Fundamentals of Water System Design Second Edition Mark Hegberg | = Pp Richard A. Hegberg Inch-Pound A Course Book for Self-Directed or Group Learning | | ASHRAE Learning Institute Includes Skill Development Exercises for PDH, CEU, or LU CreditsFundamentals of Water System Design Second Edition Mark Hegberg Richard A. Hegberg ASHRAE AtlantaFundamentals of Water System Design (I-P), Second Edition A Course Book for Self-Directed or Group Learning ISBN 978-1-936504-66-4 (paperback) ASHRAE Learning Institute SDL Number: 98020 © 1996, 2000, 2015 ASHRAE All rights reserved, ASHRAE is a registered trademark in the U.S. Patent and Trademark Office, owned by the American Society of Heat- ing, Refrigerating and Air-Conditioning Engineers, Inc [No part of tis publication may be reproduced without permission in writing from ASHRAE, except by a reviewer who ‘may quote brief passages or reproduce illustrations in a review with appropriate credit, nor may any part ofthis public tion be reproduced, stored in a retrieval system, or transmitted in any way or by any means—electronic, photocopying, recording, of other—without permission in writing from ASHRAE. 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ASHRAE STAFF ASHRAE Learning Institute Karen Murray Manager of Professional [Eitor/Group Manager of Development Handbook and Special Publications Martin Kraft Cindy Sheffield Michaels Managing Editor of Professional Managing Editor Development Matt Walker Associate Editor Sarah Boyle ‘Assistant Editor Lauren Ramedell Assistant Editor Michshell Philips Editorial Coordinator For course information or to order additional materials, please contact: ASHRAE Leaming Institute 1791 Tulle Cirele, NE Atlanta, GA 30329 Errors or omissions in the data should be brought tothe attention of Special Publications via SDLeorrections@ashrac.org ‘Telephone: 404/636-8400 Fax: 404/321-5478 Web: wwvcashrac.org/ali E-mail edu@ashrac.ong Any updates/erata to this publication willbe posted on the ASHRAE Web ste at wwwiashrac.org/publicatiomupdates,ASHRAE Learning Institute Your Source for HVACER Professional Development 1791 Tull Cirle, NE + Atlanta, GA 30329-2305 USA + Tel 404.636.8400 + Fax 404.321.5478 + wnwashrac.org Karen M. Murray Email: kmurray@ashrae.org Manager of Professional Development Dear Student, ‘Welcome to the ASHRAE Learning Institute (ALI) Fundamentals of HVACR Series of self-directed or group learning courses. We look forward to working with you to help you achieve maximum results from this course. ‘You may take this course on a self-testing basis (no continuing education credits awarded) or on an ALL-monitored basis with credits (PDHs, CEUs or LUs) awarded. ALI staff will provide support and you will have access to tech- nical experts who can answer inquiries about the course material. For questions or technical assistance, contact us at 404-636-8400 or edu@ashrae.org, ‘Skill Development Exercises at the end of each chapter will gauge your comprehension of the course material If you take this course for credit, please complete the exercises and send copies from each chapter to edu@ashrae.org (preferred method) or ASHRAE Learning Institute, 1791 Tullie Circle, Atlanta, GA. 30329- 2305. Be sure to include your student ID number with each set of exercises. Your student [D can be the last five digits of your Social Security number or another unique S-digit number you create. We will retum answer sheets to the Skill Development Exercises and maintain records of your progress. Please keep copies of your completed exercises for your own records. ‘When you finish all exercises, please submit the course evaluation, which is located at the back of your course book. Once we receive all chapter exercises and the evaluation, we will send you a Certificate of Completion indicating 35 PDHs/LUs or 3.5 CEUs of continuing education credit. The ALI does not award partial credit for SDLs, All exercises must be completed to receive full continuing education credit, You will have two years from the date of purchase to complete each Self-Directed Learning Course. ‘We hope your educational experience is satisfying and successful, Sincerely, racy, Karen M. Murray ‘Manager of Professional Development “American Society of Heating, Refrigerating and Air-Conditioning Engineers, In. AN INTERNATIONAL ORGANIZATIONCon Self-Directed or Group Learning uing Education Opportunities from the ASHRAE Learning Institute ASHRAE Learning Institute ASHRAE offers texts for self-study or group training with instructor materials. Texts cover the basics of what a practicing engineer needs, and skill development exercises are included to evaluate progress. ASHRAE offers the following course books: Fundamentals of Air System Design Fundamentals of Building Operation, Mainte- nance, and Management Fundamentals of Heating and Cooling Loads Fundamentals of Heating Systems Fundamentals of Psychrometries Fundamentals of Refrigeration Fundamentals of Steam System Design Fundamentals of Thermodynamics Fundamentals of Water System Design Each course book includes the following: + Clear and concise discussion of the technical topic covered + Examples that show how to apply the lesson’s principles + Skill development exercises that test students” ability to apply the newly acquired knowledge and answer sheets to assess progress in learning the material ‘Those who complete a course receive a certificate designating continuing education (CE) credits. Note that individuals are responsible for contacting their relevant governing body to deter- mine whether an activity qualifies for that body’s continuing education credits ASHRAE eLearning ASHRAE is a continuing education provider of the American Institute of Architects (AIA) and the Green Building Certification Institute (GBC1), a third-party certification administrator of the United States Green Building Council (USGBC). Continuing Education (CE) hours earned from ASHRAE courses may be applied toward maintenance of state-licensed professionals (Architects and Professional Engineers) and Leadership in Energy and Environmental Design” (LEED®) Green Building Rating System credentials, ASHRAE offers over 130 eLearning courses focusing on specific topics and 18 course pack- ages that cover a topical area and include several related courses. ASHRAE offers the following course packages: AC Design Electrical System Design HVAC Systems Standard 62.1 HVAC Control Systems Standard 90.1 DDC Controls ‘Small Office Buildings ‘Small Retail Buildings Sustainable Buildings AC and Refrigeration Principles AC and Refrigeration Equipment Fundamentals: Electricity Standard 90.1 for Architects Standard 189.1 for High-Performance Green Buildings Data Center Equipment Load Trends and Planning, Data Center Thermal Guidelines Data Center Liquid CoolingMark C, Hegberg: Mark Hegberg has spent major portions of his career involved in direct digital control system application for Tour & Andersson, consulting engineering for A. Epst and Sons and others, and hydronic training and product development for ITT Bell & Gossett. In recent years Mark has been significantly involved in hydronic system testing and balancing and the issues associated with flow control in the field. Mark has chaired and been involved with sev- eral ASHRAE committees and is a recipient of the ASHRAE Exceptional Service Award. He too has been associated with the Illinois Chapter HVAC training class for many years. Richard (Dick) A. Hegberg, PE: Dick Hegberg spent the majority of his career in the area of temperature control application for Powers Regulator company (now Siemens Building Technol- ogy), where he lead their early application engineering efforts and development of their building automation systems. In particular, he devoted much time to valves and dampers. Dick was actively involved in several ASHRAE TCs regarding controls and hydronies, as well as other groups that used both as part of their processes. Dick is an ASHRAE Life Member, Fellow, and recipient of the Distinguished Service Award. Locally, he inaugurated and directed for over thirty years the Illinois Chapter HVAC training class which is taught to this day.Table of Contents Preface... Acknowledgments Chapter I: Water System Design Concepts . Introductory Concepts... 66. e cc cvcteeeeteeeeeeeeeeeee | Basic System Components. .....000cccescseeeeeee Heat Transfer in Hydronic Systems ..... ee mis Load Systems . Chapter 2: Piping System Design. . Basic Considerations Design Philosophy. Sizing Piping . . Flow-Rate Measurement... Chapter 3: Pipe Materials and Fittings.........2.00000000eeee Pipe Materials oe ee eee SD Corrosion... . vee 7B Valves and Fittings : ieee 75 Backflow Prevention Devices 80 Pipe Selection : al Chapter 4: Centrifugal Pumps. a soa 93) Types of Pumps : ee - 93 Operation 95 Pump Selection 104 System Design Considerations 120 Variable-Speed Pumping 127 Chapter 5: Terminal Unit Performance and Control ........... 139 Types of Terminals 0... cc eeecee cece eevee arene BBY Performance and Control .....6.scceeeseseeeeeeeescvees 142 System Control Characteristics «0.0.60 eeeeeeeee eves 150 System Control Configurations ...... vette 159 Caspmer&s Eagan Tare are Ale Elie seeeee II Open and Closed Water Systems .... . 71 Hydronic Accessories .... : 173 Sizing Expansion Tanks : 184 Chapter 7: Piping System Development ......... = 193 Piping System Design. 193 Direct-Return Analysis 197Reverse-Retum Analysis. Primary/Secondary Analysis Types of Pumps and Valves Primary/Secondary Application Study : Antifreeze Solutions for Low-Temperature. ‘Applications Z Pumping Design Factors. Chapter 8: Matching Pumps to Systems .. Matching the Pump to the System Parallel Pumping Series Pumping Standby Pumps Trimming Pump Impellers and ‘Adjusting Pp Speed Two-Speed Pumping cee . Variable-Speed Pumping Source Distribution Pumping . Chapter 9: Water Chillers and Load Control . Basic Water Chiller Components. Refrigeration Cycle . Heat Transfer Chiller Refrigeration Power. Chiller Types and Control . Chiller Piping Arrangements... Chiller Energy Performance ‘Thermal Storage ........ Skill Development Exercises 210 215 218 221 226 229 235 235 247 251 255 255 258 261 266 273 273 274 277 279 279 288 295 298