft of pipe? _ __ _
10. If you have 3 pumps in parallel and the system flow is 400 gpm @ 60ft. of hd, what is the
flow through each pump? What is the head at each pump? _ _ _ __
11. Which piping system offers true simultaneous heating and cooling without mixing of the hot
and cold water flows?
- ---- - - - - - -
12. When should there be concern regarding NPSH?
13. What type ofwater control valve would be used on the coils in a variable flow chilled-water
system? __________ _____
14. What kind of water control valve is used in a conventional constant flow primary-secondary
system? _ ______ ______
15. Which piping system required a seasonal "changeover" from cooling to heating and vice
versa?
- - ---------- --
..
Turn to the ExpettS: - -- - ---- - - -- -
· -- - -
48
- -- --
Appendix
References
Bell & Gossett, Morton Grove, IL. http://www.bellgossett.com/

Flexicraft Industries, Chicago, IL. http://www.flexicraft.com/
Weiss Instruments, Inc., Holtsville, NY. http://www.weissinstruments.com/
Cleaver-Brooks, Milwaukee, WI. http://www.cbboilers.com/
Charts and Tables

Chart 1 - Friction Loss for Closed Pipe
Chart 2 -Friction Loss for Open Piping System Schedule 40 Steel
Chart 3 - Friction Loss for Closed and Open Copper Tubing System
Table 4- Physical Properties of Steel Pipe
Table 5- Friction Loss of Valves in Equivalent Length of Straight Pipe (Feet)
Table 6- Friction Loss of Pipe Fittings in Equivalent Feet of Straight Pipe
Table 7 - Special Fitting Losses in Equivalent Feet of Straight Pipe
Table 8- Control Valves and Strainer Losses in Equivalent Feet of Straight Pipe
Tum to the Experts.
49
_WATE;R PIPING AND PUMPS~-----------------
Chart 1 -Friction Loss for Closed-Loop

System Schedule 40 Steel
20,000 ~-~-..~..;;:8~~~,.,.....~-1-.
5~~-2~0~~~""""'"r---~--:---:::.,-
14~,...~
10
4000-
5
2000
4
1000 3 1/2
E
a. 2 1/2 c
rn
2 (1)
~ 200 .t:!
0 (f)
't: (1)
Q) 1 1/2
....... a.
sro 1 1/4 0..
20 3/4
1/2
3/8
I ~ , i
• I - j
0.1 0.2 0.4 0.6 0.8 2 4 6 8 10 20 40 60 80 100
Friction Loss (Feet of Water I 100ft)
~ : : w Distributio n Systems
Tum to the ExpertS-----·- ·- -------------------- --·-------- --------·------
50
_ ______,W
_. : . ATER_PI
:. PING AN D PUMP$.
Chart 2 - Friction Loss for Open-Loop

System Schedule 40 Steel
6 B 10 15 24 20 20 18 16 14
20,000
12
10
4
3 1/2
3
400 - c
E
a.. 21/2 Q)
0)
.~
(/)
s0 2 Q)
a..
't:
.....,
Q)
11/2
a:
sco 1 1/4
40 ·-
20
3/4
10 .
8
6 1/2
1
0.1 0.2 0.4 0.6 0.8 2 4 6 8 10 20 60 80 100
Friction Loss (Feet of Water per 100ft of Pipe)
51
..
(
___ Tum to the ExpertS:
Chart 3
31/2
21/2
2
E
Q..
0>
11/2 -~
'
1 114 ~
U5
(1)
Q..
0..
3/4
1/2
6
3/8
4
1
0.1 0.2 0.4 0.6 0.8 1 2 4 6 8 10 20 40 60 80 100
Friction Loss (Feet of Water /100ft)
-- ; - Distribution Systems
Tum to the Experts.---------------------------------------------------------------- -- - - - - -- - -
52
TABLE 4, PHYSICAL PROPERTIES OF STEEL PIPE
NOM. WTOF TRANS-

PIPE OUTSIDE INSIDE WALL WEIGHT WATER IN OUTSIDE INSIDE VERSE
SIZE SCHEDULE DIAM DIAM THICKNESS OF PIPE PIPE* SURFACE SURFACE AREA
(in.) NO. (in.) (in.) On.) (lb/ft) (lb/ft) (sa ft/ft) (sa ft/ft) (sa in.)
1/8 40(S) 0.405 0.269 0.068 0.244 0.0246 0.106 0.0705 0.0568
80(X) 0.405 0.215 0.095 0.314 0.0157 0.106 0.0563 0.0364
1/4 40(S) 0.540 0.364 0.088 0.424 0.0451 0.141 0.0955 0.1041
80(X) 0.540 0.302 0.119 0.535 0.0310 0.141 0.0794 0.0716
3/8 40(S) 0.675 0.493 0.091 0.567 0.0827 0.177 0.1295 0.1910
80(X) 0.675 0.423 0.126 0.738 0.0609 0.177 0.1106 0.1405
1/2 40(S) 0.840 0.622 0.109 0.850 0.1316 0.220 0.1637 0.3040
80(X) 0.840 0.546 0.147 1.087 0.1013 0.220 0.1433 0.2340
3/4 40(S) 1.050 0.824 0.113 1.130 0.2301 0.275 0.2168 0.5330
80(X) 1.050 0.742 0.154 1.473 0.1875 0.275 0.1948 0.4330
1 40(S) 1.315 1.049 0.133 1.678 0.3740 0.344 0.2740 0.8640
80(X) 1.315 0.957 0.179 2.171 0.3112 0.344 0.2520 0.7190
1 1/4 40(S) 1.660 1.380 0.140 2.272 0.6471 0.434 0.3620 1.495
80(X) 1.660 1.278 0.191 2.996 0.5553 0.434 0.3356 1.283
1 1/2 40(S) 1.900 1.610 0.145 2.717 0.8820 0.497 0.4213 2.036
80(X) 1.900 1.500 0.200 3.631 0.7648 0.497 0.3927 1.767
2 40(S) 2.375 2.067 0.154 3.652 1.452 0.622 0.5401 3.355
80(X) 2.375 1.939 0.218 5.022 1.279 0.622 0.5074 2.953
2 1/2 40(S) 2.875 2.469 0.203 5.790 2.072 0.753 0.6462 4.788
80(X) 2.875 2.323 0.276 7.660 1.834 0.753 0.6095 4.238
3 40(S) 3.500 3.068 0.216 7.570 3.20 0.916 0.802 7.393
80(X) 3.500 2.900 0.300 10.25 2.86 0.916 0.761 6.605
31/2 40(S) 4.000 3.548 0.226 9.110 4.28 1.047 0.929 9.89
80(X) 4 .000 3.364 0.318 12.51 3.85 1.047 0.880 8.89
4 40(S) 4.500 4.026 0.237 10.79 5.51 1.178 1.055 12.73
80(X) 4 .500 3.826 0.337 14.98 4.98 1.178 1.002 11.50
5 40(S) 5.563 5.047 0.258 14.62 8.66 1.456 1.321 20.01
80(X) 5.563 4.813 0.375 20.78 7.87 1.456 1.260 18.19
6 40(S) 6.625 6.065 0.280 18.97 12.51 1.735 1.587 28.99
80(X) 6.625 5.761 0.432 28.57 11.29 1.735 1.510 26.07
8 40(S) 8.625 7.981 0.322 28.55 21.6 2.26 2.090 50.0
80(X) 8.625 7.625 0.500 43.39 19.8 2.26 2.006 45.6
10 40(S) 10.750 10.020 0.365 40.48 34.1 2.81 2.62 78.9
60(X) 10.750 9.750 0.500 54.70 32.4 2.81 2.55 74.7
80 10.750 9.564 0.593 64.33 31.1 2.81 2.50 71.8
12 30(S) 12.750 12.090 0.330 43.80 49.6 3.34 3.17 115.0
40 12.750 11.938 0.406 53.53 48.5 3.34 3.13 111.9
(X) 12.750 11 .750 0.500 65.40 46.9 3.34 3.08 108.0
80 12.750 11.376 0.687 88.51 44.0 3.34 2.98 101.6
14 30(S) 14.0 13.250 0.375 54.60 59.8 3.67 3.46 138.0
40 14.0 13.125 0.438 63.37 58.5 3.67 3.44 135.3
(X) 14.0 13.000 0.500 72.10 55.8 3.67 3.40 133.0
80 14.0 12.500 0.750 106.31 51.2 3.67 3.27 122.7
16 30{S) 16.0 15.250 0.375 62.40 79.1 4.18 3.99 183.0
40(X) 16.0 15.000 0.500 82.77 76.5 4.18 3.93 176.7
80 16.0 14.314 0.843 136.46 69.7 4.1 8 3.75 160.9
18 (S) 18.0 17.250 0.375 70.60 100.8 4.71 4.52 234.0
(X) 18.0 17.000 0.500 93.50 98.3 4.71 4.45 227.0
40 18.0 16.874 0.562 104.75 97.2 4.71 4.42 224.0
80 18.0 16.126 0.937 170.75 88.5 4.71 4.22 204.2
20 20(S) 20.0 19.250 0.375 78.60 126.7 5.24 5.04 291.0
30(X) 20.0 19.000 0.500 104.20 122.5 5.24 4.97 284.0
40 20.0 18.814 0.593 122.91 120.4 5.24 4.93 278.0
80 20.0 17.938 1.031 208.87 109.4 5.24 4.70 252.7
24 20(S) 24.0 23.250 0.375 94.60 184.6 6.28 6.08 426.0
(X) 24.0 23.000 0.500 125.50 179.0 6.28 6.03 415.0
40 24.0 22.626 0.687 171.17 174.2 6.28 5.92 402.1
80 24.0 21 .564 1.218 296.36 158.2 6.28 5.65 365.2
Data from Crane Technical Bulletin No. 410-1991, reprint pages B-16 thru B-19
..
To change "Wt of Water in Pipe (lb/ft)" to "Gallons of Water in Pipe (gal/ft)," divide values in table by 8.34.
(S) is designation of standard wall pipe.
(X) is desionation of extra stron!=l wall pipe.
-------------------------------------------------------------------Tmntoilie~erti
53
I~
il
Table 5- Fnctlon Loss of Valves 1n EQUIValent Len ~th of Stral~ht PI pe (Feet
Screv.ed Screv.ed I-I
I~
90deg
ActuaiiD and and 45 Swing 90deg 90deg 45deg
flanged 45 deg weld Plug valve 3 way plug valves P=1 Butterfly
!aminal Pipe Steel Friction flanged flanged check swing weld angle weld Ball Valve
;:;. angle lift check striaght way Valve,
lr Tube Size Pipe, Factor, f gate globe valve, check valve angle valve ~=1, 0=0
i"'• inches valves valves, p =1 valve, ~ =1
valve,
p=1 fl=1 P=1
valve ~"'1 P=1 centered disc lJ
P=1,e=o ~ =1 z
thru branch G)
318 0.493 0.028 0.33 13.97 4.11 2.05 6.16 2.26 2.26 2.26 0.74 1.23 3.70 0.12 - i)>
1/2 0.622 0.027 0.41 17.62 5.18 2.59 7.78 2.85 2.85 2.85 0.93 1.56 4.67 0.16 - z
0
-
I 3/4
1
0.824
1.049
0.025
0.023
0.55
0.70
23.35
29.72
6.87
8.74
3.43
4.37
10.30
13.11
3.78
4.81
3.78
4.81
3.78
4.81
1.24
1.57
2.06
2.62
6.18
7.87
0.21
0.26 - lJ
·C
1 1/4 1.380 0.022 0.92 39.10 11.50 5.75 17.25 6.33 6.33 6.33 2.07 3.45 10.35 0.35 - 1lJ
$:
1 1/2 1.610 0.021 1.07 45.62 13.42 6.71 20.13 7.38 7.38 7.38 2.42 4.03 12.08 0.40 - (j)
2 2.067 0.019 1.38 58.57 17.23 8.61 25.84 9.47 9.47 9.47 3.10 5.17 15.50 0.52 7.75
21/2 2.469 0.018 1.65 69.96 20.58 10.29 30.86 11.32 11.32 11.32 3.70 6.17 18.52 0.62 9.26
lI 3
31/2
3.068
3.548
0.018
0.018
2.05
2.37
86.93
100.53
25.57
29.57
12.78
14.78
38.35
44.35
14.06
16.26
14.06
16.26
14.06
16.26
4.60
5.32
7.67
8.87
23.01
26.61
0.77
0.89
11.51
13.31
j 4 4.026 0.017 2.68 114.07 33.55 16.78 50.33 18.45 18.45 18.45 6.04 10.07 30.20 1.01 15.10
Ol ! 5 5.047 0.016 3.36 143.00 42.06 21.03 63.09 23.13 23.13 12.62
~ ~
23.13 7.57 37.85 1.26 18.93
l 6 6.065 0.015 4.04 171.84 50.54 25.27 75.81 27.80 27.80 27.80 9.10 15.16 45.49 1.52 22.74
8 7.981 0.014 5.32 226.13 66.51 33.25 99.76 36.58 36.58 36.58 11.97 19.95 59.86 2.00 29.93
I 10
12
10.020
11.938
0.014
0.013
6.68
7.96
283.90
338.24
83.50
99.48
41.75
49.74
125.25
149.23
45.93
54.72
45.93
54.72
45.93
54.72
15.03
17.91
25.05
29.85
75.15
89.54
2.51
2.98
29.23
34.82
I 14
16
13.124
15.000
0.013
0.013
8.75
10.00
371.85
425.00
109.37
125.00
54.68
62.50
164.05
187.50
60.15
68.75
60.15
68.75
60.15
68.75
19.69
22.50
32.81
37.50
98.43
112.50
3.28
3.75
38.28
31.25
!I 18
20
16.876
18.814
0.012
0.012
11.25
12.54
478.15
533.06
140.63
156.78
70.32
78.39
210.95
235.18
n.35
86.23
77.35
86.23
77.35
86.23
25.31
28.22
42.19
47.04
126.57
141.11
4.22
4.70
35.16
39.20
!
24 22.628 0.012 15.09 641.13 188.57 94.28 282.85 103.71 103.71 103.71 33.94 56.57 169.71 5.66 47.14
i
1o
1-. NOTES
~~
' cr:
~~ 1. All valvesa$..1med in wide open postion.
2. Row a$.Jmed to be in fully turbulent region of Moody Diagram
l10
I ::I
t;::
......~,.
....~
3.
4.
The friction factorf isa$.Jmed coi'Santoverthe fully turbulent region.
r/ d=bend radiusdivided by fitting imide diameter.
5. B:juivalent length valuescalculated from equations in 1991 Crane Technical Paper 410 pagesA27-A29.
~~
lC/1 6. ~ = ratio of diameter of fitting to diameter of pipe
It,; 7. e= angle of entrance and exit to fitting
~~ 8. For batt valves and butterfly vatvesu93 manufacturersCv values if available, otherwire Uffi equivalent length va lues above for preliminary eaimati<
-0
ur
" 'f
a-:
t::
Table 6 • Friction Loss of Pipe Fittings in Equivalent Feet of Straight Pipe
90 deg weld elbow

o·:J"*' Nominal Pipe ActuaiiD
Friction 45deg std 90 Deg Std
Long radius
Std tee Std tee Reducing tee thru flow Mitre Bend
or Tube Size, Steel Pipe, 90deg
(/) Factor f elbow elbow thru flow branch flow
'< inches inches elbow
Ill r/d:::1 r/d=2
"""
(tl
3 1/4 1/2 45 deg 90deg
I~ 3/8
1/2
0.493
0.622
0.028
0.027
0.66
0.83
1.23
1.56
0.66
0.83
0.82
1.04
2.47
3.11
1.09
1.38
1.27
1.60
-
-
-
-
-
-
-
-
3/4 0.824 0.025 1.10 2.06 1.10 1.37 4.12 1.83 2.12 - - - -
I 1 1.049 0.023 1.40 2.62 1.40 1.75 5.25 2.33 2.70 - - - -
11/4 1.380 0.022 1.84 3.45 1.84 2.30 6.90 3.06 3.55 - - - -
I 1 1/2 1.610 0.021 2.15 4.03 2.15 2.68 8.05 3.57 4.14 - - - -
2 2.067 0.019 2.76 5.17 2.76 3.45 10.34 4.58 5.31 3.45 2.07 2.58 10.34
2 1/2 2.469 0.018 3.29 6.17 3.29 4.12 12.35 5.47 6.35 4.12 2.47 3.09 12.35
3 3.068 0.018 4.09 7.67 4.09 5.11 15.34 6.80 7.89 5.11 3.07 3.84 15.34
I 31/2 3.548 0.018 4.73 8.87 4.73 5.91 17.74 7.86 9.12 5.91 3.55 4.44 17.74
c.n j 4 4.026 0.017 5.37 10.07 5.37 6.71 20.13 8.92 10.35 6.71 4.03 5.03 20.13
()1 1 5 5.047 0.016 6.73 12.62 6.73 8.41 25.24 11.19 12.98 8.41 5.05 6.31 25.24
6 6.065 0.015 8.09 15.16 8.09 10.11 30.33 13.44 15.60 10.1 1 6.07 7.58 30.33
I 8 7.981 0.014 10.64 19.95 10.64 13.30 39.91 17.69 20.52 13.30 7.98 9.98 39.91
10 10.020 0.014 13.36 25.05 13.36 16.70 50.10 22.21 25.76 16.70 10.02 12.53 50. 10
12 11.938 0.013 15.92 29.85 15.92 19.90 59.69 26.46 30.70 19.90 11.94 14.92 59.69 I~
14 13.124 0.013 17.50 32.81 17.50 21 .87 65.62 29.09 33.75 21.87 13.12 16.41 65.62 _,
)>
16 15.000 0.013 20.00 37.50 20.00 25.00 75.00 33.25 38.57 25.00 15.00 18.75 75.00 m
18 16.876 0.012 22.50 42.19 22.50 28.13 84.38 37.41 43.39 28.13 16.88 21.10 84.38
;o
20 18.814 0.012 25.09 47.04 25.09 31.36 94.07 41.70 48.38 31.36 18.81 23.52 94.07 ""0
""0
24 22.628 O.Qi£. 30.17 56.57 30.17 37.71 113.14 50.16 58.18 37.71 22.63 28.29 113.14
--
NOTES:
z
G)
1. Flow assumed to be in fully turbulent region of Moody Diagram )>
d 2.The friction factor f is assumed constant over the fully turbulent region. .Z
0
li . 3.r/d=bend radius divided by fitting inside diameter.
""0
~ "' 4.Equivalent length values calculated from equations in 1991 Crane Technical Paper 410 pages A2.7-A29. c
~
"0
~ ®
Yl •
'
~~
i~
il
1>-
1-l
1m
l::u
:4 i""U
!-
1-u
lz
r· Table 7 Special Fitting Loses in Equivalent Feet of Straight Pipe
IG)
~~
'0
Nominal Actual Sudden Enlargement,d/D Sudden Contraction,d/D Pipe Entrance Pipe Exit -u
Pipe Inside c
Diameter, Diameter, Friction 1/4 1/2 3/4 1/4 1/2 3/4 Projecting Flush (SE) Projecting Flush(SE) Rounded ·$:
inches inches Factor f 1-u
3/8 0.493 0.028 1.29 0.83 0.28 0.69 0.55 0.32 1.14 0.73 1.47 1.47 1.47 IU)
i 1/2
3/4
0.622
0.824
0.027
0.025
1.69
2.41
1.08
1.55
0.37
0.53
0.90
1.29
0.72
1.03
0.42
0.60
1.50
2.14
0.96
1.37
1.92
2.75
1.92
2.75
1.92
2.75 I
I
01 1
1
1 114
1 3/4
1.049
1.380
0.023
0.022
3.34
4.59
2.14
2.94
0.73
1.00
1.78
2.45
1.43
1.96
0.83
1.14
2.96
4.08
1.90
2.61
3.80
5.23
3.80
5.23
3.80
5.23
l
(J") ! 1.610 0.021 5.62 3.59 1.22 2.99 2.40 1.40 4.98 3.19 6.39 6.39 6.39
I
2 2.067 0.019 7.97 5.10 1.74 4.25 3.40 1.98 7.07 4.53 9.07 9.07 9.07
l 2 112
3
2.469
3.068
0.01 8
0.018
10.05
12.48
6.43
7.99
2.19
2.72
5.36
6.66
4.29
5.33
2.50
3.11
8.92
11.08
5.72
7.10
11 .43
14.20
11.43
14.20
11.43
14.20
Ii
iI 31/2
4
3.548
4.026
0.018
0.017
14.44
17.35
9.24
11.10
3.14
3.78
7.70
9.25
6.16
7.40
3.59
4.32
12.81
15.39
8.21
9.87
16.43
19.74
16.43
19.74
16.43
19.74
iI
I
I 5 5.047 0.016 23.10 14.79 5.03 12.32 9.86 5.75 20.50 13.14 26.29 26.29 26.29
6 6.065 0.015 29.61 18.95 6.45 15.79 12.64 7.37 26.28 16.85 33.69 33.69 33.69 I
8 7.981 0.014 41 .75 26.72 9.09 22.27 17.81 10.39 37.05 23.75 47.51 47.51 47.51
10
I
10.02 0.014 52.42 33.55 11 .42 27.96 22.37 13.05 46.52 29.82 59.64 59.64 59.64
IQ
I :e~
12
14
11.938
13.124
0.013
0.0 13
67.26
73.94
43.05
47.32
14.65
16.10
35.87
39.44
28.70
31.55
16.74
18.40
59.69
65.62
38.26
42.06
76.53
84.1 3
76.53
84.13
76.53
84.13 l
I ~
16
Jcr
,,... 18
15.000
16.876
0.013
0.012
84.51 54.09 18.40 45.07 36.06 21 .03 75.00 48.08 96.1 5 96.15 96.15
I
l - 103.00 65.92 22.43 54.93 43.95 25.64 91.41 58.60 117.19 117.19 117.19
I~
.o 20 18.814 0.012 114.83 73.49 25.01 61.24 48.99 28.58 101.91 65.33 130.65 130.65 130.65
j::J
24 22.628 0.012 138.1 1 88.39 30.08 73.66 58.93 34.37 122.57 78.57 157.14 157.14 157.14
'w
I« {I) Notes:
~~ I
1. Equivalent loss values calculated from data in 1991 Crane Technical Paper 410 pages A27-A29 and based on smaller pipe diameter.
2. SE = sharp edge
i
3. Ratio d/0= diameter of smaller pipe divided by larger pipe
'o
I~::::.
Table 8 - Control Valves and Strainer Losses in Equivalent Feet of Straight Pipe
0"
c::: Actual
:::. Norlina! Pipe Inside Noninal Friction
0
:J Diameter, Diameter, Valve Size, Factorf Butterfly Valve1·3 Ball Valves1•3 Globe Valves1•3 Y-Strainers6
w inches inches inches P= l.04.s p< 1.ct 13 =1.04,5 0< 1.ct 5
13 =1.0~' 13 < 1.0
2
Ranged Screv.ed
'<
(1"1
t'f'
(\.)
3(II
318
1/2
0.493
0.622
-- 0.028
0.027
-
-
-- 0.12
0.16
-
-
14
18
-
-
-
-
314 0.824 - 0.025 - - 0.21 - 23 - -
1 1.049 - 0.023 - - 0.26 - 30 - - 5
1 1/4 1.380 - 0.022 - - 0.35 - 39 - - 9
1 314 1.610 - 0.021 - - 0.40 - 46 -- -
I 2
21/2
2.067
2.469 2
- 0.019
0.018
8
8 9
- 0.52
0.62
-
2
59
59 61
27
28
14
20
3 3.068 2 1/2 0.018 9 11 0.77 2 70 72 42
! 31/2 3.548 3 0.018 12 13 0.77 2 86 88 48 -
01 1
4 4.026 3 0.017 12 16 1.01 5 114 117 60 -
-.....! 5 5.047 4 0.016 15 19 1.26 5 143 146 80
6 6.065 4 0.015 19 22 1.52 12 172 179 110 -
8 7.981 6 0.014 23 39 2.00 11 226 237 150
10 10.020 8 0.014 30 46 2.51 12 284 294 190
12 11.938 10 0.013 29 35 2.98 11 338 346 250 -
-
14
16
13.124
15.000
12
14
0.013
0.013
35
38
38
42
3.28
3.75
11
12
372
425
379
431
-
-- ~m
18 16.876 16 0.012 31 44 4.22 12 478 484 - :::0
20
24 -
18.814
22.628
18
20
0.012
0.012
35
39
61
82
4.70
5.66
25
39
533
641
543
671
-- - -a
-a
---- - - - -- ------ - - - - -- -- -- - --- - - - - - --- - -- - --- - - - - - - - - -
Notes: z
G)
1. Equivalent loss values calculated from data in 1991 Qane Technical Paper 410 pages P\2.7-P\2.9.
)>
I 2. Calculations based on rrethod of .ANSI/ISA-875.01 (R1995)-valve assurred one size smaller than pipe and indudes reducer I ses.
z
3. Values are for estimating only. Check Vvith valve manufacturer for specific details. 0
II
4. f3 = diarreter ratio of valve to pipe. f3 =1 valve and pipe sarre diarreter and assurred full bore.
5. Control valves \Mth f3=1 may have reduced ports or shaped discs for irrproved control >Mlich \11.111 increase loss rrore than full bore values.
6. Strainer dean- no dirt. For dirty strainers multiply values by 2.
~~
1,(/)
""'0
~.
_wATER PIPING AND PUMPS - - - -- -
Work Session Answers

I
1. closed
2. open
3. butterfly, globe, angle, plug
4. butterfly, gate, ball
5.
Valve Price Pressure Drop (ft)

Butterfl_y 220 22.74
Globe 2500 171.80
Gate 1000 4.04
Ball 375 1.52
6. The amount of water volume in the chilled water system when compared to the manufac-
turer's requirement of typically 3 gallons per ton of installed chiller for comfort air
conditioning or 6-10 gallons per ton for process cooling.
7. See Figure 35, Pump Piping Detail.
8. Pushing is considered better since the heat of the pump can be picked up in the cooler or con-
denser as opposed to going into the piping system after the equipment.
9. 4,-in. 3-1/2-in. is not a common size. Velocity is 8 fps. Approximately 5 ft per 100ft of pipe
is the friction loss.
10. 133.33 gpm; 60ft ofhead
11 . 4-pipe system
12. When the NPSH at the pump suction is less that the NPSH required at the pump. This is most
likely to occur if the cooling tower is located a distance beneath the condenser water pump.
13. 2-way modulating valve
14. 3-way mixing valve
15. 2-pipe
~: ~ Distribution Systems
Tum to the Experts.--- - - - - - - - - - - - - - - - - -- ········-------- ------- - - - - - --
58
Prerequisites:
- -'..·
' .:1.--
Color Instructor
Book Presentation Title
TDP-102 796-026 797-026 ABCs of Comfort
TDP-103 796-027 797-027 Concepts of Air Conditioning
'.
TDP-201 796-030 797-030 Psychrometries Level1 - Introduction 1
TDP-301 796-034 797-034 Load Estimating Level 2 - Fundamentals

\.
Learning Objectives:
"(, .....
After reading this module, participants will be able to:
• Compare the three types of piping systems.

• Identify the four types of water distribution systems.
• Differentiate between direct return and reverse return systems.
• Identify the various valves and hydronic accessories available for use in piping ~ystems.
• Diagram typical piping hookups for chillers, pumps, and cooling towers.
• Size the piping for a closed-loop and an open recirculating loop system.
• Identify the types of water pumps, their features, and the selection process. ,.
....J "
' .
__ ...................._
........................................._..__... , ..............................,................._._............."""'-.......
~ ~ __
.........................._.........,........................ ................................._...,_....,..........,..................,_........,....,•.,..............,.................... ... __..
,.............,_ __,...................................... .. .
.........,, _................_~ ..--..
Supplemental Material: . l
Instructor
Presentation Title
Calculator Bell & Gossett System Syzer® Calculator
Instructor Information
~
Each TDP topic is supported with a number of different items to meet the specific needs of the
user. Instructor materials consist of a CD-ROM disk that includes a PowerPoinf" presentation
with convenient links to all required support materials required for the topic. This always.=-includes:
slides, presenter notes, text file including work sessions and work session solutions, quiz and
quiz answers. Depending upon the topic, the instructor CD may also include sound, video, ,,
spreadsheets, forms, or other material required to present a complete class. Self-study or student
material consists of a text including work sessions and work session answers, and .may also
include forms, worksheets, calculators, etc.

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Te.c hnical Development Program

© 2005 Carrier Corporation. All rights reserved.

Types ofPiping Systems

In an open-loop piping system,

from an environmental perspective.

• Much less common due to environmental concerns

Water Distribution Systems

1-Pipe System Uses

throughoul, and all o f the water in -..._sys;em

Distribution Systems _ __ ___ Turn to the ExpertS.

Direct and Reverse Return Systems

Distribution Systems __________________________________ _Turn(~

Water Piping Components and Accessories

Female The threaded joint design has

Mechanical groove joints have

valves and their applications are listed

Globe, angle, and "Y" valves are of the same Handwheel

Plug valves, also called plug

Horizontal use or Check valves prevent the flow of

The lift check operates in a man-

Control Valves: 3-Way and 2-Way

A Triple Duty Valve™ is often Triple Duty ValveTM

Relative Valve Comparison Chart $

Hydronic System Components

Bladder tanks are another type of closed tank and cost

Locate at high points

.. " • Distribution Systems

Thermometers, Gauges, Pete's Plugs

after the valve the pressme reading

Pipe Hangars and Anchors

Horizontal expansion is usually taken up in

An important factor in piping design in-

Typical Piping Details at Equipment

Distribution Systems (8Jt> .

Coil control valves can be 2-

Shut-Off Valve - Balancing Valve

System Piping Arrangements

Parallel and Series Chiller Evaporators

Single Water-Cooled Chiller Loop

Multiple Water-Cooled Chiller Loop with Dedicated Pumps

Primary-Secondary Chilled Water System

In a primary-secondary system, Production Loop (primary)

acts as a hydraulic decoupler line, or

Primary-Only, Variable-Flow Chilled Water System

Two-way control valves are used on the coils and a

Chiller Head Pressure Control

Dl..,.!>r'"-l ~t; ...,,,., ~::oH~~t~.}·..~·'~

Head Pressure Control Piping Methods with Diverting Valve

Head Pressure Control Piping Method with VFD or Modulating Valve

Pump Basics and Types of Pumps

Failure to do so would allow fluid Impeller Eye

NPSH = 2.3I(Pa -Pvp)+(Hs -HI)

Figure 50 shows a cross-section

1. Varying the speed - proportion- Figure 51

A given pump operates along its

horsepower or possible overloading of u<tl

Variable Sp eed Pumping

Energy savings are excellent at Capacity - gpm 1000" ~

Pump catalogs, with pump f:11"

Distribution Systems _ _ Turn to the ExpertS.