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    Reverse Return/Direct Return Piping

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    maddy_gift
    The document discusses two types of piping systems - reverse return and direct return. Reverse return piping has equal pressure drops across loads but requires more piping and is more expensive. Direct return piping has varying pressure drops with shorter paths having less drop, requiring balancing valves and saving on piping costs. The decision depends on balancing operability versus first costs. Piping design impacts energy efficiency and operating costs through pressure drops, so minimizing drops through materials, sizing, fittings and other factors should be considered over the system lifetime.

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    Reverse Return/Direct Return Piping

    Uploaded by

    maddy_gift
    159 views2 pages
    The document discusses two types of piping systems - reverse return and direct return. Reverse return piping has equal pressure drops across loads but requires more piping and is more expensive. Direct return piping has varying pressure drops with shorter paths having less drop, requiring balancing valves and saving on piping costs. The decision depends on balancing operability versus first costs. Piping design impacts energy efficiency and operating costs through pressure drops, so minimizing drops through materials, sizing, fittings and other factors should be considered over the system lifetime.

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    The document discusses two types of piping systems - reverse return and direct return. Reverse return piping has equal pressure drops across loads but requires more piping and is more expensive. Direct return piping has varying pressure drops with shorter paths having less drop, requiring balancing valves and saving on piping costs. The decision depends on balancing operability versus first costs. Piping design impacts energy efficiency and operating costs through pressure drops, so minimizing drops through materials, sizing, fittings and other factors should be considered over the system lifetime.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    159 views2 pages

    Reverse Return/Direct Return Piping

    Uploaded by

    maddy_gift
    The document discusses two types of piping systems - reverse return and direct return. Reverse return piping has equal pressure drops across loads but requires more piping and is more expensive. Direct return piping has varying pressure drops with shorter paths having less drop, requiring balancing valves and saving on piping costs. The decision depends on balancing operability versus first costs. Piping design impacts energy efficiency and operating costs through pressure drops, so minimizing drops through materials, sizing, fittings and other factors should be considered over the system lifetime.

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    Reverse Return/Direct Return Piping

    Figure 6 - Reverse Return Piping

    Figure 6 shows reverse return piping. Reverse return piping is designed such that the path through
    any load is the same length and therefore has approximately the same fluid pressure drop. Reverse
    return piping is inherently self-balancing. It also requires more piping and consequently is more
    expensive.

    Figure 7 - Direct Return Piping

    Direct return piping results in the load closest to the chiller plant having the shortest path and
    therefore the lowest fluid pressure drop. Depending on the piping design, the difference in pressure
    drops between a load near the chiller plant and a load at the end of the piping run can be substantial.
    Balancing valves will be required. The advantage of direct return piping is the cost savings of less
    piping.
    For proper control valve selection, it is necessary to know the pressure differential between the supply
    and return header (refer to Control Valve Basics, page 20). While at first it would appear with
    reverse return piping, that the pressure drop would be the same for all devices, this is not certain.
    Changes in pipe sizing in the main headers, different lengths and fittings all lead to different pressure
    differentials for each device. When the device pressure drop is large relative to piping pressure
    losses, the difference is minimized.
    In direct return piping, the pressure drops for each device vary at design conditions depending on
    where they are in the system. The valve closest to the pumps will see nearly the entire pump head.
    Valves at the furthest end of the loop will see the minimum required pressure differential. Assuming

    Application Guide AG 31-003-1 9


    the pressure differential sensor is located at the furthest end, all valves in a direct return system should
    be selected for the minimum pressure differential. This is because if any one device is the only one
    operating, the pressure differential controller will maintain the minimum differential across that
    device.
    The decision whether to use direct or reverse return piping should be based on system operability vs.
    first cost. Where direct return piping is used, flow-balancing valves should be carefully located so
    that the system can be balanced.

    Piping and Energy Efficiency


    Piping materials and design have a large influence on the system pressure drop, which in turn affects
    the pump work. Many of the decisions made in the piping system design will affect the operating cost
    of the chiller plant every hour the plant operates for the life of the building. When viewed from this
    life cycle point of view, any improvements that can lower the operating pressure drop should be
    considered. Some areas to consider are:
    Y Pipe material. Different materials have different friction factors.
    Y Pipe sizing. Smaller piping raises the pressure drop. This must be balanced against the capital
    cost and considered over the lifetime of the system.
    Y Fittings. Minimize fittings as much as possible.
    Y Valves. Valves represent large pressure drops and can be costly. Isolation and balancing valves
    should be strategically placed.
    Y Direct return vs. Reverse return.
    Piping insulation reduces heat gain into the chilled water. This has a compound effect. First, any
    cooling effect that is lost due to heat gain is additional load on the chiller plant. Second, in most
    cases, to account for the resultant temperature rise, the chilled water setpoint must be lowered to
    provide the correct supply water temperature at the load. This increases the lift on the chillers and
    lowers their performance.
    ASHRAE 90.1-2001 requires the following for piping systems:
    Y Piping must be insulated as per ASHRAE Standard 90.1 Table 6.2.4.1.3. (See Table 1)
    Exceptions include:
    Y Factory installed insulation.
    Y Systems operating between 60°F and 105°F.
    Y The hydronic system be proportionally balanced in a manner to first minimize throttling losses
    and then the impeller trimmed or the speed adjusted to meet the design flow conditions
    (6.2.5.3.3)
    Exceptions include:
    Y Pumps with motors less than 10 hp.
    Y When throttling results in no greater than 5% of nameplate horsepower or 3 hp, whichever is
    less.
    Y Three pipe systems with a common return for heating and cooling are not allowed. (6.3.2.2.1)
    Y Two pipe changeover systems are acceptable providing: (6.3.2.2.2)
    Y Controls limit changeovers based on15°F ambient drybulb deadband.
    Y System will operate in one mode for at least 4 hours.
    Y Reset controls lower the changeover point to 30°F or less.
    Y Systems with total pump nameplate horsepower exceeding 10 hp shall be variable flow able to
    modulate down to 50%. (6.3.4)

    10 Application Guide AG 31-003-1

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