Primary Factors in Designing
Efficient Hydronic Heating Systems
Presented by Steve Connor
November 19, 2014
Market Drivers
• Reduced Energy Consumption
• Lower Life Cycle cost
• LEED Certification
2
Today’s Agenda
• Why variable flow pumping started
• ASHRAE 90.1
• Differences in hydronic boiler system design
• Primary secondary vs Variable flow primary
• Condensing boiler technology review
• High mass vs low mass
• Characteristics of condensing boilers
• System comparison
• Review Primary secondary vs variable flow primary at various load conditions
• Summary
• Q&A
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Guest Presenter: Gregg Achtenhagen
PE, LEED AP BD&C, & Certified Geo-Exchange Designer
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The Hydronic System
Heating Load Heating Load Heating Load
Air Elimination
Pump(s)
3-way valves for
Expansion constant volume pumping
Compensation
Heat
Generation
5
Why Variable Flow Pumping Started
Primary-Secondary Pumping Arrangement
Return Supply
Secondary pumps
(variable speed)
Buffer Tank
Decoupler
Primary pump Primary pump Primary pump
Boiler 1 Boiler 2 Boiler 3
6
System Comparison
Primary-Secondary:
Hydraulic De-Coupler
Primary Secondary Primary Secondary Primary Secondary
Gp Gs Gp Gs Gp Gs
Courtesy of Caleffi North America, Inc.
Why Variable Flow Pumping Started
Variable Flow Primary w/ High Mass Pumping Arrangement
Return Supply
Primary pumps
(variable speed)
Boiler 1 Boiler 2 Boiler 3
Boiler Isolation Boiler Isolation Boiler Isolation
valve valve valve
8
Definitions
• High Mass = More than 50 Gallons per MMBTU
• Low Mass = Less than 25 Gallons per MMBTU
• Outdoor reset of temperature = Adjust set point seasonally
• Delta T (∆T) = Difference between supply and return water
temps
• Condensing mode = Operating below the flue gas Dew point
• (less than 127F return temperature required – natural gas)
• Non-condensing mode = Operating Above the Flue gas Dew
point
• (greater than 127F return temperature – natural gas)
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Definitions
Outdoor Temperature Reset
BIN Data – Load Profile
Average/yr of hours from 2002 to 2006
Avg T Range Total Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Easton, PA 63 62-64 335 23 45 46 40 45 102 23 11
61 60-62 308 20 45 45 48 40 59 40 10 1
59 58-60 200 17 39 33 13 42 36 16 3 1
57 56-58 273 4 4 29 71 36 22 21 32 45 8 1
55 54-56 351 8 4 5 38 68 32 10 17 46 89 31 2
53 52-54 285 5 3 28 46 42 16 6 2 38 51 47 11
51 50-52 232 2 3 16 35 38 11 1 32 64 27 3
49 48-50 238 1 7 18 52 22 5 33 42 47 11
47 46-48 258 4 27 45 23 1 28 58 51 21
45 44-46 227 2 2 30 55 22 8 53 39 15
43 42-44 287 4 5 69 76 24 12 48 30 19
41 40-42 180 3 8 56 42 10 5 26 15 15
39 38-40 273 8 20 50 50 32 4 40 41 28
37 36-38 337 24 23 80 46 20 4 41 60 39
35 34-36 257 24 31 39 28 11 18 59 47
33 32-34 313 46 50 53 8 4 10 69 91
31 30-32 380 50 62 71 9 9 68 91
29 28-30 298 44 79 45 12 4 49 65
-5 [-6 to -4] 4 4
6414
Hours at Temperature
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Why Variable Flow Pumping Started
ASHRAE 90.1
6.5.4.2 – Hydronic Variable Flow Systems
• HVAC pumping systems having a total pump
system power exceeding 10 hp shall be designed
for variable fluid flow.
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Differences in Hydronic System Design
Traditional Boiler Limitations
12
Differences in Hydronic System Design
Thermal Shock
13
Differences in Hydronic System Design
Corrosion
If return water is too cold, condensation
can form inside of the boiler
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Condensing Boiler Technology
Different Boiler Designs
Firetube [SS] Modified Firetube [SS] Cast Aluminum
Cast iron w/ Copperfin
add-on HX w/ add-on
HX
15
Condensing Boiler Technology
Key Operational Criteria
• Most designs offer no minimum return temperature
• Inherently corrosion resistant
• Not subject to thermal shock or stress
• Provides longevity and reliability
• Modularity provides better system turn down and
redundancy
16
Condensing Boiler Technology
Key Operational Criteria
• Most efficient at lowest possible return water temperature
• Efficiencies above 87-88% only possible if return water
temperatures are below the flue gas dew point (127⁰F for
typical Natural Gas combustion)
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Condensing Boiler Technology
Key Operational Criteria
• Inverse efficiency characteristic
• More efficient to run more boilers at lower firing rates
• Coordinated control strategy of boilers and pumps.
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Condensing Boiler Technology
Low Mass Boiler Design
Advantages Disadvantages
• Lower first cost • Needs minimum
• Quick response to load circulation
variations • Higher energy
• Compact requirement
• Excellent efficiencies • Erosion problems
• More maintenance
• Lower life expectancy
• More frequent cycling
• Often need buffering
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Condensing Boiler Technology
High Mass Boiler Design
Advantages Disadvantages
• Rugged construction • Higher first cost
• Less cycling • Heavier
• Lower thermal stress • Somewhat larger than
on the boiler low mass
• Stable temperature
control
• Minimal pump head
• Low flow or no flow
tolerant
• Compact
• Excellent efficiencies
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System Comparison
Primary-Secondary: 100% Design Load = 6000 MBH
120F 160F
300gpm
Buffer Tank
300gpm
0 gpm
100gpm 100gpm 100gpm
100% FR 100% FR 100% FR
300gpm
120F 120F 120F 120F
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System Comparison
Variable Flow Primary: 100% Design Load = 6000 MBH
120F 160F
300gpm
100gpm 100gpm 100gpm
100% FR 100% FR 100% FR
300gpm
120F 120F 120F 120F
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System Comparison
100% Design Load
Primary-Secondary
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 100%
Boiler Efficiency: 90%
Boiler Input: 6700 MBH
Pumping Energy: 10.5 HP
Variable Flow Primary w/ High Mass Boilers
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 100%
Boiler Efficiency: 90%
Boiler Input: 6700 MBH
Pumping Energy: 6.2 HP
23
System Comparison
Primary-Secondary: 70% Part Load = 4200 MBH
120F 160F
210gpm Buffer Tank
300gpm
90 gpm
100gpm 100gpm 100gpm
75% FR 75% FR 75% FR
210gpm
120F 130F 130F 130F
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System Comparison
Variable Flow Primary: 70% Part Load = 4200 MBH
Hydronic piping system arrangements
120F 160F
210gpm
70gpm 70gpm 70gpm
70% FR 70% FR 70% FR
210gpm
120F 120F 120F 120F
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System Comparison
70% Part Load
Primary-Secondary
Boiler Inlet Temperature: 130F
Boiler Firing Rate: 75%
Boiler Efficiency: 88%
Boiler Input: 4775 MBH
Pumping Energy: 6.6 HP
Variable Flow Primary w/High Mass Boilers
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 70%
Boiler Efficiency: 91%
Boiler Input: 4600 MBH
Pumping Energy: 2.1 HP
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Impact of Higher Inlet Temperature
On Efficiency
Vari Flow Primary
Primary-Secondary
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System Comparison
70% Part Load
Primary-Secondary
Boiler Inlet Temperature: 130F
Boiler Firing Rate: 75%
Boiler Efficiency: 88%
Boiler Input: 4775 MBH
Pumping Energy: 6.6 HP
Variable Flow Primary w/ High Mass Boilers
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 70%
Boiler Efficiency: 91%
Boiler Input: 4600 MBH
Pumping Energy: 2.1 HP
28
System Comparison
Primary-Secondary:
50% Part Load – With Outdoor Reset = 3000 MBH
Hydronic piping system arrangements
110F 150F
150gpm Buffer Tank
200gpm
50 gpm
100gpm 100gpm 0gpm
75% FR 75% FR 0% FR
150gpm
110F 120F 120F OFF
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System Comparison
Variable Flow Primary:
50% Part Load – With Outdoor Reset = 3000 MBH
Hydronic piping system arrangements
110F 150F
150gpm
50gpm 50gpm 50gpm
50% FR 50% FR 50% FR
150gpm
110F 110F 110F 110F
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Inverse Efficiency Curve on Condensing Boilers
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System Comparison
Variable Flow Primary:
50% Part Load – With Outdoor Reset = 3000 MBH
Hydronic piping system arrangements
110F 150F
150gpm
50gpm 50gpm 50gpm
50% FR 50% FR 50% FR
150gpm
110F 110F 110F 110F
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System Comparison
50% Part Load – W/ Outdoor Reset
Primary-Secondary
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 75%
Boiler Efficiency: 90%
Boiler Input: 3330 MBH
Pumping Energy: 3.8 HP
Variable Flow Primary w/ High Mass Boilers
Boiler Inlet Temperature: 110F
Boiler Firing Rate: 50%
Boiler Efficiency: 93%
Boiler Input: 3225 MBH
Pumping Energy: 0.8 HP
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System Comparison
50% Part Load – W/ Outdoor Reset
Primary-Secondary w/ 3 boilers operating
Boiler Inlet Temperature: 137F
Boiler Firing Rate: 55%
Boiler Efficiency: 88%
Boiler Input: 3400 MBH
Pumping Energy: 5.3 HP
Variable Flow Primary w/ High Mass Boilers
Boiler Inlet Temperature: 110F
Boiler Firing Rate: 50%
Boiler Efficiency: 93%
Boiler Input: 3225 MBH
Pumping Energy: 0.8 HP
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System Comparison
Primary-Secondary:
33% Part Load – With Outdoor Reset = 2000 MBH
Hydronic piping system arrangements
100F 140F
100gpm Buffer Tank
200gpm
100 gpm
100gpm 100gpm 0gpm
50% FR 50% FR 0% FR
100gpm
100F 120F 120F OFF
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System Comparison
Variable Flow Primary:
33% Part Load – With Outdoor Reset = 2000 MBH
Hydronic piping system arrangements
100F 140F
100gpm
33gpm 33gpm 33gpm
33% FR 33% FR 33% FR
100gpm
100F 100F 100F 100F
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System Comparison
33% Part Load – W/ Outdoor Reset
Primary-Secondary
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 50%
Boiler Efficiency: 92%
Boiler Input: 2175 MBH
Pumping Energy: 3.2 HP
Variable Flow Primary w/ High Mass Boilers
Boiler Inlet Temperature: 100F
Boiler Firing Rate: 33%
Boiler Efficiency: 96%
Boiler Input: 2080 MBH
Pumping Energy: 0.3 HP
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System Comparison
33% Part Load – W/ Outdoor Reset
Primary-Secondary w/ 1 boiler operating
Boiler Inlet Temperature: 100F
Boiler Firing Rate: 100%
Boiler Efficiency: 91%
Boiler Input: 2273 MBH
Pumping Energy: 1.7 HP
Variable Flow Primary w/ High Mass Boilers
Boiler Inlet Temperature: 100F
Boiler Firing Rate: 33%
Boiler Efficiency: 96%
Boiler Input: 2080 MBH
Pumping Energy: 0.3 HP
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System Comparison
50% Part Load – With Outdoor Reset – Redundant Boiler
Primary-Secondary w/ 2 boilers operating
Boiler Inlet Temperature: 120F
Boiler Firing Rate: 75%
Boiler Efficiency: 90%
Boiler Input: 3400 MBH
Pumping Energy: 3.8 HP
Variable Flow Primary w/ all 4 Boilers operating
Boiler Inlet Temperature: 110F
Boiler Firing Rate: 36% (was 50%)
Boiler Efficiency: 94% (was 93%)
Boiler Input: 3190 MBH (3225 MBH)
Pumping Energy: 0.8 HP
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Summary of Energy Consumption
Hydronic piping system arrangements
Load Primary-Secondary Variable Flow Primary Savings
100% 90% Efficiency 90% Efficiency 0% Eff.
6700 MBH Input 6700 MBH Input 0% Fuel
10.5 HP Pumping 6.2 HP Pumping 40% Power
70% 88% Efficiency 91% Efficiency 3% Eff.
4775 MBH Input 4600 MBH Input 3.6% Fuel
6.6 HP Pumping 2.1 HP Pumping 68% Power
Summary of Energy Consumption
Hydronic piping system arrangements
Load Primary-Secondary Variable Flow Primary Savings
50% 90% Efficiency 93% Efficiency 3% Eff.
3330 MBH Input 3225 MBH Input 3.2% Fuel
3.8 HP Pumping 0.8 HP Pumping 79% Power
33% 92% Efficiency 96% Efficiency 4% Eff.
2175 MBH Input 2080 MBH Input 4.4% Fuel
3.2 HP Pumping 0.3 HP Pumping 90% Power
41 for savings from reduced cycling.
Fuel Savings shown do not account
Comparing the Designs
Simplicity
Complexity
of Variable
of Primary
Flow
Secondary
Primary
Return Supply
Secondary pumps
Primary pumps
(variable
(variablespeed)
speed)
Buffer Tank
Decoupler
Primary pump Primary pump Primary pump
Boiler 1 Boiler 2 Boiler 3
Boiler Isolation Boiler Isolation Boiler Isolation
valve valve valve
42
Primary Secondary vs Variable Flow Primary
Comparison
Primary Secondary Variable Flow Primary Difference
• Boiler pumps • Boiler isolation
• Starter valves
• Check valves
• Strainers
• Buffer Tank
• Electrical
$ 10,450 $2,700 $ 7,750
Above estimates are equipment only – Labor savings is Additional!
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Comparing the Designs
Simplicity of Variable Flow Primary
Modulating
No need for minimum flow bypass
Bypass
Flow Meter
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Comparing the Designs
Primary-Secondary with Low Mass Boilers:
Buffer Tank
45 Co.
Courtesy of Wessels
Comparing the Designs
Primary-Secondary with Low Mass Boilers:
Hydraulic De-Coupler as Buffer Tank
Courtesy of Lochinvar, LLC
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Comparing the Designs
Primary Secondary
Advantages Disadvantages
• Protects the boiler(s) • Fairly extensive piping
- Temperature • Primary and secondary
- Flow pump requirement
• Good system control • Higher operating costs:
possible - Boiler fuel
• Works with any boiler - Electrical
design • Low mass/high DP
• Constant speed pumps
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Comparing the Designs
Variable Flow Primary
Advantages Disadvantages
• One set of pumps • Boiler first cost may be
• Significantly reduced higher
piping • Possibly a slightly
• Low installed cost larger footprint
• Large mass allows
lower firing rates
• Lowest fuel & electrical
costs
• No boiler corrosion,
thermal shock or flow
requirements
• Lowest life cycle cost
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Keys to Efficient Hydronic System Design
• Low Supply Water Temperature
• High Delta T
• Outdoor Air Reset
• Variable Flow Primary with High Mass
Condensing Boilers
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Contact Us
• Gregg Achtenhagen, P.E.
Senior Manager, Packaged Boiler Systems
[email protected] 414-577-2707
www.cleaverbrooks.com
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