FloCon Commissioning Modules Fan coil and chilled beam headers Patent No. GB B

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1 FloCon Commissioning Modules Fan coil and chilled beam headers Patent No. GB B

2 2 FloCon Commissioning Module Concept In traditional systems, using copper pipe, the valves must be close to the fan coils to allow full flushing of the pipe work. Once you employ flexible, multi-layer, plastic coated metal pipe where no flushing is needed, all valves can be centralized. This allows off-site assembly, swift commissioning and effortless maintenance. TRADITIONAL DESIGN - FLUSHING BYPASS LOCAL TO FAN COIL BSRIA FLUSHING & CLEANING GUIDE AG1/2001 FLUSHING PATH 4 Fan Coils = 8 branch tees (24 joints) - Copper pipe in 3 meter lengths FloCon MODULE DESIGN - MANIFOLD IS COMMON FLUSHING BYPASS 2-6 Fan Coils per module Flexible Multi-layer Pipe Recommend 15m to furthest terminal Flexible Multi-layer Pipe Max module inlet size - 32mm Valve Module Max pipe feed to terminal units - 20mm FLUSHING PATH 4 Fan Coils need only 2 branch tees (just 6 joints in all) Manifold & multilayer pipe more cost efficient to install (See BSRIA costing sheets) Simple multi-layer pipe installation Multi-layer pipe supplied in up to 200 metre coils Joint-less continuous pipe runs from FloCon module to fan coil

3 FloCon Commissioning Module Features 3 Return manifold Flow manifold Large bodied strainer Flushing bypass and air vent FULL OFF-SITE ASSEMBLY AND TESTING UNDER STRICT QUALITY CONTROL COMPACT BOX IS VAPOUR SEALED TO PREVENT CONDENSATION THE BIG 3 Large Bodied Strainer Centralized Flushing, Back Flushing, Venting & Balancing Insulated and Vapour Sealed Box FLUSHING THROUGH MAIN BRANCH TERMINAL BRANCH AIR PURGE BACK FLUSHING THROUGH TERMINAL BRANCH As BSRIA Guide AG1/2001: - Remove CM strainer baskets - flush/chemical clean steel pipes - final fill with treated water - replace CM strainer baskets - vent all CMs.

4 4 Commissioning Traditional Commissioning Extremely laborious - decentralized valves at remote terminal units mean much use of stepladders! Step 1 Step 2 Start Step 3 Step 4 Step 4 Finish Step 1: Flush Pipework up to Fan Coil Step 2: Vent Fan Coils Step 3: Back-Flush Fan Coils Step 4: Proportional Flow Balance As BSRIA Guide AG1/2001 FloCon Commissioning Modules Grouping makes life so much easier. Step 1 Step 2 Start Step 3 Finish Step 1: Flush Valve Module Step 2: Vent, Back-Flush & Flow Balancing can be performed at one visit. Step 3: Balance modules against each other As BSRIA Guide AG1/2001: Remove CM strainer baskets,flush/chemical clean steel pipes, final fill with treated water, replace CM strainer baskets, vent all CMs.

5 Change and Churn 5 ADDING A FAN COIL 1. Drain Branch 2. Cut into pipework 3. Run new pipework out to Fan Coil 4. Re-balance flow rates to all Fan Coils on branch 1. Position new Fan Coil unit 2. Run new flexible pipes from module 3. Re-balance module balancing valves With Traditional Layout With Valve Modules MOVING A FAN COIL 1. Drain Branch / Move terminal unit 2. Remove Valves and pipework back to mains 3. Refill branch pipework 1. Move terminal unit 2. Extend or re-route pipework 3. Re-balance valves in module 4. Re-balance flow rates to all Fan Coils With Traditional Layout With Valve Modules

6 6 Variable Speed Pumping Systems Energy saving is a critical issue in the design of modern buildings and variable-speed pumps offer significant potential for energy savings. However, designers face the challenge of utilising the undoubted energy saving potential of variable speed pumps, without losing the energy efficiency of modulating control. BSRIA and CIBSE recommend a minimum Valve Authority of 0.3 to ensure acceptable modulation control. The objective of good regulation control is to minimize the difference between the actual and set point temperature to improve energy efficiency and comfort control. Traditional Layout Control valves must be sized against main branch DPCV pressure FloCon Commissioning Modules Control valves can be sized against local valve module DPCV with typical ΔP 2 of bar. DPCV MODULE WITH INDIVIDUAL TERMINAL UNIT CONTROL VALVES DIFFERENTIAL PRESSURE CONTROL VALVE MODULE WITH ZONE VALVE PRACTICAL DESIGN GUIDE FOR VARIABLE VOLUME PUMPING SYSTEMS is available upon request. Call us on or visit

7 Technical Data 7 Flow Capacities - Max. Working Temperature: 95 o C Max. Working Pressure: 10bar Note: Manifold ports can be adapted to receive different pipe sizes. Hence a mixture of sub-circuit sizes from the same manifold is possible. Inlet Pipe Size mm (OD) Maximum Flow (l/s) Terminal Pipe Sizes Maximum Flow mm (Outer Diameter) mm (Internal Diameter) (l/s) Terminal Unit Flow Equation: Q=kW/(4.2* t) where Q = flow in l/s, kw = Term. Unit duty in kw, t = difference between Flow & Return temperatures in o C Commissioning Sets Nom. Size Flow Range (l/s) Maximum balancing kv kvs pressure (kpa) 15 LL Q ML Q SL Q SS Q Q Q Q Equations: P(Pa) = 2 /2 or P(kPa) = (Qx36/kv) 2 Where Q = flow kg/s, = density kg/m 3, = velocity m/s Pipe Pressure Losses - Outer Diameter mm di 16mm di 20mm di 26mm di Pressure Drop (Pa/m) NB: Pressure losses are for straight pipe Flow Rate (kg/s) 2 pv Type - VZL2 DPCV - AVP-F 2 port valve mm kvs mm kvs DPCV DN mm kvs DN mm kvs

8 FloCon Commissioning Module Installations - Fan Coils and Chilled Beams Albion Riverside Luxury Apartments BskyB Head Office 30 St Mary Axe Harvey Nichols London Stock Exchange The SAV solution offers better more accurate control of differential pressure and easier, faster commissioning - a sixth of every floor at 30 St Mary Axe, could be balanced and finely tuned from a single point. Dave Gatwood, Project Manager, Hills Mechanical SAV FloCon Modules fitted with DPCV's allow us to commission one module at a time if necessary. Variable speed systems are simple to commission in this way and phased occupancy of the building is made easier. Adjustment of pump speed according to measured readings satisfies our responsibility under the Part 'L' regulations. Measurement of pressure drop and flow become highly predictable, so we can now truly commission the system instead of simply measuring flow rates. Duncan Selby, Comdronic Ltd The benefits at the commissioning stage have been remarkable. There were zero problems in a 125,000 ft 2 building! Our commissioning engineers describe the Modules as a dream to work with and all their figures were within the design set margins. Stuart Bareham - Waterman Building Services The installation was highly successful, resulting in an overall time saving compared to a traditional system. We are now proposing the Commissioning Module solution on a number of new projects we are now involved with. JS Key, Contracts Manager, Balfour Kilpatrick Limited UK Customer Support Centre SAV, Scandia House, 131 Armfield Close, West Molesey, Surrey KT8 2JR Tel: +44 (0) Telefax: +44 (0) info@savmodules.com Web: