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CHILLER HEAT LOAD & WATER FLOW

The flow rate necessary to deliver the full output of the heat source at a specific temperature
drop can be found using equation below:

Q = H / (8.01 x ρ x c x ▲T)

Where:

• Q= Water volume flow rate (GPM)

• H = Heat load (Btu/hr)

• ▲T = Intended temperature drop (°F)

• ρ = Fluid's density at the average system temperature (lb/ft3)

• c = the fluid's specific heat at the average system temperature (Btu/lb/°F)

• 8.01 = a constant

In small to medium size hydronic systems, the product of (8.01 x ρ x c) can be taken as 500 for
water, 479 for 30% glycol, and 450 for 50% glycol. The total heat removed by air condition
chilled-
water installation can thus be expressed as

H = 500 x Q x ▲T

Where

• H = total heat removed (Btu/h)

• Q = water flow rate (gal/min)

• ▲T = temperature difference ( 0F)

Evaporator Flow Rate

The evaporator water flow rate can be expressed as

Qe = Htons x 24 / T

Where

• Qe = Evaporator water flow rate (GPM)

• Htons = Air conditioning cooling load (tons)


• T = Temperature differential between inlet and outlet (°F)

Condenser Flow Rate

The condenser water flow rate can be expressed as

Qc = Htons x 30 / ▲T

Where

• Qc = Condenser water flow rate (GPM)

• Htons = Air conditioning cooling load (tons)

• ▲T = Temperature differential between inlet and outlet (°F)

Note the equation above assumes 25% heat of compression.

CONDENSATE GENERATION

Condensate generation in an air condition system where specific humidity before and after are
known can be expressed as

Q Cond = Q air x W Lb / (SpV x 8.33)

Q Cond = Q air x W GR / (SpV x 8.33 x 7000)

Where

• Q Cond = Air Conditioning condensate generated (GPM)

• Q air = Air Flow Rate through the air-handling unit cooling c oil (Cu-ft / minute)

• SpV = Specific Volume of Air (Cu-ft per lb of dry air)

• W Lb = Specific Humidity diff. between inlet and outlet of air stream across coil (lb-H2O per

lb of dry air)

• W GR = Specific Humidity diff. between inlet and outlet of air stream acros s coil (Gr. H2O per
lb of dry air)

FLOW RATES IN HEATING SYSTEMS

The volumetric flow rate in a heating system can be expressed by the basic equation:
Q = H / (Cp x ρ x ▲T)

Where

• Q = volumetric flow rate (GPM)

• H = heat flow rate (Btu/hr)

• CP = specific heat capacity (Btu/lb-°F)

• ρ = density (lb/ft3 )

• ▲T = temperature difference (°F)

The basic equation can be expressed for water with temperature 600F flow rate as:

Q = H (7.48 gal/ft3 ) / ((1 Btu/lb- 0F) (62.34 lb/ft3 ) (60 min/h)▲T)

Or

Q = h / (500 x ▲T)

Where

• Q = Water flow rate (GPM)

• H = Heat flow rate (Btu/hr)

• ▲T = Temperature difference (0F) (usually 20ºF)

For more exact volumetric flow rates for hot water the properties of hot water should be used.

Water Mass Flow Rate Water mas s flow can be express ed as:

m = h / ((1.2 Btu/lb- 0F) x ▲T)

Where

• m = mass flow (lb/hr)

The specific heat of water is 1 calorie/gram °C = 4.186 joule/gram °C


which is higher than any other common substance. As a result, water plays
a very important role in temperature regulation.
The specific heat is the amount of heat per unit mass required to raise the
temperature by one degree Celsius. The relationship between heat and
temperature change is usually expressed in the form shown below where c
is the specific heat.

One small calorie is approximately 4.2 joules (so one large calorie is
about 4.2 kilojoules). The factor used to convert calories to joules at a
given temperature is numerically equivalent to the specific heat capacity of
water expressed in joules per kelvin per gram or per kilogram.

The viscosity of a fluid is a measure of its resistance to


gradual deformation by shear stress or tensile stress.[1] For
liquids, it corresponds to the informal concept of
"thickness"; for example, honeyhas a much higher
viscosity than water.[2]

Pump and volute casing

The volute of a centrifugal pump is the casing that receives the fluid being pumped by the impeller,
slowing down the fluid's rate of flow. A volute is a curved funnel that increases in area as it
approaches the discharge port.[1] The volute converts kinetic energy into pressure by reducing speed
while increasing pressure, helping to balance the hydraulic pressure on the shaft of the pump.[2]

Pipe sizing guide based on 10' Head loss/100' of pipe (Old steel pipe C = 100 )

1-1/2" = 30
1/2" = 2 GPM 4" = 320 GPM
GPM
3/4" = 5 GPM 2" = 50 GPM 5" = 600 GPM
2-1/2" = 90
1" = 10 GPM 6" = 900 GPM
GPM
1-1/4" = 20
3" = 160 GPM 8" = 2000 GPM
GPM
These figures are based on a 100 ft run in steel pipe. In most cases the flow rates will be
better.

Worked Example
Design/size the chilled-water pipe for an AHU of capacity 50 tons (176 KW).

Step 1: Calculate chilled-water flow rate


Capacity = 50 Ton
dT = 5.5 oC
CHW flow = 7.63 l/s

Step 2: Calculate pipe size


Flow rate = 7.63 l/s
Pipe vel = 2.1 m/s
Pipe size = 68.02 mm dia
Selected pipe = 80 mm dia
Actual vel = 1.52 m/s

Step 3: Calculate pipe friction loss


(Pipe frictional loss calculations by Darcy method)
Flow rate = 7.63 l/s
Pipe size = 80 mm dia
Density = 1000 kg/m3 (Water @ 10 oC)
Dynamic viscosity = 1.306 cP
Roughness = 0.046 mm (Steel)
Velocity = 1.52 m/s
Reynolds number = 92,982
friction factor = 0.020818
Friction loss = 0.00300 bar/m
Friction loss = 0.29980 kPa/m
Friction loss = 0.03058 m/m

Step 4: Calculate pipe insulation thickness


[1] Ambient Conditions:-
Temperature = 28 oC
RH = 76 %
Dewpoint Temp = 23.37 oC

[2] Surface Air Film:-


Outer Surface = 0.100 m2K/W

[3] Inside Pipe:-


Fluid Temp = 6.7 oC

[4] Bare Pipe:-


Outer Diameter = 88.9 mm

[5] Insulation:-
Thermal Conductivity = 0.023 W/mK
Min. Thickness = 7.70 mm
Surface Temp = 23.37 oC
---------------------------------------
Recommended min. thickness = 19.70 mm
Surface Temp = 26.10 oC

[6] Heat Gain Calculation:-


Insulation thickness = 19.70 mm
Heat gain = 7.64 W/m run
Heat gain = 18.96 W/m2
Surface Temperature = 26.10 oC

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Pump Equations Formulas Calculator


Fluid Mechanics and Hydraulics

Solving For Flow Rate or Discharge


Note: Equation for water at 68 Fahrenheit. Usually, temperature correction for water
is negligible.

Inputs:
water horsepower (WHP)

3.1

horsepower

total head (H)

42

foot

Calculate

Conversions:
water horsepower (WHP)

= 3.1

horsepower

= 3.1

horsepower

total head (H)

= 42

foot

= 42

foot

Solution:
flow rate or discharge (Q)

= 292.28571428571
gallon/minute

Other Units:
= 0.0184403631192

meter^3/second

= 66385307.22912

cc/hour

= 18440.3631192

centimeter^3/second

= 66385307.22912

centimeter^3/hour

= 11064.217871498

deciliter/minute

= 39.072916666667

foot^3/minute

= 0.65121527777778

foot^3/second

= 292.28571428571

gallon/minute

= 1593247.373922

liter/day

= 1106.4217849392

liter/minute

= 18.4403631192

liter/second

= 1593.2473734953

meter^3/day
= 1.1064217871498

meter^3/minute

= 66385307.22912

milliliter/hour

= 1106421.787152

milliliter/minute

Change Equation
Select to solve for a different unknown
Water Horsepower
Solve for water horsepower

Solve for flow rate or discharge

Solve for total head

Solve for pump efficiency

Solve for brake horsepower

Net Positive Suction Head and Cavitation


Solve for NPSH - net positive suction head

Solve for fluid or liquid velocity

Solve for pressure at impeller inlet

Solve for fluid or liquid vapor pressure


Solve for specific weight of fluid or liquid

Solve for the acceleration of gravity

Where
WHP = water horsepower
Q = flow rate or discharge

H = total head

n = pump efficiency

BHP = brake horsepower

NPSH = net positive suction head

V = velocity of fluid or liquid

p = impeller inlet pressure

pv = vapor pressure of fluid or liquid

SW = specific weight of fluid or liquid

g = acceleration of gravity

References - Books:
1) P. Aarne Vesilind, J. Jeffrey Peirce and Ruth F. Weiner. 1994. Environmental
Engineering. Butterworth Heinemann. 3rd ed.

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Ta WK2 x Change in RPM


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FL Speed = Full Load Speed (Rpm)


Where
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Reflected
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(Reduction Ratio)2

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What is the head pressure of water per foot?
1 foot of water = 0.433 pounds per square inch pressure.
2.31 feet of water = 1 pound per square inch pressure.
A PSI to Feet Scale illustrates a scale for converting units of pressure and head.

How many PSI is a foot of water?


x 1 in.). The column exerts 0.433 pounds per square inch of pressure. One
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Definition: Pound/square inch

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in air at sea level.

How many meter of head in 1 pounds per square inch? The answer is 0.703249614902.

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PUMPS

Understanding NPSH: NPSH Definitions


THIS TOPIC SPONSORED BY
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by Terry Henshaw, P.E.

Definition of NPSH
The margin of pressure over vapor pressure, at the pump suction nozzle, is Net Positive Suction
Head (NPSH). NPSH is the difference between suction pressure (stagnation) and vapor pressure.
In equation form:

NPSH = Ps - Pvap
Where:

NPSH = NPSH available from the system, at the pump inlet, with the pump running

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Ps = Stagnation suction pressure, at the pump inlet, with the pump running
Pvap = Vapor pressure of the pumpage at inlet temperature
Since vapor pressure is always expressed on the absolute scale, suction pressure must also be in
absolute terms. In U.S. customary units, both pressures must be in psia. Gauge pressure is
converted to absolute pressure by adding atmospheric pressure. In equation form:

absolute pressure = gauge pressure + atmospheric pressure


The above equation provides an answer in units of pressure (psi). This can be converted to units
of head (feet) by the following equation:

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h = 2.31p/SG
Where:

h = Head, feet
p = Pressure, psi

SG = Specific gravity of the liquid

Problem No. 1: NPSH


Stagnation suction pressure is determined to be 1-psig at a sea level installation. The vapor
pressure of the liquid is 8-psia. Calculate NPSH in PSI and feet for a 0.9 SG liquid

NPSH = Ps - Pvap = 1 + 14.7 - 8 = 7.7 PSI


NPSH = 2.31p/SG = (2.31) (7.7)/0.9 = 19.8 FEET
Velocity Head is Included
Note that suction pressure is stagnation pressure (total pressure); it includes velocity head.
Adding velocity head puts all pumps on the same basis, otherwise a pump would require
different amounts of NPSH when tested with different sizes of suction lines (assuming that
suction pressure is measured in the suction line, which is normally the case).

It should also be noted that the velocity head is normally quite small, relative to the NPSH, so it
can usually be ignored.

Units of NPSH
For centrifugal pumps, NPSH values are expressed in units of specific energy (equivalent
column height) such as feet or meters. For displacement pumps (rotary and reciprocating), NPSH
values are normally expressed in pressure units such as pounds per square inch (psi), kilopascals,
or bars.
NPSH values are neither gauge pressures nor absolute pressures. The g in psig means that the
pressure is measured above atmospheric pressure. The a in psia means that the pressure is
measured above absolute zero, a perfect vacuum. NPSH is a measurement of pressure above
vapor pressure, so the units of NPSH (in the U.S.) are just psi or feet.

Pumps:
Different Types of Pumps – Positive Displacement Pumps
Positive Displacement Pumps

Positive Displacement pumps are generally used for specialist applications such as for pumping viscous liquids
or liquids that contain suspended or fragile solids. These pumps are typically not capable of such a high flow
rate as say, a centifrugal pump, but they are capable of producing much higher pressures.

Principle of Operation

A positive displacement pump makes a fluid move by trapping a fixed amount of the fluid and forcing
(displacing) that trapped volume into a discharge pipe or discharge system.

Some positive displacement pumps use an expanding cavity on the suction side and a decreasing cavity on the
discharge side. Liquid flows into the pump as the cavity on the suction side expands and the liquid flows out of
the discharge as the cavity collapses. The volume remains constant through each cycle of pump operation.
Positive Displacement pumps do not use impellers, but rely on rotating or reciprocating parts to directly push
the liquid in an enclosed cavity, until enough pressure is built up to move the liquid into the discharge system.
The pump does not rely on raising the velocity of the fluid as the centrifugal pump does by moving the liquid
through the impeller. Consequently, the fluid velocity inside a positive displacement pump is much lower than
that of a centrifugal pump. This is often a desirable feature for certain applications, such as when needing to
pump a media containing fragile solids.

Pump Characteristics

Positive displacement pumps, unlike centifrugal or roto-dynamic pumps can theoretically produce the same
flow at a given speed (RPM) no matter what the discharge pressure. Therefore, positive displacement pumps
can be regarded as constant flow devices. However, a slight increase in internal leakage as the pressure
increases can prevent a truly constant flow rate.
In application, a positive displacement pump must not be allowed to operate against a closed valve on the
discharge side of the pump, because it has no shutoff head like a centrifugal pump. With the pump operating
against a closed discharge valve, it will continue to produce flow and the pressure in the discharge line will
increase until the pipeline can either fracture or the pump can become severely damaged, or both.

To prevent this, a relief or safety valve on the discharge side of the positive displacement pump is therefore
often necessary. This relief valve can be positioned either internally or externally to the pump. The pump
manufacturer normally has the option to supply internal relief or safety valves. An internal valve is usually
only used as a safety precaution, but an external relief valve in the discharge line, with a return line back to the
suction line or supply tank will provide increased safety.
Typical Specification of Positive Displacement Pumps

Positive displacement pumps are generally available to deliver performance in accordance with the following
ranges:

 Flow rates range between 0.4 to 55,000 lpm

 Total head (pressure) ranges between 0.7 and 6800 Bar

 Horsepower ranges between 0.5 and 4,900 hp

 Viscosity limits vary with pump type.

Different types of positive displacement pumps

There are various types of positive displacement on the market and they are often classified according to the
mechanism used to move the fluid. For example;

Rotary Pumps Positive Displacement


These include gear, screw, vane, peristaltic, lobe, and progressive cavity and they all use rotating parts to move
the liquid into and out of the pump chamber. Some rotary pumps, such as gear pumps, must have very tight
clearance between the rotating elements and the walls of the chamber, and between the rotating parts, which
means they generally can’t be used to pump large solids or abrasive fluids that may wear the parts. Other types
such as lobe pumps and progressive cavity pumps are designed to move liquids containing solids.

Reciprocating Pumps Positive Displacement


Including plunger, diaphragm, piston, hydraulic, and many others – use a repetitive reciprocating mechanism
to expand and contract the chamber at regular intervals. Reciprocating pumps incorporate one or more sets of
check valves at the inlet and outlet of the pump to help guild the liquid through the pump and to prevent
reverse flow.

Linear Type Positive Displacement


The chain pump is type of a water pump in which several circular discs are positioned on an endless chain.
One part of the chain dips into the water, and the chain runs through a tube, slightly bigger than the diameter of
the discs. As the chain is drawn up the tube, water becomes trapped between the discs and is lifted to and
discharged at the top.

Diaphragm Pumps Positive Displacement


A diaphragm pump is a particular type of positive displacement pump that uses the reciprocating action of a
flexing diaphragm to move fluid into and out of the pumping chamber.
The flexing diaphragm creates a vacuum at the inlet of the chamber that draws the fluid into the chamber.
When the diaphragm moves in the opposite direction, it causes the volume of the pumping chamber to
decrease, forcing the fluid out the discharge port of the pump.

Diaphragm pumps use check valves at the inlet and outlet of the pumping chamber to ensure that the fluid
flows in one direction and out the other without leaking backwards.

Primary advantages of Positive Displacement pumps


1. In general, positive displacement pumps are ideal for applications where a constant flow is needed.

2. They create medium to high pressure and are often an excellent way to pump oils and other viscous
fluids.

3. Positive displacement pumps are also extremely useful for applications requiring a combination of low
flow and high pressure. For example, to move fluids containing suspended or fragile solids.
- See more at: http://www.processindustryforum.com/article/different-types-pumps-positive-displacement-
pumps#sthash.BpHnuVfa.dpuf

How do Centrifugal and Positive Displacement Pumps Work?

Nearly all pumps fall within these two categories, with centrifugal being the most
common. However, positive displacement pumps come in a wider variety such as gear,
lobe, peristaltic, screw, and many other types of pumps.

The most common type among centrifugal pump is the radial flow pump. These
centrifugal pumps use a rotating impeller to create a vacuum in order to move fluid.
The pump’s impeller rotates within the housing and reduces pressure at the inlet. This
motion then drives fluid to the outside of the pump’s housing, which increases the
pressure enough to send it out the discharge.

There is also the axial flow centrifugal pump which uses a curved propeller-shaped
impeller, whereas the impeller on a radial flow centrifugal pump looks more like a fan.
Axial flow pumps move fluid by drawing fluid into their axis and using the impeller to
send fluid out on the other side of the pump.
Positive displacement pumps draw fluid into a compartment at the inlet and move it to
an outlet for discharge, most typically using a rotary, reciprocating, or diaphragm
method to move fluid. The main difference between these types of pumps and
centrifugal is that positive displacement pumps will move fluid at the same speed
regardless of the pressure on the inlet end and centrifugal pumps will not.

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