2. The differential pressure across control valves must not vary too much
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1 2. Te differential pressre across control valves mst not vary too mc Common roblems roblems, typical indicating tat condition nmber two is not met: - Continos oscillation of room temperatre. - Room temperatres not reacing reired set point at low loads. - Maintenance problems wit control valves and actators, de to fatige from nting. - Higer energy costs tan expected, de to nfavorable control settings to avoid instability. Backgrond Variable flow systems are becoming more and more poplar, mainly de to te advantages compared to constant flow systems: Te pmping costs are redced Te retrn temperatre is minimised in eating systems Te retrn temperatre is maximised in cooling systems Bt tere is one major disadvantage: Te differential pressres in te plant may vary considerably dring operation By flfilling te second condition, te negative impact on system fnction and performance from tis disadvantage can be redced and even avoided. How it is done? By sing good ydronic! Te essential objective in ing any eating and air conditioning plant is to obtain a comfortable indoor climate, minimising costs and operating problems. In teory, new control tecnologies appear adeate to satisfy te most demanding reirements and to provide opportnities for increasing comfort wile making sbstantial energy savings. In practice, owever, even te most sopisticated controllers cannot acieve teir teoretical performances nless te conditions for teir operation are correct. Tese conditions are settled by te of te ydronic system. Simply pt; control cannot compensate for a poorly ed system, wic is wy te system mst be ed as controllable as possible. Circit One important measre of ydronic ality is te circit. Fig 1 represents a typical ydronic circit for an air eating/cooling coil. Te circit is te relationsip between te control signal and te reslting termal power from te coil. It determines te controllability of te system. Termal power [] Control signal []
2 Te steeper te slope of te circit crve, te iger te risk for control instability becomes and as a reslt, te more difficlt te control becomes. Tis is ite easy to imagine. At a low slope, any actions from te control will reslt in marginally canges of te termal otpt, making te system ite indifferent. However, at a ig slope, even tiny alterations of te control signal will reslt in large canges of te termal otpt, making te system sensitive and possibly nstable. To avoid instability problems, wic effectively will rin te control fnction, a low set vale of te gain (corresponding to a wide -band) is reired in te controller. However, te reslt of a low controller gain is less control accracy and slower response to distrbances. It is terefore crcial to avoid steep slopes of te circit. In sc perspective, te ambition sold be to acieve a linear circit since it will minimise te slope across te entire control range. Circit compond Te circit consist of: Actator Inerent valve Terminal atority Actator (inerent) atority effect Terminal Circit Te actator sows te relationsip between te incoming control signal from te controller to te actator and te reslting valve lift. Usally, te is linear bt for simple actators, te crve may be ite nlinear. Te inerent valve, wic sows te relation between valve opening and valve capacity ( vale), depends solely on te mecanical of te control valve. Tere are few different types of valve s on te market; te most common ones are te linear and te eal-percentage, or actally eal-percentage modified (EQM) s.
3 Te terminal may vary a lot depending on, size and temperatres bt is definitely nlinear. A typical gives 50% power at 20% flow and 80% power at 50% flow, ite te opposite sape compared to an EQM valve. Tis is also te reason wy EQM is sally preferred, wen coosing control valve, since it conteract te nlinearity of te terminal. atority is a measre of te cange in differential pressre across a control valve dring operation. Te flow trog a control valve depends on te differential pressre across te valve and its vale. Te vale is given by te inerent valve for any valve opening. If te differential pressre is constant dring operation, te relationsip between and water flow wold be completely linear. However, in variable flow system, te differential pressre varies dring operation, wic means tat te relationsip becomes more or less nlinear. Te magnitde of te nlinearity is expressed by te valve atority: β = st β = atority [-] = Differential pressre across flly open control valve at flow [ka] st = Differential pressre across flly st control valve [ka] β = 0.1 β = 1.0 A ig vale of valve atority means tat te differential pressre is close to constant and te relationsip between vale and water flow becomes ite linear. A low vale, on te oter and, means tat te differential pressre will increase mc wen te valve closes, reslting in large nlinearity between vale and flow. Te lower te valve atority is, te more nlinear te crve becomes. Simply by looking at te compond of te circit, it is ite clear tat a low valve atority will make te circit crve nfavorable. Tis is wy te second condition mst be flfilled; too mc variation in differential pressre across a control valve leads to low atority, distorted circit and poor control. In addition, large variations in differential pressre will lead to interactivity between circits, making control even more difficlt. Design and minimm valve atority Te available differential pressre across te ydronic circit is transferred to te control valve once it sts, wic means tat size, and control of te system determines te differential pressre across te control valve flly st (denominator in te expression above). Hence, te circmstance of te system at any given time determines te available differential pressre across te circits, wic means tat te valve atority varies dring operation. If, for instance, only one control valve sts in a system wile te oters are flly open, te differential pressre across tat specific valve will become significantly lower tan if all control valves st at te same time. Tis leads to two different definitions of valve atority; atority and minimm atority. For two-way valves in variable flow systems, tese definitions become as following:
4 β = ΔH β min = ΔH max β = atority at condition [-] ΔH = Available differential pressre across circit at condition [ka] β min = Minimm valve atority [-] ΔH max = Maximm differential pressre across circit dring operation [ka] Bot te and minimm atority definitions sold be regarded wen ing a system, since te level of te valve atority will vary somewere between te atority (igest possible level) and te minimm atority (lowest possible level) dring operation. Te implication of varying valve atority on te circit dring operation is sown in te figre below. Te best case represents te of te considered circit for atority, corresponding to a sitation were all oter control valves in te system are maintained flly open. Te worst case, owever, represents te circit for minimm atority, corresponding effectively to a sitation were all oter control valves are maintained flly st. Te latter case reslts in mc iger differential pressre across te circit and, ts, steeper slope of te circit and also sbstantial overflow wen te control valve is flly open. Worst case β min β Best case Actator (inerent) atority effect Terminal Circit
5 Hydronic Te impact of te cosen control valve on te circit and, ence, on te controllability of te system, is ite obvios since bot te valve as well as te valve atority depends on te control valve selection. Wen coosing control valves bot of tese aspects mst be taken care of. Te flow mst be obtained for te control valve flly open in conditions. In order to facilitate control, te valve sold matc te terminal nlinearity. To maintain a favorable circit, te valve atority mst not be too low. In order to prevent te valve atority from distorting te circit too mc, te lowest vales of and minimm atority are: β 0.5 β min 0.25 Te atority for a control valve sold not be less tan 0.5, wic effectively means tat te pressre drop trog te flly open (two-way) control valve at flow sold at least be eal to alf of te available differential pressre across te circit at condition. Te prpose of tis gideline is to make sre tat te circit at its best becomes ite close to linear, assming tat te inerent of te valve is appropriately cosen. Te second condition states tat te minimm atority sold not fall sort of 0.25, wic sets te lowest level of te circit, wen it is at its worst. Evidently, tis condition is of mc importance since it effectively settles te limit for te control to andle. Besides coosing te control valves careflly, tere are oter measres to implement in order to avoid low atority: Avoid large pipe pressre drops Use variable speed pmps Use Δp stabilization valves wen needed Even if te control valve is selected wit great care, tere migt arise sitations were te valve atority becomes too low anyway, simply becase it depends not solely on te control valve sizing bt on te of te rest of te system as well. An effective measre in sc perspective is to install differential pressre stabilization valves. Tese migt improve te prereisites for problem free control radically. Conclsions Te objective of any HVAC plant is to provide a comfortable indoor climate wilst minimising costs and operational problems. In teory, modern control tecnologies make tis objective possible. In practise, owever, not even te most sopisticated controllers perform as promised. Te reason is often tat te conditions necessary for good control are not flfilled. One sc condition is tat te differential pressre across control valves mst not vary too mc. Te reason is to maintain te valve atority at a sfficient level in order to prevent te circit from distorting too mc and, ts, avoiding control problems. Tor & Andersson AB Bo G Eriksson, Senior Engineer
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