City University of Hong Kong

Division of Building Science and Technology

Associate of Science in Building Services Engineering

BST20532 HVAC SERVICES 2

HYDRONIC SYSTEMS & APPLICATIONS (2)

AIMS & OBJECTIVES

After studying this lecture notes, students are expected to:
• appreciate the role of chemical water treatment and feed and expansion system in hydronic systems;
• appreciate the common practice and applications of hydronic systems.

OUTLINE
(Cont’d)

4. Chemical Water Treatment System

4.1 Benefits and Control of Water Treatment (Water Conditioning)
4.2 Equipment of Water Treatment System
4.3 Design Scheme of Water Treatment for Hydronic Systems

5. Feed and Expansion System

6. Pipes and Accessories of Hydronic Systems

6.1 Pipes and Fittings
6.2 Valves
6.3 Measuring Devices
6.4 Thermal Insulation
6.5 Accessories
6.6 Typical Connection Arrangement of Equipment

Tutorial
BST20532 HVAC Services 2 - Hydronic Systems & Applications (2)

4. CHEMICAL WATER TREATMENT SYSTEM

Water used in water side systems may create problems to equipment and pipework
itself such as scale formation, corrosion, and organic growths. As a universal solvent,
water dissolves gases from the air and mineral matter from the soil and rock with
which it comes in contact. Environmental conditions at the air conditioning
equipment may promote slime and algae. Moreover, hard water in a natural state is
scale forming and, when heated, tends to deposit a lime scale. This deposit and other
impurities accumulate in tubes, valves, pumps and pipe lines, restricting flow and
affecting heat transfer. Therefore application of water treatment system helps to
insure a satisfactory and more continuous operation of the air conditioning system.
Water treatment lowers power and maintenance costs, and increases the equipment
life. A good water treatment programme produced high equipment efficiencies.

4.1 Benefits and Control of Water Treatment (Water Conditioning)

The benefits of water treatment are:

• to insure continuous operation of air conditioning system;
• to lower power and maintenance costs;
• to increase the equipment life; and
• to produce high equipment efficiencies.

Problems Control Remarks

Corrosion – destructive • Use of corrosion resistant materials e.g.
process, by chemical or Titanium
electrochemical reaction • Use of protective coatings for metal
• To add inhibitor
• To reduce or remove O2
Deposits / Scale – increase • Regular blow-down Creating less
the fouling factor, depending • To control pH of water environmental
on hardness of water • Crystal modifier and sequestering chemicals to problems
increase the solubility of the calcium
carbonate
Microbiological e.g. • Biocides* *Detrimental to
bacteria, algae & fungi, • Chlorine & chlorine compounds* environment if
macro-organisms • Biostat they are used in
• Chlorine* excess
Suspended Solids – abrade Strainer, filter
equipment and pipelines
when flowing at high speed

In any case, blow-down / bleed-off is effective to maintain the water quality.

4.2 Equipment of Water Treatment System

In order to feed the chemical into the water side systems for water treatment
and conditioning, a packaged chemical feed system which comprises full set
of equipment including:

a. Chemical tank: made of polyethylene (or steel), with lid;

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b. Chemical feed pump: positive displacement diaphragm type

providing fully adjustable output capacity over the operating range
(typically 2 litre to 90 litre per hour), timer controlled and programmed
to provide scheduled dosage to the hydronic systems;
c. Liquid agitator: for well mixing and preventing settlement of
chemicals;
d. Liquid level switch: to switch off the chemical feed pump and agitator
when the tank becomes empty;
e. Discharge tube: usually 10 mm internal diameter and of suitable PVC
to transport the chemical solutions involved;
f. Accessories mainly including suction side strainer and discharge side
relief valve.

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4.3 Design Scheme of Water Treatment for Hydronic Systems

The treatment equipment and chemicals should be selected according to the

make up flow rates, system temperatures and pressures, system water capacity,
etc. The treatment plants will maintain the water system quality requirements
according to certain standard during system operation. The following
illustration shows the requirements for a typical hydronic systems.

pH value: 8.0 - 10.0

Turbidity: < 20 ppm
Total iron increment: < 0.2 ppm
Total dissolved solid: < 0.2 ppm
Nitrite: 500 - 1000 ppm
Bacterial count: < 10000 npml
Total hardness (as CaCO3): < 50 ppm

According to the above requirements, the treatment chemicals and method of

application are proposed in the following table:

Hydronic System Chemicals Method

(for illustration only)
Chilled water Drewsperse 734, 738, Time controlled dosing into
Drew CWT 110, the main return flow header
Biosperse 201 and 240 with of the chilled water pumps.
appropriate defoamer.
Condenser (cooling) Drewsperse 734, 738, Time controlled dosing into
water Drewgard 180, the main return flow header
Biosperse 240 with appropriate of the condenser (cooling)
defoamer. water pumps.

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5. FEED AND EXPANSION SYSTEM

No matter the water side system carries closed-loop chilled water or hot water, the
water inside the pipework will undergo expansion and contraction, especially during
start-up or turn-off of the chillers or boilers. In this situation, a tank system which can
make up the deficiency of water due to contraction; and store up the surplus of water
due to expansion is required for such thermal change. Therefore this is called the
“feed” and “expansion” system and the types are discussed as follows.

Open F & E Tank System

An ordinary water tank is connected to the suction side of the water system (usually
before pump set) and would be situated at the highest point (usually the roof) of
whole water system.

Closed F & E Tank System

Sometimes there may have space problem to locate an ordinary tank at the highest
point of the water system, then a closed type of F & E tank will be used. The tank is
still connected to the suction side of the water system, but it can be installed at any
convenient location inside the building. However the configuration of the tank is
different that usually has a pressurized diaphragm to cater for the buffer (contraction
and expansion) requirement, so this is more expensive than the open type system.

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6. PIPES AND ACCESSORIES OF HYDRONIC SYSTEMS

6.1 Pipes and Fittings

Different water circuit would use different type of pipes as follows:

Water Circuit Material

Chilled water Black steel
Hot water Black steel
Condenser water Galvanized steel
Condensate drain uPVC

The major fittings will include the following type:

• Bend
• Tee
• Reducer/Expander

The pipe connection will have:

• Union joint
• Flanged joint
• Welded joint

6.2 Valves

Valves can be used for isolation, regulation, commissioning of water circuits

according to their design purpose. The commonly adopted types are:
• Gate valve: for isolation and on-off purpose. It can be manual or motorized.
• Globe valve: for regulation, commissioning and isolation of smaller size
pipework.
• Butterfly valve: for regulation, commissioning and isolation of larger size
pipework.
• Check valve/non-return valve: to confine water flow in one direction.
• Double regulating valve: for commissioning.
• Constant flow valve: to keep water flow constant, i.e. not more or less than the
preset value.
• 3-way valve: to mix or divert the water flow.
• Angle valve: similar to gate valve, but installed at pipe turning.
• Ball valve: similar to gate valve, but has more linear characteristic.
• Ball float valve: commonly installed in water tank to stop water flow when the
required water level has been achieved.
• Solenoid valve: electric on-off valve.

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Gate Valve Globe Valve

Butterfly Valve Check Valve

6.3 Measuring Devices

In the water pipework, measuring devices would be installed for monitoring different
characteristics of water flow, these will include:
• Temperature gauges/thermometer
• Pressure gauge
• Flow meter

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6.4 Thermal Insulation

A variety types of thermal insulation are commonly applied in HVAC systems, they
include:
• Phenolic foam (PF)
• Fibre glass (FG)
• Hydrous calcium silicate (HCS)
• Rock wool (RW)
• Magnesia (MN)
• Flexible elastomeric pipe insulation (FE)
• Polystyrene (PS)

Type of System System Equipment/Component Type of Insulation

Water Side
Chilled Water System Pump
Pipe
Valves PF/FG
Fittings and accessories
F & E tank
Condensate Drain System Pipe PF/FG
Valves, fittings and accessories
Hot Water System Pump
Pipe PF/FG
Valves or
Fittings and accessories HCS & RW
F & E tank
Steam System Pipe
Valves PF/FG or MN
Fittings and accessories
Boiler Flue RW
Refrigeration Side Pipework FE

Apart from suitable selection of the insulation type, the following points should also
be noted:
• Pre-formed type is commonly used for pipework insulation.
• Appropriate thickness is required, as usually determined by the fluid temperature,
pipe diameter, shape of the related components, etc.
• Vapour barrier coating is necessary together with the usage of thermal insulation.
• Smoke produced from burning the insulation should be non flammable and toxic.
• For pipework or ductwork inside plant room or exposed outside, PS would be
used, together with wire mesh/cement plastering and the enclosed casing.

For phenolic foam, the thicknesses of insulation to be used for pipework are shown as
follows:

Pipe Diameter (mm) Thickness of Insulation (mm)

50 or below 25
65 - 80 35
100 - 250 40
Above 250 50

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For fibre glass, the thicknesses of insulation to be used for pipework are shown as
follows:

Pipe Diameter (mm) Thickness of Insulation (mm)

Chilled/Heating Water:
up to 40 25
50 - 65 40
65 - 300 50
Above 300 65
Condensate Pipes (all): 15

6.5 Accessories

• Strainer: to remove debris inside the water circuit.

• Automatic air vent: to purge the air trapped inside the water circuit.
• Flexible connector: to be installed at the pipework where it is connected with the
vibrating equipment such as pumps.
• Expansion joint/loop: usually applied at the location where crossing building
joint.

Y-type Strainer (for small installation) Bucket Type Strainer (for large installation)

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6.6 Typical Connection Arrangement of Equipment

Upstream (In) Downstream (Out)

Pump Gate valve Expander (eccentric)
Strainer Flexible connector
Pressure gauge Pressure gauge
Flexible conncector Check valve
Reducer (eccentric) Control valve (on-off)
Globe valve (or butterfly valve)
Cooling coil of AHU/PAU Gate valve Flexible connector
Strainer Temperature gauge
Temperature gauge Control valve (modulating)
Flexible connector Globe valve
Cooling coil of FCU Gate valve Control valve (on-off)
Globe valve
Chiller Gate valve Flexible connector
Temperature gauge Temperature gauge
Flexible conncector Flow switch
Control valve (on-off)
Globe valve (or butterfly valve)

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TUTORIAL - Design of Hydronic Systems in High-rise Buildings

Typical
AHU or
Floor FCU

Chiller

Chiller

Typical Chilled Water Distribution with Reverse Return Arrangement

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Typical AHU or
Floor FCU

Secondary pump
(could be variable
speed pump)
Pumps can size up
to different duties
to match different
zone demands
Primary pump
Chiller

Chiller
Common pipe

Typical Chilled Water Distribution with Primary and Secondary Circuits,

Hydraulically Divided by the Common Pipe

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AHU or
FCU
High zone operate
at a high chilled High
water temperature
e.g. supply at 7°C zone
return at 12.5°C

Mechanical floor/
Heat Exchanger Refuge floor

AHU or
FCU
Low zone could
operate at a lower
chilled water temperature Low
e.g. supply at 4°C zone
return at 9.5°C

Chiller

Chiller

Typical Chilled Water Distribution for High-rise Building more than 100 metres in Height,
Heat Exchanger(s) for Hydraulically Dividing the Circuits of Low and High Zones

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Open Type Feed & Expansion Tank

Min. 1 m
AHU or static head
FCU

To be used when
open type cannot be
installed due to height
or space limitation

Break
Tank
Chiller
Pressurized
Feed & Chiller
Expansion
Tank

Typical Chilled Water Distribution with Open Type Feed and Expansion Tank

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