Sure Flow Presented by Ron Porter LEED AP

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

Topics • • • Fan Coil Basics Traditional System Design Sure. Flow Hydronics Sure. Flow Unit Design Sure. Flow Applications

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

How Do They Work ? Moves air through a coil with: Chilled Water Hot Water Electric Heat R 410 a Let’s focus on the water systems…

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

How Do We Size The Main Pump ?

Central Pump Horsepower = __Head x GPM__ 3960 x Efficiency

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

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

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

Continuity : Water In = Water Out (GPM Per Minute) Velocity : Speed of Travel (Feet Per Second) D 1 D 2 Flow In “Q” Area 1 Flow Out “Q” Vel 1 Vel 2 Area 2 Flow In “Q” = 10 GPM Flow Out “Q” = 10 GPM D 1= 1 Inch “L” Copper D 2= 2 Inches “L” Copper Vel 1 = 3. 9 Ft Per Second Vel 2 = 1. 05 Ft Per Second

Pressure drop is defined as: The difference in pressure between any two points on a piece of equipment. D 1 D 2 Flow In “Q” Area 1 Flow Out “Q” Vel 1 PD 1 Vel 2 Area 2 PD 2 Flow In “Q” = 10 GPM Flow Out “Q” = 10 GPM D 1= 1 Inch “L” Copper D 2= 2 Inches “L” Copper Vel 1 = 3. 9 Ft Per Second Vel 2 = 1. 05 Ft Per Second PD 1 = 6. 71 Ft per 100 Ft PD 2 = 0. 29 Ft per 100 Ft

Coil Pressure Drop = Cost of Operation Example @ 3. 0 GPM Coil Pd. Ft = 5. 9 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

Valve Pressure Drop: • Resistance to water flow • Based on water volume through the valve at Full Open • Calculated using Cv Rating Number • Pd. Ft = ( GPM / ( 0. 658 x Cv ))^2

Typical Ball Valve Pressure Drop: • Pd. Ft = ( GPM / ( 0. 658 x Cv ))^2 • Ball valve Cv = 5. 84 (1/2 inch) • GPM = 3 • Pd. Ft = (3 / (0. 658 x 5. 84))^2 • Pd. Ft = 0. 61

Full-Port Ball Valve Pressure Drop: • Pd. Ft = ( GPM / ( 0. 658 x Cv ))^2 • Ball valve Cv = 14. 2 (1/2 inch B&K # 107 -503 T) • GPM = 3 • Pd. Ft = (3 / (0. 658 x 14. 2))^2 • Pd. Ft = 0. 10

Erie Valve Pressure Drop: VT 2213 3. 5 Cv (7/16” Port) • Pd. Ft = ( GPM / ( 0. 658 x Cv ))^2 • Cv = 3. 5 (1/2 inch VT 2213) • GPM = 3 • Pd. Ft = (3 / (0. 658 x 3. 5))^2 • Pd. Ft = 1. 7 25 PSI Close-Off

Erie Valve Pressure Drop: VT 2212 2. 5 Cv (5/16” Port) • Pd. Ft = ( GPM / ( 0. 658 x Cv ))^2 • Cv = 2. 5 (1/2 inch VT 2212) • GPM = 3 • Pd. Ft = (3 / (0. 658 x 2. 5))^2 • Pd. Ft = 3. 3 40 PSI Close-Off

Erie Valve Pressure Drop: • Pd. Ft = ( GPM / ( 0. 658 x Cv ))^2 • Cv = 1. 0 (1/2 inch VT 2211) • GPM = 3 • Pd. Ft = (3 / (0. 658 x 1. 0))^2 • Pd. Ft = 20. 8 VT 2211 1. 0 Cv 60 PSI Close-Off

Analyze Combined Unit And Valve Package Pressure Drop @ GPM = 3. 0 Ball Valve Pd. Ft = 0. 1 FCU Coil Pd. Ft = 5. 9 Total Pd. Ft = 9. 4 ÷ 2. 33 Erie Valve Pd. Ft = 3. 3 = 4. 0 PSI Diff Ball Valve Pd. Ft = 0. 1 Total Value Required For Proper Fan Coil Operation

Will This Design Operate Properly ? 65 PSI 70 PSI Return Units & Valves @ 3. 0 GPM FCU Require Typical of 20 Units FCU Boiler 4. 0 PSI Diff Pump 60 GPM Supply 80 PSI 85 PSI 60 PSI Δ 10 PSI Δ 25 PSI 60 Ft Head

Water Balancing Is Required 70 PSI 4 PSI Return Units & Valves @ 3. 0 GPM FCU FCU Boiler Require 4. 0 PSI Diff Pump 60 GPM Supply 5 PSI 80 PSI 60 PSI Δ 10 PSI Δ 25 PSI Low Flow Excessive Flow 60 Ft Head

Cartridge Valves For Automatic Balancing Return FCU Supply FCU FCU Boiler

Hays 2517 Automatic Balancing Valve 2 -80 PSID range up to 5. 5 GPM +/- 10% Accuracy

Valve Will Add Resistance As Required For Specified Water GPM

Analyze Combined Unit And Valve Package Pressure Drop @ GPM = 3. 0 Ball Valve Pd. Ft = 0. 1 Hays Valve Pd. Ft = 4. 6 FCU Coil Pd. Ft = 5. 9 Erie Valve Pd. Ft = 3. 3 Ball Valve Pd. Ft = 0. 1 Total Pd. Ft = 14 ÷ 2. 33 = 6. 0 PSI Diff

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

Part-Load Variable Frequency Drive 70 PSI Δ 10 PSI ΔP FCU OFF FCU Boiler Part Load Pump 45 GPM 80 PSI VFD

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

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. ΔP FCU FCU Chiller FCU VFD

System Design Issues Ø Ø Ø 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 Complexity Issues There Must Be A Better Way

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

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

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

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

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

Westin Cupples Station St. Louis, Missouri

CPF Sure. Flow Unit What Happened To The Zone Valves and Flow Control Valves ?

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

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

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

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

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

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

1 Ton 14424 t 10448 s 13177 t 9954 s 1 Ton 12052 t 9519 s Off 52. 1ºF 42ºF 44. 4ºF 46. 6ºF 48. 6ºF Chiller Water Temperature Changes As BTUs Are Injected Into The Sure. Flow Loop

Cooling Loop Water Pipe Size Design Guide Type L Copper Pipe Size 1” 1 -1/4 1 -1/2 2 2 -1/2 3 GPM 8 16 25 53 85 127 FPS Vel 3. 13 4. 1 4. 53 5. 54 5. 74 6. 01 Pd. Ft / 100 Ft 4. 53 5. 66 5. 46 5. 58 4. 57 4 Tons @ 8ΔT 2. 7 5. 3 8. 3 17. 7 28. 3 42. 3 Tons @ 10ΔT 3. 3 6. 7 10. 4 22. 1 35. 4 52. 9

Heating Loop Water Pipe Size Design Guide Type L Copper Pipe Size 1” 1 -1/4 1 -1/2 2 2 -1/2 3 GPM 8 16 25 53 85 127 FPS Vel 3. 13 4. 1 4. 53 5. 54 5. 74 6. 01 Pd. Ft / 100 Ft 4. 53 5. 66 5. 46 5. 58 4. 57 4 MBH @ 20ΔT 80 160 250 530 850 1270 MBH @ 25ΔT 100 200 312 662 1062 1587

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

Peak Load Analysis Sample 10 Tons Peak x 3 GPM per Ton = 30 GPM 1 -1/2” L Copper @ 30 GPM = 5. 43 fps = 7. 55 ftpd/100 ft 2” L Copper Pipe @ 30 GPM = 3. 14 fps = 2. 02 ftpd/100 ft

Block vs Peak Load Analysis 7. 5 Tons Block / 10 Tons Peak = 75% Diversity Ratio

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

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

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

Sure. Flow 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

Horsepower Savings Ø Circulators Only Consume Power When Running Ø Local Circulators Controlled by Room Thermostats Ø System Strategy: Demand Controlled Pumping Ø The Building Hydronic System Becomes An Energy Management System LEED 2009 -NC Credit EAc 1 Optimize Energy Performance Up To 19 Points Available

Installation and Maintenance Savings Complex 2 -way valve package Sure. Flow valve package = 32 solder joints = 16 solder joints

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

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

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

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

Case Study 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 Sure. Flow Fan Coils Hotel Monaco Washington DC

Fernando Garcia, P. E. Vice President CTA Consulting Engineers Inc. Rockville, MD (301) 637 -0058

Chicago Blackstone Renaissance Hotel 636 South Michigan 332 Rooms Restoration of 1908 Hotel Opened Fall 2007 1920: Location of the famous “Smoke Filled Rooms” where Warren G. Harding was chosen as the Republican nominee for President. 1940: Franklin Delano Roosevelt’s 3 rd-term Democratic Nomination was forged here. 1944: Harry S. Truman stayed here when he received Vice Presidential Nomination. 1952: Dwight D. Eisenhower stayed here during first Republican ballot.

Portland, Oregon The Nines, The Luxury Collection, Starwood Hotels Top 9 Floors - 331 Guest Rooms Portland’s First 5 -Star Hotel Lower 5 Floors is Macys Dept Store Redevelopment of 1909 Meier & Frank Department Store National Register of Historic Places Opened Oct 2008 LEED Silver

Chicago Elysian / Waldorf Astoria 60 Stories on East Walton Street in the Gold Coast 52 Private Residences 188 Room Waldorf Astoria Hotel Constructed 2006 -2010 Renamed Waldorf Astoria Chicago February 1, 2012 AAA Five Diamond Trip. Advisor. com Ranked # 1 Hotel in USA Conde Nast Traveler Ranked Best Hotel in USA 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

12, 000 Units over 12 Years

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

www. fancoil. com www. iec-okc. com

Application: Sure. Flow 75

Standard Piping Method FCU FCU Chiller Part Load Pump Controls 76

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

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

79

Sure. Flow Average 40% Less Piping Less Core Drills on Renovation Contractor Savings 80

Sure. Flow 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 81

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

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

Sure. Flow System Pumping 1 Ton 14424 t 10448 s 13177 t 9954 s 1 Ton 12052 t 9519 s Off 52. 1ºF 42ºF 44. 4ºF 46. 6ºF 48. 6ºF Chille r Central Pump Is NOT Responsible For Pressure Drop Of Coil Or Valve Packages 84

Block vs Peak Load Analysis 7. 5 Tons Block / 10 Tons Peak = 75% Diversity Ratio 85

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

Application: Sure. Flow 87

Standard Piping Method FCU FCU Chiller 88

Standard Piping Method FCU FCU Chiller Primary-Secondary Pumping 89

Standard Piping Method FCU FCU Chiller Part Load Pump Controls 90

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

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

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

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 94 12. Chapter

95

Sure. Flow Average 40% Less Piping Less Core Drills on Renovation Contractor Savings 96

Sure. Flow 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 97

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

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

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

Sure. Flow System Pumping 1 Ton 14424 t 10448 s 13177 t 9954 s 1 Ton 12052 t 9519 s Off 52. 1ºF 42ºF 44. 4ºF 46. 6ºF 48. 6ºF Chille r Central Pump Is NOT Responsible For Pressure Drop Of Coil Or Valve Packages 101

Coil Pressure Drop is Redesigned to Match Circulator Pump Curve 102

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

Sure. Flow Peak Load Design 10 Tons Peak x 3 GPM per Ton = 30 GPM 1 -1/2” L Copper @ 30 GPM = 5. 43 fps = 7. 55 ftpd/100 ft 2” L Copper Pipe @ 30 GPM = 3. 14 fps = 2. 02 ftpd/100 ft 104

Block vs Peak Load Analysis 7. 5 Tons Block / 10 Tons Peak = 75% Diversity Ratio 105

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

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

10, 000 Units over 10 Years 108

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

Fernando Garcia, P. E. Vice President CTA Consulting Engineers Inc. Rockville, MD (301) 637 -0058 110

Chicago Blackstone Renaissance Hotel South Michigan Location of 636 the famous “Smoke Filled 332 Rooms” where Warren G. Harding Restoration of 1908 Hotel was chosen as the Republican Opened Fall 2007 nominee for President in June 1920. Franklin Delano Roosevelt’s 3 rd-term Democratic Nomination was forged in 1940. Harry S. Truman stayed when he received 1944 Vice Presidential Nomination. Dwight D. Eisenhower stayed during first Republican ballot in 1952. 111

Portland, Oregon The Nines Hotel Part of The Luxury Collection, Starwood Hotels & Resorts Top 9 Floors - 331 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

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

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

www. fancoil. com www. iec-okc. com 115