ISHRAE

Variable Volume Pumping Fundamentals

HVAC engineers have been using primary-secondary pumping to design the
most cost-effective pumping system while meeting their clients' needs.

By Kenneth R. Luther
Manager Engineering Services,
TT Fluid Handling,
Morton Grove, III
It is the objective of the HVAC engineer to design the most cost-effective
pumping system while meeting the clients' needs. Primary-secondary pumping is
a tool HVAC engineers have been using for nearly 50 years to accomplish this
objective.'
ASHRAE/IES Standard 90.1- 1989 - Energy Efficient Design of New
Buildings Except Low-Rise Residential Buildings requires "all pumping systems
2

with modulating or step open and closed valves which have total pump system
horsepower greater than 10 must be capable to flow at 50 percent of design value
or less." The standard 90.1 - 1989 User's Manual "highly recommends" primary-
3

secondary pumping for "systems with large, high pressure drop distribution
systems such as those serving campuses and airports."
Primary-secondary pumping (Fig. 1) provides the means for the constant
volume pumping of the low horsepower primary pumps through the chiller.
These pumps are lower horsepower than the secondary pumps because they only
haves to overcome the friction loss associated with the chiller, pipes, and valves
in the primary loop. The chiller pumps are balanced to the design flow rate.
Pump impellers should be trimmed discharge of the pump. This is an important
energy saving measure.
The secondary pumps are higher horsepower because they must overcome
the friction loss associated with the secondary loop-the distribution piping,
fittings, valves, coils, etc. These pumps operate in the energy saving variable
volume mode. Depending on the return on investment, the secondary pumps
either remain constant speed and ride their characteristic head-capacity curve, or
the designer can incorporate adjustable frequency drivers to saves additional
pumping energy (Fig. 2)
There are three critical design areas that must be considered for any variable
volume pumping system:
• The common pipe
• Chiller sequencing
• Control valves and actuators

[top]

Common pipe design

The design of the common pipe (Fig. 3) is critical to the performance of a
primary-secondary system. The function of the common pipe is to decouple
hydraulically the primary and secondary pumps while still providing thermal
interaction. To ensure proper system performance, the common pipe design
criteria are:
• The maximum pressure drop in the common pipe shall not
exceed 1.5 ft - Establish the pressure droop in the common pipe by assuming
the flow of the largest resultant pressure drop should not exceed 1.5ft. This is the
basis of primary-secondary pumping. Higher friction loss in the common tends to
make the primary and secondary pumps act in series, resulting in an induced
flow in the system. (This incorporates a safety factor.) Typically, a chiller is
usually sequenced on or off y the time one half of the flow of the largest pump is
achieved. For simplicity of design and installation, the common pipe is often the
same diameter as the distribution piping.
• Maximum three pipe diameters of separation between the
secondary supply tee and the secondary return tee - A common pipe of
this length is more than adequate to eliminate mixing due to excessive return
velocity in the secondary return piping. Loner length common pipes may result in
an excessive pressure drop greater than 1.5 ft with results as described above.
Under no circumstances should a check valve be located in a common pipe.
The addition of a check valve will result in the primary and secondary pumps
acting in series when secondary (distribution) flow exceeds primary (production)
flow. The increase in demand results in an increase in flow through the chiller
that fan lead to higher chiller discharge temperatures and chiller tube erosion.
Further details on this subject are discussed below in the chiller sequencing
section.
Other terms are often used interchangeably when discussing primary-
secondary pumping. The primary system is also known as the production system
- the place where the chilled or hot water is produced.
The secondary systems are also called the distribution because its purpose is
to convey the chilled and hot water to and from the load(s).
The common pipe is also known as a decoupler. This pipe - common to both
the primary and secondary systems - provides the hydraulic separation between
the two.
Chiller sequencing
Proper chiller sequencing plays an important role in the overall performance
of a primary-secondary pumping systems. The operator of the system must
recognize the three flow conditions that can occur. These are:
• Distribution (secondary) flow equals production (primary) flow.
• Distribution flow is greater than production flow. ·
 • Production flow is greater than distribution flow.
• Distribution flow equals production flow - Although this flow
condition rarely occurs, we will observe the flow pattern of this scenario (Fig. 4).
The chiller is supplying 1500 gpm of 45F water to the load systems. The two way
valves in the secondary are responding to conditions equal to 1500 gpm x 10F ∆T
x 500 = 7.5 MBtuh or 625 tons. The two-way valves, coils, and associated piping
represent a pressure drop of 100ft. The secondary pump is riding its curve,
producing the required 1500 gpm at 100ft of head. Because the load is equal to
625 tons, the return water temperature to the chiller is 55F at a flow rate of 1500
gpm. The thermal balance is complete. There is no flow in the common pipe. The
remainder of the time the secondary or load flow will be greater or less increases
in the space, the two-way valves begin modulating to a more open position and
deliver additional chilled water to satisfy the additional load. When this occurs,
the pressure and flow relationship changes such that the distribution flow is
greater than the production flow (Fig. 5)
 [top]
• Distribution flow greater than production flow - With this
condition, the flow rate through the chiller is 1500 gpm at 45F. Because the flow
rate is fixed at 1500 gpm, the pressure drop in the primary loop is constant. As
the load increases in the secondary and the two-way valves modulate open in
response, the secondary pumps run out on their curves corresponding to the
reduced pressure, flow increases to the required 2000 gpm. If 2000 gpm is
flowing into the secondary, 2000 gpm must return from the secondary. The
balanced chillers will only accept 1500 gpm.
To balance the mass flow, the excess 500 gpm must run through the common
pipe. The temperature of the 500 gpm in the common pipe is 55F. This blends
with the 1500 gpm of 45F supply water, resulting in 2000 gpm of 47.5F blended
supply water.
Whenever the flow is greater in the distribution loop than in the production
loop, the excess flow in the common pipe is in the direction towards the
secondary pumps. The result will always be a blending of the return water with
the supply water at a temperature higher than what the chiller produces. What
will happen to the temperature control? A higher supply water temperature could
mean a loss of humidity control in the Zones. Higher supply water temperatures
must be considered during the coil selection process.
 Other options can be considered. For example, chiller temperature reset can
be employed. Within the limits of the type of machine, chiller temperatures can
be reset to a lower temperature to compensate fort he increased load and
secondary flows. In essence, more capacity is provided at a lower operating
efficiency. The increase in cost of chiller operation due to the lowering of the
chiller supply temperature can range from 1 to 3 percent per degree of reset. This
is a very desirable alterative, especially when large chillers are in use. The longer
the start of a lag chiller can be in use. The longer the start of a lag chiller can be
delayed, the better it will perform when it is finally brought on line.
If a small portion of the load requires a fixed temperature, a small chiller in
series with the load may also be considered.
• Production flow greater than distribution - When incremental chiller
capacity is added, the third flow condition occurs (Fig 6). The flow rates through
the chillers are again fixed, this time at 3000 gpm. The new load is 875 tons. As
we are again seeing a 45ºF supply water temperature and a 55ºF return water
temperature, the flow rate for the secondary pump is 2100 gpm delivered to the
secondary and 3000 gpm being pumped in the primary loop, there is an excess
flow of 900gpm. The 900 gpm excess must flow through the common pipe at the
chilled water supply temperature of 45ºF. The 900 gpm common flow blends
with the 2100 gpm secondary chilled water return to produce 300gpm at a
reduced entering chilled water temperature of 52ºF.
All chilled water retuning to the chilled waters plant is blended prior to
reaching the chillers. All t of the chillers on line will therefore be receiving the
same temperature water at their return. When the system is piped in this
manner, the chillers will always be equally loaded. Furthermore, the chillers will
always be subjected to their design flow at an equal temperature. Because the
chillers are receiving heir design flow rate at 52ºF rather than the design
temperature of 55 F, the chilers will be "unloaded" at the ratio of:

DT = Design return temperature

R
 AT = Actual return temperature
R

DT = Design water temperature

W

DT = Design supply temperature

S

When piped with a common, the flow through the chillers is a constant. In
our example, the two steps are either 50 percent flow (1500 gpm) or 100 percent
flow (3000 gpm). The secondary flow is very close to a "linear function." As the
two-way valves modulate in response to a varying load, the flow follows directly.
The more chillers in the plant, the smaller the steps. If we incorporate chillers in
a variety of sizes, the incremental steps are smaller. The additional chillers and
variety of chiller sizes can produce a curve that is nearly linear. When the chiller
plant is designed to produce a near-linear flow function, the supply temperature
rises, the secondary is minimized, and the increased supply waters temperature
lasts for a shorter duration. This is a very critical factor in design regions where
humidity control is a concern.
Chiller sequencing can be as simple as manually turning on and off a second
chiller. It can also become complex when multiple chillers of different sizes,
types, and efficiency are installed. The chiller manufacturer is usually best suited
to provide the information and instrumentation to effectively stage and destage
its product.
 [top]
Conceptually, the designer needs to determine the best combination of
chillers that will meet the flow demand. This is often done by calculating the Btuh
consumed (Fig 7). Instrumentation must be provided to determine:
Secondary supply water temperature, T . S.S

Secondary return water temperature, T S.R

Secondary flow, F S

The amount of cooling Btuh produced is also valuable information. The

necessary instrumentation is:
Primary supply water temperature (chiller leaving), T P.S

Primary return water temperature (chiller entering), T P.R

Primary flow (chiller flow), F P

An algorithm is then prepared, which utilizes the best combination of chillers

for the actual load. The measurement of flow and direction in the common pipe
does not provide the operator with enough information to determine the time of
sequencing. The same can be said for the measurement of flow in the secondary
system.
Control valves and actuators
Control valves are a critical part of the variable volume hydronic system. The
control valves functions are to vary flow properly through the water coil in
response to a variety of building load conditions. Because of their critical nature,
great care must be taken when selecting control valves so they perform properly.
Undersized valves may provide insufficient capacity while oversized valves
provide poor control. Equal percentage type valves are typically applied to
cooling and heating coils because of their favorable flow characteristic. They
provide a high degree of control accuracy with wide variations in pressures, flow
the heat transfer characteristic of a cooling coil, the change in stem position
almost provides a nearly linear change in heat transfer if an equal percentage
control valve is used.
Knowing the maximum differential pressure across the valve at any flow is an
important criterion for valve selection for two reasons (Fig 7):
• Choosing the appropriate actuator
• Avoiding valve noise and cavitation in valves and piping
In variable volume systems, the selected valve actuator must be capable of
closing the valve against the maximum pump head pressure (Fig 8). In variable
volume closed loop systems, all loads could be reduced causing the pump to ride
back on the pump curve. As the pump rides back on the curve, the head being
produced by the pump increases. The control valve actuator must be strong
enough to continue modulating the valve closed as the pressure increases. In the
worst case, this could be the "shutoff pressure" being produced by the pump.
Improper actuator sizing may result in some water passing through the valve and
coil, which add to low return water temperatures.
Excessive valve noise and valve cavitation are caused by high liquid velocities.
As water passes through a valve, it is accelerated. With the increase in velocity
pressure, the static pressure falls. If it droops below the vapor pressure, bubbles
form. Then immediately downstream of the valve, velocity decreases and the
static pressure increases, causing the bubbles to collapse. The result is noises
coupled with excessive wear in the valve body, throttling mechanisms, and
sometimes in the downstream piping where this takes place.
When variable speed secondary pumping is employed, valves are normally
subjected to less differential pressure. In this mode the pump follows the
characteristic control curve (Fig. 2) This results in reduced differential pressure
when conditions are at less than maximum design. Care must still be taken if an
across-the-line (ATL) adjustable frequency drive bypass (electrical bypass) is
used. When the system function in the ATL mode, the pump acts like a constant-
speed pump. It is now following the pump flow-head curve at a much higher
pressure. The designer may overlook this condition. Under low flow conditions,
the valves may lift up as described earlier. If the selected actuators have in
adequate holding power at the higher head shut-off condition, the valves may lift
up as previously described.
Three-way valves have little use invariable volume pumping systems. Three-
way valves bypass unused chilled water past the load; this results in multiple
problems. Bypassed water lowers the return water temperature and increases
flow rates. As a result, additional chillers and pumps are brought on-line to
provide flow, rather than to control the cooling load.
 A circumstance where three-way valves can be used (carefully) in the system
is to maintain minimum flow as a means of pump protection. As a rule of thumb,
the Hydraulic Institute and ITT Fluid Handling recommend a minimum flow
4

rate of 20 percent of the best efficiency point flow rate. To limit the radial and
axial loads and shaft deflection, our recommendation is to maintain a minimum
flow rate of 25 percent of the best efficiency point flow rate.
The Hydraulic Institute and ITT Fluid Handling also recommend limiting the
temperature rise of the fluid flowing through the pump to 15F. (This is not to be
confused with the system temperature rise.) When a pump is operating in a low
flow condition, the temperature rise occurs in a small volume of water. If an
insufficient volume of water flows through a pump, the inefficiency of the pump
is converted to heat. In time, the heat build-up can cause the fluid to vaporize and
eventually result in cavitation.
To calculate the flow rate for a 15F temperature rise use the following
equation :

Where:
Q = Minimum flow rate, gpm
P = Input power at the minimum flow rate, hp. Assume that the shutoff hp is
approximately equal to the minimum flow rate hp
2.95 = Constant, (hp - lb - min - F) /(Btu.gal)
C = Specific heat, Btu/(lb.F)
P

S = Specific gravity
When careful attention is given to these fundamentals, energy savings will be
achieved and design system ∆T will be achieved. As system characteristics change
due to load changes, the aging of the piping and coils, or even as coils get dirty,
system ∆T may suffer. There is no substitute for knowledgeable operators and
proper thermostats and the lowering of supply air temperatures will only add to
the inefficiency. Unless problems are cured only patches can be applied to treat
symptoms. "Fixes" consume additional energy. The only way to keep a properly
designed HVAC system operating efficiently is to maintain it in the appropriate
manner.

[top]

Conclusion
To optimize system performance and design flexibility, the designer must
select the type of distribution piping and pumping configuration that will best
meet the needs of the client. The following are the four basic types of pump0ing
systems in use today.
• Primary-secondary
• Primary-secondary-tertiary
• Primary-secondary zone
• Primary variable speed
These pumping methods will be discussed in a second article in this series.

References
1. Primary-Secondary Pumping Application Manual, ITT Fluid Technology
Corp., Morton Grove, III., 1968
2. ASHRAE/IES Standard 90.1-1989-Energy Efficient Design of New
Buildings Except Low-Rise Residential Buildings, Section 9.5.5, AHSRAE,
Atlanta, Ga., 1993
 3. ASHRAE/IES Standard 90.1-1989-User's Manual, pp 9-59, ASHRAE,
Atlanta, Ga., 1993
4. American National Standard for Centrifugal Pumps for Nomenclature,
Definitions, Application, and Operation, ANSI/HI 1.1-1.5-1994, Section
1.3.3.2.4.2, pp 83-84, Hydraulic Institute, Parsippany, N.J., 1994

Biblography
1. ASHRAE Handbooks: 1995 HVAC Applications; 1996 HVAC Systems and
Equipment; 1997 Fundamentals, Atlanta, Ga.
2. Bell & Gossett Large Chilled Water System Design Manual, ITT Fluid
Handling Corp., Morton Grove, III., 1965.
3. Bell & Gossett Large Chilled Water System Design Manual, ITT Fluid
Handling Corp., Morton Grove, III., 1996.