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SureFlow Presented by: Ron Porter LEED AP IEC Oklahoma City Copyright 2012.

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Presentation on theme: "SureFlow Presented by: Ron Porter LEED AP IEC Oklahoma City Copyright 2012."— Presentation transcript:

1 SureFlow Presented by: Ron Porter LEED AP IEC Oklahoma City Copyright 2012

2 Topics Fan Coil Basics Traditional System Design SureFlow Hydronics SureFlow Unit Design SureFlow Applications

3 This Is A Fan Coil Fan + Coil = Fan Coil Room Air Conditioner

4 Moves air through a coil with: Chilled Water Hot Water Electric Heat R410a Let’s focus on the water systems… How Do They Work ?

5 FCU Chiller FCU Central Pump Pushes Water Through Piping to Supply Each Fan Coil Standard Water Pressure Differential System

6 How Do We Size The Main Pump ?

7 Central Pump Horsepower = __Head x GPM__ 3960 x Efficiency

8 FCU Chiller FCU Calculate All Circuits Pump Sizing Based On Highest Pressure Drop Circuit

9 FCU Chiller FCU Water Always Takes The Path Of Least Resistance How Do We Know The Fan Coils Will Operate As Advertised ?

10 FCU Chiller FCU Water Pipe Has Resistance To Water Flow Pipe and Riser Diameters ?

11 Continuity : Water In = Water Out (GPM Per Minute) Velocity : Speed of Travel (Feet Per Second) D1 D2 Vel1 Vel2 Area1 Area2 Flow In “Q”Flow Out “Q” Flow In “Q” = 10 GPM D1= 1 Inch “L” Copper Vel1 = 3.9 Ft Per Second Flow Out “Q” = 10 GPM D2= 2 Inches “L” Copper Vel2 = 1.05 Ft Per Second

12 Pressure drop is defined as: The difference in pressure between any two points on a piece of equipment. D1 D2 Vel1 Vel2 Area1 Area2 Flow In “Q”Flow Out “Q” Flow In “Q” = 10 GPM D1= 1 Inch “L” Copper Vel1 = 3.9 Ft Per Second PD1 = 6.71 Ft per 100 Ft Flow Out “Q” = 10 GPM D2= 2 Inches “L” Copper Vel2 = 1.05 Ft Per Second PD2 = 0.29 Ft per 100 Ft PD1 PD2

13 Coil Pressure Drop = Cost of Operation Determined from several parameters- Unit size Coil rows Coil circuits GPM Tube water velocity Water temperature Use IEC Rating Program to determine pressure drop through the coil at actual operating conditions 3.0 GPM Coil PdFt = 5.9

14 Valve Pressure Drop : Resistance to water flow Based on water volume through the valve at Full Open Calculated using Cv Rating Number PdFt = ( GPM / ( x Cv ))^2

15 Typical Ball Valve Pressure Drop : PdFt = ( GPM / ( x Cv ))^2 Ball valve Cv = 5.84 (1/2 inch) GPM = 3 PdFt = (3 / (0.658 x 5.84))^2 PdFt = 0.61

16 Full-Port Ball Valve Pressure Drop: PdFt = ( GPM / ( x Cv ))^2 Ball valve Cv = 14.2 (1/2 inch B&K # T) GPM = 3 PdFt = (3 / (0.658 x 14.2))^2 PdFt = 0.10

17

18 Erie Valve Pressure Drop : PdFt = ( GPM / ( x Cv ))^2 Cv = 3.5 (1/2 inch VT2213) GPM = 3 PdFt = (3 / (0.658 x 3.5))^2 PdFt = 1.7 VT Cv (7/16” Port) 25 PSI Close-Off

19 Erie Valve Pressure Drop: PdFt = ( GPM / ( x Cv ))^2 Cv = 2.5 (1/2 inch VT2212) GPM = 3 PdFt = (3 / (0.658 x 2.5))^2 PdFt = 3.3 VT Cv (5/16” Port) 40 PSI Close-Off

20 Erie Valve Pressure Drop: PdFt = ( GPM / ( x Cv ))^2 Cv = 1.0 (1/2 inch VT2211) GPM = 3 PdFt = (3 / (0.658 x 1.0))^2 PdFt = 20.8 VT Cv 60 PSI Close-Off

21 FCU Analyze Combined Unit And Valve Package Pressure GPM = 3.0 Ball Valve PdFt = 0.1 Coil PdFt = 5.9 Erie Valve PdFt = 3.3 Ball Valve PdFt = 0.1 Total PdFt = 9.4 ÷ 2.33 = 4.0 PSI Diff Total Value Required For Proper Fan Coil Operation

22 Boiler FCU Will This Design Operate Properly ? Supply Return 80 PSI Δ 10 PSI 70 PSI 65 PSI 85 PSI Δ 20 PSI Units & 3.0 GPM Require 4.0 PSI Diff Pump 60 GPM 60 Ft Head 60 PSI Δ 25 PSI Typical of 20 Units

23 Boiler FCU Water Balancing Is Required Supply Return 5 PSI Δ 1 PSI 4 PSI 70 PSI 80 PSI Δ 10 PSI Pump 60 GPM 60 Ft Head 60 PSI Δ 25 PSI Units & 3.0 GPM Require 4.0 PSI Diff Excessive FlowLow Flow

24 Boiler FCU Cartridge Valves For Automatic Balancing Supply Return

25 Hays 2517 Automatic Balancing Valve 2-80 PSID range up to 5.5 GPM +/- 10% Accuracy

26 Valve Will Add Resistance As Required For Specified Water GPM

27 Analyze Combined Unit And Valve Package Pressure GPM = 3.0 Ball Valve PdFt = 0.1 Hays Valve PdFt = 4.6 Coil PdFt = 5.9 Erie Valve PdFt = 3.3 Ball Valve PdFt = 0.1 Total PdFt = 14 ÷ 2.33 = 6.0 PSI Diff FCU

28 Boiler FCU 80 PSI 70 PSI Full Load Pump 60 GPM 60 Ft Head VFD ΔPΔP Δ 10 PSI Full-Load Variable Frequency Drive

29 Boiler FCU OFFFCU 80 PSI 70 PSI Part Load Pump 45 GPM VFD ΔPΔP Δ 10 PSI Part-Load Variable Frequency Drive

30 Boiler FCU 80 PSI 70 PSI Full Load Pump 60 GPM 60 Ft Head VFD ΔPΔP Δ 10 PSI Direct Return System

31 Chiller Reverse Return – Balancing is reduced, therefore the need for balancing valves is reduced, but only if all coils have identical ΔP and system pressure differential always equals coil required ΔP. VFD ΔPΔP FCU

32  Chiller / Boiler Equipment Plant  Pumps Create Water Pressure Differential  Pipes Running To and From Each Unit  Valves – On/Off or Modulating  Balancing Valves – Flow Regulators  Strainers  Pressure Relief Valves  Variable Speed Drives on Pumps  Controls, DDC, Building Energy Management System  Installation Labor – vs. – 2/Pipe – vs. – 4/Pipe  Test & Balance  Maintenance System Design Issues

33 System Complexity Issues There Must Be A Better Way

34 Primary Circuit Water Flow Integrated Circulator Cycles on Thermostat Demand 2008 ASHRAE Handbook HVAC Systems and Equipment Chapter 12. Thermostat OFF

35 Cool Air Primary Circuit Water Flow 2008 ASHRAE Handbook HVAC Systems and Equipment Chapter 12. Thermostat ON

36 Primary Circuit Water Flow 2008 ASHRAE Handbook HVAC Systems and Equipment Chapter 12. Thermostat OFF

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38

39 Average 40% Less Piping Fewer Pipe Hangers Less Insulation Massachusetts College of Pharmacy and Health Sciences Worcester, Massachusetts

40 Reduced Core Drilling Fewer Joints = Fewer Leaks Contractor Savings Westin Cupples Station St. Louis, Missouri

41 Westin Cupples Station St. Louis, Missouri

42 CPF SureFlow Unit What Happened To The Zone Valves and Flow Control Valves ?

43 Circulator – 1/40 HP 30+ Years In Production Millions In Use Quiet Operation Chilled Water CERTIFIED Wet Rotor Cartridge Design Internal Flow Check Valve 200 PSI Rating Cycles On-Off (Thermostat Controlled) Low Energy Consumer – 65 Watts

44

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46 Two Pipe Cooling With Only One Installed Pipe Chiller FAN COIL Water Circulation Rate ≈ 3 GPM per Ton Pump Head & Energy Reduced

47 Chiller FAN COIL Boiler Two Pipe Cooling & Heating “Change Over” With One Installed Pipe

48 2-Pipe Cooling and Heating Changeover With Only One Installed Pipe Massachusetts College of Pharmacy and Health Sciences Worcester, Massachusetts

49 Four Pipe Heat & Cool With Only Two Installed Pipes Chiller FAN COIL Boiler FAN COIL

50 1.What Happens To The Water Temperature ? 2.Will It Control Humidity ? Challenges:

51 42ºF 46.6ºF 48.6ºF 44.4ºF Chiller Off 52.1ºF Water Temperature Changes As BTUs Are Injected Into The SureFlow Loop 1 Ton 13177t 9954s 1 Ton 12052t 9519s 1 Ton 14424t 10448s 1 Ton

52 Cooling Loop Water Pipe Size Design Guide Type L Copper Pipe Size1”1-1/41-1/222-1/23 GPM FPS Vel PdFt / 100Ft ΔT ΔT

53 Pipe Size1”1-1/41-1/222-1/23 GPM FPS Vel PdFt / 100Ft ΔT ΔT Design Guide Type L Copper Heating Loop Water Pipe Size

54 8 Degree Loop Delta-T = 3 GPM per Ton Cooling Loop Water Temperature

55 10 Tons Peak x 3 GPM per Ton = 30 GPM 1-1/2” L 30GPM = 5.43 fps = 7.55 ftpd/100ft 2” L Copper 30GPM = 3.14 fps = 2.02 ftpd/100ft Peak Load Analysis Sample

56 7.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio Block vs Peak Load Analysis

57 With 42F Supply, 3 GPM Per Ton, 75% Ratio Max Actual Water Temperature = 48F BLOCK LOAD RATIO Design For Diversity

58 With 42F Supply, 3 GPM Per Ton, 75% Ratio Max Actual Water Temperature = 48F Design For Diversity SOME UNITS ARE NOT RUNNING ARE SOME UNITS OVER SIZED ?

59 SureFlow Allows Adjustment Of The Design For Occupancy –School Classroom vs. Common areas –Hotel Rooms –Offices –Usage patterns, time of day

60 SureFlow Allows Modification Of The Design For Run Time and Fan Speed –Actual hours of operation with full water flow –Good water flow rate results in excellent humidity control –Take full advantage of controls capabilities –Always recommend automatic fan speed reduction for extended run-time on coil

61  Circulators Only Consume Power When Running  Local Circulators Controlled by Room Thermostats  System Strategy: Demand Controlled Pumping  The Building Hydronic System Becomes An Energy Management System Horsepower Savings LEED 2009-NC Credit EAc1 Optimize Energy Performance Up To 19 Points Available

62 Complex 2-way valve package = 32 solder joints SureFlow valve package = 16 solder joints Installation and Maintenance Savings

63 Primary Pump Common Load Secondary Pump Chiller - Or - Heat Exchanger Compound Primary-Secondary Pumping

64 Building 1 of X Building 2 of X Central Plant Campus Chilled Water

65 Balance Valves 3 Way Control Valve Load Replace Your Original Existing 2-pipe FCU…. CW Supply CW Return

66 …. With a New SureFlow Unit and Have 4-Pipe Performance With Two Pipes Existing Pipes Heating Coil Heating Coil Cooling Coil Cooling Coil CW Supply /Return HW Supply /Return

67 1839 US Tariff Building – General Post Office Owner: US Department of Interior – Park Service Lease: Kimpton Hotel & Restaurant Group 232 Rooms – AAA 4 Diamond Opened Summer 2002 SureFlow Fan Coils Hotel Monaco Washington DC Case Study

68 Fernando Garcia, P.E. Vice President CTA Consulting Engineers Inc. Rockville, MD (301)

69 Chicago Blackstone Renaissance Hotel 636 South Michigan 332 Rooms Restoration of 1908 Hotel Opened Fall : Location of the famous “Smoke Filled Rooms” where Warren G. Harding was chosen as the Republican nominee for President. 1940: Franklin Delano Roosevelt’s 3 rd -term Democratic Nomination was forged here. 1944: Harry S. Truman stayed here when he received Vice Presidential Nomination. 1952: Dwight D. Eisenhower stayed here during first Republican ballot.

70 The Nines, The Luxury Collection, Starwood Hotels Top 9 Floors Guest Rooms Portland’s First 5-Star Hotel Lower 5 Floors is Macys Dept Store Redevelopment of 1909 Meier & Frank Department Store National Register of Historic Places Opened Oct 2008 LEED Silver Portland, Oregon

71 Elysian / Waldorf Astoria 60 Stories on East Walton Street in the Gold Coast 52 Private Residences 188 Room Waldorf Astoria Hotel Constructed Renamed Waldorf Astoria Chicago February 1, 2012 AAA Five Diamond TripAdvisor.com Ranked # 1 Hotel in USA Conde Nast Traveler Ranked Best Hotel in USA Chicago As of Feb 1, 2012: Hotel rates: start at $395 Condo Sales up to $8 Million Condo Rent: $16,000/month 3-Bed, 3.5-Bath, 3,747 Sq Ft

72 12,000 Units over 12 Years

73 Cool Air Average 40% Less Piping Installed Cost Savings $$$ Pump Energy Savings For Owner $$$ Reliable Operation Occupant Comfort LEED Credit Opportunities 4 – Pipe Performance With 2 Installed Pipes Low Maintenance Easy To Design

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75 Application: SureFlow 75

76 FCU Chiller FCU Part Load Pump Controls Standard Piping Method 76

77 System Design Issues Chiller / Boiler Equipment Plant Pumps Create Water Pressure Differential Pipes Running To and From Each Unit Valves – On/Off or Modulating Balancing Valves – Flow Regulators Strainers Pressure Relief Valves Variable Speed Drives on Pumps Controls, DDC, Building Energy Management System Installation Labor – vs. – 2/Pipe – vs. – 4/Pipe Test & Balance Maintenance 77

78 Primary Circuit Water Flow Integrated Circulator Cycles on Thermostat Demand Thermostat OFF 78

79 79

80 SureFlow Average 40% Less Piping Less Core Drills on Renovation Contractor Savings 80

81 30+ Years In Production Millions In Use Quiet Operation Chilled Water CERTIFIED Wet Rotor Cartridge Design Internal Flow Check Valve 200 PSI Rating Cycles On-Off (Thermostat Controlled) Low Energy Consumer – 65 Watts SureFlow Circulator – 1/40 HP 81

82 Two Pipe Cooling With Only One Installed Pipe Chiller FAN COIL 82

83 Two Pipe Heat & Cool With Only One Installed Pipe Chiller FAN COIL Boiler 83

84 42ºF 46.6ºF 48.6ºF 44.4ºF Chille r Off 52.1ºF Central Pump Is NOT Responsible For Pressure Drop Of Coil Or Valve Packages 1 Ton 13177t 9954s 1 Ton 12052t 9519s 1 Ton 14424t 10448s 1 Ton SureFlow System Pumping 84

85 7.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio Block vs Peak Load Analysis 85

86 1839 US Tariff Building – General Post Office Owner: US Department of Interior – Park Service Lease: Kimpton Hotel & Restaurant Group 232 Rooms – AAA 4 Diamond Opened Summer 2002 SureFlow Fan Coils Hotel Monaco Washington DC SureFlow Installation - Case Study 86

87 Application: SureFlow 87

88 Standard Piping Method Chiller FCU 88

89 FCU Chiller FCU Primary-Secondary Pumping Standard Piping Method 89

90 FCU Chiller FCU Part Load Pump Controls Standard Piping Method 90

91 System Design Issues Chiller / Boiler Equipment Plant Pumps Create Water Pressure Differential Pipes Running To and From Each Unit Valves – On/Off or Modulating Balancing Valves – Flow Regulators Strainers Pressure Relief Valves Variable Speed Drives on Pumps Controls, DDC, Building Energy Management System Installation Labor – vs. – 2/Pipe – vs. – 4/Pipe Test & Balance Maintenance 91

92 Primary Circuit Water Flow Integrated Circulator Cycles on Thermostat Demand Thermostat OFF 92

93 Cool Air Primary Circuit Water Flow Integrated Circulator Cycles on Thermostat Demand Thermostat ON 93

94 Design Considerations: Piping Circuits - Diverting Series One-pipe diverting series circuits – “when coupled with compound pumping systems, series circuits can be applied to multiple control zones on larger commercial or institutional systems.” 2008 ASHRAE Handbook HVAC Systems and Equipment Chapter

95 95

96 SureFlow Average 40% Less Piping Less Core Drills on Renovation Contractor Savings 96

97 30+ Years In Production Millions In Use Quiet Operation Chilled Water CERTIFIED Wet Rotor Cartridge Design Internal Flow Check Valve 200 PSI Rating Cycles On-Off (Thermostat Controlled) Low Energy Consumer – 65 Watts SureFlow Circulator – 1/40 HP 97

98 Two Pipe Cooling With Only One Installed Pipe Chiller FAN COIL 98

99 Two Pipe Heat & Cool With Only One Installed Pipe Chiller FAN COIL Boiler 99

100 Four Pipe Heat & Cool With Only Two Installed Pipes Chiller FAN COIL Boiler FAN COIL 100

101 42ºF 46.6ºF 48.6ºF 44.4ºF Chille r Off 52.1ºF Central Pump Is NOT Responsible For Pressure Drop Of Coil Or Valve Packages 1 Ton 13177t 9954s 1 Ton 12052t 9519s 1 Ton 14424t 10448s 1 Ton SureFlow System Pumping 101

102 Coil Pressure Drop is Redesigned to Match Circulator Pump Curve 102

103 8 Degree Loop Delta-T = 3 GPM per Ton Cooling Loop Water Temperature 103

104 10 Tons Peak x 3 GPM per Ton = 30 GPM 1-1/2” L 30GPM = 5.43 fps = 7.55 ftpd/100ft 2” L Copper 30GPM = 3.14 fps = 2.02 ftpd/100ft SureFlow Peak Load Design 104

105 7.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio Block vs Peak Load Analysis 105

106 With 42F Supply, 3 GPM Per Ton, 75% Ratio Max Actual Water Temperature = 48F BLOCK LOAD RATIO Design For Diversity 106

107 With 44F Supply, 3 GPM Per Ton, 75% Ratio Max Actual Water Temperature = 50F BLOCK LOAD RATIO Warmer Supply Temperature? 107

108 10,000 Units over 10 Years 108

109 1839 US Tariff Building – General Post Office Owner: US Department of Interior – Park Service Lease: Kimpton Hotel & Restaurant Group 232 Rooms – AAA 4 Diamond Opened Summer 2002 SureFlow Fan Coils Hotel Monaco Washington DC SureFlow Installation - Case Study 109

110 Fernando Garcia, P.E. Vice President CTA Consulting Engineers Inc. Rockville, MD (301)

111 Chicago Blackstone Renaissance Hotel 636 South Michigan 332 Rooms Restoration of 1908 Hotel Opened Fall 2007 Location of the famous “Smoke Filled Rooms” where Warren G. Harding was chosen as the Republican nominee for President in June Franklin Delano Roosevelt’s 3 rd -term Democratic Nomination was forged in Harry S. Truman stayed when he received 1944 Vice Presidential Nomination. Dwight D. Eisenhower stayed during first Republican ballot in

112 Portland, Oregon The Nines Hotel Part of The Luxury Collection, Starwood Hotels & Resorts Top 9 Floors Rooms Lower 5 floors is Macy’s Redevelopment of 1909 Meier & Frank Department Store National Register of Historic Places Opened October 16, 2008 LEED Silver 112

113 New Orleans Monaco Hotel 250 Units Historic 1926 Masonic Temple Lodge June 2001 Conversion to a 4-Star Luxury Hotel Kimpton Sold to Dimension Development Co. Reopened 2007 as the Hilton Saint Charles Humidity Kept Under Control 113

114 Cool Air Average 40% Less Piping Installed Cost Savings $$$ Pump Energy Savings For Owner $$$ Reliable Operation Occupant Comfort LEED Credit Opportunities 4 – Pipe Performance With 2 Installed Pipes Low Maintenance Easy To Design 114

115 115


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