SureFlow

Presented by:

Ron Porter LEED AP

IEC Oklahoma City

Copyright 2012

Topics

• Fan Coil Basics• Traditional System Design• SureFlow Hydronics• SureFlow Unit Design• SureFlow Applications

This Is A Fan Coil

Fan + Coil = Fan CoilRoom Air Conditioner

Moves air through a coil with:

Chilled WaterHot WaterElectric HeatR410a

Let’s focus on the water systems…

How Do They Work ?

FCU

ChillerChiller

FCUFCUFCU

Central Pump Pushes Water Through Piping to Supply Each Fan Coil

Standard Water Pressure Differential System

How Do We Size The Main Pump ?

Central Pump Horsepower = __Head x GPM__

3960 x Efficiency

FCU

ChillerChiller

FCUFCUFCU

Calculate All Circuits

Pump Sizing Based On Highest Pressure Drop Circuit

FCU

ChillerChiller

FCUFCUFCU

Water Always Takes The Path Of Least Resistance

How Do We Know The Fan Coils Will Operate As Advertised ?

FCU

ChillerChiller

FCUFCUFCU

Water Pipe Has Resistance To Water Flow

Pipe and Riser Diameters ?

Continuity : Water In = Water Out (GPM Per Minute)

Velocity : Speed of Travel (Feet Per Second)

D1 D2

Vel1 Vel2Area1 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

Pressure drop is defined as:

The difference in pressure between any two points

on a piece of equipment.

D1D2

Vel1 Vel2Area1 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

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

Example

@ 3.0 GPM

Coil PdFt = 5.9

Valve Pressure Drop:

• Resistance to water flow

• Based on water volume through the valve at

Full Open

• Calculated using Cv Rating Number

• PdFt = ( GPM / ( 0.658 x Cv ))^2

Typical Ball Valve Pressure Drop:

• PdFt = ( GPM / ( 0.658 x Cv ))^2

• Ball valve Cv = 5.84 (1/2 inch)• GPM = 3• PdFt = (3 / (0.658 x 5.84))^2

• PdFt = 0.61

Full-Port Ball Valve Pressure Drop:

• PdFt = ( GPM / ( 0.658 x Cv ))^2

• Ball valve Cv = 14.2 (1/2 inch B&K # 107-503T)• GPM = 3• PdFt = (3 / (0.658 x 14.2))^2

• PdFt = 0.10

Erie Valve Pressure Drop:

• PdFt = ( GPM / ( 0.658 x Cv ))^2

• Cv = 3.5 (1/2 inch VT2213)

• GPM = 3

• PdFt = (3 / (0.658 x 3.5))^2

• PdFt = 1.7

VT2213

3.5 Cv (7/16” Port)

25 PSI Close-Off

Erie Valve Pressure Drop:

• PdFt = ( GPM / ( 0.658 x Cv ))^2

• Cv = 2.5 (1/2 inch VT2212)

• GPM = 3

• PdFt = (3 / (0.658 x 2.5))^2

• PdFt = 3.3

VT2212

2.5 Cv (5/16” Port)

40 PSI Close-Off

Erie Valve Pressure Drop:

• PdFt = ( GPM / ( 0.658 x Cv ))^2

• Cv = 1.0 (1/2 inch VT2211)

• GPM = 3

• PdFt = (3 / (0.658 x 1.0))^2

• PdFt = 20.8

VT2211

1.0 Cv

60 PSI Close-Off

FCU

Analyze Combined Unit And Valve Package Pressure Drop

@ 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

BoilerBoiler

FCUFCUFCU

Will This Design Operate Properly ?

Supply

Return

80 PSI

Δ 10 PSI

70 PSI 65 PSI

85 PSI

Δ 20 PSI

Units &

Valves

@ 3.0 GPM

Require

4.0 PSI Diff Pump

60 GPM

60 Ft Head60 PSI

Δ 25 PSI

Typical of 20 Units

BoilerBoiler

FCUFCUFCU

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 Head60 PSI

Δ 25 PSI

Units &

Valves

@ 3.0 GPM

Require

4.0 PSI Diff

Excessive FlowLow Flow

BoilerBoilerFCUFCUFCUFCU

Cartridge Valves For Automatic Balancing

Supply

Return

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 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

BoilerBoilerFCUFCUFCUFCU

80 PSI

70 PSI

Full Load

Pump

60 GPM

60 Ft Head

VFD

ΔP

Δ 10 PSI

Full-Load Variable Frequency Drive

BoilerBoilerFCUFCUOFFFCU

80 PSI

70 PSI

Part Load

Pump

45 GPM

VFD

ΔP

Δ 10 PSI

Part-Load Variable Frequency Drive

BoilerBoilerFCUFCUFCUFCU

80 PSI

70 PSI

Full Load

Pump

60 GPM

60 Ft Head

VFD

ΔP

Δ 10 PSI

Direct Return System

ChillerChiller

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

ΔP

FCU FCU FCU FCU

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

System Complexity Issues

There Must Be A Better

Way

Primary Circuit Water Flow

Integrated CirculatorCycles on Thermostat

Demand

2008 ASHRAE Handbook HVAC Systems and Equipment

Chapter 12.

ThermostatOFF

Cool AirCool AirCool AirCool Air

Primary Circuit Water Flow

2008 ASHRAE Handbook HVAC Systems and Equipment

Chapter 12.

ThermostatON

Primary Circuit Water Flow

2008 ASHRAE Handbook HVAC Systems and Equipment

Chapter 12.

ThermostatOFF

• Average 40% Less Piping

• Fewer Pipe Hangers

• Less Insulation

Massachusetts College of Pharmacy and Health Sciences

Worcester, Massachusetts

• Reduced Core Drilling

• Fewer Joints = Fewer Leaks

• Contractor Savings

Westin Cupples StationSt. Louis, Missouri

Westin Cupples StationSt. Louis, Missouri

CPF SureFlow 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 CoolingWith Only One Installed Pipe

Chiller

FANCOIL

FANCOIL

FANCOIL

FANCOIL

Water Circulation Rate ≈ 3 GPM per TonPump Head & Energy Reduced

Chiller

FANCOIL

FANCOIL

FANCOIL

FANCOIL

Boiler

Two Pipe Cooling & Heating “Change Over”

With One Installed Pipe

2-Pipe Cooling and Heating Changeover With Only One Installed Pipe

Massachusetts College of Pharmacy and Health Sciences

Worcester, Massachusetts

Four Pipe Heat & CoolWith Only Two Installed Pipes

Chiller

FANCOIL

Boiler

FANCOIL

FANCOIL

FANCOIL

1. What Happens To The Water Temperature ?

2. Will It Control Humidity ?

Challenges:

42ºF 46.6ºF46.6ºF 48.6ºF

44.4ºF

Chiller

Off

52.1ºF

Water Temperature Changes As BTUs Are Injected Into The SureFlow Loop

1 Ton13177t 9954s

1 Ton

12052t 9519s

1 Ton

14424t 10448s

1 Ton

Cooling Loop Water Pipe Size

Design GuideType 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

PdFt / 100Ft 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

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

PdFt / 100Ft 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

Design GuideType L Copper

Heating Loop Water Pipe Size

8 Degree Loop Delta-T = 3 GPM per Ton

Cooling Loop Water Temperature

10 Tons Peak x 3 GPM per Ton = 30 GPM1-1/2” L Copper @ 30GPM = 5.43 fps = 7.55 ftpd/100ft

2” L Copper Pipe @ 30GPM = 3.14 fps = 2.02 ftpd/100ft

Peak Load Analysis Sample

7.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio

Block vs Peak Load Analysis

With 42F Supply, 3 GPM Per Ton, 75% RatioMax Actual Water Temperature = 48F

BLOCK LOAD RATIO

Design For Diversity

With 42F Supply, 3 GPM Per Ton, 75% RatioMax Actual Water Temperature = 48F

Design For Diversity

SOME UNITS

ARE NOT RUNNING

ARE SOME UNITS OVER

SIZED ?

SureFlow Allows Adjustment Of The Design For Occupancy

– School Classroom vs. Common areas– Hotel Rooms– Offices– Usage patterns, time of day

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

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 EAc1Optimize Energy Performance

Up To 19 Points Available

Complex 2-way valve package

= 32 solder joints

SureFlow valve package

= 16 solder joints

Installation and Maintenance Savings

Primary Pump

Common Load

Secondary Pump

Chiller - Or -Heat

Exchanger

Compound Primary-Secondary Pumping

Building 1 of X Building 2 of X

Central Plant

Campus Chilled Water

Balance Valves

3 Way Control Valve

Load

Replace Your Original Existing 2-pipe FCU….

CW Supply

CW Return

…. With a New SureFlow Unit and Have 4-Pipe Performance With Two Pipes

Existing Pipes

HeatingCoil

HeatingCoil

CoolingCoil

CoolingCoil

CW Supply/Return

HW Supply/Return

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 CoilsHotel MonacoWashington DC

Case Study

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

Chicago Blackstone Renaissance Hotel

636 South Michigan332 Rooms

Restoration of 1908 HotelOpened 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 3rd-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.

The Nines, The Luxury Collection, Starwood Hotels

Top 9 Floors - 331 Guest RoomsPortland’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

Elysian / Waldorf Astoria

60 Stories on East Walton Street in the Gold Coast52 Private Residences

188 Room Waldorf Astoria Hotel

Constructed 2006-2010Renamed Waldorf Astoria Chicago February 1, 2012

AAA Five DiamondTripAdvisor.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

12,000 Units over 12 Years

Cool AirCool AirCool AirCool Air

Average 40% Less Piping

Installed Cost Savings $$$

Pump Energy Savings For Owner $$$

Reliable Operation

Occupant Comfort

LEED Credit Opportunities4 – Pipe

Performance With 2 Installed Pipes

Low Maintenance

Easy To Design

www.fancoil.comwww.iec-okc.com

Application:SureFlow

75

FCU

ChillerChiller

FCUFCUFCU

Part Load Pump Controls

Standard Piping Method

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

Primary

Circuit Water

Flow

Integrated Circulator

Cycles on Thermostat

Demand

Thermostat

OFF

78

79

SureFlow

Average 40%

Less Piping

Less Core

Drills on

Renovation

Contractor

Savings

80

• 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

Two Pipe Cooling

With Only One Installed Pipe

Chiller

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

82

Two Pipe Heat & Cool

With Only One Installed Pipe

Chiller

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

Boiler

83

42ºF 46.6ºF46.6ºF 48.6ºF

44.4ºF

Chiller

Off

52.1ºF

Central Pump Is NOT Responsible For Pressure Drop Of Coil Or Valve Packages

1 Ton13177t 9954s

1 Ton

12052t 9519s

1 Ton

14424t 10448s

1 Ton

SureFlow System Pumping

84

7.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio

Block vs Peak Load Analysis

85

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 MonacoWashington DC

SureFlow Installation - Case Study

86

Application:SureFlow

87

Standard Piping Method

ChillerChiller

FCUFCUFCUFCU

88

FCU

ChillerChiller

FCUFCUFCU

Primary-Secondary Pumping

Standard Piping Method

89

FCU

ChillerChiller

FCUFCUFCU

Part Load Pump Controls

Standard Piping Method

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

Primary

Circuit Water

Flow

Integrated Circulator

Cycles on Thermostat

Demand

Thermostat

OFF

92

Cool AirCool AirCool AirCool Air

Primary

Circuit Water

Flow

Integrated Circulator

Cycles on Thermostat

Demand

Thermostat

ON

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

Chapter 12.94

95

SureFlow

Average 40%

Less Piping

Less Core

Drills on

Renovation

Contractor

Savings

96

• 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

Two Pipe Cooling

With Only One Installed Pipe

Chiller

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

98

Two Pipe Heat & Cool

With Only One Installed Pipe

Chiller

FAN

COIL

FAN

COIL

FAN

COIL

FAN

COIL

Boiler

99

Four Pipe Heat & Cool

With Only Two Installed Pipes

Chiller

FAN

COIL

Boiler

FAN

COIL

FAN

COIL

FAN

COIL

100

42ºF 46.6ºF46.6ºF 48.6ºF

44.4ºF

Chiller

Off

52.1ºF

Central Pump Is NOT Responsible For Pressure Drop Of Coil Or Valve Packages

1 Ton13177t 9954s

1 Ton

12052t 9519s

1 Ton

14424t 10448s

1 Ton

SureFlow System Pumping

101

Coil Pressure Drop is Redesigned to Match

Circulator Pump Curve

102

8 Degree Loop Delta-T = 3 GPM per Ton

Cooling Loop Water Temperature

103

10 Tons Peak x 3 GPM per Ton = 30 GPM1-1/2” L Copper @ 30GPM = 5.43 fps = 7.55 ftpd/100ft

2” L Copper Pipe @ 30GPM = 3.14 fps = 2.02 ftpd/100ft

SureFlow Peak Load Design

104

7.5 Tons Block / 10 Tons Peak = 75% Diversity Ratio

Block vs Peak Load Analysis

105

With 42F Supply, 3 GPM Per Ton, 75% RatioMax Actual Water Temperature = 48F

BLOCK LOAD RATIO

Design For Diversity

106

With 44F Supply, 3 GPM Per Ton, 75% RatioMax Actual Water Temperature = 50F

BLOCK LOAD RATIO

Warmer Supply Temperature?

107

10,000 Units over 10 Years

108

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 MonacoWashington DC

SureFlow Installation - Case Study

109

Fernando Garcia, P.E.

Vice President

CTA Consulting Engineers Inc.

Rockville, MD

(301) 637-0058

110

Chicago Blackstone Renaissance Hotel

636 South Michigan332 Rooms

Restoration of 1908 HotelOpened Fall 2007

Location of the famous “Smoke Filled

Rooms” where Warren G. Harding

was chosen as the Republican

nominee for President in June 1920.

Franklin Delano Roosevelt’s 3rd-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, OregonThe Nines Hotel

Part of The Luxury Collection, Starwood Hotels & ResortsTop 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, 2008LEED 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

Cool AirCool AirCool AirCool Air

Average

40% Less

Piping

Installed Cost

Savings $$$

Pump

Energy

Savings For

Owner $$$

Reliable

Operation

Occupant

Comfort

LEED Credit

Opportunitie

s

4 – Pipe

Performance

With 2 Installed

Pipes

Low

Maintenance

Easy To

Design

114

www.fancoil.comwww.iec-okc.com

115