VARIABLE VOLUME SYSTEMS

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 Dynamic Balancing

The Bigger Energy Issue

• Environment
• Climate change
• CO2 emissions
• Who is the biggest culprit?
• Cars?
• Planes?
• No, actually, it’s buildings

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 Dynamic Balancing

World Energy Consumption

40%
buildings

40% of world energy consumption goes into buildings

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 Dynamic Balancing

Alleviating the Energy issue: Dynamic Balancing

Dynamic Balancing is a design

methodology to achieve good
environmental control ensuring that
all terminal units (Radiators / Fan Coil
Units etc.) get correct design flow
rates and therefore design chilled or
heat output

unbalanced
balanced

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 Dynamic Balancing

Why do we need Dynamic Balancing?

Move from Constant Volume to Variable Volume systems

• driven by Government legislation
• energy conservation
• subsequent CO2 emissions

The move from constant to variable flow design enables pump

energy savings

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 Dynamic Balancing

Why do we need Dynamic Balancing – constant volume

inherently very stable

constant constant pressure
pressure drops drops in circuits at
in distribution part load
pipework

constant
control valve
constant authority
pump head

Control valves easy to size with constant authority

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 Dynamic Balancing

Why do we need Dynamic Balancing – constant volume

constant amount of water

pumped around a system
controlled by 3 or 4 port control
valves and would be
• through terminal
• split between terminal and
by-pass
• diverted back if not required

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 Dynamic Balancing

Why do we need Dynamic Balancing – variable volume

inherently very unstable

variable variable
pressure pressure drops
drops in in circuits at part
distribution load
pipework

variable
control valve
variable pump authority
head

Control valves difficult to size with variable authority

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 Dynamic Balancing

Why do we need Dynamic Balancing – variable volume

Variable amount of water pumped

around a system now controlled
by 2 port control valves

open

Modulating between
open and closed

closed

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Why do we need Dynamic Balancing Valves

Constant Variable

lost stability

constant control variable control

valve authority valve authority

DPCV installed to protect 2 port control valve authority

or
PICVs installed to replace commissioning / control valves

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 Dynamic Balancing

Why do we need Variable Volume Systems

100%

Temperature variations

% plant load
• Over 70% of cooling season
• Load is less than 50%

% cooling 100%
season

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 Dynamic Balancing

Variable Volume Pump Energy Savings

100% DFR
• As system demand change, flow rate
changes

System Resistance DP
• Direct relationship between pump
speed and flow rate
system curve
• 50% pump speed = 50% flow rate

50% Flow Rate

50% flow rate = 25% System Resistance

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 Dynamic Balancing

Variable Volume Pump Energy Savings 100% DFR

System Resistance DP
• 50% speed = 50% flow rate
• 50% flow rate = 25% circuit Δp
system curve
• 25% circuit Δp = 12.5% energy

50% flow rate = over 70%

pump energy saving
energy at 100%
flow rate

Loses due to pump energy at 50%

flow rate
efficiency reducing

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 Dynamic Balancing
What are Dynamic Balancing Valves?
Dynamic Balancing
Valves

CFD DPCV PICV

Constant Flow Differential Pressure Pressure Independent
Device Control Valves Control Valves

constant flow variable flow areas variable flow areas

areas • radiators • chilled beams
• chilled beams • radiant panels
• radiant panels • FCUs
• underfloor heating • AHUs
• FCUs
• AHUs

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 Dynamic Balancing
What are Dynamic Balancing Valves?
Dynamic Balancing
Valves

CFD
Constant Flow
Device

Constant flow
areas

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 Dynamic Balancing
What are Dynamic Balancing Valves?

Dynamic Balancing
Valves

DPCV
Differential Pressure
Control Valves

Variable flow areas

• Radiators
• Chilled beams
• Radiant panels
• Underfloor heating
• FCUs
• AHUs

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 Dynamic Balancing
Why do we need Dynamic Balancing – radiator circuits

• To enable TRV (Thermostatic Radiator Valves) to correctly operate, a

DPCV is installed to limit the radiator sub-circuit pressure differential
• The installation of DPCVs in sub-circuits with TRVs reduces the pressure
that the TRV has to close against thus reducing the possibility of noisy
valves

DPCV holds pressure constant between points A and B

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 Dynamic Balancing
Why do we need Dynamic Balancing – DPCVs for FCU

• To enable modulating 2 port control valves to operate with an acceptable

authority, a DPCV is installed to limit the circuit pressure differential
• The installation of DPCVs on sub-branches with 2 port control valves is
therefore essential to achieve good control

FCU FCU FCU FCU

DPCV holds pressure constant between points A and B

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 Dynamic Balancing

Why do we need DPCVs - control valve authority

pump head
Example without DPCV available for
this circuit
Δp across 2 port
valve authority ß =
Δp across circuit
20 kPa
ß= 80kPa
80 kPa
20kPa
ß = 0.25

Δp at design
Too low - unacceptable flow rate

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 Dynamic Balancing
Why do we need DPCVs - control valve authority

Example with DPCV fitted

Δp across 2 port
Valve authority ß =
Δp across circuit
20 kPa
ß= 80kPa 40kPa
40 kPa
20kPa
ß = 0.5

Acceptable DPCV set to

control at design
flow rate

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Why do we need DPCVs - control valve authority

Position of DPCV?

Δp across 2 port
valve authority ß =
Δp across circuit
20 kPa
ß=
25 kPa 80kPa
25kPa 20kPa
ß = 0.8

position can influence authority

DPCV set to
on single terminal circuits – as closes as possible to control at design
control valves gives higher authority flow rate

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How do DPCVs work

FCU FCU FCU FCU

• For any flow rate there is only one possible pressure drop
between any 2 points
• As flow rate changes Δp changes – squared change
10% in flow = 21% in Δp

DPCV holds pressure constant between points A and B

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Why a DPCVs work

FCU 1 FCU 2 FCU 3 FCU 4

Kirchhoff's 2nd law states

‘Head loss in parallel circuits must be equal’

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Why a DPCVs work

3 1
FCU 1 FCU 2 FCU 3 FCU 4

• A terminal 4 B
• A terminal 3 B
Applying Kirchhoff's law
• A terminal 2 B
• A terminal 1 B
All have the same pressure drop irrespective of flow

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 Dynamic Balancing

Where do DPCVs go

Branches are broken down into sub-circuits, each

controlled by a DPCV

Each circuit must only flow through a single DPCV

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 Dynamic Balancing

Where do DPCVs go
Branches are broken down into sub-circuits, each
controlled by a DPCV

what about the 2 terminals

direct off main pipework
run?

Each circuit must have some protected from over flow

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 Dynamic Balancing

Where do DPCVs go
Alternative approach

Complete circuit protected by a single DPCV

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How are DPCVs selected

FCU 1 FCU 2 FCU 3 FCU 4

Δp

To size a DPCV not to add high additional load

the Δp across the DPCV

is typically 10 - 20kPa
irrespective of the Δp through the circuit

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 Dynamic Balancing

Other Valves associated with DPCVs - Companion Valve

FCU 1

Companion Valve offers

• flow measurement
• isolation
• DPCV connection
• bosses for test points

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 Dynamic Balancing
Dynamic Balancing of the System

Because each sub-circuit is

separated by a DPCV from
fluctuating system pressure &
therefore holds a constant pressure
within the sub-circuit, commissioning
sub-circuits can be carried out totally
independently

sub-circuits are independent of each other

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Dynamic Balancing of the System

reference

Commissioning within the sub-

circuits is carried out by
‘proportional balancing’ in the
conventional manner

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Dynamic Balancing of the System

Each sub-circuit is balanced

by measuring flow thro the
‘Companion Valve’ and
adjusting DPCV to regulate
flow

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Dynamic Balancing of the System

For circuits nearer the pump

the regulating function of the
companion valve may be used
to reduce the pressure drop
across the DPCV to bring it
into a better operating
position, i.e. splits residual
pressure

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 Dynamic Balancing

Dynamic Balancing of the System

FCU 1 FCU 2 FCU 3 FCU 4

1. set DPCV to highest control range setting

• highest pressure difference gives highest flow rates
2. measure flow rate at companion valve
3. adjust DPCV until design flow rate achieved

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 Dynamic Balancing

Variable Volume System

At maximum pump turndown, typically 10 - 20%, consideration

needs to be given to branches to ensure
Ø pump flow at minimum load
Ø circulation of water treatment
Ø ready supply of heating / chilled water

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Dynamic Balancing of the System

possible solution

end terminal could have a 3 or 4 port control valve

Ø on larger circuits additional 3 or 4 ports could be
added

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 Dynamic Balancing

What are Dynamic Balancing Valves?

Dynamic Balancing
Valves

PICV
Pressure Independent
Control Valves

Variable Flow Areas

• chilled beams
• radiant panels
• FCUs
• AHUs

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 Dynamic Balancing

Controlling Fluctuating System Pressures

Following the move to variable volume system design

• DPCVs were used to create areas with stable pressures

FCU FCU FCU FCU FCU

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 Dynamic Balancing

Controlling Fluctuating System Pressures

DPCVs prove difficult to select correctly
• sizing relatively easy
• gathering required information difficult / impossible
• number of terminals in protected zone / controlled Dp ?

FCU FCU FCU FCU FCU

static commissioning and control valves also

required for each terminal

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 Dynamic Balancing

Controlling Fluctuating System Pressures

PICVs replacing DPCVs
other valves required?

FCU FCU FCU FCU FCU

the PICV is fitted instead of – not as well as

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 Dynamic Balancing
Controlling Fluctuating System Pressures

• Normally fitted to each terminal unit

• Return pipework is the preferred FCU

position

• Clear / straight lengths of pipework

are not required for PICVs but ‘good
practice’ suggests some straight
lengths of pipework create a more coil kept in
stable flow pattern for the PICV to
control
highest
pressure
available

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 Dynamic Balancing

What is a PICV? flow regulation

flow control

Three functions in
one

differential pressure
control

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Pressure Drops Across PICV

P2

Differential pressure P1
controller holds the
Dp across the seat
constant

Dp confirmed by
test points

Often referred to
as P1 – P2

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Pressure Drops Across PICV

Differential pressure
across the PICV
varies

On smaller sizes
total Dp
NOT P1 P3
confirmed by test
points

Often referred to
as P1 – P3

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 Dynamic Balancing

PICV Authority

Dp across control valve

Authority h =
DP across circuit

Dp control valve = DP circuit

Considered to be ‘1’

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PICV Activation

• As flow increases Δp increases

flow rate

often referred to as • At min Δp, pressure controller

the activation Dp starts to hold differential seat
pressure constant
• Flow rate remains constant
• Pressure controller controls seat
differential pressure at min Δp
until max total Δp is reached
• Flow rate will rise as Δp continues
to rise

min max
Δp (differential pressure)

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PICV Activation P2

P1
P1 to P2
the activation Δp
always constant
measured by integral test points

Where test points measure

P1 – P3
Δp will vary
between min & max

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 Dynamic Balancing

PICV Selection
Flow rate is the main selection criteria

Other considerations could be

• minimising pressure drop
• matching line sizes

FCU FCU FCU FCU FCU

Almost always it is flow rate that determines selection

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 Dynamic Balancing
PICV Selection

DN15 Low Flow DN15 Standard Flow

setting flow rate total Δp setting flow rate total Δp
position l/s kPa position l/s kPa
2 0.008 15 2 0.04 15
3 0.010 15 3 0.060 15
4 0.020 15 4 0.080 20
5 0.030 15 5 0.105 20
6 0.040 20 6 0.120 20
7 0.050 20 7 0.140 20
8 0.060 20 8 0.155 25
9 0.070 20 9 0.175 25
10 0.080 20 10 0.200 25

selection charts are available

• flow rates
• set position
• minimum Δp (differential pressure) total loss at activation

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 Dynamic Balancing

PICV Selection – activation point

DN15 tandard Flow

setting flow rate total Δp activation
position l/s kPa Δp kPa
2 0.040 15 12
• activation Δp lower than total Δp 3 0.060 15 12
• activation Δp constant 4 0.080 20 12
• total Δp varies 5 0.100 20 12
6 0.120 20 12
7 0.140 20 12
8 0.160 25 12
9 0.180 25 12
10 0.200 25 12

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 Dynamic Balancing

PICV Selection

DN15 Low Flow DN15 Standard Flow DN20 Standard Flow

setting flow rate total Δp setting flow rate total Δp setting flow rate total Δp
position l/s kPa position l/s kPa position l/s kPa
2 0.008 15 2 0.04 15 2 0.065 15
3 0.010 15 3 0.060 15 3 0.100 20
4 0.020 15 4 0.080 20 4 0.130 20
5 0.030 15 5 0.105 20 5 0.160 20
6 0.040 20 6 0.120 20 6 0.190 25
7 0.050 20 7 0.140 20 7 0.220 25
8 0.060 20 8 0.155 25 8 0.240 25
9 0.070 20 9 0.175 25 9 0.260 25
10 0.080 20 10 0.200 25 10 0.280 25

setting 5
Example between setting 8 & 9
required flow rate 0.160l/s 8.3ish

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 Dynamic Balancing
PICV Selection

DN15 Low Flow DN15 Standard Flow DN20 Standard Flow

setting flow rate total Δp setting flow rate total Δp setting flow rate total Δp
position l/s kPa position l/s kPa position l/s kPa
2 0.008 15 2 0.04 15 2 0.065 15
3 0.010 15 3 0.060 15 3 0.100 20
4 0.020 15 4 0.080 20 4 0.130 20
5 0.030 15 5 0.105 20 5 0.160 20
6 0.040 20 6 0.120 20 6 0.190 25
7 0.050 20 7 0.140 20 7 0.220 25
8 0.060 20 8 0.155 25 8 0.240 25
9 0.070 20 9 0.175 25 9 0.260 25
10 0.080 20 10 0.200 25 10 0.280 25

total Δp (P1 – P3)

example total Δp (P1 – P3) 20 kPa
required flow rate 0.160l/s 25 kPa

Total Δp could rise to max Δp – 350 kPa

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PICV Control Characteristic

linear
=%

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PICV Control Characteristic - =%

if stem it used to
regulate flow rate
Control Characteristic
is changed at lower
settings

=%

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 Dynamic Balancing

PICV Control Characteristic - linear

If stem it used to
regulate flow rate
Control Characteristic
is NOT changed at
lower settings

linear

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PICV Control Characteristic

% heat output
Coil output characteristic

Equal percentage control valves are

output
designed with a increases

h=1

3
0.
50% output

=
Mirror image of coil characteristic

5
h

0.
=
h
flow rate
increases 1
=
h

20% flow
% open
50

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 Dynamic Balancing

PICV Control Characteristic - =%

% heat output
Coil output characteristic

• Establish a direct relationship between

open position & heat output
• 50% valve opening = 50% heat output

1
=
h

% open

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 Dynamic Balancing

PICV Control Characteristic - =%

% heat output
Coil output characteristic

• Where stem used to regulate flow rate

• Changes control characteristic

3
0.
=

5
h

0.
=
h
combined ‘linear’ position moves 1
=
due to effect of valve h

characteristic
% open

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 Dynamic Balancing
PICV Control Characteristic - =%

=%

‘Linear’ control actuator giving equal

percentage characteristic

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 Dynamic Balancing

PICV Control Characteristic - linear

% flow rate
• Establish a direct relationship between
open position & flow rate
• 50% valve opening = 50% flow rate
• Not effected by flow regulation

% open

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 Dynamic Balancing

PICV Control Characteristic - linear

linear

‘Equal Percentage’ control actuator giving

equal percentage characteristic

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 Dynamic Balancing

Variable Volume System

At maximum pump turndown, typically 10 - 20%, consideration

needs to be given to branches to ensure
Ø pump flow at minimum load
Ø circulation of water treatment
Ø ready supply of heating / chilled water

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 Dynamic Balancing

Dynamic Balancing of the System

Possible solution

End terminal could have a 3 or 4 port control valve

Ø on larger circuits additional 3 or 4 ports could be added

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 Dynamic Balancing

Flow Accuracy

Different factors affect accuracy

• pre-set position

• available pump pressure

• actuator control

Accuracy is a combination of all factors

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 Dynamic Balancing

Flow Accuracy – Pre-set Position

0
1 9

2 8
Aligning dial with scale
3 7

4 6
5

Pre-set position accuracy can be improved by the

installation of a FMD

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Flow Accuracy – Available Pump Pressure

min max

0.5
0.4
flow rate (l/s)
0.3
0.2
0.1

0 1 2 3 4
operatingpressure
differential range (Bar)

As pump pressure varies flow rate varies

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Flow Accuracy – Available Pump Pressure

25kPa

0.5
0.4
flow rate (l/s)
0.3

set
0.2

position ± 10%
4
0.1

0 1 2 3 4
20kPa differential pressure (Bar) 350kPa

As pump pressure varies flow rate varies

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Flow Accuracy – Rising / Falling Pressure

0.5
0.4
flow rate (l/s)

hysteresis
0.3
0.2
0.1

0 1 2 3 4
differential pressure (Bar)

Hysteresis is relatively low but need to be considered

and understood

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 Dynamic Balancing

Flow Accuracy – Actuator

Installed PICVs are a combination of

• PICV
• Actuator

so we should consider the assembly

and not the standalone PICV

Consider as a ‘matched’ pair

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Flow Accuracy – Actuator

coil output

• PICV can perform well as

a stand alone valve

• But when actuator is fitted

performance of valve can actuator
be undermined controlled
h=1

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 Dynamic Balancing

Actuators

Actuators are divided into 2 types

• Thermal
• Electro-mechanical

And then by control characteristic

• On / Off
• Modulating

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 Dynamic Balancing
low
PICV Commissioning pressure
high
pressure
PICVs are set to give the required flow
rate, there is no commissioning
required for the PICV

Commissioning Engineers are

required to set the pump speed to
ensure that the ‘least favoured‘ (index)
PICV generates at least the minimum
required differential pressure

if the least favoured PICV has

sufficient different pressure, all other
PICVs must have greater differential
pressure

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 Dynamic Balancing

Summary

• Change in system design to variable flow controlled by 2 port control valve

resulting in pump energy saving
• Fluctuation in system pressure undermines control valve authority
• DPCV installed into sub-circuits to ‘protect’ control valves from fluctuating
pressure to maintain control valve authority
• terminal units commissioned by conventional proportional method
• branches commissioned by use of ‘Companion’ Valve & DPCV
• branches commissioned independently of each other
• PICVs installed on terminal unit
• replacing static commissioning valves / 2 port control valve / DPCV

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