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Section C

Definitions, analysis and corrective procedures regarding the problem of System Air in closed hot water and chilled water HVAC systems

Chapter One
SYSTEM AIR ITS COMPOSITION, CHANGES OF STATE TRADITIONAL METHODS OF CONTROLLING BASIC DEFINITIONS
OF SYSTEM AIR AND ITS CHARACTERISTICS AND

PHYSICAL

To properly approach the problem of System Air and its solution, we must first understand and agree to what it is and what it does in the closed piping system. Traditionally, the term System Air had been widely used to designate the presence of gaseous fluids in the closed piping system. It should be more properly defined as a gas mixture which changes its physical form as well as its chemical composition during system operation and life. The chemical composition of air is mainly oxygen and nitrogen with a small portion of other gases which vary according to local conditions. For purposes of our discussion, here, we will assume that air is composed of 21% oxygen (including a small mixture of other gases) and 79% inert nitrogen by volume.

The Gas % of Air Nitrogen . . . . . . . . . . . . . . . . . . . . . . . .78 Oxygen . . . . . . . . . . . . . . . . . . . . . . . . .21 (plus other gases)

Changes in Chemical Composition


When air is introduced into a closed piping system filled with water, it undergoes a major change in chemical balance. As air is carried throughout the system in a dissolved state (in solution), its oxygen content combines with metallic surfaces to form oxides. In addition to causing corrosion, this portion of the air mass is no longer present as air in the system. The remaining air mass is the inert gas nitrogen. In other words, there is a reduction of the air mass in a gas state to 78% of its original volume. This change in chemistry begins fairly quickly after air is introduced. It should be noted that when in a gaseous state, oxygen will not readily combine with metallic surfaces.
Oxygen (21%) Forms Ferrous Oxide or Rust

Inert Nitrogen (78%) or "System Air"

Changes in Physical Form


System Air can exist in the water-filled piping in three physical forms: 1. Free Air Bubbles: In this state, free air bubbles locate or collect at the top of vertical and horizontal pipes as well as at the top of system components such as boilers, terminal units and the expansion tank. This occurs when high temperatures and low pressures are present to allow the formation of air bubbles and when there is no system flow or in large diameter components where extremely low velocities allow vertical travel of the free air bubbles.
Free Air Bubbles

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AMTROL, Inc. 1977, Reprinted October 2003

2. Entrained Air Bubbles: When system flow is present and velocities are in excess of 1.5 feet per second, the free air bubbles are not allowed to rise and collect, but are carried through the piping system (whenever temperature and pressure conditions will permit the formation of free air bubbles entrained in the flowing fluid).
Entrained Air Bubbles

Air in Solution

3. Air in Solution: At lower temperatures and higher pressures, air becomes more soluble in water. Under these conditions, the air is absorbed or dissolved in the water and carried in the solution. There are no bubbles present. It is much the same as the change occurring when sugar or salt is dissolved in a fluid. It is in this state that air is highly corrosive.

The Symptoms of System Air in Hot Water Heating and Chilled Water Piping Systems
Inefficient Operation = Increased Maintenance and Energy Consumption The predominant problem that occurs in piping systems afflicted with System Air is inefficient operation. Free gas bubbles entrained in system flow can cause harmful cavitation of pumps. Gas bubbles with system fluids not flowing tend to rise and collect in terminal units and high points in the piping system. Many times, a pocket of air will cause a blockage that is not dislodged when flow occurs. This restricts and even stops circulation of hot or chilled water to areas demanding space conditioning. This inefficient operation increases maintenance costs and energy consumption. Corrosion
Blockage Caused by "Air Pockets" Can Restrict or Stop Circulation of Water

The oxygen content of System Air when carried in solution combines with all metallic components of the system including the piping. Deposits of rust also reduce efficient operation, increase energy consumption, and will result in increased maintenance and eventual replacement of inoperative components. The Sources of System Air Designers have traditionally held that there are two main sources of System Air in the closed hot water heating or chilled water system.

Oxygen Forms Ferrous Oxide or Rust

1. Air Absorbed During the Initial Fill of the System It has been contended that as water fills the piping, air is trapped in the system and becomes absorbed in the system water. 2. Air Carried in Solution in Fresh Make-Up Water The other major source of System Air held by tradition is that make-up water which is added to the system during operation carries with it considerable amounts of air in the solution.

1. Initial Fill of System and Compression Tank

Air Separator

Boiler
3. Trapped Air Absorbed as Static Pressure Increases 2. Fresh Water Make-Up

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AMTROL, Inc. 1977, Reprinted October 2003

Plain Steel Expansion Tank Also Considered a Source of System Air. Designers, in recent years, contend that the air cushion in the plain steel tank also contributes air to the system. This has been refuted by advocates of the plain steel tank as they claim air control procedures properly employed will not only result in the escape of air to the system, but also will allow System Air from initial fill and make-up water to be separated, collected and directed to the air cushion in the tank removing it from system piping.
Air Cushion at Minimum Operating Pressure

Air Control vs. Air Elimination


Before a detailed examination of the characteristics of system air can be properly made, we must understand the principles or philosophies behind the two completely opposite practices currently used in combatting System Air. Air Control / Plain Steel Tank The use of the plain steel tank as the pressurizing agent for hot water heating or chilled water systems dictates the necessity of air control. Since it is acknowledged that air is absorbed by system water and carried in solution from the tank to other parts of the system, the advocates of the plain steel tank strongly recommend separating and collecting free air bubbles at a point convenient to the expansion tank. Then, using special devices, direct the collected air bubbles back to the air cushion of the tank to maintain the proper air volume needed for system pressurization. Complete air elimination would remove the effective air volume from the system, hastening the loss of pressurization through waterlogging. Air Control Based on Temperature Increase The underlying philosophy in air control is that air, carried in solution, is brought out of solution as temperature increases. As the temperature increases from ambient to design, water loses its capability to hold air in solution. The often quoted example of a glass of tap water forming air bubbles as it warms from cold tap temperature to room temperature is an example of this philosophy. The familiar term, boiling out the air, is based on this philosophy of air being brought out of solution by temperature increase. Air Control producers, then, dictate locating the separation and collection point in the system where the hottest water is found. This is the supply side, or top, of the boiler. This is also, remember, at the one system point where it is most convenient to direct free air from the separator back to the plain steel expansion tank which is installed directly above the boiler.
220 F

Air Cushion at Maximum Operating Pressure

Air Cushion Contributes Air to System Causing Loss of System Pressure

Special Device Used to Direct Collected Air Bubbles Back to Air Cushion

Compression Tank Location of Separation and Collection Point in System Where Hottest Water Air is Found Separator

240 F

Boiler 200 F

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AMTROL, Inc. 1977, Reprinted October 2003

Air Elimination Requires a Captive Air Cushion The basic difference between air control and air elimination is that with a plain steel tank air cannot be eliminated from the system as this will hasten the waterlogging problem and subsequent loss of vital system pressurization.
Point of Lowest Solubility of Air in Water is at Top of System

However, on the other hand, if the necessary air volume required to maintain system pressurization is sealed-in and not allowed contact with system water during temperature and pressure changes (as in a pre-pressurized diaphragm-type or bladder-type compression tank), then all air in the system piping can be eliminated from the system without adversely affecting pressurization and accommodation of expanded water. Furthermore, since it is not necessary, or advisable, to separate and collect free air at a point convenient to the tank (there is no need to add air to the pressure cushion), then the separation and elimination point can be located in the one place where system water has the lowest capability to hold air in the solution. This point is usually not at the boiler. Pressure Decrease is Key to Air Release A look at the solubility tables 12 and 13 (pages REF-13 and REF14 in the Reference Supplement) for System Air or nitrogen indicates that two changes in system operating conditions will lower the capability of water to hold air in solution. Temperature increase....and pressure decrease. The traditional glass of warm tap water illustrates the lowered capability of water as its temperature rises. If one could also visualize a bottle of soda water, also brought to room temperature, one would see very few bubbles, until the cap was removed. Then the instant pressure decrease would cause a multitude of gas bubbles to instantly come out of solution. This dramatically illustrates the greater affect pressure decrease has in lowering the capability of water to hold air or gas in solution. In fact, as we shall see in Chapter Two of this section, pressure decrease and increase determine the rate and amount of air that comes out of solutionwhere it comes outand where it goes back in. While temperature does have an effectthe greater impact of pressure change often counteracts the effect of temperature change and becomes the determining factor for the change from air in solution to free air bubbles and back.

Boiler

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AMTROL, Inc. 1977, Reprinted October 2003

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