Introduction Danfoss Training Module-3 Understanding Differential Pressure

Introduction Danfoss Training Module-3 ****** Understanding Differential Pressure Control Valves Back COMFORT CONTROLS Next - Page 2

Introduction Hello and welcome to the Danfoss training module ‘Understanding Differential Pressure Control valves The purpose of this training module is to give you the knowledge required to select, specify, and understand Danfoss products. Back COMFORT CONTROLS Next - Page 3

Introduction We will examine the types of valves used to balance hydronic systems. . . …and how we select the correct product for the application they are to be used in. This module takes around 20 minutes and forms part of a ‘Continuous Professional Development’ training course. Once 3 modules are complete you can apply to Danfoss for a certificate of your achievement. Now let us begin…. Back COMFORT CONTROLS Next - Page 4

The History of Danfoss Balancing Valve 1989 2003 2009 In 1989 Danfoss produced its first series of MSV commissioning and ASV automatic balancing valves. Back COMFORT CONTROLS Next - Page 5

The History of Danfoss Balancing Valve 1989 2003 2009 In 2003 Danfoss was the first major valve manufacturer to introduce a combined control and automatic balancing valve, the AB-QM. Back COMFORT CONTROLS Next - Page 6

The History of Danfoss Balancing Valve 1989 2003 2009 The LENO MSV-O, unique commissioning valve was launched by Danfoss in 2009. By choosing Danfoss you have over 75 years of expertise behind you… Back COMFORT CONTROLS Next - Page 7

Modernising Heating & Cooling Systems As clients look to improve the efficiency of heating and cooling systems, building services designers are increasingly looking at ways to reduce energy. Poor control and in-efficient system design are contributing factors to high building energy usage. By providing the correct temperature, using the least amount of energy possible, we can make heating and cooling systems comfortable for users, and run at a lower cost. A common way to improve a systems energy efficiency is to use variable speed pumps. Let us look at how variable speed pumped systems operate… Back COMFORT CONTROLS Next - Page 8

Modernising Heating & Cooling Systems Variable speed pumps work by matching the pumps flow with the requirement of the system at any one time. As parts of the system reach temperature, and the control valves close, the pump senses a change in pressure. This pressure sensor is linked to a variable speed drive which matches the pump speed with the system requirement. Variable Speed Drive Back COMFORT CONTROLS Next - Page 9

Modernising Heating & Cooling Systems Prior to variable speed, pumps ran at either 0% or 100%. Controlling the pump speed means we can provide enough flow to achieve the comfortable temperatures, and at the same time dramatically reduce the energy used to get it there. However this modulation of the pump, makes the system pressure and flow variable. This variable pressure means traditional static balancing (commissioning) valves cannot operate effectively in this type of system. In variable flow systems we need dynamic balancing valves which react to the changes in system pressure. Danfoss ASV Differential Pressure Control Valves will provide the dynamic balance required in variable flow systems. Back COMFORT CONTROLS Variable Speed Drive Next - Page 10

ASV Differential Pressure Control Valves The use of Differential Pressure Control Valves is essential in modern hydronic systems. They provide dynamic balancing to react to pressure changes from the pump and to keep constant pressure in the circuits. This constant circuit pressure enables the system to balance and be accurately controlled. Back COMFORT CONTROLS Next - Page 11

ASV Differential Pressure Control Valves The outcome of using DPCV’s is: -Good control whether the system is running at full or partial capacity -High control valve authority -Improved user comfort -Maximised pump energy savings To understand how we achieve these benefits, we first need to examine how ASV Differential Pressure Control Valves operate… Back COMFORT CONTROLS Next - Page 12

Operation of Differential Pressure Control Valves Danfoss ASV-PV DPCV’s are installed on the return pipe of the circuit. Danfoss ASV-I partner valve are used on the flow pipe. Partner Valve An impulse tube is installed from the partner valve to the DPCV and allows the flow pressure to act upon the top of the valve diaphragm. DPCV Back COMFORT CONTROLS Next - Page 13

Operation of Differential Pressure Control Valves The return pressure acts upon the underside of the diaphragm. The spring within the valve is set by the installer, using an allen key, to deliver a set circuit pressure loss. The diaphragm along with the spring act together to react to system changes and to keep this constant pressure loss. So as the system pressure rises, the diaphragm moves the valve cone down, to keep a controlled circuit pressure. Back COMFORT CONTROLS Next - Page 14

Operation of Differential Pressure Control Valves The commercial radiator heating circuit shown below demonstrates this process in action. Back COMFORT CONTROLS Next - Page 15

Operation of Differential Pressure Control Valves The pressure in the system (P 1) is variable as the pump modulates to match the systems requirements. As the Differential Pressure Control Valve detects a change in the variable system pressure it reacts to keep a constant circuit pressure (P 2). P 1 P 2 This constant pressure in the circuit gives the radiators a controlled flow. The controlled flow to the radiators allows the Thermostatic Radiator Valve to achieve a controlled temperature. This controlled temperature improves comfort for the users. Back COMFORT CONTROLS Next - Page 16

Benefits of using Differential Pressure Control Valves Whilst the operation of Differential Pressure Control Valves demonstrate the benefits of improved temperature control, we should not end there. Comfort is not just about temperature. A common problem for variable flow systems without pressure control is noise. Here is why… Back COMFORT CONTROLS Next - Page 17

Benefits of using Differential Pressure Control Valves System Noise As parts of our variable flow systems close down (this state is called partial load), the open circuits without pressure control see an increase in pressure. This increase in pressure results in a higher differential pressure across the radiator valves. If the differential pressure across the radiator valve becomes too high it will cause noise and this noise will be uncomfortable for users, Back COMFORT CONTROLS Next - Page 18

Benefits of using Differential Pressure Control Valves Differential pressure control ensures the pressure over the radiator valve will not increase at partial loads. Thus excess noise emissions caused by the radiator valves will be eradicated. Dp Without ASV’s Dp Pnom With ASV’s Dp supply system Pnom Pressure Drop 5 x 50% 0% 100% Flow 0% 50% 100% Flow The system without Danfoss ASV DPCV’s allows the excess pressure to be lost across the radiator valve (shown in red). By installing DPCV’s we remove the excess pressure in the balancing valve (yellow) giving the TRV’s a constant pressure. This eliminates noise. Back COMFORT CONTROLS Next - Page 19

Benefits of using Differential Pressure Control Valves When looking for improved efficiency we should recognise the importance of the cost of installing the system. Danfoss Differential Pressure Controls Valves give clear cost savings by reducing the time taken to balance and commission. The traditional proportional balancing method requires each balancing valve to be visited at least twice to complete commissioning. This is because the setting of each commissioning valve affects others in the system. Back COMFORT CONTROLS Next - Page 20

Benefits of using Differential Pressure Control Valves This is not the case when using DPCV’s. By installing ASV Differential Pressure Control Valve Sets you can divide the system into pressure independent zones. This means once the DPCV has been set, the flow balance in this circuit is unaffected by any other changes in the rest of the system, e. g. Other circuits opening or closing down, pump speeding up or slowing down. Each valve is only visited only once. By reducing the number of visits to each valve by more half, we more than half the cost of water system commissioning. Back COMFORT CONTROLS Heat Interface Unit Application Next - Page 21

Benefits of using Differential Pressure Control Valves To achieve the perfect balance Danfoss recommend the installation of ASV’s on all branches. When used on every branch, DPCV’s ensure accurate control and noise protection throughout the system. Time savings during commissioning are also best realised with complete DPCV coverage. Back COMFORT CONTROLS Next - Page 22

Benefits of using Differential Pressure Control Valves Common applications for DPCV’s are to balance: -Under-floor heating manifolds (as pictured) -Radiator circuits -Heat interface units -Circuits with radiant panels DPCV’s can also be used in cooling systems to balance fan coils, chilled beams and air handling units. However Danfoss recommend utilising the additional benefits of Pressure Independent Control Valves in cooling applications. Back COMFORT CONTROLS Next - Page 23

Selecting ASV-PV Differential Pressure Control Valves Sizing and selecting an ASV-PV Differential Pressure Control Valve is simple. To demonstrate how to size a DPCV we shall use an example of a radiator circuit requiring a flow of 0. 7 l/s and a total circuit pressure loss of 18 k. Pa. The pipe-work is DN 40. The 18 k. Pa total circuit pressure loss is the radiator circuit pressure loss added to the ASV-I partner valve pressure loss. Radiator Circuit Pressure Loss ASV-I Pressure Loss ASV-PV Pressure Loss 10 k. Pa is the most efficient operating pressure for a system with ASV-PV valves. Back COMFORT CONTROLS Return Pipe When sizing an ASV-PV we aim to have a valve pressure loss of 10 k. Pa. Flow Pipe The total circuit pressure loss does not include the ASV-PV DPCV pressure loss. Next - Page 24

Selecting ASV-PV Differential Pressure Control Valves Thread Flange Now we have all the information required to select our valve, the next stage is to consult the ASV-PV datasheet. In this datasheet you will find a flow chart showing the achievable flow through the different valve sizes, when we have a 10 k. Pa valve pressure loss. Firstly we turn our 0. 7 litre per second (l/s) flow rate in to litres per hour (l/h): 0. 7 l/s *3600= 2520 l/h We then take a line (red) horizontally through 2520 l/h on the chart. The smallest valve which can achieve the flow is then selected. This is a DN 40 valve. Back Next ASV Flow Chart COMFORT CONTROLS - Page 25

Selecting ASV-PV Differential Pressure Control Valves Once we have our valve size we then consult the datasheet for the available spring ranges for DN 40 valves. The spring range is the differential pressure loss, we require in the circuit, and that we set in the DPCV. As you can see below we have 3 spring ranges for DN 40 ASV-PV valves. In our example we require a circuit pressure loss of 18 k. Pa. The ideal spring range would therefore be 525 k. Pa. This leads us to select the ASV-PV DN 40 valve with a 5 -25 k. Pa spring range. This is Danfoss code number: 003 L 7605. Back COMFORT CONTROLS Next - Page 26

Danfoss ASV Range of Differential Pressure Control Valves Now we have looked at theory behind Differential Pressure Control Valves, it will be useful to look at the products in more detail. Back COMFORT CONTROLS Next - Page 27

Danfoss ASV Range of Differential Pressure Control Valves Danfoss ASV-PV’s are compact, high performance valves, available in sizes ranging from 15 -100 mm. The valves have pressure spring ranges from as low as 5 k. Pa, up to a maximum of 100 k. Pa. The 15 -40 mm valves combine three services in one. They are a differential pressure control valve, an isolation valve, and a drain point. Back COMFORT CONTROLS Next - Page 28

Danfoss ASV Range of Differential Pressure Control Valves ASV-PV valves come complete with a 1. 5 m impulse tube with connectors, moulded valve insulation, and valve tags. In addition to this they feature: - Internal or external threaded pipe connections - Pressure range spring options of 5 -25 k. Pa and 20 -40 k. Pa in sizes 15 -25 mm - Spring options in sizes 32 -40 mm of 5 -25 k. Pa, 2040 k. Pa, and 35 -75 k. Pa. - A very compact design - An operating temperature down as low as 20℃ and up to +120℃ Back COMFORT CONTROLS Next - Page 29

Danfoss ASV Differential Pressure Control Valve Danfoss ASV-PV valves in sizes 50 -100 mm are PN 16 cast iron, DPCV’s with additional spring pressure ranges for higher pressures. They also incorporate three services in one. Acting as a differential pressure control valve, an isolation valve, and a drain point. The DN 50 valve has four spring ranges. They are 5 -25 k. Pa, 20 -40 k. Pa, 35 -75 k. Pa, 60 -100 k. Pa. The DN 65 -100 valve sizes have three spring ranges, 20 -40 k. Pa, 35 -75 k. Pa, 60 -100 k. Pa. The ASV-PV valves in 65 -100 mm are capable of handling valve pressure losses as high as 250 k. Pa. Back COMFORT CONTROLS Next - Page 30

Danfoss ASV Differential Pressure Control Valve Setting the ASV-PV is very simple. Once installed an allen key is used to set the circuit pressure loss. Each turn of the allen key relates to a pressure in k. Pa. In 5 -25 k. Pa and 20 -40 k. Pa spring ranges, one turn of the allen key changes the pressure by 1 k. Pa. Back COMFORT CONTROLS Next - Page 31

Danfoss ASV Differential Pressure Control Valve In 35 -75 k. Pa and 60 -100 k. Pa valves, one turn of the allen key changes the pressure by 2 k. Pa. Setting is commonly done by the commissioning engineer who monitors the pressure whilst adjusting the valve. When the required pressure loss is achieved the valve is set. Back COMFORT CONTROLS Next - Page 32

Danfoss ASV-I Partner Valves Danfoss ASV-I partner valves are the ideal accompaniment to ASV-PV Differential Pressure Control Valves. They are four services in one: - A double regulating valve - A measuring point for commissioning - An isolation valve which is independent of the valve setting - A handy place to connect the impulse tube Back COMFORT CONTROLS Next - Page 33

Danfoss ASV-I Partner Valves By using a partner valve along with a DPCV, the partner valve becomes a flow limiting double regulating valve. ASV-I valves are available in sizes 15 -50 mm. Where a partner valve is required for sizes 65 mm and above, a Danfoss MSV-F 2 flanged commissioning valve can be used to partner the ASV-PV. Back COMFORT CONTROLS Next - Page 34

Pressure Independent Control Valves Before we conclude our look at Differential Pressure Control Valves, I’d like to look at just one more. This is the Danfoss type: AB-QM Pressure Independent Control Valve (PICV’s). AB-QM’s are used in fan coil, air handling, and chiller applications as a combined differential pressure and motorised control valve. Back COMFORT CONTROLS Next - Page 35

Pressure Independent Control Valves By using an AB-QM at each terminal, we create a self balancing system with every coil receiving only its desired flow. By combining the control and balancing valve we more than half the number of valves installed, and reduce commissioning time by up to 2/3’s AB-QM’s will be covered in detail in a future Danfoss Training Module 4 -’Pressure Independent Control Valves’ Back COMFORT CONTROLS Next - Page 36

A Final Review You now have all the information required to specify, select, and understand the Danfoss range of Differential Pressure Control Valves Before we finish, let us review the information you have learned. Back COMFORT CONTROLS Next - Page 37

A Final Review Differential Pressure Control Valves (DPCV’s) are used for dynamic balancing of hydronic heating and cooling systems. They react to changes in the system to keep a constant pressure in the circuit they control. This constant circuit pressure enables the system to balance and be accurately controlled. Differential pressure control valves are commonly used in variable flow pumping systems. Variable flow systems are used to improve the energy efficiency of heating and cooling systems. Back COMFORT CONTROLS Next - Page 38

A Final Review DPCV’s are installed on the return pipe of the circuit. Partner valve are used on the flow pipe. An impulse tube is installed from the partner valve to the DPCV and allows the flow pressure to act upon the top of the valve diaphragm. The spring within the valve is set by the installer, using an allen key, to deliver a set circuit pressure loss. The diaphragm along with the spring act together to react to system changes and to keep this constant pressure loss. Back COMFORT CONTROLS Next - Page 39

A Final Review Common applications for DPCV’s are: -Under-floor heating manifolds (as pictured) -Radiator circuits -Heat interface unit -Circuits with radiant panels Danfoss recommend the installation of DPCV’s on all branches of the system. Back COMFORT CONTROLS Next - Page 40

A Final Review Danfoss ASV-PV valves are a compact, high performance valve, available in sizes ranging from 15 -100 mm, and pressure spring ranges from as low as 5 k. Pa and up to 100 k. Pa. They incorporate three services in one. Acting as a differential pressure control valve, an isolation valve, and a drain point. Danfoss ASV-I partner valves are the ideal accompaniment to our Differential Pressure Control Valves. Back COMFORT CONTROLS Next - Page 41

Final Review Congratulations for completing your third training module! You now understand all that is required to select, and specify Danfoss balancing valves. Once you have completed three modules you can apply to Danfoss Randall for your ‘Continuous Professional Development’ Certificate. For more information on Danfoss products or for Danfoss-Randall’s contact details please visit our website at: www. danfoss-randall. co. uk Thank you for your time. Start COMFORT CONTROLS - Page 42