TEXT & REFERENCE CED y | TECHNICAL DEVELOPMENT PROGRAM e¢ DESIGN FACTORS ¢ SIZING PROCEDURES @ ° PUMP SELECTION & APPLICATION1200-33 TECHNICAL DEVELOPMENT PROGRAM WATER PIPING SYSTEMS AND PUMPS _CONTENTS, INTRODUCTION ....-..+4- 1 | FORMULAS ...eecseeeeeeeeeeeees 2 TYPES OF PIPING SYSTEMS ....... ee) GENERAL CONSIDERATIONS .......+++-+ 5 MATERIALS ......seeeereeeeees 6 SUPPORTS ......0005 eee 7 VALVES ....- eee ee @ 1. Starting and Stopping Flow ... 9 2. Regulating or Throttling Flow . ul 3, Preventing Back Plow ...++.+++ 12 STRAINERS ....... 14 EXPANSION TANKS ... 16 AIR VENTS oes eeeeeee 18 OTHER ACCESSORIES .. 19 PIPE SIZING .... cess 22 | 1. Pipe Sizing Example .....-+.-+ | 2, Total Head on Pump .... 3, Direct Return System Sizing ..... sence e wee enee 28 1, Pump Terms seeeee we 28 2, Capacity «sss. 28 '@ 3. Head ... ee 284, Suction Head .... 5. Discharge Head . 6. Total Head .... 7. Liquid Horsepower ....+.++ 8. Brake Horsepower . 9. Net Positive Suction Head ... DETERMINING PUMP HEAD . TYPES OF CENTRIFUGAL PUMPS .. PUMP PACKING .. PUMP MATERIALS .. PUMP RATINGS . NOISE IN PUMPING SYSTEMS .......+006+ CONCLUSION eset eee sees esi ‘WORK SESSION . 28 29 29 29 30 30 32 34 36 37 38 52 55TECHNICAL DEVELOPMENT PROGRAM WATER PIPING SYSTEMS AND PUMPS INTRODUCTION In air conditioning work, water is often used to carry heat from a point of generation, such as a cooling coil to a point where it can be rejected to some other medium such as the refrigerant in a water chiller. The water is often recirculated so that the pick up and re- jection of heat is a continuous process. The piping and pumping systems used to transport the water to and from the various heat exchangers are usually relatively simple and straight forward, and are complete in themselves, that is they do not function as part of a big piping network. ‘The water is usually at temperatures between 40F and 100F, although year-round air conditioning may require hot water piping for heating, ‘The motive force for circulating or "pushing" the water through the piping system is almost invariably furnished by a centrifugal pump. ‘The design of piping systems is an old art and much has been written about it. This presentation will review overall design considerations, with emphasis on those points which we consider especially applicable to the piping and pumps used in air conditioning work. Frequent reference will be made to the Carrier System Design Manual Part 3 -© Piping Design for illustrations and amplification of material presented | here. FORMULAS A review of some of the formulas pertaining to the heat carrying capacity of water is in order. Lanes RAE ACM AM, BG, 167 1. BTU/HR. = GPM x sho x water temperature change in OF 2. Tons of refrigeration effect = GPM x temperature change in °E If we use chiller tons as a base, we can arrive at approximate condenser water gpm's and/or temperature changes as follows. For mechanical refrigeration assuming a heat rejection factor of 1.25 @ (1.18 BHP per ton): 3. Chiller tons = -G2M Condensing. wae Temperature Change in OF For absorption refrigeration assuming a heat rejection factor of 2.55 (19.6 Ibs. of 12 psig steam per hour per ton of refrigerating effect). 4, Chiller tons = GPM Condensing Water x Temperature Change in °F Present design practice uses a chilled water temperature change of about 10F; a condenser water temperature change of about 10F for | mechanical refrigeration with cooling tower; a condenser water temper- ature change of about 17F for absorption refrigeration with cooling tower! and a condenser water temperature change of about 20F when using e@ city water at 70 or 75F.These values are assumed to result in reasonable economic balance among first cost, operating costs, and energy requirements. We believe that this assumption is being challenged more often than it was. Higher temperature changes result in less gpm, smaller pipe sizes, lower operating costs, and lower energy requirements. For instance, chilled water temperature changes of 20F or more can be used without incurring any great problem in the selection of water chillers and water cooled coils. TYPES OF PIPING SYSTEMS For our purpose, water piping systems can be classified as follows: 1. Once through type, where water flows from a source through the system and out to waste. Examples are a city water condensing system and a well water chilling system. A pump may or may not be required. 2. Open recirculating type, where water is pumped from a reservoir through the system and back to the reservoir for reuse, with the water being brought into intimate contact with air somewhere in the circuit. Examples are chilled water systems using washers for cooling and dehumidifi- cation and condensing water systems which use cooling towers.3. Closed recirculating type, where water is simply circu- lated through a closed system of piping and equipment, without coming in close contact with air, except at the expansion tank, whose area of contact is negligible. An example is a chilled water system using coils for cooling and dehumidifying. 4. Recirculating Piping systems are further classified as either direct return or reversed return. A direct return system is illustrated in Figure 1 on the left. The same units are shown on the right piped with a reversed return system. 1 J 7 OOE Jee a = — ‘UMS Pic HoMZONTALLY = Mis 21PED womzowraLLy Direct Return Piping System Reverse Return Piping System FIG. 1 eIf the pressure drops through the units are identical, then in the case of the direct return system, each of the first five units will required a balancing valve and means to measure flow plus balancing time to insure the same flow through all units. In the reverse return system, however, the pressure difference from supply line through the unit to return line is the same for all units. Each unit will, therefore, take an equal share of the total flow and no balancing is required. The cost of the extra length of return pipe is probably less than the cost of valves and balancing, and much time and trouble will be saved. A reversed return should always be used in a multi-room system which uses a large number of under the window units of identical pressure drop. GENERAL CONSIDERATIONS. Water piping systems should be as direct and uncomplicated as possible, Offsets, bends, and changes in elevation should be kept to a minimum. Any fitting or valve that is omitted, represents a reduction in first cost, operating cost, and maintenance cost. On the other hand, condenser and chiller tubes must be periodically cleaned, and cooling coils, control valves and pumps will eventually require repair or servicing. All of these operations must be preceededby draining the water out of the equipment involved. It is convenient and economical to be able to isolate such parts by means of shut off or isolating valves so that the entire system does not have to be drained and refilled. It may also be important that any piece of equipment. can be isolated and worked on while the remainder of the system con~ tinues to operate normally, In addition to shut off valves, unions or pairs of flanges are required at strategic locations so that the piping can be easily dismantled for the possible removal of such things as coils, and control valves. Judgment and imagination are needed to balance convenience in servicing against first cost and maintenance cost of the system. Let us examine the various parts of a piping system in some detail. MATERIALS. The usual piping materials are black steel for the large sizes say 1 1/2" and above and hard copper for the smaller sizes. Galvanized steel may be used, but usually only for drainage lines. It is now customary to specify water treatment to control corrosion and galvanized or wrought iron is not generally required. Fittings for black steel pipe are usually welded for larger sizes or malleable iron screwed type for smaller sizes, Hard copper fittings are wrought copper or brass.‘The weight of the pipe and fittings will depend on the pressures and temperatures encountered in the system. Various codes will have something to say about this and the ones that apply must be consulted. Special conditions may required special materials, but this is beyond the scope of this presentation, We refer you to Chapter 1 of the Design Manual, Part 3, for additional information on materials, pages 3-2 and 3-3. SUPPORTS. Hangers or supports are required at intervals ranging from 8 ft. to 20 ft. depending on the pipe size. See tables 7 and 8 in the Design Manual. Except at anchor points, pipe supports should not be rigid but allow some movement of the pipe. In many systems, with several changes of direction, the expansion due to temperature changes can be taken care of in this way. The hangers for chilled water piping are installed outside the Insulation to prevent sweating, and some means must be provided to prevent crushing the insulation, This is usually SHEET METAL a metal plate of suitable length and HALF SLEEVE thickness curved in cross section to fit around the bottom part of the insulation and mounted between theinsulation and the hanger. For hot water service, the hanger is usually around the pipe, and pipe and hanger are insulated together. At the flanges of pumps or heat exchangers, the piping should be supported so that no stress is imposed on the pump casing or the heat exchanger itself. At pump suction and discharge, flexible rubber connectors are sometimes used to prevent stress, and also to compensate for slight misalignment. ‘They are also supposed to prevent the transmission of vibration into the piping system, but they are not very effective for this purpose, Water is an incompressible liquid and vibrations from the pump are transmitted through the water column with very little reduction in intensity. Pump vibration problems are best handled with spring type pipe hangers and by providing a good mass under pumps or other vibrating components in a piping system. Refer to pages 7 and 8 of the Design Manual. In large and important systems, it may be desirable to consult vibration experts. Often it becomes necessary to support a long straight vertical riser which goes from the bottom to the top of the building. In large sizes, the pipe and water represent a very large weight. The accompanying sketch shows a method of support which is inexpensive and provides a dirt leg with cleanout and a solid support with a minimum of hangersand special fittings. Note that the weight of the water is carried directly into the foundation, The joint between the horizontal main and the riser should be made with @ forged welding tee and not by field cutting and welding. Ex- FOUNDATION, |._— riser a HORIZONTAL Z MAIN =—CLEANOUT RAIN STEEL PLATE FORGED TEE pansion of the pipe due to temperature changes in the riser, may need special attention in this case. VALVES. ‘BASEMENT FLOOR FIG. 3 There are hundreds of types of valves, each one of which best suits a particular application, but for our purposes only five or six types need consideration. We refer you to the Design Manual, pages 10 to 15, and also to the catalogs and other publications of the valve manufacturers. Valves perform one of three basic functions. 1, Starting and Stopping Flow. Gate valves are usually used for this function, because when wide open water flows straight through with a minimum of pressure drop. They are not practical for throttling flow.= 10- This illustration shows an OS and Y¥ gate valve with rising stem. is the type usually used for isolating pumps, coolers and condensers. quick glance at the stem reveals whether the valve is open or closed and the stem threads are outside the valve where they are free from cor- rosion and can easily be lubricated. ‘With stem extended, these valves This ono RISING STEM coursibe screw -HANOWHEEL ‘AND YOKE}. (OES NOT Rise WITH STEM) BoLTeD BOLTED SOLID WEDGE BONNET ise FLANGED ENS: Gate Valve - Rising Stem FIG. 4 are very tall and it is often difficult to install them in such a position not interfere with fixed objects or A plug cock has the same low pressure drop, when open, as a gate and is also excellent for throttling service or as a balancing valve. It can be used to perform both functions simultaneously. in the piping that the stem does block off passage. Plug Cock FIG. 5-ne- Regulating or Throttling Flow_ Globe valves or angle valves are usually used for this service. Globe valves have a relatively high pressure drop when open, but give good throttling characteristics, that is, the percent flow is nearly proportional to the per cent of opening. If a globe valve is used for balancing wanowneet —~ nse | tase sere flow, the wheel should be removed PACKING NUT after adjustment to prevent accidental iT 6LaNo— readjustment, An angle globe valve screweo union can be advantageously used for throttling. It's use saves one elbow and the pressure drop when open is less than half that of a straight Cees through globe valve. FIG. 6 If a plug cock or butterfly valve \uawomen, psa irmour cawo is used as both shut off and balancing (Gina senean valve an indicator should be provided so that after use as a shut off, the valve Sfneaoco eouver. can be reopened to the original position, ‘soreweD aRROW sear ois] Enos Control valves are usually auto- ‘eonvenonats matically controlled globe valves, although butterfly valves are be- FLow Angle Valve FIG. 7-12- coming popular for this use, especially in the larger sizes. 3. Preventing Back Flow. Check valves perform the single function of checking or preventing the reversal of flow in piping. The 15° swing check is the usual type, with lift checks often used at pump discharge. If a pump operates between two water levels in an open system, the water will surge back from the top level through the pump to the bottom level at shut- down causing it to run backwards, damage seals, or even completely drain the pump if it is above the lower resevoir. To prevent back flow, a check valve is placed near Swing Check Valve the pump discharge. This should be of the non-slam type, to prevent FIG. 8 water hammer as the check closes. Most non-slam checks are expensive and must be installed in a vertical riser. It is possible to use a pneumatically operated butterly valve at the pump discharge to perform all three functions so far considered. For this multiple use, the valve is a normally closed type so that when air is bled from the branch air line the valve goes to the closed position, Air can be bled manually, which performs function #1.-1B- If a mechanical stop is provided at the valve open position which gives rated flow in the piping system, then after use as a shut off, the valve automatically returns to the correct degree of opening, and function #2 is SCREWED UNION RING BONNET accomplished. A: bleed valve can also be installed in the branch air line, nol which will automatically open whenever I screweo eno the pump shuts down, By adjusting Lift Check Valve the bleed rate of this valve to accom- wc plish a reasonably fast closing of the valve, function #3 is attained. Finally, if several pumps are installed in parallel, a check valve should be installed in each pump discharge to hae prevent water being bypassed back Multiple Pump Piping through an idle pump, See Figure 10. FIG. 10 Pressure reducing valves are occasionally used in water piping. One instance is when supplying clean city water to the lantern ring in a pump seal, where the pressure must be regulated to about 5 psi above suction pressure at the pump. Such valves should be sized to suit the downstream flow rate and not to suit the pipe size.-u- Pressure relief valves are also sometimes required. For instance, in a chilled water system, there may be a stretch of pipe which can be accidentally valved off at each end. ‘The water trapped between the valves can exert a high pressure when warmed up and it may be desirable to supply a relief valve to prevent damage. Also, in an extensive system in which all the control valves are the throttling type rather than three-way valves, the pump can build up a high pressure when all valves are nearly closed, and a relief valve is often installed at the pump discharge to relieve the excess pressure into the pump suction. STRAINERS, In many piping systems, a certain amount of finely divided "trash" can circulate without doing any great harm. In such cases, the need of a strainer is doubtful, and if one is used it should be no finer than 20 mesh to prevent its becoming clogged too rapidly. Operators are human like the rest of us and if the task of cleaning strainers becomes too irksome, the strainer basket will get punched full of holes or be removed, In a condenser water system using a cooling tower and not using control valves, the strainer provided at the tower suction connection is usually considered sufficient. A mud ring is sometimes installed around the