Small pipe hydronic system

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ENGINEERING EXPERIMENT STATION

MECHANICAL ENGINEERING DEPARTMENT
| = B=R STEAM AND WATER HEATING
RESEARCH SERIES | = B = R-2

KCOCMK\.n JCIMCJ ■ — O — H — M.

ENGINEERING LIBRAE

SMALL PIPE HYDRONIC SYSTEM

i«

By
WARREN S. HARRIS

Sponsored by
INSTITUTE OF BOILER AND RADIATOR MANUFACTURERS

UNIVERSITY OF ILLINOIS

URBANA, ILLINOIS

MAY, 1959

•

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ENGINEERING LIBRARY

PREFACE

The following is intended as a report of the pipe sizing procedures
used in designing the small-pipe, hot-water system tested in the Research
Home during the winter of 1958=59 <= It also contains a description of
installation procedures and a discussion of test results ° This report
neither replaces nor obsoletes present I=B=R Installation Guides , but
rather it should suppliment them<> There is no change in the method of
calculating heating loads, as given in I=B=R Installation Guide H-20, nor
in the methods of selecting the heat distributing units, boiler size, air
cushion tank size and pump as directed in I=B=R Installation Guide 500°

The pipe sizing tables in Guide No0 500 limit the minimum pipe size
in the main to 3/4- in« and in branches to l/2 in = In many instances these
are larger than required.- In the design of the small pipe system these
pipe size limitations were disregarded;,

SMALL PIPE HYDRONIC SYSTEM

Introduction

The broad objectives of the research program conducted at the University
of Illinois for the Institute of Boiler and Radiator Manufacturers are to
find ways to further improve performance of hydronic systems and to reduce
the operating and installation costs. The heating project for the winter
of 1958-59 was aimed at reductions in the cost of installation.

Today quiet pumps are available which will operate at heads of more than
10 ft. of water. The system installed in the I=B=R Research Home during
the summer of 1958 was designed to take full advantage of the high head of
the modern pump. Furthermore, soft copper tube was used throughout. This
is readily bent, eliminating the need of many fittings required in systems
installed in more conventional ways. These practices resulted in a reduction
of about $150.00 in the cost of installing the piping system for a one-pipe,
hot-water system in a two-story, six-room house having a calculated heat
loss of 4-3,300 Btuh at 70 F indoors and -10 F outdoors.

System Design

The operating conditions for which the system was designed were as
follows:

Average water temperature 215 F

Temperature drop through

the system 20 F

Temperature drop through

each room heating unit 20 F

Total water circulation rate 4.3 GFM

Pump head at above flow rate L4 Ft. of water

Figure 1 is a schematic diagram of the system with the design water flow
rates for each section of piping indicated. This system was designed by
adding the equivalent length of the fittings to the measured length of the
piping to determine the equivalent length of the pipe. Knowing the rate of
water circulation through each section of the piping and the pressure head
available ,. it was possible to make a suitable selection of copper tube sizes
from a standard friction pressure loss chart. It was necessary to extrapo-
late the chart down to nominal l/U in. tube as no chart could be found con-
taining tube sizes smaller than 3/8 in.

A preliminary study indicated that pipe sizes for this system would be
too small to permit the use of present makes of one-pipe fittings. Therefore,
the fitting illustrated in Figc 2 was improvised. The diameter of the ori-
fice was such that the resistance to water flow through the orifice was
equal to the resistance offered by 12 ft. of straight tube of the same
diameter as the main. In selecting the pipe sizes for the main? the length
of main was taken as the measured length plus 12 ft. for each orifice in
the circuit* Since the resistance offered by the return tee was equivalent
to about 2 ft. of tube and at least 1 ft. of tube was located between the
supply and return tee, the head available to circulate water through the

Pushing riser through stud space to basement. When end
of tube reaches basement second man pulls the end free of
the sill and pulls enough into the basement to make con-
nection to the main. Man above then cuts riser from coil,
leaving enough tube to make connection to the heating unit.

Top end of riser is cleaned and soldered
into adaptor in the end of the heating unit.

-2-

branch circuits was assumed to be equal to the total friction head in 15 ft,

of the main. Pipe sizing calculations are summarized in Table A.

Nominal 3/4 in. type L copper tube was required in the trunk main.
The branch mains consisted of nominal 1/2 in. tube while the radiator
runouts and risers were either 3/8 in. or l/U in. tube, depending on the
capacity of the room heating unit and the length of the piping connections.
Sweat fittings were used throughout the system.

While the tube used in this system was smaller than that ordinarily
used, it should be pointed out that, at the design water flow rate of \» 3
Gpm, the maximum water velocity in the system would be 3 ft. per sec. This
velocity is low enough that there would be no danger of noise resulting
from the water flow.

Table B shows the estimated installation costs for both a conventional
one-pipe and the small pipe heating system for a new six-room, two-story
house similar to the I=B=R Research Home, Estimated installation time was
based on experience gained from the installation of such systems in the
Research Home. The total cost of materials in the conventional iron-pipe
system was $104.. 25 as compared to $87.73 for the small pipe system. Labor
costs for the conventional, and the small pipe systems were $220.50 and $84.00
respectively. These estimates cover only the costs of pipe, fittings, and
the time required to install the piping system. They do not include the
cost of the boiler and radiation nor the time required to install these
items except for connecting the piping system to them. The total cost of
installing the piping system for the small pipe system was approximately
$150.00 less than the installation cost of the more conventional piping
system.

Installation Procedure

The real advantage of using small diameter, soft copper tubing for the
piping system was in the ease and speed of installation. The following
procedure was followed in installing the experimental system in the I=B=R
Research Home= The radiation in this system consisted of cast iron base-
board. Undoubtedly a detailed study of installation procedures could
result in some further short cuts, but even so, the procedure listed below
resulted in a saving of about 4.0 man hours as compared to that required to
install the same system using the larger size of iron pipe usually employed
in systems such as this one.

Step 1. Assemble baseboard heating units and locate in rooms where they
are to be installed.
Two men required „

Step 2. Cut necessary holes for risers.
One man required.

Step 3« Rough in risers.

Two men required. Risers to second story units were pushed
down through the stud spaces in the walls from the room to
the basement. Risers for first story units were run through
floor to basement, Sufficient tube was left on both base-
ment and room ends of the risers to make connections to the
main and the baseboard. Prior to pushing the tube through
the stud space, the end of the tube was crimped with a pair
of pilars to prevent insulation or dirt from entering the tube.

After both risers are soldered into the adaptors at the ends
of the heating unit, the unit is pushed back into place along
the wall. Surplus riser slips through stud space to basement.

After installation of room heating units is completed
the basement ends of the risers are cut to length and
soldered into the tees in the main. As the connection
to the tee is completed, the main is fastened into place
following the chalk line indicating its proper location.

•3-

Step U> Connect risers to room heating units.

One man required. The baseboard unit was laid on the floor
just in front of the wall along which it was to be located
and iron to copper adaptors were screwed into the ends.
Following this the unit was placed in an upright position
a few inches from the wall. Fireproof insulating board was
placed under the end of the unit to protect the floor*
The end of the riser was cut and cleaned and sweat into
the fitting at the end of the heating unit.

Step 5. Locate unit against wall.

Two men required. After soldering the risers to the heating
unit, the heating unit was pushed back into place along the
wall. The extra length of the riser required to reach
the heating unit when in position for sweating was pushed
back into the stud space for second story units and through
the floor into the basement for first story units.

Step 6. Indicate position of basement heating main by chalk line
across the bottom of the studs.
Two men required.

Step 7. Connect main to the boiler.

One man required. Work can start at either the supply or
return connection to the boiler. If two men are working,
one can start at the boiler supply and the other at the
return .

Step 8. Run mains.

One man required. One end of tubing was cleaned and
sweat to the fitting at the boiler supply <> Tubing was
bent as required to follow the position indicated by the
chalk line. Tube was fastened to bottom of joists with
staples or straps as work progressed. Fasteners were
located about 3 ft. apart and care was taken to see that
they were not tjght on the tube. This permitted freedom of
movement without causing expansion and contraction noises.
Tubing was cut to length where tees were required and fit-
tings were sweat into place before the tube was fastened
to the bottom of the joists. The bottom end of radiator
risers were cut to length and soldered to the main in turn.
The orifice was inserted in all supply tees in the position
indicated in Fig. 2. The tubing held the washer in place.

If two men were working, they started at opposite ends of
the main and worked toward each other, (if there are two
or more circuits, they may work on separate circuits.)

Performance of small pipe system

Performance of the small pipe system was observed in the I=B=R Research
Home throughout the winter of 1958-59. This was one of the most severe
winters in Urbana, Illinois, in recent years . Minimum temperatures were
as low as -9 F and these were accompanied by average wind speeds of about
10 miles per hour with gusts up to about 30 miles per hour. All through the
winter the operation of the small pipe system was satisfactory in all

-k-

respects. No difficulty was experienced in maintaining the desired room
air temperatures even during the coldest and most incliment weather . Floor
to ceiling air temperature differences were the same as those obtained in
previous years when testing baseboard heating systems having conventional
one-pipe piping systems.

Because of restrictions on the use of gas, it was necessary to use oil
as the fuel during the tests on the small pipe system , No other base-
board heating system has ever been tested in the Research Home using fuel
oilj however, the oil consumption obtained with the small pipe system in
1958-59 compared favorably with that obtained with the first heating
systems ever installed in the Research Home. These early systems were
oil fired and used small tube radiators.

According to the design assumptions the rate of water circulation
through the trunk main should have been 4<=3 Gpm. By actual measurement
it was found to be about 5>8 Gpm. No actual measurement was made of the
pump head developed , The high measured water flow rate indicated that
either the pump head was well above the catalogued value or else the total
resistance of the piping system was less than assumed 0 It is probable that
the latter was the principal factor for the following reasons; (l) a
large section of the return trunk of the small pipe system was not changed
from the 1 inch iron pipe used in previous systems o This was left in as
it contained the flow measuring station.- (2) the required water flow rate
in some sections of the piping was less than the maximum carrying capacity
and (3) in estimating the pipe resistance no allowance was made for the
fact that the actual flow rate through the parts of the main located
between each pair of risers was at a reduced rate due to diversion of part
of the water through the radiator circuit, The calculated friction pressure
loss through the main obtained by substituting 1 in.- iron pipe for 3/4- in.
copper tube in the trunk and using the observed flow rate of 5°8 Gpm is
20 ft of water = Since this is a greater friction pressure loss than that
obtained by using the tube sizes and flow rates indicated in Table A, it
is apparent that the pipe sizing procedures for the small pipe system
were on the safe side.- Furthermore,, since the calculated friction head for
actual conditions of operation exceeded the catalogued pump head by 6 ft
of water, it seems probable that the allowance for fittings and orifices
was more than actually required .-

Table C shows the measured temperature drops in all parts of the
heating system: ''Tith the exception of the drop through the dining room
baseboard, all were less than the design value of 20 F which should be
expected since the actual water flow rate exceeded the design value 0 There
were two factors contributing to the high temperature drop through the
dining room baseboard; In the first place the 3/8" tube used in the
radiator circuit was slightly undersized, As shown in Table A the allowable
friction head in this circuit was 745 milinches per foot while the friction
head in a 3/8 in. tube carrying 0.87 Gpm is 762 milinches per foot. In
addition to this the main circuit to which this unit was connected was
slightly overloaded and furthermore the supply tee and orifice for the
dining room baseboard were located just downstream of the supply tee for
the S. V. bedroom baseboard , All of these tended to reduce the flow
through the dining room baseboard . A high temperature drop through a
room heating unit is not as serious as it appears since the mean radiator
temperature is decreased only one half as much as the temperature drop
is increased and the decrease in output of the heating unit is only about
0.9 percent per degree Fc If it is assumed that changes in water flow

rate have a negligible effect on the output of a baseboard, the following
equation is true.

where

AT x W = C

AT = Temperature drop through the baseboard

W = Water flow rate through the baseboard

C = a constant

The water flow rates through the individual baseboard circuits were not meas-
ured. Nevertheless it is true that the ratio of the water flow rate through
the radiator circuit to the water flow rate through the main is a constant
and therefore, by changing the value of C in the preceeding equation the
water flow rate in the main may be substituted for the flow rate through
the radiator. In this way it may be shown that reducing the water flow
rate in the system from 5.8 Gpm to 4.. 5 Gpm would increase the average
temperature drop through the heating units to about 20 F, the design
value. This indicates that the sizing of the orifices in the supply tees
and the method of sizing the piping for the radiator branch circuits was
satisfactory.

When the system was first started, a few expansion and contraction
noises in the piping system were observed. These were traced to pipe straps
which were too tight to permit movement of the main. These were loosened
and from that time on no noise in the piping system was observed, either
as a result of expansion and contraction or from high water velocity.

No unusual venting problems were encountered even though there were
places in the piping system where air could be trapped. The water velocity
was apparently sufficient to carry the air along with the water until it
reached either the boiler or the radiation where the water velocity was
low enough to permit separations

Summary

The use of small diameter, soft, copper tube for the construction of an
experimental one-pipe hot-water system for the I=B=R Research Home resulted
in a reduction of about -$150.00 in the installation cost with no sacrifice
in the overall performance of the system. The design procedures used
proved to be on the conservative side and may be incorporated in the I=B=R
Installation Guides without introducing an entirely new method of design.
All that would be required is an expansion of the pipe sizing table and
some comments on the installation techniques of installing the small
diameter pipe efficiently.

Appendix A,

Revisions Required in Installation Guide 500 to Make It Adaptable

To Small Pipe Systems

A revision of the pipe sizing table (Table 3) in I=B=R Installation
Guide No, 500 is required to make this guide applicable to the design of
small pipe systems o A suggested revision is shown in Table D. This table
is applicable to copper tube only as the friction heads of copper tube and
iron pipe are quite different for the same nominal size in the smaller
diameters*

The carrying capacities of the radiator circuits in Table D are based
on the use of an orifice as illustrated in Fig0 2; or other suitable
device which will develop a pressure head in the radiator circuit equi-
valent to the friction head in approximately 12 ftc of the main to which
the radiator circuit is joined .

Table E summarizes the pipe size selection for the system installed
in the I=B=R Research Home using Table D and the procedure described
on pages 23 through 25 of I=B=R Installation Guide No» 500„ Comparing
the pipe sizes shown in Table E with those in Table A it is found that the
use of Table D and the simplified procedure resulted in the same pipe size
selection as the more exact method of using the equivalent length of each
circuit (Table A) » The dining room riser size in Table E is l/2 in. while
in Table A it is only 3/8 in, However it should be noted that the 3/8 in*
tube was actually undersized .

It is also suggested that some description of installation methods for
small diameter soft copper tube should be included in the revisions as
these procedures are not familiar to most contractors »

-7-

Appendix B

Method of developing pipe sizing table, Table D

Step 1. Select a unit friction heado

Example: Unit friction head taken as 600 milinches per ft,
(this represents the third column in Table D)

Step 2. For each available head, determine the equivalent length of the
circuit by dividing the available head in milinches by the
unit friction head selected in step 1.

Example: Available head = 8 ft of water

Equivalent length s 8 x 12000/600 - 160 Ft.

Step 3. For each equivalent lengthy determine the measured length from

table F. Round out measured length to nearest 10 ft. and record
in upper portion of Table D under total length of circuit.
Examples 160/1,63 = 98 fto Record 100 ft.

Step U» For selected unit friction head (Step l), determine the carrying
capacity of main sizes from an accepted friction pressure loss
chart. Record to nearest 0,1 Gpm opposite trunk or circuit in Table D
Example: Unit friction head = 600 milinches per ft.

Carrying capacity 3/4- in. type L copper tube =
4,0 Gpm,

Step 5. Multiply the selected unit friction head (step l) by 15 to determine
the available head to overcome friction in the branches.
Example: 600 x 15 = 9000 milinches

Step 6, Assume the equivalent length of the branch to be 30 ft. This was
the average equivalent length of a branch circuit in the I=B=R
Research Home,

Step 7 o Divide the available h^ad determined in Step 5 by the equivalent
length of the branch (Step 6),

Example: 9000/30 = 300 milinches per ft.

Step 8. For each unit friction head in branch (Step 7) determine the
carrying capacity of each branch size from accepted friction
pressure loss charts. Record to nearest 0.1 Gpm in Table D,
Examples Unit friction head = 300 milinches per ft.

Carrying capacity 3/8 in type L copper tube = 0,5
Gpm,

Appendix C
Determination of Orifice Size

The size of the orifice required to increase the equivalent length of the
main by 12 ft. may be determined by the following formula.

Q = KA*/2gh or A = Q/K ^'2gh

where

Q = Flow rate in cu, ft, per sec,

A = Orifice area in sq. ftc

K = Orifice coefficient (assumed as 0.65)

g = Gravitational acceleration, ft. per sec^ (32.2)

h = Head Loss through orifice in ft. of water

It is apparent that the area of the orifice is a function of the flow
rate. However, the changes in flow rate normally encountered in any main
of a given size in a conventional heating system are not large enough to
have much effect on the orifice size.

Sample calcula t i on :

Main size = l/2 in.
Flow rate =1.0 Gpm

Unit pressure loss in main = 330 milinches per ft,
(from friction pressure loss chart)

h = 12 x 330/12000 = 0,33 ft. of water

A = 1.0/450 x 1/0.65 x 1//6TT4 x 0.33 = 0,000738 sq. ft. or

^^^ 0,106 sq, in,
Diameter of orifice = */0o 106/0, 786 = 0.384 in.

Using the above procedure and selecting flow rates corresponding to
representative carrying capacities of the main the following orifice
diameters were found to be required to increase the equivalent length of
the main by approximately 12 ft.

Main size Orifice diam

in. in,

3/8 0,27

1/2 0,38 (13/32 or 0,41 in, was used in the

installation in the I=B=R Research
Home)

3/4 0.61

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TABLE B.

ESTIMATED INSTALLATION COSTS - NEW CONSTRUCTION
Conventional Iron Pipe vs Small Diameter Copper Tube

Conventional iron
pipe system

Small diameter copper
tube system

Item

Quantity

Cost Quantity

Cost

Pipe or Tube

341 Ft0

$47.90

323 Ft.

$64.26

Fittings

159

56o35

85

23.47

Labor
$3.50 per hour

63 Hr.

220.50

24 Hr.*

84.00

Total

$324.75

$171.73

* = Estimated for new construction by installer
of system in I=B=R Research Home

TABLE Co

WATER TEMPERATURE DROPS, SMALL PIPE SYSTEM

Location

Temp.
Drop F

Location

Temp.
Drop, F

Kitch. Rad.

18.3

Bath Rad.

13.5

Din. Baseboard

25.6

S0W0Bed.Basebd.l7.2

Liv.

10o2

N.W. "

14.3

Vest. Rad.

5.3

N.Eo "

12.0

Lav.

17.6

Av

. all heating
units

15.0

Stair. "

15.8

Boiler

16.4*

* temperature rise

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TABLE E.
PIPE SIZE SELECTION USING TABLE D.

Section
(Fig. 1)

Flow Rate
GPM

Ja + dhi

4.32

abed

2.13

Totals

N. W. Bed.

1.02 Supply
.45 Return

N. E. Bed.

•44

Liv.

.57

Vest.

.48

Lav.

.15

Ja + dhi

4.32

a f e d

2.19

Totals

S. W. Bed.

1.02 Supply
.53 Return

Din.

.87

Bath.

.26

Kitch.

.31

Stair.

.22

Measured
Length , Ft .

26

JlL.
63 + 48 = 111

26

65 + 60 = 125

Pipe Size
(Table D)*

3/4
1/2

1/2
3/8

3/8

3/8

3/8

3/16

3/4
l/2+

1/2
3/8

1/2

1/4

1/4

1/4

* Available Pump Head = 14 Ft. of Water

TABLE F.

EQUIVALENT VS MEASURED LENGTH

Measured = (L)
Lengths

Ratio of
Equivalent Length = (R)
Measured Length

Equivalent
Length

50

lo72

86

75

lo67

125

100

1.63

163

125

1.59

199

150

lc56

234

200

1.50

300

250

1.45

363

300

1.41

423

350

1.38

483

4.00

lo35

540

450

. 1.33

599

500

1.31

655

600

lo29

774

700

1.27

889

800

1.26

1008

Equivalent Length = (R)(L)

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