TEXT & REFERENCE CED y | TECHNICAL DEVELOPMENT PROGRAM e¢ DESIGN FACTORS ¢ SIZING PROCEDURES @ ° PUMP SELECTION & APPLICATION1200-33 TECHNICAL DEVELOPMENT PROGRAM WATER PIPING SYSTEMS AND PUMPS _CONTENTS, INTRODUCTION ....-..+4- 1 | FORMULAS ...eecseeeeeeeeeeeees 2 TYPES OF PIPING SYSTEMS ....... ee) GENERAL CONSIDERATIONS .......+++-+ 5 MATERIALS ......seeeereeeeees 6 SUPPORTS ......0005 eee 7 VALVES ....- eee ee @ 1. Starting and Stopping Flow ... 9 2. Regulating or Throttling Flow . ul 3, Preventing Back Plow ...++.+++ 12 STRAINERS ....... 14 EXPANSION TANKS ... 16 AIR VENTS oes eeeeeee 18 OTHER ACCESSORIES .. 19 PIPE SIZING .... cess 22 | 1. Pipe Sizing Example .....-+.-+ | 2, Total Head on Pump .... 3, Direct Return System Sizing ..... sence e wee enee 28 1, Pump Terms seeeee we 28 2, Capacity «sss. 28 '@ 3. Head ... ee 284, Suction Head .... 5. Discharge Head . 6. Total Head .... 7. Liquid Horsepower ....+.++ 8. Brake Horsepower . 9. Net Positive Suction Head ... DETERMINING PUMP HEAD . TYPES OF CENTRIFUGAL PUMPS .. PUMP PACKING .. PUMP MATERIALS .. PUMP RATINGS . NOISE IN PUMPING SYSTEMS .......+006+ CONCLUSION eset eee sees esi ‘WORK SESSION . 28 29 29 29 30 30 32 34 36 37 38 52 55TECHNICAL DEVELOPMENT PROGRAM WATER PIPING SYSTEMS AND PUMPS INTRODUCTION In air conditioning work, water is often used to carry heat from a point of generation, such as a cooling coil to a point where it can be rejected to some other medium such as the refrigerant in a water chiller. The water is often recirculated so that the pick up and re- jection of heat is a continuous process. The piping and pumping systems used to transport the water to and from the various heat exchangers are usually relatively simple and straight forward, and are complete in themselves, that is they do not function as part of a big piping network. ‘The water is usually at temperatures between 40F and 100F, although year-round air conditioning may require hot water piping for heating, ‘The motive force for circulating or "pushing" the water through the piping system is almost invariably furnished by a centrifugal pump. ‘The design of piping systems is an old art and much has been written about it. This presentation will review overall design considerations, with emphasis on those points which we consider especially applicable to the piping and pumps used in air conditioning work. Frequent reference will be made to the Carrier System Design Manual Part 3 -© Piping Design for illustrations and amplification of material presented | here. FORMULAS A review of some of the formulas pertaining to the heat carrying capacity of water is in order. Lanes RAE ACM AM, BG, 167 1. BTU/HR. = GPM x sho x water temperature change in OF 2. Tons of refrigeration effect = GPM x temperature change in °E If we use chiller tons as a base, we can arrive at approximate condenser water gpm's and/or temperature changes as follows. For mechanical refrigeration assuming a heat rejection factor of 1.25 @ (1.18 BHP per ton): 3. Chiller tons = -G2M Condensing. wae Temperature Change in OF For absorption refrigeration assuming a heat rejection factor of 2.55 (19.6 Ibs. of 12 psig steam per hour per ton of refrigerating effect). 4, Chiller tons = GPM Condensing Water x Temperature Change in °F Present design practice uses a chilled water temperature change of about 10F; a condenser water temperature change of about 10F for | mechanical refrigeration with cooling tower; a condenser water temper- ature change of about 17F for absorption refrigeration with cooling tower! and a condenser water temperature change of about 20F when using e@ city water at 70 or 75F.These values are assumed to result in reasonable economic balance among first cost, operating costs, and energy requirements. We believe that this assumption is being challenged more often than it was. Higher temperature changes result in less gpm, smaller pipe sizes, lower operating costs, and lower energy requirements. For instance, chilled water temperature changes of 20F or more can be used without incurring any great problem in the selection of water chillers and water cooled coils. TYPES OF PIPING SYSTEMS For our purpose, water piping systems can be classified as follows: 1. Once through type, where water flows from a source through the system and out to waste. Examples are a city water condensing system and a well water chilling system. A pump may or may not be required. 2. Open recirculating type, where water is pumped from a reservoir through the system and back to the reservoir for reuse, with the water being brought into intimate contact with air somewhere in the circuit. Examples are chilled water systems using washers for cooling and dehumidifi- cation and condensing water systems which use cooling towers.3. Closed recirculating type, where water is simply circu- lated through a closed system of piping and equipment, without coming in close contact with air, except at the expansion tank, whose area of contact is negligible. An example is a chilled water system using coils for cooling and dehumidifying. 4. Recirculating Piping systems are further classified as either direct return or reversed return. A direct return system is illustrated in Figure 1 on the left. The same units are shown on the right piped with a reversed return system. 1 J 7 OOE Jee a = — ‘UMS Pic HoMZONTALLY = Mis 21PED womzowraLLy Direct Return Piping System Reverse Return Piping System FIG. 1 eIf the pressure drops through the units are identical, then in the case of the direct return system, each of the first five units will required a balancing valve and means to measure flow plus balancing time to insure the same flow through all units. In the reverse return system, however, the pressure difference from supply line through the unit to return line is the same for all units. Each unit will, therefore, take an equal share of the total flow and no balancing is required. The cost of the extra length of return pipe is probably less than the cost of valves and balancing, and much time and trouble will be saved. A reversed return should always be used in a multi-room system which uses a large number of under the window units of identical pressure drop. GENERAL CONSIDERATIONS. Water piping systems should be as direct and uncomplicated as possible, Offsets, bends, and changes in elevation should be kept to a minimum. Any fitting or valve that is omitted, represents a reduction in first cost, operating cost, and maintenance cost. On the other hand, condenser and chiller tubes must be periodically cleaned, and cooling coils, control valves and pumps will eventually require repair or servicing. All of these operations must be preceededby draining the water out of the equipment involved. It is convenient and economical to be able to isolate such parts by means of shut off or isolating valves so that the entire system does not have to be drained and refilled. It may also be important that any piece of equipment. can be isolated and worked on while the remainder of the system con~ tinues to operate normally, In addition to shut off valves, unions or pairs of flanges are required at strategic locations so that the piping can be easily dismantled for the possible removal of such things as coils, and control valves. Judgment and imagination are needed to balance convenience in servicing against first cost and maintenance cost of the system. Let us examine the various parts of a piping system in some detail. MATERIALS. The usual piping materials are black steel for the large sizes say 1 1/2" and above and hard copper for the smaller sizes. Galvanized steel may be used, but usually only for drainage lines. It is now customary to specify water treatment to control corrosion and galvanized or wrought iron is not generally required. Fittings for black steel pipe are usually welded for larger sizes or malleable iron screwed type for smaller sizes, Hard copper fittings are wrought copper or brass.‘The weight of the pipe and fittings will depend on the pressures and temperatures encountered in the system. Various codes will have something to say about this and the ones that apply must be consulted. Special conditions may required special materials, but this is beyond the scope of this presentation, We refer you to Chapter 1 of the Design Manual, Part 3, for additional information on materials, pages 3-2 and 3-3. SUPPORTS. Hangers or supports are required at intervals ranging from 8 ft. to 20 ft. depending on the pipe size. See tables 7 and 8 in the Design Manual. Except at anchor points, pipe supports should not be rigid but allow some movement of the pipe. In many systems, with several changes of direction, the expansion due to temperature changes can be taken care of in this way. The hangers for chilled water piping are installed outside the Insulation to prevent sweating, and some means must be provided to prevent crushing the insulation, This is usually SHEET METAL a metal plate of suitable length and HALF SLEEVE thickness curved in cross section to fit around the bottom part of the insulation and mounted between theinsulation and the hanger. For hot water service, the hanger is usually around the pipe, and pipe and hanger are insulated together. At the flanges of pumps or heat exchangers, the piping should be supported so that no stress is imposed on the pump casing or the heat exchanger itself. At pump suction and discharge, flexible rubber connectors are sometimes used to prevent stress, and also to compensate for slight misalignment. ‘They are also supposed to prevent the transmission of vibration into the piping system, but they are not very effective for this purpose, Water is an incompressible liquid and vibrations from the pump are transmitted through the water column with very little reduction in intensity. Pump vibration problems are best handled with spring type pipe hangers and by providing a good mass under pumps or other vibrating components in a piping system. Refer to pages 7 and 8 of the Design Manual. In large and important systems, it may be desirable to consult vibration experts. Often it becomes necessary to support a long straight vertical riser which goes from the bottom to the top of the building. In large sizes, the pipe and water represent a very large weight. The accompanying sketch shows a method of support which is inexpensive and provides a dirt leg with cleanout and a solid support with a minimum of hangersand special fittings. Note that the weight of the water is carried directly into the foundation, The joint between the horizontal main and the riser should be made with @ forged welding tee and not by field cutting and welding. Ex- FOUNDATION, |._— riser a HORIZONTAL Z MAIN =—CLEANOUT RAIN STEEL PLATE FORGED TEE pansion of the pipe due to temperature changes in the riser, may need special attention in this case. VALVES. ‘BASEMENT FLOOR FIG. 3 There are hundreds of types of valves, each one of which best suits a particular application, but for our purposes only five or six types need consideration. We refer you to the Design Manual, pages 10 to 15, and also to the catalogs and other publications of the valve manufacturers. Valves perform one of three basic functions. 1, Starting and Stopping Flow. Gate valves are usually used for this function, because when wide open water flows straight through with a minimum of pressure drop. They are not practical for throttling flow.= 10- This illustration shows an OS and Y¥ gate valve with rising stem. is the type usually used for isolating pumps, coolers and condensers. quick glance at the stem reveals whether the valve is open or closed and the stem threads are outside the valve where they are free from cor- rosion and can easily be lubricated. ‘With stem extended, these valves This ono RISING STEM coursibe screw -HANOWHEEL ‘AND YOKE}. (OES NOT Rise WITH STEM) BoLTeD BOLTED SOLID WEDGE BONNET ise FLANGED ENS: Gate Valve - Rising Stem FIG. 4 are very tall and it is often difficult to install them in such a position not interfere with fixed objects or A plug cock has the same low pressure drop, when open, as a gate and is also excellent for throttling service or as a balancing valve. It can be used to perform both functions simultaneously. in the piping that the stem does block off passage. Plug Cock FIG. 5-ne- Regulating or Throttling Flow_ Globe valves or angle valves are usually used for this service. Globe valves have a relatively high pressure drop when open, but give good throttling characteristics, that is, the percent flow is nearly proportional to the per cent of opening. If a globe valve is used for balancing wanowneet —~ nse | tase sere flow, the wheel should be removed PACKING NUT after adjustment to prevent accidental iT 6LaNo— readjustment, An angle globe valve screweo union can be advantageously used for throttling. It's use saves one elbow and the pressure drop when open is less than half that of a straight Cees through globe valve. FIG. 6 If a plug cock or butterfly valve \uawomen, psa irmour cawo is used as both shut off and balancing (Gina senean valve an indicator should be provided so that after use as a shut off, the valve Sfneaoco eouver. can be reopened to the original position, ‘soreweD aRROW sear ois] Enos Control valves are usually auto- ‘eonvenonats matically controlled globe valves, although butterfly valves are be- FLow Angle Valve FIG. 7-12- coming popular for this use, especially in the larger sizes. 3. Preventing Back Flow. Check valves perform the single function of checking or preventing the reversal of flow in piping. The 15° swing check is the usual type, with lift checks often used at pump discharge. If a pump operates between two water levels in an open system, the water will surge back from the top level through the pump to the bottom level at shut- down causing it to run backwards, damage seals, or even completely drain the pump if it is above the lower resevoir. To prevent back flow, a check valve is placed near Swing Check Valve the pump discharge. This should be of the non-slam type, to prevent FIG. 8 water hammer as the check closes. Most non-slam checks are expensive and must be installed in a vertical riser. It is possible to use a pneumatically operated butterly valve at the pump discharge to perform all three functions so far considered. For this multiple use, the valve is a normally closed type so that when air is bled from the branch air line the valve goes to the closed position, Air can be bled manually, which performs function #1.-1B- If a mechanical stop is provided at the valve open position which gives rated flow in the piping system, then after use as a shut off, the valve automatically returns to the correct degree of opening, and function #2 is SCREWED UNION RING BONNET accomplished. A: bleed valve can also be installed in the branch air line, nol which will automatically open whenever I screweo eno the pump shuts down, By adjusting Lift Check Valve the bleed rate of this valve to accom- wc plish a reasonably fast closing of the valve, function #3 is attained. Finally, if several pumps are installed in parallel, a check valve should be installed in each pump discharge to hae prevent water being bypassed back Multiple Pump Piping through an idle pump, See Figure 10. FIG. 10 Pressure reducing valves are occasionally used in water piping. One instance is when supplying clean city water to the lantern ring in a pump seal, where the pressure must be regulated to about 5 psi above suction pressure at the pump. Such valves should be sized to suit the downstream flow rate and not to suit the pipe size.-u- Pressure relief valves are also sometimes required. For instance, in a chilled water system, there may be a stretch of pipe which can be accidentally valved off at each end. ‘The water trapped between the valves can exert a high pressure when warmed up and it may be desirable to supply a relief valve to prevent damage. Also, in an extensive system in which all the control valves are the throttling type rather than three-way valves, the pump can build up a high pressure when all valves are nearly closed, and a relief valve is often installed at the pump discharge to relieve the excess pressure into the pump suction. STRAINERS, In many piping systems, a certain amount of finely divided "trash" can circulate without doing any great harm. In such cases, the need of a strainer is doubtful, and if one is used it should be no finer than 20 mesh to prevent its becoming clogged too rapidly. Operators are human like the rest of us and if the task of cleaning strainers becomes too irksome, the strainer basket will get punched full of holes or be removed, In a condenser water system using a cooling tower and not using control valves, the strainer provided at the tower suction connection is usually considered sufficient. A mud ring is sometimes installed around theais) intake as shown in the illustration to hold back heavy dirt so that it accumulates in the bottom of the pan ayoues, where it can be easily removed at the wu epoUNG TOWER yearly maintenance period. Spare E tower sump screens should be provided “STRAINER BASKET —-suwp so that when the dirty screen is \To CONDENSER PUMP SUCTION removed, it can be replaced immediately FIG. 11 without shutting down the tower. If a strainer is used it is usually placed at the pump suction and a "y" pattern strainer as shown in Figure 12 is often used. In some instances, continuous and positive cleaning is absolutely necessary, Perhaps dirty river water is being used in a once through system ab 2 p for condensing purposes. In such cases, a double basket type strainer such as the type illustrated in Figure GATE VALVE FOR BLOW OUT ™ 13 should be provided. It should be installed in a location that is easily FIG. 12 accessible, and everything should be done to make the task of routine cleaning as easy and convenient as“iGo possible, otherwise the cleaning will be neglected. ‘These strainers contain two strainers baskets and an easily operated transfer valve diverts flow from the dirty basket to the clean one. The dirty basket can then be removed and a spare clean basket installed, ‘The cleaning can then be done at a convenient time and place, and the piping system is not shut down for even a short time. These strainers are expensive but in an extreme case, their cost is well justified. Self-cleaning strainers are also available, for use in extreme cases where dirt accumu- lates rapidly or for remote locations which cannot be conveniently serviced at frequent intervals. FIG. 13 EXPANSION TANKS Every closed recirculating system needs an expansion tank to take care of expansion and contraction of water due to temperature change; and to provide a place to automatically replace water lost through pump-i7e gland leakage and other losses. An open tank is preferred, and is usually placed at the top of the return main closest to the pump so as to maintain a positive suction pressure at the pump intake. (See Figure 14). If it is impractical to install an open tank at the top of the system because of difficulty in protecting the tank from freezing, obtaining city water supply, or providing overflow drains, a closed expansion tank may be installed at any convenient point in the system, It should be tied in as close as possible to the lowest pressure point, LT oat collapse of the tank if the system is cd drained. See Figure 15. = The variation in volume of the water can and may need a vacuum breaker to prevent be calculated by obtaining the total inter- EXPANSION LINE Seale oP aa nal volume of the system including aa . ee piping, heat exchangers, pumps, etc. wus om Une 82 and multiplying the volume by the change Qe : in specific volume of water between the FIG. 14 highest and lowest temperature expected. This change in volume is usually about 1% for chilled water systems and 3% for hot water systems, (See Table 15, page 3-31 of the Design Manual). A safety factor of about 25% shouldSia be added. Note that the volume calculated is not the volume of the expansion tank but the volume of the space above the normal water level in the tank. The equalizer line from the expansion tank to the system should be at least 1 1/2" size and should not be pro- ——_stass| vided with a shut off valve. In a chilled water system, the sides and bottom of the tank and the equal- izer line may have to be insulated to prevent sweating. care val a VE. ace. vanve7 FIG. 15 ‘The connection of potable water to any system is usually restricted by water department rules. These local codes should be consulted to be sure that the method of connecting is approved. AIR VENTS When properly placed, an open expansion tank acts as an air vent. Entrained air in water can be expected to collect as bubbles of air where the water stream reduces velocity, changes direction, or is-19- heated. Any such point in the system should have either a manual or an automatic air vent. Figure 16 shows how an EI automatic air vent is installed. VANE The outlet should be piped to a drain, Manual vents should be provided at heat exchangers ue GLOBE and cooling coils. MAIN OTHER ACCESSORIES FIG. 16 Piping systems are meant to circulate definite gpm's at specified points in the system. After the system is in operation, it often becomes necessary to find out if the specified quantities are in fact being delivered. Pressure gages, thermometer wells, and possibly flow meters should be provided at all necessary locations so that ‘ this may be done and to assist the operator in trouble shooting. Each pump should be furnished with a certified characteristic curve or plot showing head versus gpm and gages should be provided as close e@ as possible to the pump suction and discharge flanges so that totalSoyo pressure rise across the pump can be found. By referring to the charac- teristic curve, the gpm can then be read from the chart. This will give a fairly accurate reading. Flow meters can be installed which give a continuous reading of the gpm flowing but the expense is usually not considered justified. Often times, it is only necessary to accurately determine the flow at very infrequent intervals, or perhaps only once to demonstrate that specified gpms are being delivered. In such cases, a standard ASME orifice plate installed between two flanges, with the necessary auxiliary tappings can be provided. Figure 17 shows a rough sketch of a concentric orifice plate with its pressure tappings. For accurate readings of gpm flows, the orifice plate must be made, installed, and STRAIGHT PIPE pSTRaleT OPE varies 3 b-varies > used in strict accord with the specifications of the ASME Power Test Code, For information,refer to the “Flow Meter Computation FIG. 17 Handbook" or the supplement to the Power Test Code, Chapter 4, Flow Measurement, Part 5 - Instruments and Apparatus. Both publications are available from the-21- ASME. Note that the orifice plate forms a dam across the pipe and dirt can collect and restrict flow, This orifice type of flow meter also imposes a fairly substantial additional pressure drop in the system, For these reasons, it is often removed after use and replaced with a flat disc which has a hole equal in diameter to the inside diameter of the pipe. Thermometers or thermometer wells should be installed to assist the system operator in routine operation and troubleshooting. Permanent thermometers of correct scale range and with separable sockets should be used at all points where temperature readings are regularly needed. Thermometer wells only, should be installed where readings will be needed during start up and infrequent troubleshooting. Gage cocks should be installed at points where pressure readings will be required. It should be remembered that gages installed permanently in the system will deteriorate rapidly due to vibration and pulsation and will not be reliable for use in troubleshooting when needed. For this reason, gages should be removed from the system except when readings are being taken. Good practice is to install gage cocks and provide the operator with (or request that he obtain) several good quality gages for troubleshooting. Sleeves are usually provided at points where piping passes thru walls and floors. In finished areas, sleeves are fabricated by cutting ae7 length of pipe of sufficiently large diameter for pipe and insulation to pass thru. In unfinished areas, sleeves may be fabricated from sheet metal, Wall sleeves are generally flush with both sides of the wall, Floor sleeves in equipment rooms usually project several inches above the floor to prevent water leakage around the pipe in case of flooding, Pages 33 and 42 of the Design Manual give detailed information on the recommended accessories, and method of piping around various pieces of equipment, such as are found in air conditioning systems. PIPE SIZING After a piping system has been laid out and the gpm figured it becomes necessary to size the pipe and determine the total resistance in the system so as to know what head the pump must work against. Pipe size is limited by the maximum velocity permissible. Table 13 on page 21 of the Design Manual gives some recommended water velocity limits, based on noise considerations and the effect of water and entrained air wearing away or eroding the pipe. Erosion is, of course, increased with high velocity but it is also affected by the number of hours of operation per year. Table 14 on page 21 of the Design Manual gives some recommended velocity limits, which are based on experience and are designed to give a good balance between23 pipe size (or cost) and a reasonable life before the pipe is eroded away. | Pipe velocity may also be limited by the total head available or desirable. For instance, in a city water system, the total head (including static lift; pressure drops through meters, condensers, control valves; and pipe friction) cannot exceed the total pressure available in the city main. Economic considerations such as high pumping costs, may also place a ceiling on velocity. Friction Loss rate in pipe may be found by using Charts 3, 4, and 5 on pages 22, 23, and 24 in the Piping Design Manual. Chart 3 applies to new, smooth, clean standard weight steel pipe and can be used to determine the friction loss rate in a closed piping system, such as a chilled water recirculating system. Chart 4 applies to steel pipe which has been subjected to scaling and corrosion for 15 to 20 years, This chart is used to determine the friction loss rate in open recirculating type systems such as condenser water systems using cooling towers. Chart 5 is used to determine friction loss in copper tubing which can be expected to stay clean throughout its normal life. |= 24 = Note that the friction loss or head is given in feet of water per 100 ft. of straight pipe. Friction loss in valves, fittings, or obstructions can be evaluated by assigning an equivalent length of straight pipe to each size and type of fitting as shown in Tables 10, 11, and 12 in the Piping Design Manual. For instance, in Table 10, we note that a 4" globe valve has an equivalent length of 120 feet. In other words, the friction loss in one 4" globe is the same as that through 120 feet of 4" straight pipe. Note that a 4" angle valve is equivalent to only 47 feet of 4" pipe, yet both valves perform the same function. In a closed system, friction is the only loss or head which the pump has to overcome. The height of water on the suction side of the pump 4s always exactly equal to the height on the discharge side. In open systems, this is not true, and there is always a difference in head on the two sides of the pump, In a cooling tower, for instance, the height between the water in the pan and the exit from the distribution at the top of the tower constitutes an unbalanced head which must be overcome by the pump. If the distribution system consists of spray nozzles which require a pressure behind them to force water through the nozzles, this pressure must be added to the unbalanced static head.Ba The total head on the pump will consist of the following: pipe friction head, including entrance and exit losses; losses through fittings, valves, and accessories; pressure losses through equipment, such as coolers, condensers, cooling coils, etc.; any unbalanced head between reservoirs and at the base of cooling towers; and pressure drops through nozzles or similar equipment. Pipe Sizing Example baa T Tower Nozzles Require - 8 psi (COOLING Pressure drop thru cond, = 13 psi TOWER (Including ent. & exit losses) Pressure Drop thru Strainers = 4 psi GPM = 1200 Max. Velocity = 8 ft. per second Pump ~ suction connection 6" discharge All elbows are long radius COND. b-12—j 12+ Fig. 18 Since this is an open recirculating system, we will use Chart 4 on page 23 of the Piping Design Manual, to determine friction losses. Referring to the Chart, we find that an 8" pipe size gives 7.7 ft. per sec. velocity and 3.8 ft. per 100 ft. friction loss.- 26 = Total equivalent length of straight pipe (Tables 10, 11, and 12) Straight pipe = 10 + 85 + 12 +12 +3 +2+8+ 20499 + 2148 +3 = 283 Equivalent lengths 283" Exit loss - sump 2a" Ells = 10 @ 13° 130" Gate Valves = 2 @ 9 1g" Lift Check 220° 675" 675 x 3.8 = 26° Friction Loss Tap 26' Note that if we had used an angle lift check instead of one elbow we could have reduced the total equivalent lengths by the following: Deduct one ell = 13" Diff. in checks = 220' - 85' = 135" 148" This is 5.6" friction head or ae x 100 = 21% of the total friction head. Total Head on Pump Friction Head = 26° Unbalanced head at base of tower = iat Pressure drop in strainer = 4 psi Pressure drop in condenser = 13 psi Pressure drop in nozzles = _8 psi TOTAL 25 psi 25 psi x 2.31 = 58° TOTAL HEAD ACROSS PUMP 96"-27- At this point, some designers add a safety factor of 5 to 10%. We have neglected the loss in the 6" to 8" increaser at the pump dis- charge. On the other hand, we are starting out with clean pipe and it is unknown whether the pipe will "age" to the predicted condition. At the start, the pump has a tendency to pump more gpm than needed which might overload the pump motor, Note that the reduction in head due to clean pipe would be (refer to Chart 3 page 22 of the Design Manual). 675. 1 875 4 2.2 = 26 - 1s! = 11" 26' top X 2-2 = 26 - 15 or 11 1/2% of the total head. Let us be conservative and select a pump to handle 1200 gpm at 100" total head. Direct Return System Sizing In any direct return system which contains several parallel circuits, the pressure drop through each circuit at its rated flow must equal the available difference in pressure between the supply and return mains at the circuit connections, Since the available pressure differences will vary with the distance from the pump, balancing valves may be required in’ some of the circuits to insure rated flow in that circuit. At the end of this presentation, a work session is included to illustrate problems encountered in designing a direct return system.So PUMPS After the designer has leid out the piping system and figured out the total pumping head, he must select a pump. The pump (or pumps) must fit into the space available, and should be easy to service, ‘and be able to pump the necessary gpm against the existing head at the lowest possible horsepower. Information about pumps is found in the manufacturers catalogs. Such information is usually based on pumping clear water at 60P and is applicable without correction to most conditions found in air conditioning work. PUMP TERMS Capacity is usually given in gallons per minute, although other units may be used. In any case, the basis is volume per unit of time. Head is a form of energy and is usually expressed in feet of the Liquid being pumped or pounds per sq. in, Total head against which 2 pump must work consists of suction head (or lift); discharge head; friction head; and velocity head. Suction Head is the total pressure at the pump suction nozzle and includes; static suction head (or lift); entrance loss and friction head= 29 - in the suction line; velocity head; and any positive pressure which may exist on the suction reservoir. With the system in operation, a pressure gage at the pump suction would indicate a positive static suction head minus suction line friction head; minus velocity head. A vacuum gage would read suction lift plus friction head plus velocity head. Discharge head is the total pressure at pump discharge and includes static discharge head; plus any positive pressure existing at the discharge reservoir; discharge pipe friction loss; plus equipment pressure drop; and velocity head. A discharge pressure gage would indicate total discharge head but not including velocity head. Total head is the discharge head minus the suction head, or discharge head plus suction lift where suction pressure is below atmospheric pressure, Velocity head is usually neglected in pump calculations because it is a very small part of the total head (at 8 fps velocity it equals v*/2g or 64/64.4 = 1 ft.) Calculations of pumping head are not sufficiently accurate to warrant concern with velocity head. It should be remembered, however, that the pump must furnish the additional energy represented by the velocity head, and in open systems the velocity head is lost when the water is discharged to atmosphere. Liquid horsepower is obtained by the following formula ~ _ GPM x 8.33 (Ib./gal) x Hd. (ft.) _ GPM x Hd. ee 33, 000 3960Ss Brake Horsepower - is the power required to drive the pump and equals Liquid Horsepower divided by the overall efficiency of the pump. Overall efficiency is determined by test measurement and includes mechanical as well as hydraulic losses. Net Positive Suction. Head _(NPSH) If the pressure anywhere in a piping system falls below the vapor pressure of the liquid, vapor bubbles will form. When moved into a higher pressure area, these bubbles will collapse. This is called cavitation and is most apt to occur at the inlet to the pump impeller. It causes noisy pump operation, rapid erosion and wear, or in extreme cases, violent water hammer, and it must be avoided. Pump manu- facturers give the NPSH required by their pumps, usually on the characteristic curves, at various capacities (see figure 35 & 36). NPSH is equal to the pressure drop in feet of liquid from suction flange to the point inside the impeller where pressure starts to rise. Available NPSH at the pump suction must always be greater than NPSH required by the pump. To find the available NPSH in a given system at the pump suction flange, use the following formula: NPSH = ~ho + (hl - bh, )