Piping systems

for Chillers equipments

Dr. Ali Hammoud

EDU -2015

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 Pipe sizing
The pipe size in any pipe systems depends on:

1. Pipe material & interior surface roughness.

2. Water velocity limitations.
3. Pipe diameter from pipe flow chart.
4. Pipe length+ Equivalent length (return pipe).
5. Water Piping Diversity “DF” to prevent over
design condition & cost .For large systems
DF is between 0.75 up to 0.85 of the total
gpm.

3
 Pipe Material
The materials most commonly used in piping in
HVAC systems are the following:
1. Steel - black and galvanized.
2. Wrought iron – black and galvanized.
3. Copper – soft and hard.
The table below illustrates the recommended
materials for various services.

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Pipe Absolute roughness ( practical values)

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 Roughness
Relative
roughness

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Flow rate in gpm / pipe size
Design velocity
Water piping diversity procedure:
A diversity factor of 0.75-0.85 was
multiplied by the total gpm through each main
pipe . The Pipe flow chart presented below was
used to determine the pipe diameter taking
into consideration the given boundaries.
The principle of diversity evaluation and
calculation of the reduced water quantity was
used since the system water quantity actually
required during normal operation is less than
the total quantity required for the peak design
conditions.
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Closed system

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 Water velocity limitation ASHRE
The velocities recommended for water piping
depend mainly on two conditions:
Is based on the service for which the pipe is to be
used.

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Piping systems -2 for
Chillers & Radiators

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 Applications

• Direct return piping layout

• Reveres return piping layout
• Primary-secondary pumping layout
• Example problems “ Pipe sizing “

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Direct return piping layout

Figure 1
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Reverse return piping layout

Figure 2
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 Direct return & reverse return system

a) In the pressure distribution of a direct return system (in

Figure 1), the available pressure drop for a load circuit is
greatest near the system pump and decreases the farther
away the load is from the source-pump. Care must be taken
by the designer to size and select the control valves to
ensure adequate flow distribution and proper close-off.
b) In the pressure distribution of a reverse return system (in
Figure 2), the pressure drop for a load circuit is uniform (if
the load pressure drops are similar), even as the distance is
increased from the source pump. A key reason for the reverse
return design is to assist the two-way control valve with a
more uniform pressure drop. Selection of control valves must
ensure adequate flow and proper close-off, but this is not as
critical as the direct return design.
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Riser diagram

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 Chiller Piping Systems

Chiller
Pipe Systems

Two pipe Systems Three pipe Systems Four pipe Systems

Heavy duty equipment

 Two-pipe systems

Boiler - Off

Consists of one supply and one return pipe for either

chilled or hot water supply . The two-pipe system is limited
during changeover season.
 Two-pipe systems

Chiller - Off
 Three-Pipe System

It has three pipes to each terminal unit. These pipes are a

cold water supply, a hot water supply and a common return.
The return pipe has a mixture of chilled & hot water during
changeover operation,. These systems are rarely used today
because they consume excess energy.
 Four-Pipe System

Four-pipe systems have a cold water supply, cold water

return, hot water supply, and hot water return. The
terminal unit usually has two independent secondary
water coils: one served by hot water, the other by
cold water.
4 pipe systems
 Comparison

The four-pipe system has the following advantages:

1- Responding quickly to load changes.

2- Operates with the summer-winter changeover.

3- Efficiency is greater and operating cost is lower, though

initial cost is generally higher.

4-The system can be designed with no interconnection of the

hot and cold water secondary circuits.
Two & Three way -valve
 Open & Closed
Systems

• A “Open” hydronic system is one

that has only one interface with air

• An “Closed” hydronic system is one

that ,the water flow is not exposed to
the atmosphere at any point. But
some times contains an open
expansion tank, but water area
exposed is insignificant.
Closed Systems
3-Way Isolating
Balancing Control Valve
Valve
Valve
LOAD

LOAD

LOAD
BUILDING
HEIGHT

LOAD

EXPANSION

SOURCE
“Closed” System Resistance Curve

System Resistance Curve

Friction
Losses

CAPACITY
Open Systems

Static Head

Static
Suction Head

CONDENSER
“Open” System Resistance Curve

System Head Curve Friction

Losses
HEAD

Total Static
Head

CAPACITY
Chiller Equations

Summer 2004
 Chiller Pump discharge gpm
& Pipe sizing

We could also using the basic equation to determine the

flow rate in the evaporator (chiller flow): :

C.L. = 500 × gpm × (Tin − Tout )

C.L. is the cooling load in BTU / hr.
gpm is the flowrate or pump disch arg e
Tin − Tout is the temperature drop of
water across Fan coil in ∆ T = 10.8  F , (about 5.5 − 6 C )
In the condenser, the heat transferred to the condenser
water includes the heat from the Evaporator, plus the heat
of compression.
For most practical comfort air-conditioning applications, a
value of 14,400 Btu/h may be used as the total heat
transferred to the condenser water.

q W = 500 × Q(gpm) × ΔT (Bth/hr)

14 400 = 500 × Q(gpm) × ΔT

28.8 × Tons
gpm =
ΔT
Example 1:

What chilled water flow will a 100 -ton chiller handle for a
ΔT=12°F rise in water temperature and a Δ= 8°F drop in
tower water ? First, determine the flow rate in the
evaporator (chiller flow):
×
gpmΔT ×
gpm ΔT
=
Tons = ;
1200/500 24
Tons × 24 100 Tons × 24
gpm = = 200
ΔT 12 F
28.8 × Tons
The flow in the condenser: gpm =
ΔT

28.8 × 100
gpm = = 360
8F
 Example
Suppose you want to calculate the required flow
rate in gpm for a chiller Fan coil , assuming that,
the required C.L. is 1 Tons-ref and ∆T =10.8 º F,
(5-6 ºC ) gpm × ΔT
Tons =
Solution:
;
24
Tons × 24 1 Tons × 24
gpm = = = 2.22
ΔT 10.8 F

Or
1 × 12000 = 500 × gpm × 10.8  F
The flow Rate = 2.22 gpm
The correspond ing pipe size is = 1 / 2"
From Chart
Black steel pipe is recommended
Closed system
 Chiller Pump selection
Care should be taken when selecting chiller pump :

1- The required flow rate & head

2- Up feed or down feed , If Up feed system is used
,the shut off head of the pump must be greater than the
required head to push water up to highest level,
However if down feed system is used remember to
include gravity assist flow effect.
 Example

Suppose you want to calculate the required flow rate

for a chiller centrifugal pump sizing the main pipe &
,assuming that, the C.L. is 180 Tons and ∆T = 6 ºC =
10.8 º F. The D.F=75-80% is included in the
calculation of the total Cooling Load.
Solution:

180 × 12000 = 500 × gpm ×10.8 F
The Pump discharge = 400 gpm
The corespondi ng pipe size = ??
Typical Fan coil arrangement
 Fan Coil
The Fan coil inlet cold water temperature is about 7 ºC
the outlet 13 ºC. Whereas the hot water temperature
inlet is about 40 ºC.
Practically, the temperature change across the Fan coil
varies from 5 -7 º C in the summer. Whereas ,in
Winter the hot water temperature difference is about
11ºC.
Maximum water operating pressure is about 3
Bars.
 C’ont Fan Coil

The Fan coil air flow rate in CFM ranges from

200,300, 400, 600, 800 and1200.
The Fan coil gpm is about = 2.4 gpm/ton. Based
on temperature difference between in & out
10 ºF, which is about 5.5 ºC.
Chiller Piping
Arrangements

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 In general, we see multiple chiller designs applied in parallel instead of
series because this permits adding chillers in the future due to single or
multiple building additions, such as campus-type site plans: The designer
must allow space in the chiller plant for the additions and the distribution
mains must be sized for the future flows (see Figure ).
Early chiller applications employed three-way valves on unit terminals to
permit part-load terminal control by reducing the coil flow to bypass
flow around the coil. The result is that the chilled water pumping
power is a constant and cannot be reduced with load. As the size of
the system increases, this means that the distribution system is
pumping a constant volume and is not energy efficient.
The use of the two-way valve gives the opportunity to reduce the
distribution pumping with the load but, as discussed before , must have
provision to reduce the potential valve differential by staging parallel
pumps or by reducing the distribution pump's capacity with a variable
speed pumping control system. The chillers are piped in parallel in a
primary- production loop (see Figure ) with a common bridge to
hydraulically decouple the chiller pumps from the distribution pumping,
and determine from recirculation at part load if chillers should be shut
down. The location of the common bridge determines how the chillers will
be loaded or unloaded. 44
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(Figure a). (Figure b). 47
Primary –Secondary pumping
system

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 Primary-secondary pumping

Controlling water temperature in a primary-secondary pumping

arrangement with a two way valve is another approach to
improving valve coil control, as shown figure (3-a ) .This
permits constant flow at all times at a variable
temperature in the coil circuit, at the design velocity, to
maximize coil heat transfer.
A common pipe (a-b )is connected to both the primary and
secondary circuits with no pressure drop. This common-pipe is
usually located in a bridge between the supply and return
mains of the primary. The common pipe is selected with "no-
pressure drop" to either the secondary or primary circuits.

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Figure (3-a)

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The primary-secondary concept allows the distribution
pumping of the source supply from a central pumping facility.
(see Figure 4-a) or distributing the pumping to remote
buildings or zones of a large facility (see Figure 4-b).
The primary-secondary concept allows continual flow
through the source and still permits two-way valve control in
the loads. There is flexibility in dedicating a pump to a
chiller or boiler or manifolding the pumps. This might
simplify the need for having backup pumps for every system.
Pumps, manifolds, accessories and associated pumping
control may be assembled to match installation constraints,
or can be factory prepackaged as an assembly for a
designated mounting location. The designer work to
determine the best arrangement .
Figure (4-a)
Figure (4-b)
 Application

Cooling Systems

ASME Dr.Hammoud BAU-2012 54

 Chillers system application
Primary/Secondary System

Secondary Pumps

Typical
load
with
two
Primary Pumps way
valve
Common Pipe

ASME Dr.Hammoud BAU-2012

 Primary/Secondary System at Design

500 ton chillers

56.0 °F 44.0 °F 1000 GPM Each
56.0-44.0°F

Secondary Pumps 100% system load

3000 GPM @ 44.0 °F
56.0 °F

44.0 °F

44.0 °F

56.0 °F Typical
Coil

44.0 °F
Primary Pumps
1000 GPM Each No flow
56.0 °F

3000 GPM @ 56.0 °F

 Primary/Secondary System at Part Load

53.0 °F 44.0 °F 75% System Load

Secondary Pumps
2250 GPM @ 44.0 °F
53.0 °F

44.0 °F

44.0 °F

53.0 °F Typical
Coil

44.0 °F
Primary Pumps
750 GPM @ 44.0 °F
1000 GPM Each
56.0 °F

3000 GPM @ 53.0 °F

2250 GPM @ 56.0 °F
 Primary/Secondary System

OFF 50% System Load

Secondary Pumps
1500 GPM @ 44.0 °F
53.0 °F

44.0 °F

44.0 °F

53.0 °F Typical
Coil

44.0 °F
Primary Pumps
500 GPM @ 44.0 °F
1000 GPM Each
56.0 °F

2000 GPM @ 53.0 °F

1500 GPM @ 56.0 °F
Parallel Chiller
arrangement

Dr. Ali Hammoud

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 Example

Suppose we have a chiller-system consists of three chillers,

as shown in Figure (A) below. Each chiller is fed by a
constant-speed chiller pump (with a check-valve) that
Operates only when the chiller is on. Each chiller pump is sized
to achieve a ∆T of 16°F (8.8 °C), and the chiller is controlled
by a discharge thermostat at 42°F(5.5 °C). The chiller inlet
temperature is 58 °F (14.3 °C ), With the common bridge
located between the load and the production sections (see
Figure ) .
Now the system need to operate at part-load (1200 gpm, 800
ton load), Calculate the required load in chiller 2 & 3 and the
corresponding flow rate in the main pipe and return pipe when
chiller 1 is off.
Solution:
Due to the hydraulics inherent in the design, chillers 2 and 3
will load proportionally and chiller 1will shut down. Chillers 2
60
and 3 receive the same temperature water from the return
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Fig.A

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The chillers load in proportion to the ratio of their flow
rates to the total load flow. Chiller 2 loads to 320 tons and
chiller 3 loads to 480 tons (each is 64% of their full load
output because the load is 800/ 1250= 64 % of the combined
chiller flow rate). Because the chiller pumps are constant
speed, chiller 2 delivers 750 gpm and chiller 3 delivers
1125gpm, for a total of 1875 gpm. Because the load is calling
for 1200gpm, 675 gpm must flow in the common-bridge.
The calculation is shown below:
Mixing equation of water occurs at the return tee:
675 gpm at 42F° + 1200 gpm at 58F° = 1875gpm at 52.24°
(675× 42F°) + (1200 × 58F°) / 1875 = 52.24F° (return water
temperature)
The load on chiller 2 is:
Tons = gpm × ∆T /24 =750 × (52.24°- 42°) / 24 = 320 tons
For on chiller 3 is:
Tons = 1125 × (52.24°- 42°) /24 = 480 tons 63
 Fig.B

Dr. Ali Hammoud 65

 Class exercise 1
Determine the pipe sizing and the total pressure drop for
the zone A-B of the system shown below. Assuming the
following:
1. Heating coil rated 38 gpm & ∆P=3ft wg.
2. One gate valve -2in screwed type.
3. One Control valve -1.5 in rated 38 gpm & ∆P=8.2ft wg.
4. One Balance valve -2 in rated 40gpm & ∆P=2ft wg.
5. Two tees ( branch flow )
6. Four Elbows (screwed type).
7. Total pipe length L= 300 ft.

Use the K values methods 66

Closed system
 Closed loop
Sc-40

Closed system

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Solution:
From the pipe flow chart closed loop & for flow of 40 gpm the
corresponding pipe diameter is 2”. The pressure drop per 100
ft is 3.1 ft/100 ft which is less the limited 4 ft/100ft
[boundary] . However if 1.5 in pipe is selected the pressure
drop will be 8.5 ft/100ft this value is outside the acceptable
boundary. Then 2 in pipe is selected. The corresponding flow
velocity is 4 ft/s.
The pressure drop due to pipe friction
∆P = 3.1 ft/100ft×300 ft = 9.3 ft.
Adding the aging effect (15 %) we get:
∆P =9.3×1.15 =10.7 ft.
Since V= 4 ft/s , V2/2g=0.227 ft.

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The K values were selected from
the corresponding charts. The
pressure for each fitting is
calculated from ∆ P=K(V2/2g)
The K value for 2 in gate valve = 0.17 ft
The K value for 2 in 90 regular elbow =1 ft
The K value for 2 in Tee branch = 1.4 ft
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 Pressure drop due to fittings & valves
1. Heating coil rated 38 gpm ∆P=3ft wg. (given)
2. One gate valve -2in screwed ∆P=0.17(0.277)=0.04ft wg.
3. One Control valve-1.5 in rated 38 gpm & ∆P=8.2ft wg (given)
4. One Balance valve -2 in rated 40gpm & ∆P=2ft wg. (given)
5. Two tees ( branch flow ) ∆P=2 ×1.7(0.277)=0.64ft wg
6. Four Elbows (screwed type) ∆P=4×1(0.277)=0.91ft wg
The total pressure drop:
∆P= Coil+ pipe friction+ balance valve +control valve + gate
valve+ tee branches + elbows=
= 3+10.7+2 +8.2+0.04+0.64+0.91 =25.49 ft
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 Class exercise

Figure below shows an open re-circulating pipe system

where a centrifugal pump is used to circulate 250 gpm of
water from the cooling tower to the condenser. During
the pump’s operation, it is assumed that the water level
in the cooling tower tank keeps a constant level.
Calculate the total head of the pump and pump shaft
power Assuming that: The pump efficiency η = 60 % ,
The pipe material is galvanized steel pipe .
All the necessary dimensions and fittings are shown in
the corresponding figure.

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 6m 4m Cooling tower
3m
E

Pressure drop 4m
1

Tower nozzles pressure required: 0.6 Bar

2m
Pressure Drop
Through Condenser 0.88 bar
Including ( entr. & Exit losses) 30 m Ø 4"
3
Q= 57 m /h
250 gpm
Pressure drop 5”6 "
Ø
Through strainer 0.27 bar.
25 m

Open system
3m

2m
3m
Condenser Pump
3m Valve
P S
3m
Check Srainer
Valve
4m 5m

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Determine the total pressure drop of the system & the
pump’s power in Kw. Assuming the following:
1. The flow Q = 250 gpm .Suction diameter D=5” & Discharge
diameter D= 4 “.
2. Tower nozzles pressure required ∆P=0.6 bar.
3. Pressure drop through Condenser including (entry& exit
losses) ∆P=0.88 bar
4. All elbows are flanged long radius
5. Elevation difference in the cooling tower is 4 m (13 ft)
6. Pump efficiency 60%

Use the “Le” equivalent technique

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Solution:
The total head of the pump is given by:
The head loss between 1 to S is hL1-S :
The total energy loss due to the pipe friction, fittings:
Where hl is the head loss per 100 ft, which can be determined from the pipe
flowchart for pipe as follows:
For Q = 250 gpm & D= 5 “,the head loss per 100 ft is = 2 ft/100 ft.
The total effective length:
L is the length of straight pipe L1-S= 2+25+5 = 32 m = 106.5 ft
From equivalent length tables, we select the equivalent length for fittings.
2 (5”)long radius (90°) elbows = 2x 8.2 = 16.4 ft.
The equivalent length of full open gate valve D= 5” is 6 ft,
The pressure drop due to the presence of 5”strainer = 80 ft from table 2
then Le = 16.4 + 6 + 80 = 102.4 ft

L effective = 106.5 + 102.4 = 208.9 ft

h L = h1.Leffective = 2/100 × 208.9 = 4.089 ft 75
The head loss between 1-S hL1-S is = 4 ft add the aging effect 1.15 x4≈5 ft
Open loop
Sc-40

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The head loss between P to E is hLP-E :
Discharge pipe:
The length of straight pipe L= 4+3+2+3+3+3+30+6+3+4 = 61 m (203.3 ft)
From the pipe flow chart for pipe we get:

For Q = 250 gpm & D = 4 “ the pressure drop due to pipe friction =3 ft/100 ft.
The corresponding flow velocity is V= 5.7ft/s (1.71 m/s)
The equivalent length in ft:
8 long radius (90°) elbows = 8 × 6.7 =53.6 ft
2 Gate valves = 2× 4.5 = 9 ft
Check valve swing type = 40 ft
The total effective length in ft:

Leffective = 203.3 + 53.6 + 9 + 40 = 305.9 ft

h L = h 1 .L effective = 3 ft/100ft (305.9) = 9.177 ft
The head loss between P-E hLP-E is ≈ 9.177 ft. add the aging effect 10.5 ft 77
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End of the lecture

ASME Dr.Hammoud BAU-2012 80