MEP EXAM III REVIEW [from email]

Pumps and pump types (physical differences and such)

CSI Section 23 21 23- Hydronic Pumps
Pumps are the prime mover for chilled water, hot water, and cooling tower water in HVAC
systems.

Centrifugal Pumps are the primary type of pump used for water delivery and as with chillers or
air handlers.

End suction pumps are a type of centrifugal pump with the suction (inlet) of the pump 90˚ offset
from the discharge (outlet) of the pump.

Example of an End-Suction Pump

The volute (or case) of the pump is designed to increase water flow and pressure through the
pump body. The impeller is driven by an electric motor which is located outside of the pump
(typically in line with the pump). These types of pumps can vary in capacity to handle small 50
gallon aquariums up to 500 horse power pumps used in energy plants.

Drive Shaft

Impeller
 Example of a typical large End-Suction Pump
In this particular example the parts that rotate are the shaft (silver) and impeller (silver with red
vanes)
•Maintenance issues with these pumps are the impellers, bearings, and seals

Pumps
Example of hot water pumps serving two zones in this particular building. Note inertia bases
with vibration isolators

Example of concrete pad being ground to align the pump shaft with the motor shaft. Improper
alignment can lead to pump/bearing failure, as well as likely noise complaints from your client.

There are TWO common configurations of end suction pumps used in HVAC applications:
1. Close-Coupled end suction pumps
2. Frame-Mounted end suction pumps

The close-coupled end suction pump is a compact version where the pump is physically attached
to the body of the electric motor. Close coupled are usually physically smaller than frame-
mounted pumps and circulate a smaller volume of water. They can be placed in-line in piping
systems.
 Example of close coupled pump

Another example of close coupled pump, this particular example is still labeled close coupled
due to its smaller size. Note it is NOT end-suction (90˚ change of direction)

CSI Section 23 21 23.16 – Base-Mounted, Centrifugal Hydronic Pumps

Frame Mounted, End Suction Pumps

Another version of an end-suction pump is the frame mounted pump.

Motor (s)
Pump (s)

Example of a chilled water pump installation using four frame mounted end-suction pumps.
•The frame is literally the frame to which the electric motor and pump are attached.
•The shaft that connects a motor to a pump is a safety hazard while in operation
•Vibration isolators (you’ve seen this plenty of times)
•Overall these types of pumps are mainly used in applications where high flow rates and high
operating pressure is required.
Horizontal Split Case Pumps
Horizontal split case (HSC) pumps are another option for applications requiring movement of
large volumes of water and at low-to-medium operating pressures.

There are several advantages to using an HSC pump:

•These pumps generally have a smaller footprint compared to a frame mounted pump of
similar capacity (save some space)
•The top of the case (split case) can easily be removed for servicing of internal pump
components.
•There is no need to disconnect the shaft from the pump as with a frame mounted pump and
pumping efficiencies are generally higher for an HSC pump than a frame mounted pump of
the same capacity.

Example of HSC Pump. Seam that can be popped open for maintenance shown by red lines.

Engineering Design Disadvantages of HSC Pumps [Pumps&Systems.com]

•The pump is sensitive to horizontal elbows on the pump’s suction side. Fluid flow through the horizontal
elbows induces asymmetrical pressures on the impeller that lead to shortened bearing and seal life.
•The casing does not lend itself to a confined gasket design, so there are consequential horsepower and
pressure limits.
•Because the casing halves are truly not halves from a mass standpoint, the pump’s upper and lower portions
will expand and contract at different rates with temperature changes, leading to alignment, bearing life and
sealing issues. Compounding the problem is the fact that the pump is foot-mounted. The foot design and
differing masses restrict the pump from a temperature aspect, so most manufacturers limit these models to less
than 400 F.
•The pump can carry increased costs because it has two stuffing boxes, so two seals or sets of packing are
required per pump. Many models are restricted in stuffing box sizes that preclude the use of standard or less
expensive seals.
•Many claim that these pumps are more sensitive to pipe strain, but this factor may vary based on model and
manufacturer.
•While the dual-suction impeller is a benefit from an NPSHR aspect, the shaft running through the impeller
reduces the effective eye area, creating problems with suction specific speed factors and multiple issues with
any departure from the best efficiency point (BEP). Recirculation and separation issues when operating away
from the BEP cause impeller damage and thrust issues.
•This pump design is sensitive to problems with ring clearances. Issues will arise from either the amount of
clearance as it opens up from wear or the differences in clearances from one side of the pump to the other.
There are also concerns with what is often referred to as “A” and “B” gaps (clearances involving the impeller
to casing).
 “Deferred maintenance” is a fancy way of saying there’s bigger fish to fry. Remember Bryant’s example of
just shielding a small leak instead of sealing it?
Strainer

Discharge
Suction

Example of Horizontal Split Case (HSC) pump serving condenser water

The dead give away the pump is serving condenser water is the lack of insulation

Another great example of HSC pump and its direction of flow

In regular application this

pump being serviced would
also have a safety screen like
the one already circled as
protection from the rotating
member
 Example of vertically installed HSC pump (used for a cooling tower)
Regular position of impeller/bearings indicated by red lines.

Pump Head
“Head” is the height to which a pump can raise a column of water. When applied in units, this is
usually expressed as “feet of head”.

Head generated by a pump MUST be able to overcome all pressure losses that exist in any
HVAC piping system.

Referencing back to air handlers, remember the chilled water cooling coil. While the maze of
copper tubes on the interior are great for heat transfer they simply are not great for flow. Because
of this coil manufacturers will provide information for the expected head loss (pressure drop)
through their heat exchanger for differing fluids at various flow rates.

Example of typical conversion “Good enough for us engineers”: Multiply the height of any given
column of water by 0.5 (half) and boom. You’re in range in terms of PSI.

Example air temp.

Turns at the end of each tube

create friction, due to water
always wanting to take path of
least resistance
“Pressure Drop” WILL BE
PROVIDED by manufacturer
of AHU

Example of heat exchanger in a roof top AHU

Q = 500 x GPM x (Treturn - Tsupply). KNOW THIS INSIDE AND

OUT! And be able to think beyond the equation. That is, once you find GPM
for a load, be able to work forward to the CFM at the fan (Q = 1.1 x CFM x
(Treturn - Tsupply)) or size of building or...

Energy in has to = energy out. So to solve problems of this sort you’re going to set the GPM and
CFM equations equal to eachother.
Both equations 2(CFM) and 3(GPM) are based off the chemistry equation (eq 1)below:
Q= m Cp T Where M is the mass flow rate (lb/unit time)
Where Cp is the specific heat of the fluid
(delta) T is the temperature difference experienced by the fluid
Given: Air-side load of 960,000.

Q = ( 500 x gpm x T) or 960,000 Btu/hr = 500 x gpm x (55°F – 45°F), solving for gpm we
get – 192 gpm.

Solving:
960,000 Btu/hr = 5000 x GPM
5000 5000
192=GPM

Lets go ahead an expand this example further and say there’s three Air Handling Units serving
the building and that each AHU is evenly loaded at about 320,000 BTU/hr. Meaning each AHU
would has a chilled water flow rate of about 63 GPM with S of 45˚F and 10˚F rise in water
temperature through the cooling coil. ! Info like this is important for when it comes to sizing
pumps and the piping system as a whole.
Example of Primary/Secondary Loop System Below

We will be using the above diagram for our next flow rate example.

Assume each chiller has a cooling capacity of 500 tons which implies each load is about 500 tons
(6,000,000 Btu/hr). That is a total load of 1,500 tons or 18,000,000 Btu/hr. The question: What is
the total water flow required at the pipe section labeled as “1”?
Q=500 x GPM x T (or 18,000,000 Btu/hr) = 500 x GPM x (55˚F – 45˚F)
18,000,000 Btu/hr = 5000 x GPM
5000 5000
3,600=GPM

Now with this info we can figure out (assuming equal flow rate for each chiller) that it would be
1,200 GPM per chiller. Using this logic assuming the loads are equal, the pipe section for each
chiller would also have to be 1,200 GPM.

If the load at AHU #3 is lets say 200 tons, following the same examples of solving for above we
would get 480 GPM.
Same picture from flow rate calculation examples plus labeling of primary and secondary loop(s)

Pipe performance (velocity and relation to size)

ASHRAE 90.1-2010 Energy Design Standard
Standard Pipe Velocity is 3-15 FPS. With a real common design suggestion(s) of 5 to 8 fps.

V=VA (remember VAV?)

Common range for HVAC piping
If you reduce the velocity to deliver a certain amount of water, the pipe sizing increases.
Moreover if you were at 15 FPS for example you could get away with much smaller piping.

/\ Re-watch the rest of this associated lecture I’m not gonna type all that sh*t out /\

Three Primary Piping Materials:

•Copper: Copper piping systems provide excellent corrosion resistance, good workability, flexibility in joining
methods, long lifespan, and is readily available in a variety of types. The most common ways to join pipe and fitting
in copper are brazing and soldering. Brazing is used where a very high strength connection is required. For
example, refrigerant piping in systems using R-410a must be brazed. The operating pressures (see the refrigeration
section) of this refrigerant would cause a soldered joint to fail. The major drawback to the use of copper (since
about 2004) has been volatile pricing. As a commodity, copper has been as low as $0.75 to $4.50/lb since 1989
(InfoMine, 2017). This volatility translates to uncertainty (risk) for the contractor who often has to bid a project 12
– 18 months out from award of the project and in that time, the price of copper in any piping systems could have
changed (upward) dramatically.
•Schedule 40 Carbon Steel: This common pipe type is available in diameters of ½” up to 36”. This material can
be joined by welding, flange fittings, threaded, and grooved methods. Schedule 40 is used for both chilled and hot
water systems and fire protection piping distribution. Other schedule piping is available, but this depends on the
need of the project.

•PVC: Schedule 40 Polyvinyl Chloride (PVC) piping is used extensively in residential applications for domestic
water systems and for drain/waste/vent systems. Schedule 20 PVC is only used in low pressure applications like
plumbing venting piping or condensate drain systems. This material is easily cut, lightweight, and widely
available. Though widely accepted in the construction of new and existing buildings, the most common use of PVC
is in residential construction. The use of PVC in commercial construction would be determined by the preferences
of the client and local code jurisdiction.

Diffuser performance for air distribution

CSI Section 23 37 13 – HVAC Air Distribution

Diffusers are the most obvious component a building occupant would see. The purpose of a
diffuser is to provide thermal comfort for the occupants of a space.

Three Main Terminology associated with diffusers: “Throw”, “Drop”, “Spread”

A primary descriptor for a given diffuser is the “throw” that it produces.

Three velocities: 150 fpm, 100 fpm, 50 fpm. 50 fpm is terminal

50 is more towards our comfort threshold as humans.

Spread is how wide that flow pattern ends up getting, multiple variables to this.
 /\ Think comfort in regard to DB (ex. what do you typically hear from your unit sitting home alone)/\

Four-Way Diffuser

Linear Slot Diffuser Perforated Diffuser

In all examples make note of accumulated dust from Coanda Effect

Dan Krueger from R&D Laboratory claims 85% of linear slots in the US are installed
incorrectly. An easy way to check is to stand underneath, if air blows right down on you then its
been installed incorrectly. Downflow from a linear slot should only exist at a perimeter location.
Very Basics of Duct Materials
CSI Sections 23 31, 32, and 33 00 – HVAC Ducts and Casings, Air Plenums & Chases, Air Duct Accessories)

Plenums are the actual physical space that matter (ductwork) would occupy

Example drawn up application of plenums. Think flex duct work coming from an AHU in a
residential system, how it’s set.

In an AHU the inlet to the fan is where you would find the lowest pressure, the highest pressure is right at
the discharge (exit of the fan).

Plenum Return: open duct up above the ceiling, air just kind of finds its way back to the AHU, cheaper
option.

Duct Return: Complete second set of ductwork in the plenum, for return. Ducted return would require
more pressure than plenum return. Common in a hospital maybe where you don’t want cross
contamination.

Dr. Bryant’s hospital example of duct runout

•There was only a six foot max allowed to reduce the friction in the system, “that 6 feet of flex is equivalent to about
50-60 feet of sheet metal work in terms of friction.”

Configurations of Duct Systems: Radial (very common in residential) and reducing trunk (very common
in commercial systems) are the two most popular duct design choices.

Three basic Descriptors: 1. Low velocity, 400 – 2,000 feet per minute (fpm), 2. Medium velocity, 2,000 –
2,500 fpm, and 3. High velocity, 2,500 – 3,500 fpm. As with hydronic piping velocity design, higher air
velocity means smaller duct, but also greater pressure losses which, in turn, means more fan energy.
Lower velocity systems, on the other hand, will reduce friction losses, but also means larger ductwork and
higher first costs. It should be noted low or medium is all you’ll see in commercial construction.
Metallic Duct: CSI Section 23 31 13 – Metal Ducts
•Galvanized Steel – Probably the most common duct material used for HVAC ductwork systems. Advantages
of this material include good strength, rigidity duct sections, long material life, resists rust/corrosion, it is
widely available, impermeable, has good machining and workability characteristics, and can be welded.
Common steel gauge thicknesses range from 24 ga. up to 16 ga. and sometimes even heavier gauge is required.

•Aluminum - Aluminum ducting is most commonly used for clean room and specialized healthcare
applications. This material is used where high moisture levels would be encountered, and for special or
decorative duct systems. Some advantages of this material includes low weight, non-magnetic (good
application for MRI rooms in hospitals), and resistance to corrosion from moisture. There are some limitations
to using aluminum which include its low strength, cost, ability to be welded, and high coefficient of thermal
expansion.

•Stainless Steel – Commonly used in commercial exhaust and specialized duct systems. Typically applications
might include kitchen/restaurant exhaust, exhaust with high moisture content, and combustion fume exhaust.
Advantages include very good resistance to corrosion from moisture (Type 304 and 316L) and most chemicals
(Type 316L), and weldability. There are issues with material costs, availability, and workability.

Non-Metallic Duct: CSI Section 23 31 16 – Nonmetal Ducts

•Fiberglass duct board is commonly available in 1-1/2” or 2” thick rectangular boards that are 48” x 120”.
They are inherently insulated through the use of resin-bonded inorganic glass fibers. The exposed side of this
material has a reinforced aluminum facing that acts as vapor barrier and impermeable air barrier. Fiberglass
duct board has excellent sound attenuation qualities, but its durability depends on the quality of installation.
The tape and mastics use for closure and fastening are very specific to the product. Corrosion resistance and
ease of duct/fitting modifications are advantages of this material. Duct board can be used for supply and return
distribution trunks, branch ducts, and supply/return plenums at fans.

•Flexible Nonmetallic Duct: Flexible or flexduct consists of an impervious inner air barrier liner supported by
a helically wound spring-steel wire, covered by thermal and acoustic insulation, and with an external flexible
vapor-barrier jacket. Flex duct is almost exclusively used for HVAC supply duct run outs (commercial).
Metal collars (Spin-in) are used to connect flex duct to sheet metal or duct board supply plenums, trunks, and
branches. Flexduct comes in factory sizes of 3 to 20 inches in diameter and a standard box contains 25 lineal
feet of this material. Flexible duct can be easily torn, crushed, pinched, or otherwise damaged during
installation. This duct has a high resistance to air flow because of the “accordion” pleats inherent in the duct.
This resistance is seen as pressure drop by the fan and as a result, air flow can be seriously reduced at run-outs.
Flex duct runs (drops) should be limited to six feet or less. Flexduct is used almost exclusively in most
residential markets. So, if flex is used, it must be properly specified and installed. When longer runs of flex
must be used, the duct should be supported at a maximum of five foot intervals to minimize sag or pinching.
In all applications, flexible duct should be fully extended to minimize pressure drop.

•Fabric: This material is really move of an air distribution device and not true ductwork. For the other
materials described, impermeability is a primary characteristic of the duct. So, “fabric duct” is a bit confusing.
However, in practice it is typically used in exposed applications and is easy to identify as the “ductwork”.
Fabric duct is usually made from either polyester or polyethylene and in porous or non-porous configurations
where the ultimate application determines which configuration to use. Polyester is considered a low velocity
diffuser because the entire length of “duct” is permeable to the supply air. The non-porous version is usually
manufactured with integral supply vents or orifices. Fabric ducts can be manufactured in a variety of colors,
and can be silk screened with designs for added aesthetic interest.
ERCOT
Energy Reliability Council of Texas

Where the other major sections of the U.S. grid (Western Interconnect, Eastern Interconnect) are under the jurisdiction of the
Federal Energy Regulatory Commission (FERC), Texas is under ERCOT control. Though there are a few places in the EROCT
grid that actually ARE connected to electrical systems outside the state of Texas, these do not trigger federal regulation for
ERCOT.

Electrical Power generation

Simplified rendering of an electrical power distribution system from the generation station, through the step-up/step-down
transformers and ultimately to the customer. Note that we aren’t yet describing single or three phase distribution. We’re still at
20,000 feet.

Simplified schematic of the major components of a typical coal-fired power plant. This plant uses lake water for the heat
rejection of the steam condenser. A “typical” large coal fired plant is around 1,000 – 1,500 MW in power capacity.

Thermodynamic “Rankine cycle” - Water, under high pressure, is sent through a large boiler where it is turned into
high pressure, super-heated steam. This steam is sent through a series of turbines that convert that steam pressure
and flow into rotational energy. That, in turn, causes the generator to rotate and generate power. The steam is
condensed back into water and the cycle repeats.

If the plant could run perfectly, the best efficiency (energy out/energy in) would be about 34%. The remainder
(about 65%) is lost through inefficiencies in the process (look back at the Sankey diagram in Chapter 1).

It turns out that all major power generation facilities in the US generate at 3 phase and 60 Hz. Why 3 phase?
Basically, it is the result of the operation of the type of generator used (more in just a bit), and Tesla won with
patents and Westinghouse over Edison. Edison preferred a direct current (dc) type system.
 ! Energy Content on this review somewhat limited for Sect. E.3!
Commercial voltage systems

Wye schematic for 3-phase, 4-wire, 277/480 voltages.

Phase-to-phase voltages are 480V and Phase-to-Neutral voltages are 277V.
A-B = 480V, A-C = 480V, B-C = 480V and A-N = 277V, B-N = 277V, and C-N = 277V.

“A motor for a spit

sucker in a dentist
office would be a 208 3
phase (ABC)” Electric
motors DO NOT USE
A NEUTRAL WIRE

Small Commercial Dentist office, 711, gas station, etc.

Wye Distribution

Lay-In Lighting: 277V

Large Commercial Standard

Commercial Standard for Motors: Cooling

Tower, Pumps, Chillers, Large Equip.

At this point at the bottom of the diagram, there would need to be a step-down transformer to feed into general
electrical equipment such as office lights, computers, etc
Residential voltage

Same Wye configuration, but for a different step-down transformer.

Phase-to-phase voltages of 208V and Phase-to-Neutral voltages of 120V.
A-B = 208V, A-C = 208V, B-C = 208V and A-N = 120V, B-N = 120V, and C-N = 120V.

Single phase residential service entrance on secondary of distribution level transformer. 1-ph, 3-wire, 120/240V.

Sankey Energy diagram (in general what it is telling us)

In general, raw inputs are on the left of the diagram, paths follow through processes for energy use and we end up on the far right with two blocks; useful energy and
rejected energy. The total for this estimate is 97.3 quads. That is 97,300,000,000,000,000 Btu. The “biggies” for raw input are petroleum (37%), natural gas (29%), and coal
(14%). These three fossil fuels comprise about 80% of the total energy picture for the United States. There are some sobering aspects to this diagram. Note that the bulk of
petroleum fuel goes to the transportation sector and that only about 6 Quads of that 27.9 Quad block ends up as “useful” energy!! The rest, 22 Quads, ends up as rejected energy.
This says that transportation (cars, trucks, aircraft, boats, ATVs, lifted F-250s...) are only about 20% efficient. Fact. So, what is “rejected” energy? That is a term for all of the
inefficiencies inherent in systems that cannot be converted to energy we can use for something. Think of heating a pan of water on a natural gas stove. The flames are set to heat
the bottom of the pan and through convection and conduction heat transfer, we add energy from the flame to the water through the metal container. However, you know from
direct experience that not all of that heat is going into the water. Much of it escapes around the sides of the pan and out into the kitchen (kitchens are ALWAYS hot), some goes
into heating the metal pan (that hot handle), and the some of the heating energy in the water is lost through evaporation of the water at the surface and to the air surrounding the
pan. Your car is no different. Most internal combustion engines only have a thermal efficiency of about 20%. That is, 20% of the power in a gallon of gasoline is converted into
useful (moving the car) energy while the rest of the power heats up the engine block, is lost in the incomplete combustion inside the engine, overcomes friction of the bearings and
other mechanical moving parts inside the engine, overcomes friction of the wheel bearings, and overcomes friction of the tires on the road surface, etc. For ALL energy streams, it
is the same sad story. We put a lot of energy in and at the end of the game, we are only getting about 40% as useful energy while the other 60% is lost (rejected to the atmosphere
as heat). Bummer, puts things in perspective. Or at least, it should.

W = V x A for single
 Dr. Bryant’s single phase toaster example

V x A x 3^.5 x pf (for three phase) and able to solve for any of them. That is,
given V and W, find A... ! “Being saved for the last exam”