Upon completion of this training one should be able to:

•Identify different types of hydronic heating systems•Identify key components in a simple hydronic heating system•Understand the benefits of a variable speed/variable volume hydronic heating system•Recognize the retrofit opportunities for converting cs/cv and cs/vv systems to vs/vs systems

Learning Outcomes

2

Multi-use Facility

3

Multi-use Facility

Occupancy – 140 personsBuilding Characteristics

• Single story• 20,000 square feet (250’ x 80’)• Standard construction

4

What we will cover:

• Types of hydronic heating systems

• Closed loop perimeter heating• Closed loop radiant systems• Water source heat pumps• Ground source heat pumps

• Piping methods• Constant speed/constant volume• Constant speed/variable volume• Variable speed/variable volume

• Retrofit market• Significant opportunities!

5

HW Closed Loop Perimeter/ Fan Coil System

Optional Variable Speed Components

∆P Sensor

ModulatingControl Valve (typ.)

Secondary Pump

Common Pipe

2-way or Two Position Valve (typ.)

Bo

iler

Primary Pumps

Air Separator

Balance Valve (typ.)

Bo

iler

Load (typ.)

Expansion Tank

Manual balance valve 3-way control valve

2-way control valveAir separator

System piping components

7

System piping components

Fan coil VAV box

8

HW Closed Loop Radiant Floor/Snow Melt System

Radiant Floor orSnow Melt Panels

P1P2

SecondaryPump

MixingValve

Primary PumpsP1 & P2*

Redundant*

Air Separator

Common Pipe

Expansion Tank

9

HW Closed Loop Radiant Floor/Snow Melt System

10

HW Closed Loop Radiant Floor/Snow Melt System

11

Heat Pumps

60ºF HPWS

53ºF HPWR

Heat Pump

160ºF HHWR

180ºF HHWS

53ºF CHWR

Fan Coil Unit

45ºF CHWS

Air

Air

60ºF HPWS

67ºF HPWR

60

ºF H

PW

R

60

ºF H

PW

SHeat Pump

Cooling

Heating

Heat Pump Operation

12

53ºF HPWR

Fan Air

60ºF HPWS

Heating

Water to Refrigerant Heat Exchanger

Compressor

Reversing Valve

Refrigerant Coil

ExpansionValve

RefrigerantPiping

13

Heat Pumps

• Types• Water source

• Boiler and chiller• Ground source

• Bore field / pond loop / well• Hybrid

• A ground source plus supplemental heating or cooling

Closed Circuit Cooling Tower

WSHP

BufferTank

( Optional ))

Compression Tank

14

Water Source Heat Pump (WSHP)

Bo

iler

WSHP

WSHP WSHP

WSHP

Make-upWater

Primary PumpsP1 & P2*

Redundant*

Expansion TankAir Separator

15

WSHP Components

Cooling Towers

Boilers

16

Ground Source Heat Pump (GSHP)

Bore Field

GSHP

BufferTank

( Optional )

Compression Tank

GSHP

GSHP GSHP

GSHP

Make-upWater

HP Loop PumpsP1 & P2*

Redundant*

Expansion TankAir Separator

Bore Field Loop Pump

17

GSHP

18

Hybrid Ground Source Heat Pump

Bore Field

GSHP

BufferTank

( Optional )

Compression Tank

GSHP

GSHP GSHP

GSHP

Make-upWater

HP Loop PumpsP1 & P2*

Redundant*

Expansion TankAir Separator

Bore Field Loop Pump

19

Hydronic Piping SystemsTypes:

• Constant Speed/Constant Volume (CS/CV)• Piping & equipment requirements• Deficiencies • Energy usage

• Constant Speed/Variable Volume (CS/VV)• Piping & equipment requirements• Advantages• Energy usage

• Variable Speed/Variable Volume (VS/VV)• Piping & equipment requirements• Advantages• Energy usage

20

CS/CV Piping System

3-wayValve

Load

Balance Valve (Typ.)

Air Separator

Bo

iler

2*

Bo

iler

1

Primary Pumps P1 & P2*

* Redundant Expansion Tank

21

CS/CV System Deficiencies

• High return water temperatures• Robs hot water from other coils at part loaded conditions

• Increases flow• Adds additional boilers on line• Boiler performance is reduced

22

CS/CV System

• Load for Multi-use Facility: Chicago, IL• Plot load profile • Select pump for 108 gpm @ 36 ft

40

35

30

25

20

15

10

5

00 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340Flow (gpm)

Head (

ft)

23

108 gpm @ 36 ft

CS/CV Pump

97%

24

Pump Energy Consumption - CS/CV

00.250.5

0.751

1.25

1.5

kWHr

Pump Energy Consumption

CS/CV

25

CS/VV HW Piping Systems

Primary Pumps

P1 & P2*

*Redundant

Return

Supply

Secondary Pumps P1 & P2*

Bo

iler

1

Bo

iler

2*

Air Separator

Expansion TankAir Separator

Expansion Tank

26

CS/VV Pumping Systems

• Add secondary pumps• Add common pipe• Add system bypass• Add 2-way valves• Eliminate 3-way valves…or

27

CS/VV Pumping Systems

• Eliminate 3-way valves• Disable 3-way valves

• Shut bypass valve• Disconnect bypass pipe• Actuator may be

undersized for 2-way operation

• Does this make $ense?

40

35

30

25

20

15

10

5

00 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340Flow (gpm)

Head (

ft)

28

108 gpm @ 36 ft

CS/VV Pump Curve

97%

29

CS/VV Advantages

• Lower return water temperatures• Minimizes flow to coils• Decreases secondary flow• Reduces boilers on line• Boiler performance is increased• Ease of system operation• Energy savings• Preferred piping method

30

Pump Energy Consumption - CS/VV

0% L

oad

20%

Loa

d

40%

Loa

d

60%

Loa

d

80%

Loa

d

100%

Loa

d

00.250.5

0.751

1.251.5

kWHr

Pump Energy Consumption

CS/CV

CS/VV

31

VS/VV Pumping

Add:• Variable frequency drive (VFD)• Programmable logic controller (PLC)• Differential pressure sensors (∆P)• Direct digital controls (DDC)

Save 75% AOC versus CS/CV!

32

VS/VV Hot Water Systems

Secondary PumpsVSP1 & VSP2*

ΔPSensor

Air Separator

*Redundant Return

Supply

Bo

iler

1

Bo

iler

2*

VS PumpsAnd Controls

ExpansionTank

33

Pump Curve Summary

CS/CV

108 gpm @ 36 ft

CS/VV VS/VV

108 gpm @ 36 ft 108 gpm @ 36 ft

54 gpm @ 37 ft54 gpm @ 9 ft

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108 gpm @ 36 ft

Flow (gpm)

Head (

ft)

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340

40

35

30

25

20

15

10

5

0

VS/VV Pump Curve

35

VS/VV Advantages

• Optimizes return water temperatures• Optimizes flow to coils• Decreases secondary flow• Reduces boilers on line• Boiler performance is increased• Ease of system operation• Optimum energy savings

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Pump Energy Consumption - VS/VV

0% L

oad

20%

Loa

d

40%

Loa

d

60%

Loa

d

80%

Loa

d

100%

Loa

d

00.250.5

0.751

1.251.5

kWHr

Pump Energy Consumption

CS/CV

CS/VV

VS/VV

37

VS/VV Advantages

Cost effective design• Primary-secondary pumping• Common pipe design • 2-way valve operation

Save 75% of pumping energy over CS/CV systems

Save 50% of pumping energy over CS/VV systems

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Additional System Savings

• Additional sources of energy savings• Boiler operation• ΔT optimization

• Sources of first cost savings• Pump sizing • Boiler sizing• Valve sizing• Pipe sizing

39

VS/VV Pumping

Add:• Variable frequency drive (VFD)• Programmable logic controller (PLC)• Differential pressure sensors (∆P)• Direct digital controls (DDC)

40

Demand More

Magna3!

41

HW Systems with VS Pumps

Secondary PumpsVSP1 & VSP2*

ΔPSensorAir

Separator

*Redundant Return

SupplyB

oile

r 1

Bo

iler

2*

VS PumpsAnd Controls

Expansion Tank

42

VS/VV Retrofit Opportunities

Converting CS/CV to VS/VV • Steam systems• 3 pipe hot/chilled water systems

• One pipe hot water systems• 3-way valve hot water systems

• Uncontrolled radiant systems

• Over-sized boiler pumps

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VS/VV Retrofit Opportunities

Converting CS/VV to VS/VV • CS 2-way valve HW systems• CS three pipe systems• Systems with poor ΔT control

• Systems with over-sized pumps

• Systems with local ΔP sensors

• Systems with single VS pumps

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