Department of Mechanical Engineering

University of Malaya

Semester 2 Session 2016/2017

KMEM4347 Energy and Environment

Group assignment:

Heat Pump Water Heater System Design in a Budget Hotel

GROUP MEMBERS:

NAME MATRIC NUMBER

AW ZHE YI KEM130009
CHIA YI MENG KEM130013
HO KYE WENN KEM130021
MD. GOLAM RASSEL LINCOLN KEM140704

LECTURER: DR. MAHENDRA VARMAN A/L MUNUSAMY

Table of content

No. Content Page Number

1 1.0 Introduction 5

2 2.0 Literature review 6-11

2.1 Heat pump
2.1.1 Basic structure and functions of heat pump
2.1.2 Operation theory of heat pump
2.1.3 Types of heat sources
2.1.4 Types of heat pump

2.2 Heat Loss Calculation Formulae

2.2.1 Darcy-Weisbach Formula
2.2.2 Hazen-Williams Formula

3 3.0 Site Information 12

4 4.0 Set up 13

5 5.0 Sitting of the Heat Pump Water Heater System 14-16

5.1 Components involved and function
5.1.1 Cooling Tower
5.1.2 Heat Pump
5.1.3 Temperature and Pressure (T&P) Relief Valve
5.1.4 Pump
5.1.5 Check valve
5.1.6 Shut-off valve
5.1.7 Drain valves

5.2 Sitting of equipment on the rooftop

2
6 6.0 Selection of heat pump 17-25
6.1 Heat Pump Sizing Method
6.1.1 Average Hourly Demand
6.1.2 Based on occupancy type
6.1.3 Justification

6.2 Calculations
6.3 Hot Water Ratio
6.4 Selection of Water to Water Heat Pump

7 7.0 Selection of Storage Tank 25-31

7.1 Heat-Flo Hot Water Storage Tank
7.2 EPP Stainless Steel Storage Tank
7.3 Bradford White Commercial Jacketed Storage Tank
7.4 Comparison of the reservoir tanks
7.5 Justification: EPP M-3-ST80R5

8 8.0 Pipe material selection 31-34

8.1 Pipe size selection

9 9.0 Head loss calculation using Hazen Williams equations 34-37

9.1 For heat recovery loop (Cooling tower Heat pump)
9.2 For cold water circulation (Cold water from water tap and hot
water storage tank to Heat pump)

9.3 Minor loss and valve fitting

9.3.1 For hot water circulation (Hot water from heat pump hot
water storage tank)
9.3.2 Calculation for heat recovery from cooling tower

10 10.0 Pump selection 38-40

10.1 For heat recovery loop (Cooling tower Heat pump)
10.2 For heating water loop (Heat pump hot water storage tank)

3
11 11.0 Saving 41-43
11.1 Heat Pump Water Heater System

11.2 Calculation of electric bill

11.2.1 Instant water heater
11.2.2 Heat pump water heater system
12 12.0 Safety considerations 44-46
13 Conclusion 46
14 References 47-48

4
1.0 INTRODUCTION

In a hotel, hot water supply is an utmost important criterion for the comfort of customers
staying inside. Upon staying inside a room in the hotel, hot water service is normally used for
bathing, handwashing and face washing. Generating hot water requires heat energy to be
continued supplying to the water source so as to achieve the required temperature of hot water.
Thus, it is essential to find out a cost-effective way to continue providing hot water service to
customers.

One of the common device use in providing hot water service is electric resistance water
heater. This is due to its simple installation. Big ducting is not required and the installation
method is easy and cheap. However, the turnover to it is that the highest energy factor that it
can achieve is 0.9. Intensively operating electric resistance heater could increase the power
consumption and carbon footprint extensively.

Thus, in order to solve the current issue of global warming, the focus of this assignment
is to improve the water heater system in one of the selected budget hotel in Malaysia. The
proposed solution to it is to apply heat pump water heater system to replace the electric
resistance water heaters. Heat pump water heater system could provide a lot of benefits as
compared to conventional electric water heaters. Heat pumps concept of moving heat energy
rather than generating heat itself successfully reduces power consumption and thus electric bill.
Heat pump water heater has higher energy factor 3 or even 4 and above. Although the capital
needed in installing heat pump water heater system may seem to be higher than conventional
electric water heater, the annual return of investment calculated could cover up the initial capital
cost in a short period of time.

As a conclusion, in this project, we will explain how the heat pump water heater system
is applied into the water delivery system in one of the chosen budget hotel in SS2, Petaling Jaya.
The system design, setting, sizing, selection and safety consideration will be covered and
elaborated in detail in the following section.

5
2.0 LITERATURE REVIEW

2.1 Heat pump

2.1.1 Basic structure and functions of heat pump

Heat pump is a device that functions as a reverse of a refrigerator. It uses electricity to transfer
heat from a region to another e.g. cooler region to a warmer, resulting a cool space to be cooler
and a warm space to be warmer. Usually, heat pump is popular in temperate zone where those
countries have four season including winter. During winter season, heat pump functions in
moving the heat from the cool outdoors into the warm indoors. Since the function concept of
heat pump is to transfer heat rather than generate heat itself, heat pump is believed to be more
energy-efficient and cost-saving as compared to those conventional heating appliances which
uses electric resistance heating.

Figure 1: Generalized operation of a heat pump

Return of warm
liquid from heat Heated water out
extraction system

Cool liquid back to the Cold water in

heat extraction system

In a heat pump, it consists of at least 4 basic parts, which are the heat exchanger of
refrigerant and heat source (to obtain heat from the heat source), a heat exchanger of refrigerant
vapour with water (to transfer heat to water), a compressor (to increase pressure and enthalpy
of refrigerant) and an expansion valve. The expansion valve, is a device which allow the
pressure of the refrigerant to return to normal pressure. The fluid used in the heat pump is
refrigerant, which functions as a medium to bring heat from the heat source to heat up the water
that we want to use.

6
2.1.2 Operation theory of heat pump

The heat pump operates based on a refrigerant cycle, which is the reversed of Rankine
cycle. In refrigerant cycle, it uses refrigerant instead of water or other fluid. In refrigerant cycle,
it can be divided into 4 sections which are the heat extraction section, compressor, condenser,
and the expansion valve.

Firstly, in section 1 (refer to figure 1), there will be a heat extraction system where heat
source could be either underground, chilled water return from air handling unit (AHU), or
condenser water from cooling tower. In section 2, from example, if the heat source is
underground, low temperature heat from the ground is conveyed to the evaporator by a
refrigerant fluid. This heat is transferred into the refrigerant within the evaporator, which is
several degrees lower in temperature, causes the refrigerant within the evaporator to vaporize.

Secondly, the vaporized refrigerant doesnt not have enough enthalpy to heat up water,
thus it enters the compressor in section 3 (refer to figure 1). By using electrical energy, the
refrigerant vapor is greatly compressed, resulting in addition of energy into the refrigerant vapor,
and thus adds to its total enthalpy and heat content. As a result, its pressure and temperature are
greatly increased. Usually, the pressure and temperature is controlled up to the desired
temperature.

Next, the refrigerant hot gas at high pressure and temperature enters the condenser in
section 4. Inside the condenser, refrigerant cools down and condenses which transfer the heat
to the cold-water that passes through the heat exchanger. The water is heated up and then
circulated back as shown in section 5 to be readily used such as showering.

The refrigerant is now cooler but the pressure is still relatively high. Thus, it continues
its path to the thermal expansion valve (TXV) in section 6, which further lowers its temperature
and pressure so that it returns to its original state. The refrigerant now is in fluid form and could
starts absorb heat again in the evaporator.

The cycle continues and thus heat is transferred from the heat source (underground,
chilled water return or condensed water from cooling tower) to the water delivery system.

2.1.3 Types of heat sources

The heat pump can obtain heat from different kind of sources which present in nature,
such as from air, water e.g. water from cooling tower, chilled water returned from air handling

7
unit (AHU), geothermal and etc. In some cases, where the heat from nature is not sufficient to
heat up the refrigerant, an electrical heater is used to increase the temperature of the refrigerant.

2.1.4 Types of heat pump

There a few types of heat pump system which can be explained as below:

a) Air source heat pump system heat would be pulled from the ambient air across the
heat exchanger. The source temperature is very subjective to the ambient temperature
which varies throughout the year depending on geographic area.
b) Water source heat pump system it is further subdivided into closed loop where a closed
pipe-work loop of water which is sunk into a river or lake and open loop where the water
is actually extracted from a ground Aquifer and passed through heat pump.
c) Geothermal heat pump system heat is drawn from underground during winter. It can
complimentary with addition of desuperheater feature which uses superheated gases
from the heat pump compressor to heat water.
d) Ductless mini split heat pump it functions like an air conditioner but in reverse mode
where condensation occurs at indoors through condenser while evaporation occurs at
outdoors.

2.2 Heat Loss Calculation Formulae

2.2.1 Darcy-Weisbach Formula

It is undeniable that piping design and sizing is essential to be carefully evaluated so that the
heat pump is not over or under design as compared to the requirement by the budget hotel.
Piping design has close relationship with head loss due to pipe friction or resistance to flow.
Thus, deep understanding on various factors affecting the head loss is important to design a
high performance heat pump.

Some of the factors that affect the head loss in pipes include viscosity of the fluid being
handled, the diameter of pipes, and roughness of the internal wall of pipes. Besides, length of
fluid to travel along and the changes in elevation of system have to be taken into account for
consideration as well. Apart of that, resistance through various valves and fittings would also

8
contribute to head loss but less significance. Many designers normally ignore head loss due to
this in the initial stages of design.

In order to accurately evaluate the head loss in piping design, Weisbach has proposed
the equation which is known as Darcy-Weisbach formula as shown:

2
= ( ) ( )
2

Where:

= head loss (m)

= friction factor
= length of pipe (m)
= inner diameter of pipe (m)
= velocity of fluid (m/s)
= acceleration due to gravity (m/s2)

If the pipe is non-circular, the equivalent diameter hydraulic diameter is used as the
characteristic length where:

4
, =

While for friction factor, its value is dependent on several characteristics such as relative pipe
roughness and Reynold numbers. A Moody chart which relates these characteristics has been
constructed for accurate choice of friction factor in different characteristics.

9
 Figure 2: Moody diagram

Moreover, we could also determine the friction factor by adopting specific equations in
different range of fluid flow situation. In laminar flow, where Reynold number is less than 2000,
the friction factor can be calculated as:

64
=

While in turbulent flow (Re > 4000) in pipe, the friction factor can be calculated using
Colebrook-White equation as:

1 2.51
= 2.0 log ( + )
3.7

Where is the roughness of the pipe and is its diameter.

2.2.2 Hazen-Williams Formula

Before the advancement of computerized calculator, Hazen-Williams formula was extremely

popular in piping design due to its simplicity in calculation as compared to Darcy-Weisbach
formula. It was normally being used for water flow in larger pipes with diameter more than 5cm
within a moderate velocity which is less than 3m/s. However, head loss calculated from Hazen-
Williams formula depend on pipe material, pipe size, fluid velocity in which the pipe material

10
could affect the value of Hazen Williams coefficient, C. The Hazen Williams formula is written
as:

= 0.849 0.63 0.54

Where,

= water velocity
= Hazen Williams coefficient
= hydraulic radius
= slope of the energy grade line, or head loss per unit length of pipe

Figure 3: Hazen-Williams Coefficients

11
3.0 Site Information

The budget hotel that we had chosen to implement the water heater heat pump system is is JJ
Boutique Hotel. The building is located in SS2, Petaling Jaya, Kuala Lumpur in a row with
other shops and outlets rather than an` individual building. However, we were unable to access
to the floor plan of each level of the hotel, but we were acquired the information as shown
below:

No. of floor :4
No. of rooms : 30
No. of rooms which rain shower :30
No. of rooms with bathtub :0
Water usage from 28th Feb to 14th March 2017 : 135.5m3

Figure 4: The front look and the back look of the budget hotel

The hotel business operating hours is based in whole-day basis. The water heater system
installed is decentralised system, in which each room is equipped with individual electrical
heater as shown in figure below:

Figure 5: Electrical heater

12
4.0 Set up

The setup of the heat pump water heater system is installed on the rooftop of the JJ Boutique
Hotel. This is due to unavailability of the vacant space for installation of the system on the
ground level. Typically, there are two types of hot water system, which are Storage or
Continuous Flow.

4.1 Storage System:

Storage type hot water system heats the water to the required temperature and it is stored in the
insulated tank for future usage. As the hot water is used during operation, it will be displaced
by the incoming cold water which will be heated in the heat pump. Therefore storage system
consistently heated the incoming water even there is low or no demand for hot water. The hot
water will be maintained at the set temperature usually at 60.

4.2 Continuous or Instantaneous Flow System:

Continuous flow systems only heat the amount of hot water according to demand. The system
is started as the tap water is turned on to heat the water and it stops heating when tap is turned
off. With this system, storage tanks is not needed and there is always available on demand and
having less chance running out of hot water. This system tends to save energy and cost as
compared to storage type. The main drawback of this system is such that is only suitable for
low demand, for instance around 100L/day

4.3 Justifications:

The chosen hot water system will be a storage system, at which the water is heat up in the water
heater heat pump and it is then stored in the storage tank with continuous heating of the water.
This is due to the large demand of the budget hotel. The instantaneous flow system is only
suitable for the low demand usage such as medium sized household with more than one
bathroom. The storage system chosen is of low pressure type which is suitable to be installed
in the roof space and the pressure is depends on the vertical distance between the system and
the fixtures, which is also known as gravity feed system.

13
5.0 Sitting of the Heat Pump Water Heater System

Figure 6: The schematic diagram

Table 1: Symbols and its component

Symbol Component

Temperature and Pressure Relief Valve

Shut-off Valve

Pump

Drain Valve

Check Valve

Flow direction of hot water

Flow direction of cold water
Flow direction of circulated hot water
from storage tank at lower temperature

14
5.1 Components involved and function:

5.1.1 Cooling Tower

The return warm liquid from the cooling tower is used to preheat the refrigerant in
evaporator before it is compressed in the compressor. The inlet of the source water inlet
is 30 and the source water leave the outlet at 25 after the heat transfer processed
took place.

5.1.2 Heat Pump

Consisted of compressor, condenser, expansion valve and evaporator. The working fluid
is refrigerant in which heat transfer takes place to transfer the heat to the cold water.

5.1.3 Temperature and Pressure (T&P) Relief Valve

T&P relief valve used in water heater system are designed to relieve on pressure at
1034.21kPa and on temperature at 210. This is to protect the storage tank or heat
pump from excess pressures and temperatures by discharging water.

5.1.4 Pump

The device that moves the water through the piping system and also to compensate for
the pressure loss during the transmission of the water.

5.1.5 Check valve

To prevent the backflow of the hot water back to the heat pump and causes mixing of
water at different temperature

5.1.6 Shut-off valve

Designed to shutoff or fully open the flow of the water in the piping system.

5.1.7 Drain valves

It drains and removes excess water from the system.

15
5.2 Sitting of equipment on the rooftop

Since we are not able to reach to the rooftop of the JJ Boutique Budge Hotel, we try to estimate
the length and deep of the rooftop through the use of Google Map Satellite View and utilise
the measure distance function to measure rooftop dimension of hotel.

Figure 7: Rooftop of the hotel from the view of satellite

9 77.54

77.54
= = 8.62
9
8.5

22.35

22

Heat pump
Cooling tower

22m

Storage tank

16

8.5m
6.0 Selection of heat pump

6.1 Heat Pump Sizing Method

By using the adequate information, the load profile and peak demand can be calculated. There
are two method presented here for the calculations of load of the building which are outlined
from he American Society of Plumbing.

6.1.1 Average Hourly Demand

This is the first method where the sizing is based on the average hourly data. The calculation
involves the counting of number of fixtures such as basins, showers, bathtubs and etc. The
figure is then multiplied by the usage per hours for the particular type of building and
multiply the total by the simultaneous usage factor to get the maximum hourly demand for the
whole system. The table below shows the hot water demand for different fixture.

Figure 8:Hot water demand for different fixture

(Source: ASHRAE Applications Handbook, Chapter 45, Table 9)

However, the limitations of this method is as show below:

It only applied to the facilities as listed in the table

It only can be used for the sizing of the storage tank
It does not consider the number of occupants

17
6.1.2 Based on occupancy type

The second method is outlined in the Domestic Water Heating Design Manual. This manual
specifies the occupancies and tailors the calculation to the type of occupancy. Although not all
types of facilities are mentioned, but it can be calculated by using this method. This method can
be used to establish the sizing for the storage tank of the water heater, instantaneous or semi-
instantaneous heater. The other superiority is such that it also categorised the occupant
demographic. The tables below show the occupant demographic classification and hot water
demand based for multifamily buildings.

Table 2: Occupant demographic classifications

(Source : Domestic Water Heating Design Manual)

6.1.3 Justification

The method employed in the sizing of water heater heat pump is based on the occupancy type.
The reason is such that the data given is based on hotel rather than budget hotel. There is a
significant different in terms of water usage in a relatively larger scale of accommodation
facility such as hotel as compared to budget hotel. In this case, we are considering the demand
based on the hour instead of number of occupants.

18
6.2 Calculations:

Water consumption from 28th Feb to 14th March = 135.5m3 or 135500L

135500
Water consumption per day = 15 = 9033.33

9033.33
Average water consumption per hour, = 376.40/h
24

6.3 Hot Water Ratio

Often the higher temperature hot water is mixed with cooler water temperature to obtain a
desired mixed water temperature. Therefore, it is necessary to determine the relative amount
of water at the three temperatures involved.

Assumptions:

Mixed Water Temperature, : 38

Hot Water Temperature, : 60

Cold water Temperature, : 25

Hot Water Ratio,

38 25
= =
65 25

= 0.325

Therefore, the hot water consumption per hours = 0.325376.4 = 122.33/

It is necessary to verify the hot water consumption during peak hour as the data
collected is not during the peak season where the budget hotel is assumed to be more
occupied as compared to now. To do this, the following assumptions have been made:
i. An average of 2 occupants per room
ii. Shower is the only facilities that uses hot water
iii. The usage of shower lasted for peak 5minutes
iv. Assuming the demand for hot water is high
v. Budget hotel is considered as short stay facilities where the peak demand can be
compressed to an hour basis as the guests check-in and out faster than normal.
By referring to the table above, consumption of hot water per person is equals to 4.5L
for peak 5minutes in a hour. Therefore:
19
 For a room with average of 2 occupants, hot water consumption per room = 4.5L x 2 =
9L
For fully occupied situation during peak season, total hot water consumption = 9L x
30 = 270L
The ratio of hot water consumption peak season to the normal season:

270
= 2.21
122.33

This implies that the hot water usage during peak season is 2.2 time more than that of
normal season. For the ease of calculation and tolerance, we shall scale the factor to 2.5
which is total hot water consumption of:

122.33L x 2.5 = 305.825L/h

Heat input to increase water temperature from 25 to 65 for 305.825L/h of hot water:

305.825
4.187(60 25) = 12.45 42478.44 /
3600

6.4 Selection of Water to Water Heat Pump

There is various type of heat pump available in the market, however, the water to water heat
pump is a more suitable choice for our application. The selected water to water heat pump has
to connect to a cooling tower setting so that to pre-heat the refrigerant before it is compressed
in the compressor. There are some criteria to be considered in selecting appropriate heat pump,
which are

Heating Capacity/ Heat Output

Power Input
Coefficient of Performance (COP)
Maximum Flow Temperature
Pressure Drop
Dimension

20
a) Dimplex WI 18TU

Product Description:

High COP during operation through minimal overheating

High domestic hot water temperature at 60
Able to utilised the ground water heat source through stainless steel coil heat
exchanger
Less acoustic emissions through free swinging compressor baseplate with noise
insulation
WPM EconPlus heat pump manager that used to control the electronic expansion
valve for high performance and low operating costs.

Technical data are as shown below:

21
b) Deron Water-Water Heat Pump

Product Description:

Compact design for outdoor installation

With suction gas cooled scroll compressor
Can be mounted on the wall
Low noise design for indoor installation with noise insulation and floating support for
compressor
Extensive aluminium/copper lamellar tube evaporator and coaxial condenser

Technical data:

22
c) Nyle systems geyser C-Series

Product Description

Commercial units able to heat water up to 150

Operating COP ranges from 3 to 5 and expected to save 60% to 75% versus the cost of
operating on an electric water
Painted aluminium cabinets to provide good protection against corrosion
Cooled source water can be pre-chill the return water to a chiller plant.
Uses environmentally friendly R134a as refrigerant

Technical Data:

23
 Table 3: Comparison Chart of the heat pump available

Model Dimplex WI 18TU Deron DE-36W/S Nyle systems

geyser C60W
Heating Capacity 17.1 16.5 20
(kW)
Power Input (Kw) 2.95 3.6 3.89
COP 5.8 4.58 5.14
Maximum Flow 62 60 65.56
Temperature (C)
Pressure Drop (kPa) 16.2 Not specified 44.12 (condenser)
Sound Power Level 44 44 79
(dB)
Dimension (mm) 650 x 845 x 665 790x620x850 686x965x737

6.5.1 Justification: Dimplex WI 18TU

Heating Capacity:

The heating capacity of all the three models are sufficient as the required capacity is
12.45kW. However the Nyle System Geyser is slightly too high for our application.

Power Input:

The power consumption for Dimplex is the lowest, therefore it can be considered the most
economic model over the other choices for commercial application.

COP:

Undoubtedly the COP of Dimplex model is the highest due to the lowest power consumption,
therefore this causes the model to be more efficient and energy saving.

Maximum Flow Temperature:

Nyle systems geyser is the highest therefore it has a higher upper boundary temperature and
followed by Dimplex model. However the maximum flow temperature is 60C, although it suits

24
our desired temperature, it is not recommended to operate the heat pump at the maximum
allowable temperature. Therefore it is better to go for a higher upper boundary temperature.

Pressure Drop

The pressure drop aspects is not so comparable as the tehnical data for Deron is not provided
and the pressure drop of each component are not specified.

Sound Power Level

Sound power level has a great influence on the comfortability of the guest in the budget hotel
especially those staying in the upper floors that closed to the hot water system site. Therefore
the first two models are having a lower power level of 44dB which is considered acceptable.

Dimension

Dimension is important for the space saving purpose. The most space saving model is Derons
model. However, the Dimplex model is also considered acceptable.

7.0 Selection of Storage Tank

There are various types of storage tanks for hot water system such as copper, stainless steel
tanks or glass lined steel tank. Normally the copper and glass-lined tanks will have a
sacrificial anode to decrease the corrosion and it has to be replaced from time to time. There
are some criteria to be considered while selecting the storage tank, which are:

Capacity
Material
Insulation
Dimension
Piping Connection
Working Pressure

25
7.1 Heat-Flo Hot Water Storage Tank

Features and Benefits:

Quality Design and Construction

All stainless steel.

R-12 insulation, less than 1/ hr. heat loss.
Flexible thermoplastic jacket that wont dent or corrode.
Stainless steel dip tubes.

Easy Installation

All connections are on top on standard units. Connecting to a high efficiency wall-mount
boiler or instantaneous water heater is about as easy as it gets.
Units are provided with two separate connections for heat source supply and return and
an aquastat. The result is excellent temperature control and no guesswork. These two
connections are hydraulically decoupled from cold and hot. High hot water draw rates
will not affect the circulator/ control performance

The technical sheet is as shown below:

26
7.2 EPP Stainless Steel Storage Tank

Features

Safe, Hygienic, and Durable

Designed for Efficient Water Storage
Low Standby Heat Loss
Easy Installation
Warranty: 10 Year for Residential.

Quality Construction

Tank constructed from High Grade Stainless Steel

Extra sturdy 14GA internal tank for years of trouble-free performance.
AISI 316L for proven dependability and superior weld integrity
Baked Enamel Casing with Galvanized Base
Magnesium Anode
Passivated for additional Corrosion Protection

The detailed specifications is as shown below:

27
28
7.3 Bradford White Commercial Jacketed Storage Tanks

Models Feature:

Designed for the use with hot circulation system and large dump volume applications
Tank lined with engineered enamel that provides superior protection from high
corrosive effect of high temperature.
Hand Hole Cleanout for removal o accumulated lime and sediment
Two Protective Magnesium Anode Rods to provide protection against corrosion

29
7.4 Comparison of the reservoir tanks

Table 4: Comparison Chart

Model Heat Flo 80-ST EPP 80-ST M-3-ST80R5

Capacity (gal) 80 80 80
Material Stainless steel High Grade Stainless steel
jacketed with Stainless steel with lined with enamel
thermoplastic baked enamel and added
casing protection against
corrosion
Insulation Refrigerant R-12 Low heat loss 2 of Non CFC
Insulation less than Foam Insulation
1 deg.F/hr heat loss
Diameter 0.7112 0.7122 0.61
(m)
Dimension
Height 1.4224 1.601 1.492
(m)
Weight 63.5 89.81 87
Maximum Working 1034.21 1034.21 1034.21
]Pressure (kPa)
Warranty (years) 5 10 5

7.5 Justification: EPP M-3-ST80R5

Capacity:

The three chosen models for this screening process are all 80 gallons which is sufficient for
our application of 66gallons of hot water.

Material:

EPP model is equipped with extra magnesium anode rods to protect against corrosion with its
original heavy gauge steel. The enamel casing even harden the tank in terms of corrosion
resistance

30
Dimension:

The diameter of the tank is smaller as compared to the other, therefore it is consider to be
more space saving, if it were to be installed on the rooftop of the budget hotel.

Weight:

The weight is ranked the second out of the three-chosen model, nevertheless, the weight is
acceptable.

Maximum Working Pressure, Warranty and extra feature:

The working pressure is the same for all the models with a 5 years warranty. A user-friendly
feature is added that allow the removal of accumulated lime and sediment for maintenance.

8.0 Pipe material selection

It is essential to determine the most suitable material during piping design in the heat pump
water heater system. Various aspects have to be taken into consideration when determining
suitable pipe material such as such as corrosion resistivity, maximum allowable of fluid
pressure and temperature flow, costing, type of fluid flow and many others. Some of the
common pipe materials are:

Galvanized steel or iron (GS/GI)

Copper tubing
Polyvinyl chloride (PVC)
Chlorinated polyvinyl chloride (CPVC)
Poly propylene random copolymer (PP-R)

31
 Table 5: Comparison between these materials

GS/GI Copper PVC CPVC PP-R

Corrosion Corrodes Corrode after No effect No effect due Corrosion
faster & a period of to superb resistant to
deteriorates time chemical certain
resistance amount of
chemical
Thermal Very high Very high Low Lower Higher than
conductivity CPVC
& insulation
levels
Bacterial More than More than More than Extremely More than
growth copper CPVC CPVC low CPVC
Fire Good Good Low Moderate Low
resistance
Thermal Low thermal Low thermal Low and less Lower and High
expansion expansion expansion looping and less looping expansion
but stress but tress offsets offsets and requires
induced are inducted are more looping
high. high. and offset
Range of Limited Limited Wide range Wide range Nominal
fittings range of range of of fittings of fittings range of
fittings fittings fittings
Maximum 1400 1085 60 94 90
allowable
water flow
temperature
()
Cost per 19.62 23.90 3.10 4.42 5.30
meter (RM)

32
Based on the schematic diagram, we can see there are two piping circuits, which are the circuit
that connect the water from cooling tower to flow through the heat pump, and the second circuit
that connect the water supply from the water source to the hot water reservoir tank.

For these two piping loops, the preferable temperature range will be 15 oC ~ 80 oC. In addition,
other factors that are considered while selecting pipe will be the cost of piping material and
the durability while exposing at outdoor.

**Price is roughly estimated based on internet references. The link can be found in the reference
list.

Based on the above table, we found that PVC and CPVC are the cheapest material among other
material. However, due to the required temperature range of hot water is around 60 degree
Celsius of slightly higher than this, PVC is not suitable to be the piping material because it can
only withstand up to 60 degree Celsius. Above 60 degree Celsius, the PVC pipe will start to
soften and resulting in piping and joint failure. Water leakage or frequently maintenance might
be needed if PVC is chosen. Furthermore, long term exposure of the piping under sunlight and
rainy weather might cause corrosion to the iron or copper piping, however CPVC is chemically
non-reactive to low concentration acid, thus corrosion will not happen. Overall, by considering
the cost of material, the temperature range, and the long term outdoor exposure, CPVC is the
most suitable material chosen to be the piping material in this case.

8.1 Pipe size selection

In order to determine the pipe size of chlorinated polyvinyl chloride (CPVC), a list of CPVC
pipe dimension and pressure rating is referred. This list of pipe dimension is made based on
ASTM F441 standard.

33
 Figure 9: ASTM F441 Standard

Pipe dimension schedule 80 is chosen since the pipe has higher allowable water pressure
resistant. From the list of nominal pipe size in the list, 1 14 " in is chosen as it is the same as
the technical rating of pipe connection in the heat pump selected above.

9.0 Head loss calculation using Hazen Williams equations

9.1 For heat recovery loop (Cooling tower Heat pump)

Given:
Pressure drop across evaporator in heat pump, =
Total pipe length used, =
Diameter of CPVC pipe used, = . = .
Flow rate of water from cooling tower (given in the technical rating in heat pump section), =
. = . /
Hazen William coefficient for CPVC pipe material, = 150
Thus, from Hazen William/s equation:
= 0.849 0.63 0.54
0.63 0.54
= 0.849 ( ) ( )
4
9.1667104 0.0319 0.63 0.54
2 = 0.849150 ( ) ( )
0.0319 4 4 10

34
 = = .
Considering the minor loss and valve fitting:
Minor loss/Valve fitting Coefficient, K value Quantity
Gate valve (fully open) 0.15 2

Head loss due to valve fitting or minor loss is calculated as:

2 2
, = =
2 22
(9.1667104 )2
, = 20.15 4
29.81 2 0.0319 16
, = .
, = 0.457 + 0.020
= .
, = + = 0.47710009.81 + 16200
= . .

9.2 For cold water circulation (Cold water from water tap and hot water storage tank
Heat pump)

Given:
Total pipe length used, =
Head loss through elevation from ground to rooftop, , =
Diameter of CPVC pipe used, = . = .
Water flow rate (given in the technical rating in heat pump section), = . =
. /
Hazen William coefficient for CPVC pipe material, = 150
Thus, from Hazen William/s equation:
= 0.849 0.63 0.54
0.63 0.54
= 0.849 ( ) ( )
4
8.0556104 0.0319 0.63 0.54
2 = 0.849150 ( ) ( )
0.0319 4 4 20

= = .

35
9.3 Minor loss and valve fitting

Minor loss/Valve fitting Coefficient, K value Quantity

Gate valve (fully open) 0.15 2
Regular 90 threaded elbow 1.5 1
Line flow threaded tee valve 0.9 1
Branch flow threaded tee 2.0 2
valve

Head loss due to valve fitting or minor loss is calculated as:

2 2 2 2 2
, = = 21 + 2 + 3 + 4
2 22 22 22 22
2
, = (21 + 2 + 3 + 24 )
22
(8.0556104 )2
, = (20.15 + 1.5 + 0.9 + 22.0) 4
29.81 2 0.0319 16
, = .
, = 15 + 0.720 + 0.347
= .
, = = 16.06710009.81
= . .

9.3.1 For hot water circulation (Hot water from heat pump hot water storage tank)

Given:
Pressure drop across condenser in heat pump, =
Total pipe length used, =
Diameter of CPVC pipe used, = . = .
Water flow rate (given in the technical rating in heat pump section), = . =
. /
Hazen William coefficient for CPVC pipe material, = 150
Thus, from Hazen William/s equation:
= 0.849 0.63 0.54
0.63 0.54
= 0.849 ( ) ( )
4

36
 8.0556104 0.0319 0.63 0.54
2 = 0.849150 ( ) ( )
0.0319 4 4 5

= = .
Considering the minor loss and valve fitting:
Minor loss/Valve fitting Coefficient, K value Quantity
Gate valve (fully open) 0.15 1
Swing check valve 2.0 1
Branch flow threaded tee 2.0 1
valve

Head loss due to valve fitting or minor loss is calculated as:

2 2 2 2
, = = 1 + 2 + 3
2 22 22 22
2
, = (1 + 2 + 3 )
22
(8.0556104 )2
, = (0.15 + 2.0 + 2.0) 4
29.81 2 0.0319 16
, = .
, = 0.180 + 0.215
= .
, = + = 0.39510009.81 + 16200
= . .

9.3.2 Calculation for heat recovery from cooling tower

Given:
Flow rate of water from cooling tower (given in the technical rating in heat pump section), =
. = . /
Specific heat capacity of water, = . /
Thus, heat recovery from cooling tower is calculated as:
= = = 9.1667104 10004.1873
= .

37
10.0 Pump selection

In this section, we will need to find out and choose a suitable pump to compensate the pressure
loss in the piping system. A total of 3 pumps have to be selected and placed in different section
to compensate the pressure loss calculated in previous section. The main criteria in searching a
suitable pump to be installed in our piping system is the flow rate requirement.

10.1 For heat recovery loop (Cooling tower Heat pump)

As given in the technical rating in the brochure of selected heat pump, the flow rate requirement
in the heat recovery loop is 3.3 m3/hr.

Figure 10: Pedrollo Pump

38
As shown in the technical information from the brochure above, this self-priming pump from
Pedrollo company is able to cope a flow rate up to 3.6m3/hr which fulfil the flow rate
requirement by the heat pump. Moreover, the pump has working water flow temperature range
from -10 to 40, it is suitable for the cooling tower water loop which has temperature range
in between 20 to 30. This pump is manufactured based on construction and safety standard
such as EN60335-1 and IEC60034-1. The Pedrollo company is also certified by ISO9001:
Quality and ISO14001: Environment and Safety. Thus, this pump is suitable to be selected and
installed in our heat pump water heater system.

10.2 For heating water loop (Heat pump hot water storage tank)

In the heating water loop, there will be two pumps needed to be installed. The flow rate
requirement in the heating water loop is 2.9m3/hr.

Figure 11: Pedrollo Pump 2

39
As shown in the technical information from the brochure above, this self-priming pump with
peripheral impeller from Pedrollo company is able to accommodate flow rate up to 3.0m 3/hr
which fulfil the flow rate requirement by the heat pump in the heating water loop. Moreover,
the pump has working water flow temperature range from -10 to 60. Thus, it is suitable for
this heating water loop as one pump will need to handle water temperature around 25 while
another pump will need to handle hot water at around 60. Since the pump manufacture is
from the same company Pedrollo, thus, there is no much concern for the issue of safety and
standard that the company complies to. As such, this pump is suitable to be selected and
installed in our heat pump water heater system.

40
11.0 Saving

The current water heater system equipped in the JJ Boutique budget hotel is using the instant
water heater installed in each of the room. The brand of the instant water heater is called Jomex
as shown in figure below:

Information and assumptions:

Power Consumption of the Jomex Water Heater : 5.5kW

Average duration of bath : 7.5 minutes
Number of Occupants using the water heater : 2 person
Frequency of taking bath in a day : 3 times
No. of rooms : 30 rooms

The power consumption of the of the water heater is taken from the supplier on the internet in
which it is up to 5.5kW. 7.5 minutes bath is taken as the average bath time in the budget hotel
as we considered female guests take longer time. The rooms is assumed to be occupied by an
average of 2 persons per room. The frequency of bath is 3 due to the check-in and out activities.
The first customers is assumed to take bath in the morning and check-out during the noon time
and therefore there are new customers check-in after noon time and take bath at noon and night
time.

=
.

7.5
= 5.5 2330
60

= 123.75 3712.5

41
11.1 Heat Pump Water Heater System

Information and assumptions:

Nominal Power Consumption of Heat Pump : 2.95kW

Power Consumption of Water Pump per unit : 0.37kW

Operating Hours : 24 hours during peak season

=
.

= (2.95 + 30.37)24

= 97.44 2923.2

Total Energy Saving by Converting from instant water heater to Heat Pump Water Heater
System during peak season:

= 3712.5 2923.2 = 789.3

11.2 Calculation of electric bill

The Hotel JJ falls under commercial category. Thus, we assume that the tariff code is according
to Tariff B Low Voltage Commercial Tariff: 021, 022, 024 or 030.

11.2.1 Instant water heater

Total power consumption per day = .

Monthly power consumption = 123.7530 = .

Current tariff calculation:

1) First 200kWh (1-200 kWh): RM0.435 per kWh

2) Next kWh (201 kWh onwards): RM0.509 per kWh

Estimated bill per month is calculated as:

= (2000.435) + (3512.50.509) = 1874.86

With implementation of 6% GST, the total electric bill is:

= 1874.861.06 = .

42
11.2.2 Heat pump water heater system

Total power consumption per day = .

Monthly power consumption = 97.4430 = .

Current tariff calculation:

3) First 200kWh (1-200 kWh): RM0.435 per kWh

4) Next kWh (201 kWh onwards): RM0.509 per kWh

Estimated bill per month is calculated as:

= (2000.435) + (2723.20.509) = 1473.11

With implementation of 6% GST, the total electric bill is:

= 1473.111.06 = .

Total cost saving = 1987.35 1561.50 = .

43
 12.0 Safety considerations

1. We need to install temperature and pressure protective equipment recommended by

local codes to reduce risk of excess pressure and temperature in water heater. The combination
of temperature and pressure (T&P) relief valve should be certified by a well-known recognized
testing laboratory. These relief valves should be labeled by the AGA, ANSI Z21.22 or ASME
Boiler and pressure vessel code.

2. We should not place any valve between T&P relief valve and tank connection, or on
T&P relief valve discharge piping because wrong placement and piping of T&P relief valve
can cause serious injury, property damage or even death.

3. We need to place a relief valve in any place of the system where valves can be used to
separate a heat input device. It can be any heat input device like solar water heating panels, heat
recovery devices or any other similar devices. The valve should be at a maximum working
pressure of the water heater and it need to prevent the rise of the water temperature above 210
F.

4. We need to prevent the rise of pressure when water is heated in a closed system by
thermal expansion control devices. If a backflow preventer, check valve, or pressure reducing
valve is piped on cold water inlet of water heater then we need to place an expansion tank on
cold water supply line so that normal thermal expansion cannot open T&P relief valve. The
T&P relief valve is not for constant duty like preventing pressure from normal system expansion.
We should refer to expansion tank manufacturers instructions for proper sizing. If we dont
follow above method then serious injury, property damage or even death.

5. We need to stop flow of fuel or energy by temperature limiting devices so that water
temperature does not exceed 200F.

6. We should use suitable pipe dope or tape to place automatic air vent with water heater.

7. We should follow manufacturers instructions and also where applicable local, state,
provincial, and national codes, laws, regulations and ordinances for installation.

44
8. ASME Section VIII, Division 1 Code construction per Interpretation VIII-1-86-136
released most of the hot water heaters so we should check with local codes for applicability.

9. There must be enough space in installation location for servicing and suitable operation
of the water heater. Zero clearance is allowable to either side of water heater, but there should
be at least 12" clearance from the top.

10. Water shock is developed by dishwashers, fast-closing positive shutoff valves and
clothes washers so we should install a water hammer arrester so that there is no damage to pipes
and appliances.

11. Researchers have found that dangerous bacteria, including legionella, pneumophila, can
live in the potable water distribution system if certain minimum water temperature is not
maintained so we should contact our local health department to get more information on this.

12. Heaters can leak after a certain time of their life thats why they need to be placed in
such a place so that such leakage does not cause damage. We should use drain pans pipes to
drains.

13. We can place water heaters which does not require combustion air in any place as long
as relief valve release pipes open to a safe location.

14. We need to place water heaters which require combustion air in a place where there is
enough opening to expel combustion/dilution air.

15. When we use gas or oil fired water heaters then extra precaution need to be taken in
areas where flammable vapors are present so that there is no ignition of flammable vapors.

16. Water need to be passed at maximum 120C to residential area by new hot water system
for personal hygiene system so that there is no burning of skin. We can use temperature flow
control valve to control this temperature.

17. We should pipe union on domestic hot water outlet at a higher elevation than domestic
water drain valve so that water heater can drain easily.

45
18. We should place unions for easy removal of water heater. We need to use dielectric
unions or couplings so that during connection of dissimilar materials like copper and galvanized
iron pipe, hot and cold-water fittings can be protected from corrosion.

19. When we are going to use copper pipe for domestic water connections, then first we
solder pipe to a threaded adapter and screw adapter into cold-water inlet on top of water heater.
20. If water supply pressure is higher than T&P relief valve rating, then we place a pressure-
reducing valve on cold water supply line so that there is no water loss through T&P relief valve.

21. If we use less coil inlet and outlet in tank then there can be serious injury, property
damage or even death.

13.0 Conclusion

In a conclusion, from calculation the heat rating required by the heat pump is 12.45kW.
The selected heat pump is model Dimplex WI 18TU which is nearest to our requirements. The
selected reservoir tank is model EPP M-3-ST80R5 which is suitable in terms of cost, materials
and other considerations. The selected pumps are Pedrollo Pump (which can sustain the flow
rate at 3.3 m3/hr), and the other Pedrollo Pump (which can sustain the flow rate at 2.9m3/hr).
Finally, we calculated that the cost saved by installing the heat pump instead of using current
electrical heater is RM425.85 per month.

46
14.0 References:

Internet references

1. Heat pump systems, retrieved on 20 March 2017 from https://energy.gov/energysaver/heat-

pump-systems
2. Heat pump water heaters, retrieved on 20 March 2017 from
https://energy.gov/energysaver/heat-pump-water-heaters
3. Types of Heat Pump, retrieved on 20 March 2017 from
http://www.heatpumps.org.uk/TypesOfHeatPump.html
4. How does a heat pump works, retrieved on 22 March 2017 from
http://ehprenewables.com/ecoforest-heat-pumps/how-a-heat-pump-works/
5. Reference for price for PVC, retrieved on 27 March 2017 from
http://www.ewarehouse.atkc.com.my/plumbing/pvc-pipe-fittings&filter=206,161
6. Reference for price for steel, retrieved on 27 March 2017 from
http://www.ewarehouse.atkc.com.my/plumbing/stainless-steel-pipes-
fittings&filter=164,184
7. Reference for price for CPVC, retrieved on 27 March 2017 from
https://www.alibaba.com/trade/search?fsb=y&IndexArea=product_en&CatId=&SearchTe
xt=cpvc+pipe+malaysia+price&isGalleryList=G&viewtype=G
8. Reference for price for cast iron, retrieved on 27 March 2017 from
http://buildsoft.com.my/plumber.pdf
9. Pedrollo Pump 1, retrieved on 28 March 2017 from
http://www.pedrollo.co.uk/pdf/2016/PKS.pdf
10. Pedrollo Pump 2, retrieved on 28 March 2017 from
http://www.pedrollo.co.uk/pdf/2016/JCR1.pdf
11. Minor loss coefficient, retrieved on 29 March 2017 from
https://vanoengineering.wordpress.com/2012/12/30/head-loss-coefficients/
12. Cpvc Pipes & Fittings - ASHIRVAD, retrieved on 29 March 2017 from
http://www.krishnachennai.com/49-cpvc-pipes-fittings-
ashirvad-?info&back=?info=&back=
13. Complete pipe system catalogue, retrieved on 29 March 2017 from http://www.national-
plastic.com/media/docs/np-CPVC-Pipe-System.pdf
14. Standards for materials used in plumbing systems, retrieved on 29 March 2017 from
http://www.who.int/water_sanitation_health/hygiene/plumbing10.pdf

47
15. geyser C-Series catalogue, retrieved on 30 March 2017 from http://water.nyle.com/wp-
content/uploads/2017/03/Catalog-2016-4.2.pdf
16. WI 18TU heat pump, retrieved on 30 March 2017 from http://www.dimplex.de/en/heat-
pumps/water-to-water/water-to-water-heat-pumps-with-stainless-steel-coil-heat-
exchangers/wi-18tu.html
17. DERON Water-Water Heat Pump, retrieved on 30 March 2017 from
http://www.heatpumpindonesia.com/wp-content/uploads/2013/12/Deron-Water-to-water-
heat-pump-catalogue.pdf

Book

18. Domestic Hot Water Systems, Plumbing Engineering Design Handbook, Volume 2
2014, American Society of Plumbing Engineers

48