Marketing Guide FO Titus Vertical tack Fan Coil isers 1
Table Of Contents Page Introduction 3 iser izing 3 2 Pipe ystem tandard eturn 4 2 Pipe ystem everse eturn 5 Vertical tack 4 Pipe tandard & everse eturn 6 iser Location 7 iser Insulation and pacing 8 iser Installation 9 Marketing Advantages of Titus Method 12 iser Extension Length Formula 14 2
Introduction This application guide will assist Titus representatives in the sale of vertical stack fan coils, particularly as it relates to the application of risers. The term riser is used to describe the piping used to supply or return water from the vertical stack fan coil (chilled or hot water) as well as the piping used to run off condensate water from the coil. Fan coils have three risers on a two-pipe system (one each supply, return and condensate) and five risers on a four-pipe system (chilled water supply, chilled water return, hot water supply, hot water return and condensate). isers are typically insulated with elastomeric, closed cell thermal insulation to minimize heat loss or gain from the water to the ambient space. The diameter of the riser will decrease or increase as the piping extends throughout the building, in order to equalize the pressure and velocity of water flow. This is not dissimilar to duct sizing in an air delivery system. Pipe sizing and insulation are the domain of the consulting engineer for the project, their discussion in this guide serves to explain concepts used. The nature in which risers are supplied on a unit in order to meet the engineers design vary by manufacturer. The concept Titus utilizes in its risers is not the norm in the industry. Titus methods offer shipping advantages as well as labor savings for the installing contractor, and these methods are presented in detail. iser izing Design operating pressure differentials between the supply and return riser is typically 10 to 15 psi. Design velocities are typically between 1 and 4 feet/second. Typical riser pressure loss is designed for about 3 feet of head pressure loss per 100 feet of piping. As a rule of thumb, 10 feet of head pressure equates to about 5 psi. Two types of systems are used in piping fan coils, 2 pipe and 4 pipe. A standard two-pipe system utilizes a supply riser, return riser and condensate riser. In a twopipe system, hot water and chilled water share the same piping network, but the system can only be in the heating or cooling mode at any one time. A four-pipe system can operate simultaneously in the heating and cooling mode, and thus has separate supply and return risers for hot and chilled water. In both systems, the risers are sized for the amount of water they will carry at various points within the system. Two different configurations are available for return piping, standard return and reverse return. In the standard configuration, water flows from the first fan coil in the loop through the last, and returns from the last unit back through the first. In a reverse return system, both the supply and return flow run from the first unit in the system through the last and returns to the chiller through a separate riser. 3
Pictured below are horizontal and vertical layout configurations of standard return piping systems. ample diagrams for reverse return piping systems are also featured. Horizontal Piping Layout For a 2 Pipe ystem with tandard eturn Piping CHILLE BOILE Vertical Piping Layout For a 2 Pipe ystem with tandard eturn Piping CHILLE BOILE 4
Horizontal Piping Layout For a 2 Pipe ystem with everse eturn Piping November 21, 2003 CHILLE BOILE Vertical Piping Layout For a 2 Pipe ystem with everse eturn Piping CHILLE BOILE 5
Vertical tack 4 Pipe ystem with tandard eturn Piping CHILLE BOILE Vertical tack 4 Pipe ystem with everse eturn Piping CHILLE BOILE 6
iser Locations The location of supply, return and condensate piping risers are flexible in order to meet construction constraints found on the job. Featured below are drawings, which show riser options, supply locations and typical configuration arrangements for vertical stack fan coils. IGHT HAND EA IGHT FONT ETUN AI FLOW LEFT LEFT HAND IGHT EA LEFT FONT ETUN AI FLOW EA EA IGHT FONT ETUN AI FLOW LEFT 7
iser Insulation and pacing The consulting engineer for the project specifies riser insulation thickness. Typically, elastomeric, closed cell thermal insulation is the material used for insulating risers and is normally ½ inch thick, providing for an -value of approximately 2.5. ome local codes have recently begun mandating increased -values for thermal efficiency. The use of thicker insulation in these cases affects spacing of the risers, particularly in four pipe systems. Generally speaking, you do not want the total width of the riser package to exceed 17 inches. Pictured below is the standard riser spacing. In the event the cumulative dimensions of the riser diameter and insulation thickness exceeds 17 inches, contact Titus for a special riser design. tandard Insulation Thickness and iser pacing 2 PIPE 3.25" 3.00" 17.00" UPPLY DAIN ETUN 5.00" 3.25" ½" WALL INULATION LAB CUT-OUT 3.50" 3.25" 4 PIPE 3.00" 17.00" CW CW DAIN HW HW 3.25" 3.50" 5.00" ½" WALL INULATION LAB CUT-OUT 8
iser Installation The term riser refers to the supply/return/condensate piping attached to a vertical stack fan coil. The term riser extension refers to the piping, which connects risers associated with vertical stack fan coil units located on different floors, one above or below the other (see illustration on page 14 for riser extension length formula). There are a number of general principles, which apply to any fan coil riser installation. iser connections made by Titus at the factory are always brazed joints, while recommended field connections should be made with 95/5 solder. When making field connections of riser extensions, the correct method is to push the insulation down and clamp before soldering. In situations where the insulation cannot be pushed down far enough, the insulation should be neatly sliced vertically (parallel to the piping) and clamped before soldering. Once the joint has been connected, the insulation should be glued. Use of this methodology will not only provide for the best aesthetics, it will also maintain the integrity of the thermal protection provided by the insulation. The top of every riser should incorporate a female fitting while the bottom of every riser extension should be male. (ee below) Also shown below are pictures detailing correct and incorrect methods of connecting riser extensions in the field. For fan coil specific installation information, refer to the IOM (Installation, Operation and Maintenance) guide. Push insulation back before soldering Cut insulation neatly in vertical manner 9
Top of riser incorporating female fitting Correctly soldered extension joint How to and how not to field solder riser connections! 10
Care must be taken during shipment and installation not to damage risers. Titus provides an optional metal enclosure to encapsulate risers for extra protection. (ee drawing below) Units should never be handled by the riser for transportation purposes, as they are not load bearing devices. Master and lave Configuration IE PIPE CHAE PLATE TYPICAL MATE V LAVE with Pipe Chase OPTIONAL IE PIPE CHAE 10" 11
Marketing Advantages of Titus isers In the fan coil industry, some manufacturers incorporate riser extensions onto risers at the factory. While some contractors may prefer this, Titus utilizes a process in which the extensions are shipped with the unit and connected to risers in the field. There is a common misconception that the Titus method calls for additional field labor for the contractor, but in fact, the reverse is true. In addition, the Titus method is more advantageous from a shipping perspective. Details for both these issues are outlined below. Labor Advantages Installation of a vertical stack fan coil with riser extensions applied at the factory requires the labor of three contractor technicians to set the unit and one technician to field solder the connections. A two-pipe system has three connections and the average installation time to set the unit is twenty minutes per unit, or a total of thirty man minutes. Average field labor for soldering is ten minutes per joint. If the average chargeable field labor were $90 per hour, unit installation labor would be $45. Field soldering labor would be $23; total field labor costs would be $68/unit. Using the Titus method, two technicians are required to set the unit and a two-pipe system would have six connections per unit. Average installation time is five minutes per unit or 10 minutes total. Average field labor for soldering is five minutes per joint. Again using a figure of $90/hour, installation cost would be $15 and soldering costs would be $45. Total field costs using the Titus system are $60, while traditional costs are $68. If there are 350 units on the job, savings to the contractor equal $2800 using the Titus method. There are some considerations regarding these savings. The field supplied riser extensions are loose so there is potential for misplacement. In addition, some incremental time may be required to set up prior to soldering the field joints, which may detract from savings shown. At a minimum however, these two methods are equal in terms of installation costs. In addition, units with field risers are easier to handle on the job and will be subject to less damage. hipping Advantages Units which have extensions applied at the factory consume a lot more cubic space than those with extensions applied in the field. On a typical 53 open top truck; the maximum quantity of vertical stack units that can be shipped per truck with factoryapplied extensions is 48 (36 if all the units on the load are the 1000 or 1200 CFM size). On a job with 350 units, 8 trucks would be required to complete shipment. 12
Using the Titus method of applying extensions, you can load a minimum of 88 units per truck. On a job with 350 units, four trucks would be required, saving 50% in freight costs. If the average cost per truckload were $2100, the non-preferred method would cost $16,800 to ship while the Titus method would cost $8400 to ship. On a job with 350 units, the Titus method of applying riser extensions has a potential of saving the contractor $11,200! In addition to the cost advantages outlined above, there are intangible benefits to the Titus method. First, the potential for damage during transit and at the jobsite is greatly reduced. Time (and cost) spent handling these types of problems becomes direct profit when eliminated for a contractor. In addition, units shipped in the traditional industry fashion require flat bed trucks. Depending on time of year and location, these types of trucks may be harder to get (fewer of them in the national transit system) which could delay shipment, and as a result they may cost more per mile. Even though units shipped on these trucks are protected from weather by tarps, they are much more prone to weather damage than units shipped in plentiful, lower cost closed trailers. Given all the advantages of the Titus method, this method merits a presentation of alternatives to the contractor. Titus representatives are always looking for a specification hook; this can be a point of differentiation. Don t settle for the status quo if local installation preferences are for factory-applied risers. Demonstrate the installation advantages to all your mechanical contractors and get them to commit to trying one floor of field-supplied risers on their next project. Work with them to document actual savings and preferences. In addition, work with your consulting engineers to specify field applied riser extensions. Ultimately, changing the approach to field applied risers will make you more competitive on your fan coil bids. 13
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iser Extension Length Formula X H h+3 h Key: h = Height of fan coil X = H - (h+3") + 4" overlap h + 3 = iser length X = Extension length H = Height between floors (measurements in inches) 15