13

5.1 The operating point of the circulation system

In the circulation system, pressure drop and volume flow are
directly dependent. Equilibrium always occurs between the pres-
sure drop in the plant, which must be converted into a pressure
head drop, and the delivery height of the pump. The pressure
height drop in the system corresponds to the delivery height of
the pump at the system operating point.
Because each pump delivery height has one specific pump flow,
the recirculated volume flow is clearly determined from the pres-
sure drop in the plant. The pressure drop is determined by pro-
jecting the pipeline network performance curve and the pump
performance curve in a common diagram.
The intersection between the two curves is the operating point of
the circulation system that then occurs.
Fig. 20: Performance curves for pipeline network and pump
The operating point can be arithmetically determined by calculat-
ing the pressure losses from the individual resistances in the
pipeline network.
5.1.1 The pump performance curve
The hydraulic behaviour of the circulation pump is described
by its performance curve. This shows the relationship between
delivery height and flow rate. The following relationship applies:
As the flow rate increases, the delivery height decreases.
As the delivery height increases, the flow rate decreases.
The flow rate is the volume flow conveyed by the pump.
The delivery height is the pressure differential applied by the
circulation pump and converted to the height of a liquid column.
The pump performance curve is shown in a diagram.
The flow rate is plotted along the horizontal axis V

P
and the
delivery height H along the vertical axis.
Fig. 21: Performance curve for VORTEX circulation pumps with
V-pump housing
The pump performance curve shows that flow rate and delivery
height are independent:
At maximum delivery height of H = 1.25 m,
the flow rate V

P
= 0.
At delivery height of H = 0.75 m,
the flow rate V

P
= 0.37 m
3
/h.
At maximum flow rate V

P
= 0.64 m
3
/h,
the delivery height is H = 0.
5. Circulation pump dimensioning
Delivery height H [m]
Pump characteristics
System operating point
Performance
curve for pipeline
Flow rate V

P
[m
3
/h]
Delivery height H [m]
Flow rate V

P
[m
3
/h]
1.50
1.25
1.00
0.75
0.50
0.25
15.0
12.5
10.0
7.5
5.0
2.5
0,0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
15.0
12.5
10.0
7.5
5.0
2.5
0,0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
1.50
1.25
1.00
0.75
0.50
0.25
[kPa]
[kPa]
Techn_Brosch_GB 12.05.2005 9:58 Uhr Seite 14
14
Fig. 22 Fig. 23
If the pipe length, measured from the medium level, corre-
sponds to the maximum delivery height of the pump - H
max
=
1.25 m, no medium discharges from the end of the pipe.
The flow rate is thus V

P
= 0 (Fig. 21 and 22).
If the pipe is shortened by 0.50 m, the circulation pump must
withstand the delivery height of H = 0.75 m. The volume
discharging from the end of the pipe is equivalent to the flow
rate, V

P
= 0.37 m
3
/h when H = 1.0 m (Fig. 21 and 23).
5.1.2 The pipeline network performance curve
The pipeline network performance curve is plant-specific. The
pipeline network performance curve indicates the relationship
between the pressure drop, caused by pipe friction and individual
resistances, and the pump flow in the circulation system. Unlike
in the "open system", (Fig. 22, 23 and 24) the circulation pump
does not have to withstand a height differential. This means that
the delivery height indicated in the pump diagram bears no
relation to the height of the building in which the pump is to be
installed.
A circulation pump with a delivery height of 1.25 m, like the
VORTEX circulation pumps with spherical motor, can therefore
operate extremely efficiently in a 20 m high building.
In an "open system", the correlation between flow rate and delivery height is immediately evident. Fig. 22, 23 and 24 relate to the
pump performance curve shown in Fig. 21:
Fig. 24
If the pipe is shortened by 1.25 m, the end of the pipe is at
the same level as the medium. The delivery height is thus
H = 0. The discharging volume is equivalent to the flow rate
V

P max
=0.64 m
3
/h (Fig. 21 and 24). This theoretical example
does not take account of pipeline resistances.
V
.
p = 0
H
m
a
x

=

1
.
2
5

m
V
.
p = 0.37 m
3
/h
H
m
a
x

=

0
.
7
5

m
V
.
pmax = 0.64 m
3
/h
H=0
Techn_Brosch_GB 12.05.2005 9:58 Uhr Seite 15
15
After the settings have been made on the thermostat element
and the control cross-section of the valve, the line control valve
can automatically assume the required throttle positions. The
pre-condition for the use of such valves, which are a combination
of conventional line control valves and thermal circulation con-
trollers, is a pipeline network calculation and a determination of
the preset value. The less regulation input required at the building
site is particularly advantageous, as minor deviations between
calculation and building design at the thermostatically controlled
line valve are automatically compensated.
5.2 The calculation method according to DIN 1988, Part 3
The basis of all further calculation methods, including that of
DVGW W 553, is a pipeline design to DIN 1988, Part 3.
The supply and circulation line must be insulated in accordance
with the energy saving regulation. The permissible temperature
differential between drinking water heater outlet to the
supply pipe and circulation inlet to the heater must not exceed
the following values with pump circulation:
2 to max. 3 K with distribution systems to 200 m Expansion,
3 to max. 5 K with distribution systems over 200 m Expansion.
The dimension of the circulation line is estimated from Table 1.
The vertical circulation line is designed to at least DN 12 from
the riser connection.
Supply pipe Circulation line
Nominal width Nominal width
DN DN
20 12
*)
25 12
*)
32 12
*)
40 20
50 25
65 25
80 25
100 32
*)
With medium-weight threaded pipes in accordance with
DIN 2440: DN 15
Table 1: Reference values for nominal widths of circulation
collection mains in accordance with DIN 1988, Part 3
5.1.3 Hydraulic compensation in circulation lines
In the pressure drop calculation, the pressure differential of the
circulation pump present in each of the plant's circulation lines
must be throttled to the maximum in line control valves, taking
into account minimum diameters and maximum speeds.
If no hydraulic compensation is carried out, the calculated volume
flows do not materialise in the designed plant. However, the cir-
culation volume flow must be able to transport the heat quantity
that is lost over the surface of the pipeline system. The specified
hot water temperature can be maintained only if an equilibrium is
guaranteed at each point in the circulation system. Hydraulic
compensation of the circulation system is required in order to
guarantee safe function in accordance with DVGW Worksheet
W 551.
In accordance with DIN 1988, Part 3, the line control valves must
be installed in circulation systems. The objective of regulation is
to keep the circulation volume flows the same in all risers, which
in turn limits the temperature drop between drinking water
heater outlet and re-entry via the circulation to approx. 7 10 C.
It has been shown that in close-pump circulation systems, a
relatively large pressure differential with small circulation volume
flows must be created, while in remote-pump risers, a proportion-
ately large volume flow must occur to maintain a temperature in
excess of 55 C.
The following data is required for setting the line control valves in
the system pipeline network:
Volume flow in the part section,
determined excess pressure loss via the line control valveil
Valve temperature in the hydraulically compensated condition.
5.1.3.1 Presetting via manual line control valves
The line control valves are measured and preset by determining
their preset values. Together with the required valve data, the
circulation volume flow in the part section and the required
pressure drop via the valve, the required preset value is read
from the manufacturer's diagram and set on the line control
valve.
5.1.3.2 Thermostatically controlled line control valves
Thermostatically controlled line control valves were developed for
the purpose of keeping the temperature in hot water systems
above the set temperature.
Techn_Brosch_GB 12.05.2005 9:58 Uhr Seite 16
16
For dimensioning the circulation pump, the circulation pump
flow rate V

P
and the required pump pressure p
p
are required.
The circulation pump flow rate is based on the water contained in
the system. In accordance with DIN 1988 Part 3, a 3 x an hourly
recirculation is adequate for prevent excess cooling of the heated
drinking water.
The flow rate and thus the circulation flow is determined from 3
times the water volume contained in the circulation system
(excluding volumes in drinking water heater and tank).
The following equation applies:
The circulation pump delivery height is determined from the
sum of the pressure drop caused by pipe friction and individual
resistances of the longest flow path from circulation line
connection to supply pipe to the drinking water heater.
The pressure drops are determined using Form A 7 from DIN
1988, Part 3 and the calculation model. The flow speed in the
circulation line of max. 0.5 m/s with a copper pipe must be
observed.
The partial flows are calculated from the circulation pump flow
rate, divided by the number of circulation lines.
5.3 The calculation method for circulation systems in
accordance with DVGW W 553
Depending on the size of the plant, several procedures are
applied for measuring circulation systems. The basis of all mea-
suring procedures is compliance with the valid rules of techno-
logy. The calculation procedures described in DVGW W 553 are an
addition to DIN 1988, Part 3. DVGW Worksheet W 551 demands
hot water temperatures of 55 60 C in the circulation system, in
order to avoid legionella concentrations. This necessitates a new
calculation method that takes account of the thermal losses.
5.3.1 The short procedure
This procedure is applied for smaller plants such as those in one
and two family dwellings. A detailed calculation, due primarily
to the nominal width graduation, always produces the same
dimensions for the circulation system. None of all supply pipes
affected by recirculation may exceed 40 m in length and the
longest flow path for a circulation line should not be longer
than 20 m (Fig. 25).
Fig. 25: Maximum permitted lengths for the short procedure
If these conditions are satisfied, the circulation lines must be
designed with a minimum internal diameter of DN 10 and the cir-
culation pump DN 15.
If the circulation line is arranged in copper pipe, evidence of the
maximum permitted flow speed not exceeding 0.5 m/s must be
furnished. This can be verified using either the simplified or the
differentiated calculation procedure.
5.3.2 The simplified calculation of circulation systems
The simplified calculation procedure can be applied only if
reduced accuracies are taken into account. This method therefore
enables a relatively fast and simple calculation for small to
medium-sized systems. The free choice of temperature gradient,
precise determination of the entire circulation flow and the
adequately precise split of the circulation flow over the individual
lines offer benefits. Simplification is made possible by waiving
the differentiated calculation of the heat flows and the pressures
lost through individual resistances.
5.3.2.1 Simplification and calculation procedure
Determining the volume flows
The following simplifications can be assumed for determining
the thermal losses in the hot water lines, which can be used to
determine the volume flows of partial sections:
Thermal loss in the hot water lines laid in the cellar:
q
w, K
= 11 W/s
Thermal loss in the hot water lines laid in the shaft:
q
w, S
= 7 W/m
The thermal losses of the valves are not taken into account. The
energy saving regulation calls for insulation and they are there-
fore negligible.
The thermal loss Q

w
of all hot water lines is thus:
Q

w
= l
w, K
q
w, K
+l
w, S
q
w, S (1)
l
2
TWZ
TWE
TW
20 m
TWW
l
3
l
5
l
4
l
6
l
1
l
1
+l
2
+l
3
+l
4
+l
5
+l
6
40 m
V
RL
V

P
= 3 - ; t = 1h
t
Techn_Brosch_GB 12.05.2005 9:58 Uhr Seite 17
The following applies for the volume flow in the straight section:
Q

d
V

d
= V

-----
Q

a
+ Q

d
(4)
or
V

d
= V

a
(5)
Dimensioning the pipe diameter for the circulation line
The pipe diameters of the circulation lines are determined taking
into account a max. flow speed of 0.5 m/s (with copper pipe
max. 1.0 m/s) from R-value tables. For the circulation lines, a
minimum internal diameter of 10 mm must be provided (see
DIN 1988, Part 3).
The individual circulation lines are transferred to a suitable form
and dimensioned separately from the circulation mains.
It is perfectly possible for the flow speeds in close-pump lines are
higher than in remote-pump lines.
Determining the delivery pressure of the circulation pump
The delivery pressure of the circulation pump is determined from
the frictional loss of the difficult circulation path, usually the
longest circulation line with the greatest resistances. Redirections
and branches are considered with an overall allowance of
20 40 %.
The following delivery pressure is derived:
p
p
= 1,21,4 (l R) + p
RV
+ p
TH
+ p
AP
(6)
The calculated flow rate and the delivery pressure can now be
used to determine the actual operating point in the system and
thus the system's performance curve and the actual operating
point of the pump.
The calculated temperature differential and/or cooling down of
the hot water through to the outlet of the circulation line from
the supply pipe is:

w
= 2 K
This temperature differential can then be used to determine the
pump flow V

P
[m
3
/h] of the circulation pump:
Q

w
V

P
= ----
c
w
(2)
The following can be assumed:
= 1 kg/l
c = 1.2 Wh/kg K
The distribution of volume flows over the individual partial
sections can be determined from the circulation pump flow now
known. At an intersection, the volume flow is split into a straight
section and a branched section.
The volume flow of the branched partial section can be calculated
as follows:
Q

a
V

a
= V

-----
Q

a
+ Q

d
(3)
17
V

d
,Q

d
V

a
,Q

a
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18
5.3.2.2 Calculation example
Multiple-family dwelling with 10 apartments
Pipe material: copper
Hot water lines dimensioned to DIN 1988, Part 3
Extraction valves individually secured
Fig. 26: Line schematic
Calculation of thermal losses from partial flows
Table 2: Thermal losses from partial sections
Partial section Cellar/ Length Thermal loss per m Thermal loss Total
(TS) shaft (K/S) l [m] q
w
[W/m] l q
w
[W] l q
w
[W]
1 K 3 11 33 33
2 K 5 11 55 55
3 S 12 7 84 84
4 K 5 11 55 55
5 S 12 7 84 84
6 K 5 11 55
S 12 7 84 139
7 K 5 11 55 55
8 S 12 7 84 84
9 K 5 7 55
S 12 11 84 139
Total of Total of
lengths: 88 thermal losses: 728
Techn_Brosch_GB 12.05.2005 9:58 Uhr Seite 19
19
Calculation of volume flows
The total thermal losses from Table 2 and the calculated tempera-
ture differential of
w
= 2 K can now be used to determine the
circulation pump flow:
728W
V

P
= = 303.3 l/h
1 kg / l 1.2 Wh / kgK 2 K
(2)
The partial flows split at the intersections. The partial section,
which leads in the direction of flow to the intersection, is shown
in the 1st column in Table 3.
The first partial section is TS 1, which starts at the drinking water
heater. The volume flow of this partial section, which leads in
the direction of flow to the 1st intersection, is shown in the 2nd
column.
This volume flow splits to the left into TS 7, which is defined as a
branch, and to the right into TS 2, in this case the straight partial
section.
The thermal losses from these two outgoing partial sections are
totalled individually,
i.e. the thermal loss from the branch (3rd column) comprises
thermal losses from partial sections 7 - 9:
Q

a
= (55 + 84 + 139) W = 278 W
Selecting pipe diameter for the circulation lines
The nominal widths for the circulation lines are shown separately
in a Table according to lines and collecting mains.
The lengths and volume flows of the partial sections for the
circulation are the same as for the supply lines arranged in
parallel. These are shown in the 3rd and 4th columns of the Table.
In column 5, the volume flows are converted from l/h to l/s.
The thermal loss from the straight (4th column) is determined
from the individual thermal losses from partial sections 2 6:
Q

d
= (55 + 84 + 55 + 84 + 139) W = 417 W
If these two thermal losses are now added together, the thermal
loss in the intersection is derived (5th column).
The individual volume flows in the branch and in the straight can
be determined according to equations (3) and (4):
in the branch according to equation (3):
278 W
V

a
= 303 l/h = 121 l/h (column 6)
695 W
and in the straight according to equation (4):
417 W
V

d
= 303 l/h = 182 l/h (column 7)
695 W
In column 8, the last value according to equation (5) can be
checked:
V

d
= (303 121) W= 182 l/h
This volume flow, which leads to the next intersection, is the
starting value for TS 2 as the volume flow from TS 2 to the inter-
section, with TS 3 as the branch and TS 4 as the straight, shown
in the next line of the Table. The calculations are then carried out
as per the previous ones.
The R-value tables from DIN 1988, Part 3 are now used to select
the nominal widths of the circulation line taking into account the
maximum permitted flow speed in copper pipes of 0.5 m/s
(columns 6 8). Once the pipeline pressure loss (column 9) is
determined, the resistances plus 40 % for pipe friction (column
12) are considered.
1 2 3 4 5 6 7 8
TWW partial Volume Thermal Thermal Thermal Volume Volume Check
section to flow to loss in loss in loss flow in flow in
intersection intersection the branch the straight in the the branch the straight
intersection
V

a
Q

d
Q

a
+ Q

d
V

a
V

d
V

d
= V

a
[l/h] [W] [W] [W] [l/h] [l/h] [l/h]
TS 1 303 278
1)
417
2)
695 121 182 303-121
TS 2 182 84 278 362 42 140 182-42
TS 4 140 84 139 223 53 87 140-53
TS 7 121 84 139 223 46 75 121-75
1)
in the line schematic to left
2)
in the line schematic to right
Table 3: Calculation of the partial flows in the distribution and/or circulation lines
Techn_Brosch_GB 12.05.2005 9:59 Uhr Seite 20
20
1 2 3 4 5 6 7 8 9 10 11 12 13
TS Pipe l V

Z
V

Z
d
a
v R l R Z lR+Z
1)
p
D
[m] [l/h] [l/s] [mm] [m/s] [mbar/m] [mbar] [mbar] [mbar] [mbar]
1 Cu 3 303 0.085 18 0.43 2.1 6 8
2 Cu 5 182 0.050 18 0.25 0.84 4 6
3 Cu 5 140 0.039 15 0.29 1.46 7 10
4 Cu 5 121 0.034 15 0.26 1.16 6 8
5 Cu 12 42 0.012 12 0.16 0.72 9 13 40
6 Cu 12 53 0.015 12 0.19 1.05 13 18 25
7 Cu 17 87 0.024 12 0.30 1.84 31 43
8 Cu 12 46 0.013 12 0.17 0.83 10 14 37
9 Cu 17 75 0.021 12 0.26 1.66 28 39 17
1)
1,4 l R (+ 40 % from the individual resistances, without non-return valve)
Table 4: Determination of the pipe diameter of the circulation line
Calculation of the delivery pressure
for the circulation pump
To calculate the delivery pressure (Equation 6), the pressures lost
through friction and flow resistances are determined in the most
hydraulically unfavourable flow path (the example uses lines 1,
2, 4, 6). The pressure loss of the VORTEX non-return valve at
20 mbar and the individual resistances at 40 % of the pipe
friction are also calculated:
p
p
= 1.4 (l R
TS 1,2,4,6
) + p
RV
p
p
= 1.4 (6 + 4 + 7 + 31)mbar +20 mbar
p
p
= 87 mbar
The data for the circulation pump are thus known:
Delivery height: 0.87 m, flow rate 0.303 m
3
/h
The following diagram was compiled using the data obtained:
Fig. 27: Pipe network and pump performance curve
Line comparison through line control valves
To ensure that the desired temperatures in the individual lines are
achieved and all lines have the same pressure loss, the excess
pressure differential in all other lines is reduced evenly through
preset line control valves.
The determined excess pressure loss (column 13) is transferred
with the flow in each line to the valve manufacturer's pre-set-
tings diagram and the preset value is calculated.
5.3.3 The differentiated procedure
This procedure is suitable for any size of system, especially where
system parameter measurements are computer-supported. It dif-
fers from the simplified procedure in that it uses a differentiated
method for determining the heat losses and pressure losses. The
calculation of the pre-settings of the throttle valve is therefore
relatively precise - although always based on assumptions!
The individual calculation steps in the differentiated procedure
are carried out as follows:
1. Determination of the heat losses in the TWW lines
(depending on nominal width, insulation and room
air temperature)
2. Calculation of circulation pump flow
3. Calculation of partial flows
4. Determination of nominal widths for the circulation lines
5. Calculation of the delivery pressure for the circulation
pump using the differentiated pressure losses of the
unfavourable lines
6. Choice of circulation pump
7. Determination of pre-settings for the line control valves
Delivery height H [m]
Performance curve for VORTEX pump
with V-pump housing
System operating point
Performance
curve for pipeline
Flow rate V

P
[m
3
/h]
1.50
1.25
1.00
0.75
0.50
0.25
15.0
12.5
10.0
7.5
5.0
2.5
0,0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
[kPa]
Techn_Brosch_GB 12.05.2005 9:59 Uhr Seite 21