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5. Circulation pump dimensioning

5.1 The operating point of the circulation system In the circulation system, pressure drop and volume flow are directly dependent. Equilibrium always occurs between the pressure drop in the plant, which must be converted into a pressure head drop, and the delivery height of the pump. The pressure height drop in the system corresponds to the delivery height of the pump at the system operating point. Because each pump delivery height has one specific pump flow, the recirculated volume flow is clearly determined from the pressure drop in the plant. The pressure drop is determined by projecting the pipeline network performance curve and the pump performance curve in a common diagram. The intersection between the two curves is the operating point of the circulation system that then occurs.
[kPa]
15.0 12.5
Pump characteristics

5.1.1 The pump performance curve The hydraulic behaviour of the circulation pump is described by its performance curve. This shows the relationship between delivery height and flow rate. The following relationship applies: As the flow rate increases, the delivery height decreases. As the delivery height increases, the flow rate decreases. The flow rate is the volume flow conveyed by the pump. The delivery height is the pressure differential applied by the circulation pump and converted to the height of a liquid column. The pump performance curve is shown in a diagram.

The flow rate is plotted along the horizontal axis VP and the delivery height H along the vertical axis.

Delivery height H [m] 1.50 1.25 1.00 0.75 0.50 0.25

Performance curve for pipeline

Delivery height H [m] 1.50 1.25 1.00

[kPa]
15.0 12.5 10.0 7.5 5.0 2.5 0,0

10.0
System operating point

7.5

0.75
5.0

0.50
2.5

0.25
0,0 0.6 0.7 0.8 0.9 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

0.1

0.2

0.3

0.4

0.5

Flow rate VP [m3/h]

Flow rate VP [m3/h]

Fig. 20: Performance curves for pipeline network and pump The operating point can be arithmetically determined by calculating the pressure losses from the individual resistances in the pipeline network. Fig. 21: Performance curve for VORTEX circulation pumps with V-pump housing

The pump performance curve shows that flow rate and delivery height are independent: At maximum delivery height of H = 1.25 m, the flow rate VP = 0. At delivery height of H = 0.75 m, the flow rate VP = 0.37 m3/h.

At maximum flow rate VP = 0.64 m3/h, the delivery height is H = 0.

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In an "open system", the correlation between flow rate and delivery height is immediately evident. Fig. 22, 23 and 24 relate to the pump performance curve shown in Fig. 21:

Vp = 0 Hmax = 1.25 m

V p = 0.37 m3/h

Hmax = 0.75 m

V pmax = 0.64 m3/h H=0

Fig. 22

Fig. 23

Fig. 24 If the pipe is shortened by 1.25 m, the end of the pipe is at the same level as the medium. The delivery height is thus H = 0. The discharging volume is equivalent to the flow rate VP max =0.64 m3/h (Fig. 21 and 24). This theoretical example does not take account of pipeline resistances.

If the pipe length, measured from the medium level, corresponds to the maximum delivery height of the pump - H max = 1.25 m, no medium discharges from the end of the pipe. The flow rate is thus VP = 0 (Fig. 21 and 22). If the pipe is shortened by 0.50 m, the circulation pump must withstand the delivery height of H = 0.75 m. The volume discharging from the end of the pipe is equivalent to the flow rate, VP = 0.37 m3/h when H = 1.0 m (Fig. 21 and 23).

5.1.2 The pipeline network performance curve The pipeline network performance curve is plant-specific. The pipeline network performance curve indicates the relationship between the pressure drop, caused by pipe friction and individual resistances, and the pump flow in the circulation system. Unlike in the "open system", (Fig. 22, 23 and 24) the circulation pump does not have to withstand a height differential. This means that the delivery height indicated in the pump diagram bears no relation to the height of the building in which the pump is to be installed. A circulation pump with a delivery height of 1.25 m, like the VORTEX circulation pumps with spherical motor, can therefore operate extremely efficiently in a 20 m high building.

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5.1.3 Hydraulic compensation in circulation lines In the pressure drop calculation, the pressure differential of the circulation pump present in each of the plant's circulation lines must be throttled to the maximum in line control valves, taking into account minimum diameters and maximum speeds. If no hydraulic compensation is carried out, the calculated volume flows do not materialise in the designed plant. However, the circulation volume flow must be able to transport the heat quantity that is lost over the surface of the pipeline system. The specified hot water temperature can be maintained only if an equilibrium is guaranteed at each point in the circulation system. Hydraulic compensation of the circulation system is required in order to guarantee safe function in accordance with DVGW Worksheet W 551. In accordance with DIN 1988, Part 3, the line control valves must be installed in circulation systems. The objective of regulation is to keep the circulation volume flows the same in all risers, which in turn limits the temperature drop between drinking water heater outlet and re-entry via the circulation to approx. 7 10 C. It has been shown that in close-pump circulation systems, a relatively large pressure differential with small circulation volume flows must be created, while in remote-pump risers, a proportionately large volume flow must occur to maintain a temperature in excess of 55 C. The following data is required for setting the line control valves in the system pipeline network: Volume flow in the part section, determined excess pressure loss via the line control valveil Valve temperature in the hydraulically compensated condition.

After the settings have been made on the thermostat element and the control cross-section of the valve, the line control valve can automatically assume the required throttle positions. The pre-condition for the use of such valves, which are a combination of conventional line control valves and thermal circulation controllers, is a pipeline network calculation and a determination of the preset value. The less regulation input required at the building site is particularly advantageous, as minor deviations between calculation and building design at the thermostatically controlled line valve are automatically compensated.

5.2 The calculation method according to DIN 1988, Part 3 The basis of all further calculation methods, including that of DVGW W 553, is a pipeline design to DIN 1988, Part 3. The supply and circulation line must be insulated in accordance with the energy saving regulation. The permissible temperature differential between drinking water heater outlet to the supply pipe and circulation inlet to the heater must not exceed the following values with pump circulation: 2 to max. 3 K with distribution systems to 200 m Expansion, 3 to max. 5 K with distribution systems over 200 m Expansion. The dimension of the circulation line is estimated from Table 1. The vertical circulation line is designed to at least DN 12 from the riser connection.

5.1.3.1 Presetting via manual line control valves The line control valves are measured and preset by determining their preset values. Together with the required valve data, the circulation volume flow in the part section and the required pressure drop via the valve, the required preset value is read from the manufacturer's diagram and set on the line control valve. 5.1.3.2 Thermostatically controlled line control valves Thermostatically controlled line control valves were developed for the purpose of keeping the temperature in hot water systems above the set temperature.
*)

Supply pipe Nominal width DN 20 25 32 40 50 65 80 100

Circulation line Nominal width DN 12*) 12*) 12*) 20 25 25 25 32

With medium-weight threaded pipes in accordance with DIN 2440: DN 15 Table 1: Reference values for nominal widths of circulation collection mains in accordance with DIN 1988, Part 3

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For dimensioning the circulation pump, the circulation pump flow rate VP and the required pump pressure pp are required. The circulation pump flow rate is based on the water contained in the system. In accordance with DIN 1988 Part 3, a 3 x an hourly recirculation is adequate for prevent excess cooling of the heated drinking water. The flow rate and thus the circulation flow is determined from 3 times the water volume contained in the circulation system (excluding volumes in drinking water heater and tank). The following equation applies:
l2 TWZ l1 l3

l6

l4 TWW 20 m l5

TWE
TW

l1+l2+l3+l4+l5+l6

40 m

VRL VP = 3 - ; t = 1h t
The circulation pump delivery height is determined from the sum of the pressure drop caused by pipe friction and individual resistances of the longest flow path from circulation line connection to supply pipe to the drinking water heater. The pressure drops are determined using Form A 7 from DIN 1988, Part 3 and the calculation model. The flow speed in the circulation line of max. 0.5 m/s with a copper pipe must be observed.

Fig. 25: Maximum permitted lengths for the short procedure If these conditions are satisfied, the circulation lines must be designed with a minimum internal diameter of DN 10 and the circulation pump DN 15. If the circulation line is arranged in copper pipe, evidence of the maximum permitted flow speed not exceeding 0.5 m/s must be furnished. This can be verified using either the simplified or the differentiated calculation procedure.

The partial flows are calculated from the circulation pump flow rate, divided by the number of circulation lines.

5.3 The calculation method for circulation systems in accordance with DVGW W 553 Depending on the size of the plant, several procedures are applied for measuring circulation systems. The basis of all measuring procedures is compliance with the valid rules of technology. The calculation procedures described in DVGW W 553 are an addition to DIN 1988, Part 3. DVGW Worksheet W 551 demands hot water temperatures of 55 60 C in the circulation system, in order to avoid legionella concentrations. This necessitates a new calculation method that takes account of the thermal losses.

5.3.2 The simplified calculation of circulation systems The simplified calculation procedure can be applied only if reduced accuracies are taken into account. This method therefore enables a relatively fast and simple calculation for small to medium-sized systems. The free choice of temperature gradient, precise determination of the entire circulation flow and the adequately precise split of the circulation flow over the individual lines offer benefits. Simplification is made possible by waiving the differentiated calculation of the heat flows and the pressures lost through individual resistances.

5.3.1 The short procedure This procedure is applied for smaller plants such as those in one and two family dwellings. A detailed calculation, due primarily to the nominal width graduation, always produces the same dimensions for the circulation system. None of all supply pipes affected by recirculation may exceed 40 m in length and the longest flow path for a circulation line should not be longer than 20 m (Fig. 25).

5.3.2.1 Simplification and calculation procedure Determining the volume flows The following simplifications can be assumed for determining the thermal losses in the hot water lines, which can be used to determine the volume flows of partial sections: Thermal loss in the hot water lines laid in the cellar: q w, K = 11 W/s Thermal loss in the hot water lines laid in the shaft: q w, S = 7 W/m The thermal losses of the valves are not taken into account. The energy saving regulation calls for insulation and they are therefore negligible. The thermal loss Q w of all hot water lines is thus: w = lw, K q w, K +lw, S q w, S Q (1)

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The calculated temperature differential and/or cooling down of the hot water through to the outlet of the circulation line from the supply pipe is: w = 2 K This temperature differential can then be used to determine the pump flow VP [m3/h] of the circulation pump:

The following applies for the volume flow in the straight section:

Qd Vd = V ---- Qa + Qd Vd = V Va

(4) or (5)

Qw VP = ---- cw

(2)

The following can be assumed: = 1 kg/l c = 1.2 Wh/kg K The distribution of volume flows over the individual partial sections can be determined from the circulation pump flow now known. At an intersection, the volume flow is split into a straight section and a branched section.

Dimensioning the pipe diameter for the circulation line The pipe diameters of the circulation lines are determined taking into account a max. flow speed of 0.5 m/s (with copper pipe max. 1.0 m/s) from R-value tables. For the circulation lines, a minimum internal diameter of 10 mm must be provided (see DIN 1988, Part 3). The individual circulation lines are transferred to a suitable form and dimensioned separately from the circulation mains. It is perfectly possible for the flow speeds in close-pump lines are higher than in remote-pump lines.

Va,Q a

Determining the delivery pressure of the circulation pump The delivery pressure of the circulation pump is determined from the frictional loss of the difficult circulation path, usually the longest circulation line with the greatest resistances. Redirections and branches are considered with an overall allowance of 20 40 %. The following delivery pressure is derived:

Vd,Q d

pp = 1,21,4 (l R) + pRV + pTH + pAP (6) The calculated flow rate and the delivery pressure can now be used to determine the actual operating point in the system and thus the system's performance curve and the actual operating point of the pump.

The volume flow of the branched partial section can be calculated as follows:

Qa Va = V ---- Qa + Qd

(3)

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5.3.2.2 Calculation example Multiple-family dwelling with 10 apartments Pipe material: copper Hot water lines dimensioned to DIN 1988, Part 3 Extraction valves individually secured

Fig. 26: Line schematic

Calculation of thermal losses from partial flows Partial section (TS) 1 2 3 4 5 6 7 8 9 Cellar/ shaft (K/S) K K S K S K S K S K S Total of lengths: Length l [m] 3 5 12 5 12 5 12 5 12 5 12 88 Thermal loss per m q w [W/m] 11 11 7 11 7 11 7 11 7 7 11 Thermal loss l q w [W] 33 55 84 55 84 55 84 55 84 55 84 Total of thermal losses: Total l q w [W] 33 55 84 55 84 139 55 84 139 728

Table 2: Thermal losses from partial sections

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Calculation of volume flows The total thermal losses from Table 2 and the calculated temperature differential of w = 2 K can now be used to determine the circulation pump flow: 728W VP = = 303.3 l/h 1 kg / l 1.2 Wh / kgK 2 K

The thermal loss from the straight (4th column) is determined from the individual thermal losses from partial sections 2 6:

Q d = (55 + 84 + 55 + 84 + 139) W = 417 W

If these two thermal losses are now added together, the thermal loss in the intersection is derived (5th column). The individual volume flows in the branch and in the straight can be determined according to equations (3) and (4): in the branch according to equation (3): 278 W Va = 303 l/h = 121 l/h 695 W (column 6)

(2)

The partial flows split at the intersections. The partial section, which leads in the direction of flow to the intersection, is shown in the 1st column in Table 3. The first partial section is TS 1, which starts at the drinking water heater. The volume flow of this partial section, which leads in the direction of flow to the 1st intersection, is shown in the 2nd column. This volume flow splits to the left into TS 7, which is defined as a branch, and to the right into TS 2, in this case the straight partial section. The thermal losses from these two outgoing partial sections are totalled individually, i.e. the thermal loss from the branch (3rd column) comprises thermal losses from partial sections 7 - 9:

and in the straight according to equation (4): 417 W Vd = 303 l/h = 182 l/h 695 W (column 7)

In column 8, the last value according to equation (5) can be checked:

Vd = (303 121) W = 182 l/h

This volume flow, which leads to the next intersection, is the starting value for TS 2 as the volume flow from TS 2 to the intersection, with TS 3 as the branch and TS 4 as the straight, shown in the next line of the Table. The calculations are then carried out as per the previous ones.

Q a = (55 + 84 + 139) W = 278 W

1 TWW partial section to intersection 2 Volume flow to intersection 3 Thermal loss in the branch 4 Thermal loss in the straight 5 Thermal loss in the intersection Qa + Qd [W]
2)

6 Volume flow in the branch

7 8 Volume Check flow in the straight

V [l/h]
TS 1 TS 2 TS 4 TS 7
1) 2)

Qa [W]
278 84 84 84
1)

Qd [W]
417 278 139 139

Va [l/h]
121 42 53 46

Vd [l/h]
182 140 87 75

Vd = V Va [l/h]
303-121 182-42 140-53 121-75

303 182 140 121

695 362 223 223

in the line schematic to left in the line schematic to right

Table 3: Calculation of the partial flows in the distribution and/or circulation lines

Selecting pipe diameter for the circulation lines The nominal widths for the circulation lines are shown separately in a Table according to lines and collecting mains. The lengths and volume flows of the partial sections for the circulation are the same as for the supply lines arranged in parallel. These are shown in the 3rd and 4th columns of the Table. In column 5, the volume flows are converted from l/h to l/s.

The R-value tables from DIN 1988, Part 3 are now used to select the nominal widths of the circulation line taking into account the maximum permitted flow speed in copper pipes of 0.5 m/s (columns 6 8). Once the pipeline pressure loss (column 9) is determined, the resistances plus 40 % for pipe friction (column 12) are considered.

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1 TS 1 2 3 4 5 6 7 8 9
1)

2 Pipe Cu Cu Cu Cu Cu Cu Cu Cu Cu

3 l [m] 3 5 5 5 12 12 17 12 17

4 VZ [l/h] 303 182 140 121 42 53 87 46 75

5 VZ [l/s] 0.085 0.050 0.039 0.034 0.012 0.015 0.024 0.013 0.021

6 da [mm] 18 18 15 15 12 12 12 12 12

7 v [m/s] 0.43 0.25 0.29 0.26 0.16 0.19 0.30 0.17 0.26

8 R [mbar/m] 2.1 0.84 1.46 1.16 0.72 1.05 1.84 0.83 1.66

9 lR [mbar] 6 4 7 6 9 13 31 10 28

10

11 Z [mbar]

12 13 lR+Z1) pD [mbar] [mbar] 8 6 10 8 13 18 43 14 39

40 25 37 17

1,4 l R (+ 40 % from the individual resistances, without non-return valve)

Table 4: Determination of the pipe diameter of the circulation line

Calculation of the delivery pressure for the circulation pump To calculate the delivery pressure (Equation 6), the pressures lost through friction and flow resistances are determined in the most hydraulically unfavourable flow path (the example uses lines 1, 2, 4, 6). The pressure loss of the VORTEX non-return valve at 20 mbar and the individual resistances at 40 % of the pipe friction are also calculated: pp = 1.4 (l RTS 1,2,4,6) + pRV pp = 1.4 (6 + 4 + 7 + 31)mbar +20 mbar pp = 87 mbar

Line comparison through line control valves To ensure that the desired temperatures in the individual lines are achieved and all lines have the same pressure loss, the excess pressure differential in all other lines is reduced evenly through preset line control valves. The determined excess pressure loss (column 13) is transferred with the flow in each line to the valve manufacturer's pre-settings diagram and the preset value is calculated.

The data for the circulation pump are thus known: Delivery height: 0.87 m, flow rate 0.303 m3/h The following diagram was compiled using the data obtained:
Delivery height H [m] 1.50 1.25 1.00
System operating point Performance curve for VORTEX pump with V-pump housing

[kPa]
15.0 12.5 10.0 7.5 5.0

5.3.3 The differentiated procedure This procedure is suitable for any size of system, especially where system parameter measurements are computer-supported. It differs from the simplified procedure in that it uses a differentiated method for determining the heat losses and pressure losses. The calculation of the pre-settings of the throttle valve is therefore relatively precise - although always based on assumptions! The individual calculation steps in the differentiated procedure are carried out as follows:

0.75 0.50 0.25

Performance curve for pipeline

2.5 0,0 0.6 0.7 0.8 0.9

0.1

0.2

0.3

0.4

0.5

Flow rate VP [m3/h]

Fig. 27: Pipe network and pump performance curve

1. Determination of the heat losses in the TWW lines (depending on nominal width, insulation and room air temperature) 2. Calculation of circulation pump flow 3. Calculation of partial flows 4. Determination of nominal widths for the circulation lines 5. Calculation of the delivery pressure for the circulation pump using the differentiated pressure losses of the unfavourable lines 6. Choice of circulation pump 7. Determination of pre-settings for the line control valves

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