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Humidifier Types and Humidity Basics

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Humidifier and Humidity Basics. Direct steam humidifier, steam to steam, electrical humidifier, Evaporative and gas-Fired Humidifiers
Humidifier and Humidity Basics

Humidifiers

Humidifier Types and Humidity Basics. Humidifiers vary as to the source or energy that provides the final product produced for humidification whether that’s steam or mist. You can use Steam, Electricity, Gas, Air or Water as the main source of humidification. We’ll explain each of these humidification systems. Humidifiers can be installed within Air Handlers, ductwork or open areas. 

If you prefer to watch the YouTube Video of this presentation, scroll to the bottom.

Commercial Humidifier Types
Commercial Humidifier Types

Direct Steam Humidifiers

Using steam directly from a steam boiler eliminates the need for additional steam generating equipment. The steam will be delivered from the steam boiler to a manufactured provided direct steam humidifier. 

Checkout these Humidifiers here
Direct Steam Humidifier Design Layout
Direct Steam Humidifier Design Layout

The direct steam humidifier will have the capability to remove dirt and scale particles by straining the incoming steam. There will be a separating of the condensate from the steam, directing the steam condensate to the drain outlet. The steam leaves the humidifier in an all-vapor state where it mixes with the air stream.

Using a direct steam humidifier reducing the need for maintenance as required with other method of humidification as the steam at 212°F (100°C) provides a natural method of steam cleaning the components of the humidifier.

If the facility is existing and already has a steam boiler than this might be the cheapest alternative, depending on where the existing steam pipes are in relationship to where the steam is required.

Steam Distributors

Inserted in the air stream within the supply duct will be the steam distribution tubes that have perforated holes running along its length. The steam exits these holes along the tube, injecting steam into the air stream.

Steam to Steam Humidifiers

Unlike the direct method where steam from a boiler is used directly in the air stream, the steam-to-steam humidifier uses a heat exchanger. This separates the steam generated by the steam boiler from the steam that enters the air stream. This avoids the concern of using treated steam boiler water and the adverse health effects associated with chemicals being brought into the air stream from the boiler.

Steam-to-Steam Humidifier Design Layout
Steam-to-Steam Humidifier Design Layout

The steam from the boiler is under pressure, while the secondary steam is often under atmospheric pressure. Having a second source of water increases the concern for impurities in the water and the havoc it can create This increases the need for frequent cleaning.

The time to satisfy a demand for humidification is slower than the direct steam method because the water must be brought to a boil before it can be used.

The indirect steam humidifier provides tight control of output using a modulating control valve, positioning from closed to open based on demand. This allows for a quick response to any space demand for humidification.

Checkout these Humidifiers here

Electric Steam Humidifiers

If there isn’t a steam boiler at the facility, then there is the option of generating steam with a water source and electricity.

Electric Steam Humidifier Design Layout
Electric Steam Humidifier Design Layout

Using electrodes to pass electricity through water is one method, and the other would be to use immersed resistance heating elements to boil water for steam supply. Water quality will be important with the use of electrodes while water quality won’t affect the immersed heating element type humidifier. With both of these types the need to boil water makes it less responsive for quick control.

Gas-Fired Steam Humidifiers

Gas fired steam humidifiers use ionic beds of fibrous mediums that heat the water using gas instead of electricity. The fibrous medium will absorb several pounds of solids in the water and will require replacement when the medium is fully loaded. This leads to reduced time cleaning the tank as the fibrous medium collects a lot of the solids in the water.

Gas-Fired Steam Humidifier Design Layout
Gas-Fired Steam Humidifier Design Layout

Evaporative Humidifiers

Another option is to use an evaporative humidifier, that can be installed in an air handler or in supply or exhaust ductwork. Air passes over media as water trickles down over it, causing the air to be cooled while increasing its relative humidity.

Moisture is evaporated into the air passing over the wet media, proving an increase in the water content of the air. Sensible heat from the supply air is used for evaporation of the water into vapor, this provides for cooling of the air while also adding moisture. This reduces energy consumption without the need for boilers or gas fired units that burn fossil fuels for the evaporation process.

Evaporative Humidifier Design
Evaporative Humidifier Design Layout

The HVAC contractor will install the evaporative humidifier in the duct as shown here, then connect the electrical to power the water pumps and controls, then install the water piping to the unit. Its important to provide some form of water filtration to keep the unit from clogging or minerals from depositing on the equipment.

We’ll need a drain line to remove any unevaporated water. Also available is the ability to remotely monitor the system through a BMS system. You can monitor or make changes to the settings; this is typical with most of the humidification systems.

We show this evaporative humidifier installed in the supply ductwork, but they’re also made for installation within the air handler or on the exhaust side with the use of an energy recovery heat exchanger. There are other versions of the evaporative humidification process used for non-ducted applications.

Checkout these Humidifiers here

Atomization Humidifiers

Atomizing humidifiers don’t require a boiler or steam piping as they basically spray water through nozzles to create a mist. That is why they are the most energy efficient type of humidifier. Compressed air and water intersect to create a mist that absorbs heat from the air stream for evaporation into a vapor. This will cause a cooling of the air and will take energy from the air in the form of heat. This would require a larger heating system if using humidification and heating at the same time. If there is insufficient heat in the air stream, then moisture or water could accumulate on the surrounding surfaces of the ductwork, causing damage as water leaks out into the space. Along with direct steam, atomization is quick to respond to a demand for humidification. These systems are best served by deionized water (DI) or reverse osmosis water.

Humidifier Controls

There are several controls that are used for the proper functioning of an humidifier.

High Limit Sensor. This insure that the humidity doesn’t exceed a certain maximum. We’ve set this one for 90% relative humidity as it serves a VAV systems.

Humidifier Control Diagram
Humidifier Control Diagram with Humidistat, High Limit, Air Proofing Switch and Main Controller

Airflow Proving Switch. The humidifier must be shutoff if airflow is not blowing through the duct and over the dispersion tubes. To ensure air is moving over the dispersion tubes an airflow proving switch is proved in the duct downstream of the dispersion tubes. This can be done by using a sail switch, which has a sailboat like sail in the air stream that will rotate on a shaft to make an electrical circuit.

Humidistat. This will control the on and off of the humidifier based on the set point. It works just like a thermostat except that the controlled element is humidity. 

Humidifier Controller. Humidifier manufactures provide various levels of controllers with touch screens and LED displays. There are options to have remote monitoring, where you can see what is happening with the humidifier and make changes. It’s possible to have multiple humidifiers connected to one main controller.

Hygroscopic Materials

This is the process whereby materials will absorb water from the atmosphere by absorption or adsorption. Hygroscopic materials like paper are water lovers that absorb water, which can be a problem for a lot of industries. A museum with expensive artwork is sensitive to rapid changes in relative humidity. If the relative humidity is too low than moisture can be pulled or evaporated out of the hygroscopic material such as that which paintings are rendered on. If it can absorb moisture it will be capable of losing moisture content.

Drain Coolers

Many local codes and municipalities don’t allow the draining of 212F (100C) condensate into the sewage system. This will require the use of a drain cooler, which injects domestic cold water to mix with the steam condensate to drop the temperature of the water before it enters the drain.

Steam Boilers

Using direct steam for humidification creates a concern for the air quality when the boiler water is treated with chemicals. These water treatment chemicals can end up in the air, therefore indirect steam to steam is used as a barrier to this issue. Using Indirect steam avoids evaporating the anti-corrosive additives into the air stream, which has been known to cause health problems and the deterioration of paintings and exhibits in museum. 

What is Relative Humidity?

The Relative Humidity defines the amount of moisture in the air at the current temperature compared to the amount it could hold at that temperature when 100% saturated. Relative humidity is always expressed as a percentage. 

Warmer air can hold more moisture than colder air for the same volume (Cubic Feet) of air. Warmer temperature has a greater capacity for holding water vapor. This chart shows the maximum amount of moisture that can be held in one cubic foot of air at the temperature shown.

Relative and Absolute Humidity Chart
Relative and Absolute Humidity Chart

At 40F and 100% relative humidity the air can only hold 2.86 grains, but as the temperature increases, say to 70F, the air can now hold 8.06 grains/ft3 of air, and at 100F, the air holds 19.9 grains. So the warmer the air the greater its capacity to hold moisture. Keeping the relative humidity between 40% and 60% for human comfort and safety is the ideal setting.

When relative humidity is at 100%, then the Dew Point Temperature and the Air Temperature are equal. This means that the air is fully saturated with moisture and can’t hold any more moisture. As the dew point temperature rises, the capacity of the air to hold moisture increases. 

Relative Humidity Chart Bacteria Viruses
Relative Humidity Chart Bacteria Viruses

Relative humidity has been found to be an important factor in the control of airborne infectious diseases, reducing influenza and other viral outbreaks.

As this chart shows, bacteria and viruses love the humidity to be under 40%, or above 60%. This is where they thrive. The same for respiratory infections and Asthma. This is why controlling relative humidity is important.

ASHRAE recommends relative humidity be kept in the range of 30% to 60% for human comfort and health.

Humidification is the process of adding moisture to the air to improve health and comfort, avoid high static conditions and protect processes or products, like museum paintings. Understanding psychometrics, we know that when cold air is heated, the relative humidity drops, and the air feels dry. 

What is the best Relative Humidity for my Home or Business?

The level of relative humidity is dependent on what is being served by the HVAC system. This can be artwork in a museum, or paper manufacturing, office workers or a residential home. ASHRAE recommends a relative humidity range of 30% to 60% for comfort. Yale University has done studies that show a relative humidity range between 40% and 60% reduces the viability of viruses. So, for humans somewhere between 30% and 60% is ideal. For materials and sensitive artwork, the values will differ. There are some cases. Like a burn unit in a laboratory where skin cultures are grown that requires a strict 60% relative humidity within a 1% variance. 

Calculating the Humidification Load

Calculating the humidification load is to determine how many pounds of water per hour is required to mee the space conditions. There are three things needed before calculating the humidification load for a space. They are as follows;

  1. Space Design Temperature and Relative Humidity required to be maintained.
  2. Volume of air delivered to the space
  3. Outside Air Design conditions for Temperature and Relative Humidity

Isothermal Steam Humidification

Using steam humidifiers has little effect on the dry-bulb temperature of the supply air serving the space. All the energy required to turn the water into a vapor or steam is handled by the steam humidifier. No heat from the air stream is required to turn the water into vapor, so there is little to no effect on the dry-bulb temperature. Steam is complete water vapor at 212°F (100°C). The steam will mix with the air stream, causing the steam to drop in temperature, bringing it close to the dry-bulb temperature of the air.

If we plot this on a psychrometric chart, the dry-bulb temperature would remain unchanged as the humidification process would send a vertical line up the chart in a pure moisture increase.

Humidifiers and how they work. Humidity Basics

Air Filters and Filter Housing Basics

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Air Filters and Filter Housing Basics. MERV Rating of Air Filters.

Air Filters and Filter Housing Basics. In this article we’ll review air filters, filter housings, filter ratings, and how to use a VFD to maintain flow when filters get dirty. Most people spend the majority of their time indoors, so knowing all about filters is important for good air quality and health.

For the YouTube Video of this presentation, scroll to the bottom.

The purpose of air filters is to remove dust and particles from the air stream, not only to protect HVAC equipment, but to also to protect people, and products. This could be people in a residence, office building or hospital, in addition to protecting products during manufacturing, like computer chips and pharmaceutical drugs. 

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Air Filters and Filter Housing Basics
Air Filters for HVAC Systems – Air Filters and Filter Housing Basics

Think of a museum and the expensive paintings hanging on the wall that cost millions of dollars. Contaminated air carrying by products of combustion can damage the artwork. Selecting the correct filter is important in protecting equipment, people, or product. 

The museum may need three levels of filtration to protect the expensive artwork. This could include a 30% pleated filter, then a 65% synthetic bag filter, and then the final filter could be a 95% synthetic bag filter.

There are also filters for removing odors and gasses. We’ll first cover air filters for particle and dust removal and then for gasses and odors. A renewed concern includes viruses, bacteria, and microorganisms.

VFD Control of Dirty Filter Conditions

This air handler has a differential pressure transmitter measuring the pressure drop across the filters. When the filters become dirty, there will be an increase in the pressure across the filters, which will cause a loss in flow or CFM if nothing is done to correct the problem. Here we use a Variable Frequency Drive (VFD) to adjust the fan speed for any loss in pressure across the filters.

Dirty Air Filter VFD Control
Dirty Air Filter VFD Control

When the differential pressure reaches a certain static pressure the VFD will go into action and speed up the fan to compensate for the additional pressure drop created by the dirty filters. A set of contacts can be made that sends an email alert to the facility engineer to notify them of the dirty filters.

Checkout these Air Filters here

Pollutants to Be Removed

So, some of the items we want to filter out, everything from human hair, which is in the visible zone. The pollen to coarse dust that’s a larger particle sizes, cat dander, pet dander, fine dust which is smaller particles, tobacco smoke, some is visible, some of the particles aren’t, and then the SARS virus in respiratory droplets is about 0.1 micrometers, and then viruses 0.1 micrometer and smaller.

Air Filter Particle Sizes
Air Filter Particle Sizes in Micrometers

So, you’re looking for a filter that’s going to take out what it is you’re looking to take out. Now this shows ASHRAE standard 52.2 which is a standard used for testing filters. There’s three ranges of sizes, this is 0.3 to 1.0 micrometer, 1 to 3, and 3 to 10.

Air Filter MERV Rating
Air Filter MERV Rating from MERV-1 to MERV-16

MERV – Minimum Efficiency Reporting Value

The different sizes of microns, as you can see the MERV rating here, these filters in the beginning here, don’t take out much on the smaller particle sizes, and not that great on the larger particle sizes. So, you really want to stay in the MERV 11 and higher rating, and we’ve reduced the chart to 11 and greater, and you can see on the small particles 0.3 to 1 the MERV 11, 12 and 13 is 50% an under efficiency. 

ASHRAE Air Filter MERV Chart
ASHRAE Air Filter MERV Chart for Air Filter Efficiency.

So, if you move to a 14 you’re going to get 75% efficiency, and as you can see on the larger particles all the filters do better. It’s a little easier to catch a large particle than it is a very small one. You can see the MERV 16 is rated for 95% efficiency in all size ranges. Of course that’s a more expensive filter, so you might want to stay with a MERV 14 filter if possible, or a MERV-13. It’s depending on what particles you’re trying to capture. If it’s all large particles, then basically anyone of these filters is going to be pretty good.

Checkout these Air Filters here

Filters are rated based on their ability to remove particles from the air stream in a single pass. MERV is the industry standard indicating the effectiveness of the filter. The higher the MERV number the greater the filter is at removing contaminants and dust particles from passing through the filter.

The particle sizes are in three micro-meter ranges (0.3 µm to 1 µm, 1 µm to 3 µm, and 3 µm to 10 µm). There are 25,400 micro-meters in an inch, so were talking about small particles. The air filters are assigned a MERV number based on how they perform in one or more of these three particle size ranges. The higher the MERV rating, the higher the filtration efficiency. There are similar rating systems in other parts of the world, and some hardware stores like Home Depot have their own rating system.

When shopping for filters you should be looking at the MERV rating and what you want to remove from the air stream, such as cat dander, fine dust, coarse dust, tobacco smoke, odors, pollen or even viruses. 

The cheaper filters and lower MERV values are not very good at removing small particles which can be dangerous to your health. 

PM 2.5 Concentrations

Why bother filtering outdoor air? PM2.5 refers to particles two- and one-half microns or less in width. Particles 2.5 microns and smaller are considered dangerous to human health as they can bypass many of our body’s defenses.

PM2.5 Concentrations vary around the world.
PM2.5 Concentrations vary around the world.

Over 3,000,000 pre-mature deaths worldwide were found to be correlated with outdoor air pollutant particles 2.5 microns and smaller. People are exposed to these particles indoors where they spend most of their time, so filtration is very important in maintaining indoor air quality.

Particles less than 1 micron can stay suspended in the air for a long time. Poor indoor air quality can contribute to a wide range of health problems, including Asthma, lung, nose and throat irritation and complications.

Filter Housings

Filter housings provide an enclosure for the filters and can be installed indoors or outdoors in new systems or used for a retrofit project.

Air Filter Housing Camfil
Air Filter Housing by Camfil

Here is a filter housing manufactured by Camfil that can be used outdoors and has a 25” deep side access which accommodates a 2” or 4” deep prefilter, one 2” or 4” deep intermediate particulate or carbon filter, and a 6” or 12” deep rigid or pocket final filter.

V-Shaped filter housings allow for additional filter area using this arrangement. Housing are available for pre-filters, final filters, HEPA’s and roll filter housings.

Air Filter Housing
Air Filter Housing located outdoors in weatherproof enclosure

We can easily retrofit this air handler with a filter housing. First we cut into the main supply ductwork, then install some transition that match the size of the housing connections, then we install the filter housing, and support legs. This filter housing has a prefilter and final filter. The prefilter catches the larger particles and protects the more expensive final filter.

Filter Location and Identification for Replacing

Filters are mostly located on the return side of the HVAC equipment for residential and commercial systems, except for some special applications where there will be supply side filters, which we’ll discuss later.

This can be at a return grille mounted in the ceiling or on a wall. If not located in either of those two locations, then it will be found at the HVAC equipment. You would need to access the equipment and remove the filter access panel or filter rack to locate the filter. On the side of the filter should be the size and MERV rating.

If there is no existing filter or the information isn’t available, then you can measure the opening size. You would measure the height, width and depth of the filter. For a custom fit, make a 1/4” reduction in the height and width for a proper fitting.

Filters can be partially loaded and still a certain percentage of people will perceive the downstream air from the filter dissatisfying. This can occur even before the filters are fully loaded. Contrary to reasonable thinking the filters can be the source of sensory pollution when the filters begin to retain dust and particles.

Depending on where you live, you may need higher levels of filtration to bring down the concentration of these particles.

Contaminants can also be generated within the building from gas burning appliances, burning of candles, cooking, fireplaces, etc. This means it’s critical that you understand what generates a harmful environment in your home and how to increase the indoor air quality. See our video on the “Top 12 Ways to Increase Indoor Air Quality” for ideas.

ASHRAE now requires continuous or intermittent outdoor air by mechanical methods for residential buildings. In residences whole house fans are being installed to bring in outdoor air while also using cooler outdoor air instead of running the compressor. The only problem with this method is that the air entering the home is not being filtered, and depending on where you live, this could be bringing into the home poor quality air. Certain places in the world have higher concentrations of these pollutants and need higher levels of filtration like, parts of eastern and southern Asia, parts of western and northern Africa.

The U.S. EPA has set a maximum annual average ambient PM2.5 concentration of 12 µg/m3, while the World Health Organization maintains a guideline of 10 µg/m3

As you can see for Mumbai, India occupants to achieve the U.S. EPA guidelines of 12 µg/m3of PM2.5 concentrations, a MERV 16 filter would be required, while Los Angeles would only need a MERV-8.

Filters are rated based on a range of velocities flowing through them.

What to Consider when Choosing an Air Filter

Pressure drop needs to be considered as this could adversely affect the flow (CFM) of the system if the fan can’t handle the additional restriction or pressure drop created by the filters. Be sure to compare the pressure drops for various filters and there corresponding MERV rating.

The MERV rating or HEPA cleanliness rating. The higher the rating the better the performance. This defines the efficiency of the filter to capture particles of various sizes. Be sure to understand what it is that you want removed from the air stream, such as particles or gasses. Are you providing filtration for a home, operating room, paint booth or welding station?

The filters holding capacity for the filter is considered dirty and needing to be replaced.

Pressure Drop

Air filters create pressure drops, with the thicker filters creating more pressure loss than its similar thinner version. Pressure drop is to be considered in the design of any HVAC system to ensure that the fan can push the required amount of air (CFM) to the space. If the pressure drop is greater than the system can handle there will be a loss of air flow (CFM). 

Fans used in residential systems usually have low static pressure capabilities, so adding high pressure drop filtration would reduce the CFM, or air flow to the rooms. There is a tradeoff between increased filtration and energy consumption. The greater the filtration, the greater the pressure drop, the more fan energy needed to overcome the static pressure drop across the filters.

Dirty Filters and Notification

Dirty filters provide another challenge for the HVAC system, because as the filters do their job of entraining dirt and particles their pressure drop increases. This increase in pressure effects the air flow, so it’s important to change filters when they get dirty. How do we know if the filter is dirty or getting dirty without opening the unit and visually looking at them to see if they are dirty? This is where magnehelic gauges become important for notification of the filter’s cleanliness or level of dirtiness. 

Fans Response to Dirty Filters

With the use of Electrically Commutated Motors, (ECM) motors and VFD’s, fans can now respond to an increase in pressure drop caused by a dirty filter. As the filter gets dirty or as the pressure drop increases, the fan can speed up to maintain the same volume of airflow, because as we already learned, the air flow or CFM will diminish as the pressure drop increases. 

We the use of various differential pressure measuring devices, the increase in pressure drop across the filters can be used to send a message to the fan to speed up. This ensures that any critical spaces receive the design airflow required.

Types of Filters

Filters are available in various thicknesses, sizes, and MERV values. Panel filters and high-performance cartridge filters. Filters come in low efficiency, medium efficiency, high efficiency, and HEPA type filters. 

HEPA Filter
HEPA Filter

Pad and panel type filters are usually low efficiency types with efficiencies in the 30% range, removing particles 10 microns and larger. Medium efficiency filters will run between 40% and 60% and are usually of the bag or box type removing particles in the 3-to-10-micron range. These filters can be used before the high efficiency filters to increase the life span of the more expensive high-efficiency filters. High efficiency filters range from between 80% and 90% efficiency using a bag type or box type filter, and a particle removal rate of over 70% for particle sizes of 0.3 micron and larger. 

Filter Material Construction

Backings can be welded wire or expanded metal with welded wire be more expensive but offers better performance.

Air Filter Material
Air Filter Material

Beverage board frames, cardboard or a kraft paper frame, with the beverage board frames being the more expensive one. The beverage board frame can be chemically treated to resist moisture, bowing, or collapsing providing a better performing frame then the other two.

The use of antimicrobial agents on air filters help reduce the proliferation of microbes.

Built-up Filter Banks

In large commercial buildings you can find very large built-up filter banks that require supplemental steel for support.

Electrostatically Charged Air Filters

Carbon Air Filters

In commercial buildings where odors are a problem, the use of activated carbon filters can help. Activated carbon filters can remove molecular contaminants such as bio-effluents, volatile organic compounds (VOS’s), and organic-based odors, while also reducing ozone exposure. Carbon filters don’t increase in resistance as they are used, which is opposite of your standard air filter.

AHU Filtration

There are various quantities and qualities of filters used in air handlers. Of course, air handlers that serve a hospital operating room would have greater filtration requirements than that of an office building. Operating rooms may require three separate filter banks, a pre-filter, final filter, and HEPA filtration., while an office may have one or two filter banks, a pre-filter and final filter.

Looking at the air handler we can see that the first set of filters are pre-filters and are used before the coils. These filters are important to ensure that the coils remain clean, as any dirt on the coils will cause a loss in heat transfer.  

Commercial filtration differs from residential filtration in that in commercial buildings the ventilation rate is often much higher, meaning that a greater amount of outside air is brought in the building through a commercial filter than residential ones.

Air Changes per Hour

Another factor effecting the use of filters and their longevity is the amount of air changes per hour they receive. In your typical single-family homes, the recirculation of the air happens whenever the unit is on. Various commercial and medical buildings will have special rooms that dictate the amount of air changes for ventilation and for recirculation. Cleanrooms vary in their classification with some rooms being very clean and requiring the majority if not all the ceiling to be filters. This you may find in factories that fabricate computer chips or pharmaceuticals, where the air needs to be super clean, as any tiny particle can ruin the computer chip or spoil the drug being produced.

How Air Filters Work

There are four basics methods by which dust and particles are captured by the air filter media: Straining, Impingement, interception and Diffusion. Watch the YouTube Video of this presentation to see an animation of these methods. Air Filter Video

Straining occurs when the dust or particle is larger than the gap between filter fibers. This is one of the common methods of removal in low efficiency filters.

Impingement occurs when a large, dense particle collides with the filter fibers directly, not be able to follow the air flow around the fiber. The fibers can be coated with an adhesive to assist in retaining the particle. This is also one of the common methods of removal in low efficiency filters.

Interception occurs when the dust or particle rides the air stream through the filter media and at some point, leaves the air stream and attaches to the media fibers. This method is used for particle removal in medium efficiency filters.

Diffusion occurs when very small particles are influenced by air molecules, colliding with them, causing them to move erratically through the air stream. This allows the small particles to become attached to the filter media, which is a method used in high efficiency filters.

Electrostatic occurs when particles are given the opposite electrical charge as that of the filter. The particle will then be attracted to the filter when passing through it.

Filter Performance

There are a few metrics for measuring filter performance including Efficiency, Dust-Holding Capacity and Resistance.

Efficiency defines the percentage of dust and particles that the filter will remove.

Dust-Holding Capacity defines the amount of dust and particles that the filter can hold before being changed.

Resistance defines the amount of pressure drop created by the filter in the air stream.

ASHRAE Standard 62.1 and 62.2

This is the commercial 62.1, and residential 62.2 standard for the minimum requirements for HVAC particle filtration efficiency. To meet the minimum ventilation requirements in areas of the world where the outside air is highly polluted is challenging.

The difference between residential and commercial filtration, is that the home HVAC system doesn’t run most of the time, while in commercial buildings some form of air and ventilation is required whenever the building is occupied. Filters are used all the time in commercial buildings and less often in residences. Also, overall system efficiency drops when air bypasses the filter due to gaps in the filter racks or tracks. Be sure that the air is traversing the filter and not finding its way around the filter through cracks and poor filter rack design.

Filter Maintenance

Maintenance of filters involves reading of the filter resistance gauges, visual inspections, and scheduled filter replacement. A filter that fails or gets clogged can cause damage to products, bypass infiltered air, and increase energy usage. 

HVAC Air Filters and Filter Housings

Centrifugal Pump Basics | How they work with VFD’s in HVAC Systems

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Centrifugal Pump Basics How Pumps Work

We’ll learn centrifugal pump basics and how they work with VFD’s in HVAC Systems.

Scroll to the bottom to watch the YouTube video of this presentation.

The pump is made to put energy into water by increasing the pressure or flow. The energy is transferred from the motor to the shaft then to the impellor and the water. The centrifugal force causes the water to fly outward from the impellor.

Remember according to the first law of thermodynamics, energy can’t be created or destroyed but only transferred from one location to another or converted to and from other forms of energy.

There are many factors in the proper operation of a centrifugal pump system, including the quantity or GPM (LPS) of fluid flow, piping design and layout, method of control, and the selection of the pump.

As the head decreases, the flow rate will increase, and vice verses, if the head increases, the flow rate will decrease. Pump charts are based around these two factors, flow rate and head. See our video on How to Read Pump Charts.

Variable Frequency Drive (VFD) Pump Control

We can change the volume by speeding up or slowing down the motor using a variable frequency drive (VFD). We do this to match the load and save energy. No need for the pump to run at full speed if all that flow or GPM is not required by the air handlers or fan coils.

Centrifugal pump basics and how they work with VFD's in HVAC Systems
Centrifugal Pump basics and how they work with VFD’s in HVAC Systems

Most existing systems requiring flow control make use of bypass lines, throttling valves, or pump speed adjustments. The most efficient of these is pump speed control. When a pump’s speed is reduced, less energy is imparted to the fluid and less energy needs to be throttled or bypassed. Speed can be controlled in a number of ways, with the most popular type of variable speed drive (VSD) being the variable frequency drive (VFD).

A differential Pressure Transmitter will send a signal to the VFD controlling the pump to either speed up or slow down based on the demand of the system.

Controlling Pumps using a Variable Frequency Drive (VFD)
Controlling Pumps using a Variable Frequency Drive (VFD)

What does a HVAC Centrifugal Pump Look Like?

There are many manufacturers that make centrifugal pumps for the HVAC industry, but basically, they all function the same way and with the same purpose in mind, and that is to move a fluid through pipes and equipment while overcoming the friction. All though the colors may vary by manufacture the parts are similar.

Pump Manufactures and Color Branding
Pump Manufactures and Color Branding

Centrifugal pumps have few moving parts with minimal wear during normal operations. There are two main components, the motor which drives the pump, and the pump which contains the impellor, the propulsion vanes that pull and push the fluid. The motor takes electrical power and converts it into mechanical energy that moves the fluid through the pipe and equipment. The pump has an inlet where it sucks in the fluid and an outlet where it pushes the fluid out through the system.

Parts of a Centrifugal Pump

Pumps are relatively a simple piece of equipment when compared to other HVAC equipment. Starting with the motor we have the motor casing which is rated for various duties, such as Open Drip Proof (ODP), Totally Enclosed Fan Cooled (TEFC). Motors can also be inverter duty rated so that a Variable Frequency Drive (VFD) can vary the speed of the motor to match the load.

End Suction Pump Parts
End Suction Pump Parts

The motor has a shaft that extends into the pump portion where it attaches to the impeller, this can be a direct connection or by a coupling. The impeller is made up of vanes that rotate to impart energy to the water. The spinning vanes create a centrifugal force throwing the water from the rotating impeller. The water discharged by the impeller is thrown by centrifugal force into the spiral-shaped volute which is the housing surrounding the impeller.

Pumps are available with various impeller sizes; each size provides a different amount of flow and head. The pump may come with the option of an 7″, 7-1/2″, 8”, 8-1/2″, 9”, and 9-1/2″” impeller.

End Suction Pump Impeller Size Options
End Suction Pump Impeller Size Options

To change the flow rate of an existing pump you can trim the impeller to make it smaller or replace the impeller with a larger one if the pump isn’t already using the largest impeller for that pump model.

Disassembling the pump, we see that the motor has a fan to keep it cool when running. The motor converts electrical energy into mechanical energy and spins the shaft. See our video on how Motors Work. Attached to the shaft is an impeller which is housed inside a Volute, the protective casing surrounding the impeller, and which acts as a guide for the water being forced out of the impeller by the spinning centrifugal force.

Pump Disassembled
Pump Disassembled

Some shafts extend all the way from the motor through the impeller, while other pumps use a coupling to match up the motor shaft with the impeller/pump shaft.  Two separate shafts meeting with a coupling that attaches them together.

The shaft passes into the pump casing and is usually made of stainless steel or high carbon steel. The shaft is support by bearings.

Impellers come in various configurations including closed, semi-open and open. The impeller shown here is of the semi-open type, which means it has as shroud on the back side only.

Impeller Types - Closed, Semi-Open and Open
Impeller Types – Closed, Semi-Open and Open

If you missed our previous video on Pump Charts, check that video out to see how Impellers are chosen to meet system design conditions.

The outer casing of the pump is called the volute and directs the water exiting the impeller to the outlet.

The stuffing box contains either a mechanical seal or packing to prevent the leakage of water from around the shaft. The packing is made of fiber and lubricated with graphite or Teflon.

With the impeller surrounded by water, and the impeller rotating, the water gets thrown outwards in all directions. The water leaving the impeller encounters the volute, while creating a lower pressure region at the suction inlet where more water is sucked in.

The discharge pressure will be higher than the suction pressure, causing the fluid to flow around the system.

Cavitation

Cavitation occurs when vapor bubbles appear due to the liquid falling below its vapor pressure. When the pressure at the inlet of the pump drops below the vapor pressure of the water, bubbles will begin to appear around the eye of the impeller. Then when these bubbles encounter a pressure above the vapor pressure of the water, the bubbles will collapse causing a crackling noise, vibration, and shock waves that can damage the surface of the impeller.

Where are Centrifugal Pumps used?

Centrifugal pumps are used mostly in the commercial HVAC industry to move chilled water, heating hot water and condenser water.

Pumps used in HVAC Systems for Condenser Water, Chilled Water, and Heating Hot Water Systems
Pumps used in HVAC Systems for Condenser Water, Chilled Water, and Heating Hot Water Systems

There are chilled water and heating water systems that may be comprised of primary and secondary pumps. Condenser water system that feed a cooling tower or a water-cooled heat pump system.

Small vertical inline pumps can be used in residential projects for domestic hot water recirculation and snow melt systems.

Pump Configurations

Centrifugal pumps can be provided in various configurations from end suction, split-case and vertical turbines. The most common in the HVAC industry is the end suction pump which has the inlet centered on the eye of the impeller. They are classified as either close-coupled or frame mounted.

Centrifugal Pumps and How they Work with VFD’s

Chillers and Air Handling Units

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Air-Cooled Chillers vs Water-Cooled Chillers and Air Handling Units

In this presentation we’ll learn how Chillers and Air Handling Units (AHU’s) work together in commercial buildings. We’ll discuss the basic functions of these systems and the advantages and disadvantages of air-cooled versus water-cooled chillers.

For the YouTube video Presentation of this, scroll to the bottom.

Air-Cooled and Water-Cooled Chillers

Chillers provide the source of the chilled water that feeds the cooling coil within the air handling unit and fan coils. Supply Air will blow over the chilled water coil in the AHU or FCU to provide cool air to the spaces in the building. The chilled water coil absorbs the heat from the air passes over them and takes the heat back to the chiller where it will be rejected to the outside.

The two most common types of chillers are air-cooled and water-cooled. This refers to the method by which the chiller ejects the heat from the system. 

Air-Cooled Chiller vs Water-cooled Chiller. Image of two types of chillers.
Water-Cooled and Air-Cooled Chiller

With a packaged air conditioning unit, the room air passes directly over a coil filled with refrigerant, while in a chilled water system the room air passes over a coil filled with chilled water.

Water-cooled chillers are manufactured in larger tonnages than air-cooled. Some manufactures make water-cooled to 6,000 tons (20,500 kW), and their air-cooled versions to 600 tons (1,900 kW).

Air-Cooled Chiller vs Water-Cooled Chiller

An air-cooled chiller uses fans to reject the heat outdoors, while a water-cooled chiller will require a cooling tower that sends water to the chiller to absorb the unwanted heat, and then eject that heat through the tower process.

Air-cooled chiller serving horizontal fan coils
Roof mounted Air-cooled chiller serving horizontal fan coils

An air-cooled chiller comes as a packaged unit from the factory including the compressor, evaporator and condenser, with the option of having chilled water pumps integrated. The water-cooled chiller needs a lot more equipment including the cooling tower, water treatment, drain lines and some form of sand or centrifugal filter. This causes air-cooled chillers to have a lower installed cost, simpler installation, lower cost for maintenance due to less components and no water issues or chemicals to deal with.

The water-cooled chiller will usually be more energy efficient, due to the fact that the compressor will have to do less work because water-cooled chillers have lower condensing water temperatures and pressures. Water-cooled chiller usually have a longer equipment life because they’re mostly installed indoors, while air-cooled chillers sit outdoors exposed to the elements. Water-cooled chillers have a life expectancy of 20 to 30 years, while air-cooled chillers is around 15 to 20 years.

Roof mounted Water-Cooled Chiller serving Horizontal 4-pipe Fan Coil Units (Image)
Roof mounted Water-Cooled Chiller serving Horizontal 4-pipe Fan Coil Units

If the HVAC contractor installs an air-cooled chiller on the roof of a building with horizontal fan coils, then installs the piping and pump, the systems is complete except for electrical power and controls.

Using the same building, If the HVAC contractor were to install a Water-cooled chiller and space wasn’t available on the ground level, a penthouse might need to be built on the roof to house the chiller, while additional structural reinforcement of the roof might be required for the weight of the cooling tower full of water.

Water-cooled chillers need a cooling tower, and the tower requires makeup water and a drain. Also some form of chemical treatment will be required for the tower water to remain stable and avoid corrosive buildup. 

With an air-cooled chiller you have no cooling tower. The installation is much easier, and it avoids the additional use of water and chemicals. If water is expensive and energy is cheap, than an air-cooled chiller might be the best option. If energy is expensive and water is cheap than the water-cooled chiller may provide the best solution.

Air-Cooled Chiller serving Air Handling Units
Air-Cooled Chiller serving Air Handling Units

Here are chillers feeding air handling units and the difference between an air-cooled and water-cooled installation in the same building.

Using an air-cooled chiller can free up valuable space within a building that would otherwise be required for an water-cooled chiller. This additional space can be rented out, increasing the value of the building.

Ground floor installed Water-Cooled Chiller serving Air Handling Units
Ground floor installed Water-Cooled Chiller serving Air Handling Units

Water-cooled chillers are mostly installed indoors. This is one of the factors that leads to a longer equipment life, in the range of 20 to 30 years, as compared to an air-cooled chiller which spends all of its life outdoors and operates at a higher condenser fluid temperature. Air-cooled chillers can have a life time duration of 15 to 20 years. 

Air-cooled chillers will have lower maintenance cost due to less components, and the fact that cooling towers used in water-cooled systems need water treatment and the chiller needs condenser tube cleaning.

This leaves air-cooled chillers less expensive to install and maintain, while water-cooled systems are more energy efficient.

Water-Cooled Chillers

Water-cooled chillers can be located anywhere in the building or on the roof in a mechanical penthouse. The chiller shouldn’t be located in the basement unless access is provided for replacement. Locating the chiller on the ground floor with a removal louver or large roll up door allows for easy replacement and access for tube pulls. 

Water-Cooled Chiller serving an Air Handling Unit
Water-Cooled Chiller serving an Air Handling Unit

The chiller will need to be connected to a cooling tower for its heat rejection. This is an extra set of pipes leaving the chiller and connecting to the cooling tower outdoors. Cooling towers are mostly installed at ground level or on the roof.

The Chilled water from the chiller is circulated around the building with the use of Chilled Water Pumps. The chilled water will circulate to all the equipment requiring cooling, which includes Air Handlers, Fan Coils and Blower Coils.

As air from the rooms in the building pass over the chilled water coils, the heat will be absorbed by the chilled water circulating through the coils in this equipment.

The heat circulates from the room through the chilled water to the water-cooled chiller where the heat is transferred into the refrigerant circuit within the chiller. The refrigerant circuit moves this heat from the evaporator to the compressor where it is compressed from a low-pressure gas to a high-pressure gas in the condenser.

Water from the cooling tower will circulate through the water-cooled condenser of the chiller and absorb this heat causing the high-pressure gas to condense and turn into high pressure liquid.

The cooling tower water has now absorbed this heat and then rejects it to the atmosphere. (See our video on the explanation on how Cooling Towers work).

Air-Cooled Chillers

Air-cooled chillers are limited in size by some energy codes as they’re considered less energy efficient than water-cooled chillers. The air-cooled chiller rejects the heat absorbed from the building by blowing air from a fan over refrigerant circulating in the condenser coils. 

Air-Cooled Chiller serving an Air Handling Unit with Hot Water Coil
Air-Cooled Chiller serving an Air Handling Unit with Hot Water Coil

Air-cooled chillers are available from as small as 10-tons to as large as 600-tons. Air-cooled chillers can be order with factory installed pumps that can save on installation time.

When looking at aerial videos or images of buildings you can spot air-cooled chillers, as they’ll have a row of fans along the complete top of the chiller used for heat rejection.

Air-Cooled chillers can be ground mounted if there is space available. Consideration needs to be made for the noise generated by the condenser fans.

Water-Cooled Chiller Control Sequence of Operation

So, here’s a simple explanation of a control sequence working with the chiller, in this case the water-cooled chiller and cooling tower. Actual sequences of control can be very elaborate with the goal of optimizing energy efficiency included in the algorithms.

Water-Cooled Chiller and Cooling Tower serving Air Handling Units
Water-Cooled Chiller and Cooling Tower serving Air Handling Units

You may have a temperature sensor in the room asking for more cooling or less cooling. It’ll send a signal to the air handler controller, the controller will send an output signal to the 2-way control valve to open or close, and then the differential pressure transmitter will pick up those changes and send output signal to the VFD, which will either speed up or slow down the chilled water pump, increasing or decreasing the flow of chilled water based on the demand. 

On the condenser water side you could have a temperature sensor in the condenser water supply piping, sensing the temperature. If the water is getting too cold because the chiller demand is low, than the fan will be adjusted to a lower speed, and that’s how it works with the chiller to optimize the tower. 

Air-Cooled Chiller Control Sequence of Operation

The air-cooled chiller setup similar, but it doesn’t have to worry about the cooling tower. So, once again the temperature sensor in this space will send and input signal to the controller, and the controller will send an output signal to the 2-way control valve, whether to open or close, based on whether it needs more chilled water or less.

Air-Cooled Chiller Flow Diagram and Controls Sequence of Operation
Air-Cooled Chiller Flow Diagram and Controls Sequence of Operation

The differential pressure transmitter of course will sense that buildup of pressure if these valves are all closing, an this pump is still pumping at the same speed, this pressure is going to build up and that differential pressure will be set to reduce the speed because the pressure is increasing too much, which means the demand has dropped off, so it can save on the pump energy by reducing its speed. 

Air Handling Units

The air handling unit has a chilled water coil and a fan that blows air over the cold coil before delivering it to the space. These differ from the Rooftop units that have the complete refrigerant circuit housed within the equipment. Air handling units cool the air by passing the warm room air over a coil that has chilled water circulating through it. The heat is absorbed by chilled water, whereas the rooftop units room air will be cooled by refrigerant circulating through the indoor coil.

See our video on Rooftop Units and our other video on Air Handling Units for a better understanding of these two systems.

The Air Handler will also use heating hot water or steam to heat the building, while the rooftop unit maybe a heat pump which uses a reverse refrigerant cycle for heating, or it may contain a gas furnace. Hot water or steam from a boiler will be sent to the air handlers heating coil to transfer heat from the coil to the room air passing over the coil.

Air handlers are available in much larger sizes than rooftop units, with custom air handlers up to 400,000 CFM.

Air handlers can be roof mounted or sit in a mechanical room on any floor in the building. Often many air handlers will serve a large building being scattered throughout the building, or one dedicated per floor, or one unit may serve the complete building. One of the main decisions is where to locate the air handling units while allowing space for sheet metal ductwork throughout the building to provide fresh air, relief air, return air and supply air.

Fan Coils and Blower Coils

Fan coils and blower coils are used for smaller spaces than what an air handling unit can cover. Fan coils can be horizontal hung or vertically stacked such as used in hotels. See our video on Fan Coils for a better understanding of these systems.

The fan coil is a miniature version of an air handler, but much less sophisticated and with fewer options. Fan coils serve much smaller areas than air handlers, and are manufactured with air volumes up to 4,000 CFM

Water-Cooled Chiller with Cooling Tower serving Vertically Stacked Fan Coil Units
Water-Cooled Chiller with Cooling Tower serving Vertically Stacked Fan Coil Units

Fan coils are dedicated to a single zone, while air handling units can serve a single zone to a large quantity of zones. Another difference is that outside air or ventilation air is often provided by a separate system for the fan coil unit, while the air handling unit provides its own outside air. The fan coils are often not sized to handle the load for the ventilation requirements. 

Some of the fan coils lack the capacity to handle better filtration options such as HEPA filters, UV Lighting or MERV 13 filters, this is due to lack of physical space or fan static pressure limits. 

Often the fan coil is located in or above the room in the ceiling space which can cause the occupants to hear some fan noise. The air handler is located remotely so fan noise shouldn’t be an issue.

The fan coil can be constant or variable volume, using constant volume the fan coil can adjust the leaving air temperature, while with a VAV fan coil, the volume of air will be adjusted to meet the space temperature requirements.

Heat Recovery Chillers

With the focus on energy efficiency some chillers have the option of recovering the some of the heat that is normally rejected to the atmosphere. This recovered heat can be used for pre-heating of various systems.

Chillers and Air Handlers