ASHRAEDesignManualIntro (1)

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DI S CL I M E R

This report was prepared as an account of work sponsored by nagency of the United States Government. Neither the United StatesGovernment nor any agency thereof nor any of their employees norny of their contractors subcontractors or their employees ma ke s

any warranty expressed or implied or assumes any legal liability orresponsibility for the accuracy cornp\eteness or usefulness of anyinformation apparatus product or pro ess disclosed or representsthat its use would not infringe privately owned rights. Reference hereinto any specific commercia l product process or senrice by trade name

trademark manufacturer or otherw ise does not necess arily constituteor imply its endorsement recommend ation or favoring by the UnitedStates Government or any agency thereof. The views and opinions of

authors expressed herein do not necessarily state or reflect those ofthe U nited States Government or any agency thereof.

Although great care has been taken in the compilationand publication of t is material nowarranties

expressed or implied are given in connection herewith by the American Society of Heating Refrigeratingand Air-conditioning Engineersand no responsibility can be taken for any claims arising herewith.



Y

ESIGN

American Society of Heating Refriand Air conditioningEngineers Inc

in cooper tion with

Solar Energy Industries Association

ACEC Research Management Foundation



IS N 0-910110-54-9

Published 1988by the American Society of Heating,Refrigerating, and Air-conditioning Engineers, Inc.

1791Tullie Circle, N.E. Atlanta, GA 30329

ncooperation with

SOLAR ENERGYINDUSTRIES

SSOCI TION

Solar Energy lnduslriesAssociation1730N LynnSt. Suite610 Arlington VA 22209-2009

ACEC Research Management Foundation1015FifteenthSt. N.W., Washington, DC 20005



CKNOWLEDGMENTS

The Energy Technology E ngineering Center (ETEC ), Rockwell International, has p repared thismanual as a task in the Department of Energy s Solar in Federal Buildings Program (SFBP) withthe advice and assistance of consultants from the so lar community.

The m anual was conceived and sponsored by the U.S. Department of Energy (DOE), Division ofSolar Hea t Techno logies, Dr. Frederick H Morse, Director. The following organizations wereinstrumental in the p lanning and review of the m anual: The American Society of Heating,Refrigerating and Air Cond itioning Engineers (ASHRAE ) Research Division, William Seaton,Manager; the Solar Energy industries Association SEIA),Scott Sklar, Executive Director; andThe Am erican Consulting Engineers C ouncil (ACEC) Research nd Managem ent Foundation,Jack Warner, Program Director.

Particular recognition is due the members of the Industry Working Group (listed below) for theirdirection in defining the manual s format and for their detailed review of several drafts; to a largeextent, the man ual reflects the com ments and experience of these reviewers.

Robert ArestyWayne BryanTerry BuffumWilliam DokusRichard EvansWilliam FlemingRob GorhamRobert HassettJeffery Hatman

Don KazimirThomas KingWillard K ing

Charles KutscherGeorge LofNorman LutkefedderGene MeyerFrederick MorseArlen R eimnitzAl RichDick RittlelmannWilliam Seaton

Scott SklarJack Warner

Contributors from the solar comm unity included George Lof, Colorado State Un iversity (CSU ), onair-coo led collectors and systems; Dick Rittelmann, Burt Hill Kosar Rittelmann Associates, onconceptua l system sizing and cost estimation; Bill Duff, CSU, and M. Chandrashekar, University ofWaterloo, on evacu ated collectors; Charles Smith, CSU, and Jack Du ffie, University of Wisc onsin ,on ap plication of system simulation computer programs; and James Senn on instrumentation nd

controls. Joseph Conrad reviewed the m anual s technical language and terminology forconforma nce with indu stry practice.

The M anaging Editor of the manual was Glen Schmidt. Major contributors as authors and editorsof the techn ical sections were Ke ith Balkwill (Project Engineer), Jim Billings, and Tak Nakae .

Oscar Hillig asSF P

Program M anager, directed these ETEC efforts. Th is staff expresse s dee pappreciation to Dr. Frederick H Morse for his leadership and guidance in shaping the manu al to itsfinal form a nd for the patience and encouragement he provided throughout this task.



Contents Page

ACTIVE SOLAR HE TING SYSTEMS

DESIGN M NU L

CONTENTSPage...

PREFACE .....................................................................................................

LEGEND-ABBREVIATIONS .............. ......................................................v

EXECUTIVE SUMMARY ................... .....................................................

SECTION 1 ONCEPTU L ANALYSIS

1.1 OVERVIEW ............................................................................................................. -1

................................................2 OWNERIARCHITECTfENGINEER CONFERENCE 1-2

1 3 CONCEPTUAL SITE SURVEY ............................................................................... -24 CONCEPTUAL SYSTEM SELECTION ................................................................ 1-5

1.5 CONCEPTUAL PERFORMANCUCOST STUDY ................................................... 1-131.6 CONCEPTUAL ANALYSIS SUMMARY .................................................................. 1-29

SECTION 2 EASIBILITY STUDY

2.1 OVERVIEW .............................................................................................................-12.2 APPLICATION REVIEW .........................................................................................-22.3 SIZING/PERFORMAN CE ANALYSIS ..................................................................... 2-62.4 SYSTEM DESIGN DESCRIPTION .........................................................................-10

SECTION 3 ETAIL DESIGN

.............................................................................................................VERVIEW 3-1

OVERALL SYSTEM SCHEMATIC ........................................................................ 3-2..............OLLECTOR SUBSYSTEM DESIGN LIQUID OLLECTOR SYSTEM 3 17

................................TORAGE SUBSYSTEM DESIGN LIQUID COLLECTORS) 3-60INSTRUMENTATION ND CONTROL SUBSYSTEM DESIGNLIQUID COLLECTORS) ......................................................................................... -74

..................................OLLECTOR SUBSYSTEM DESIGN AIR COLLECTORS) 3-110........................................TORAGE SUBSYSTEM DESIGN AIR COLLECTOR) 3-121

INSTRUMENTATIONAND CONTROL SUBSYSTEM DESIGNAIR COLLECTORS) ............................................................................................... -132

...............................................................ERFORMANCEICOSTVERIFICATION 3 144

...................................................................................................ESIGN REVIEW 3-145



ACTIVE SOLAR HEATING SYSTEMS

DESIGN MANUAL

CONTENTS continued)

PageSECTION 4 ESIGN AND CONSTRUCTION PACKAGE

................................................................................................1 OVERVIEW . .... 14.2 DESIGN PACKAGE ............................................................................................... 2

4.3 CONSTRUCTION PACKAGE ...................................................................... 2

SECTION 5 LESSONS LEARNED

5.1 OVERVIEW ........................................................................................................... 15.2 SYSTEM SIZING ................................................................................................... 5 2

........................................................................................3 SYSTEM PROTECTION 5 4......................................................................................................4 COMPONENTS 5 9

EXAMPLE SYSTEM DESIGN

INTRODUCTION...................................................................................................X ?

ECTION 1 CONCEPTUAL ANALYSIS X 1

SECTION 2 EASlBlLiTY STUDY ...................................................................... X 9

SECTION ETAILED DESIGN X 30

3.2 OVERALLYSTEMCHEMATIC.....................................................................................X 303.3 COLLECTORUBSYSTEMESIGN..................................................................................X 30

3.4 STORAGEUBSYSTEMESIGN..................................................................................EX 503.5 INSTRUMENTATIONND CONTROLSUBSYSTEMESIGN X 523.9 PERFORMANCECOSTERIFICATION X 73

........................................................................................................NDEX IN I

Solar esign Manual



Contents Page iii

PREF CE

This Active Solar Heating Systems Design Manual for large comm ercial-

scale service hot water and space heating solar energy systems represents

two years of cooperative effort by the American Society of Heating,

Refrigerating and Air-conditioning Engineers (ASHRAE), the Solar Energy

Industries Association (SEIA), the American Consulting Engineers Council

(ACEC), academia and Department of Energy (DOE) contractors. The

challenge of creating a single design manual to satisfy the specific needs of

solar designers for a variety of locations, applications and system types

called on the talent and experience o specialists in many different areas.

It is Industry s responsibility to design build and maintain state-of-the-art

solar energy systems that satisfy a wide variety of markets and requirements.

The Department of Energy has assumed the role of supporting Industry in

the development o the technology base for advancement of solar energysystems that would accelerate their acceptance in the marketplace. uring

preparation of this manual, great effort was spent to distill infomation from

sources with widely varied experiences nd o translate it into a usable for-

mat that represents this collective knowledge base.

This manual is more than design information in another form. It is a design

process which together with the com panion Installation, Operation and

Maintenance Manual represents a comprehensive coverage of the major

elements that will significantly enhance the success of solar applicationsin buildings.

The Active Solar Heating Systems Design Manual was developed to give

solar designers an effective means to use the collective knowledge of

government and industry to better select options, from among the many now

available, for improving the quality and energy efficiency of solar

systems they design and build.

Solar Design Manual



Legend Abbreviations Page v

egend for Design Manual Figures

Llquid SystemMajor Component Piping and Fittings

--b- Piping

,& Air Vent Valveollector Array

Pump

kd Check Valve

-pb+.6. BacMIow Preventer

Relief Valve pressure orpressureand temperature)

Heat ExchangerValve open)

Manually Operated

Solar Stwage ank withIn-TankHeat Exchanger

Valve closed)

,nua~.pemted

Contrd Valve closed},RemotelyOperated

STORAGEl Hol Water Storage Tank

3-Way Valve& Remotely Operated

HEATER Pressure Regulating

Valveater Heater

Pipe ap

Expansion TanWAir Separator

Expansion Tank

Air SystemDucting and Filllngs

ucting

ajor Component

Fan

Control Damper,Remotely Operated

Heat Exchanger,LiquicVAir amper

ManuallyOperated

Backdraft DamperPebbleBed,

ThermalStorage

Furnace

Solar Design M anual



Legend for Design anual Figures continued)

C on t r o l s nd Instrumentation

Thermostat Switch(normally closed, open o ntemperature riseflall)

Thermostat Switch(normally open, closes ontemperature risetfall)

Differential Temperature Controller

Control Relay oil

Delay ONRelay (normallyclosed; timing starts aftercoil is energized and co ntactopens at end of period)

Time Delay Relay Coil

Delay OFF Relay (normallydosed: opens when energizedtiming starts after m l isde-energized and contactdoses at end of period)

Valve Control Relay Coil

Damper,ControlRetayCoil

Flow Switch normallyopen,doses when required low isestablished)

Motor Control RelayCoil

DoubleActing ThermostatSwitcheater Control Relay oil

Control RelayContact(normally open; closeswhen energized)

Temperature Gauge

Motor C ontrol Relay Contact(normally open; doseswhen energized)

Pressure Gauge

Prassure/Temperature Port(Pi Plug or Pete's Plug)

Control Relay Contact(normally closed; open swhen energized)

Motor Control Relay Contact(normally dosed; opens

when energized)

Flowmeter

Overload Contact(normally closed)

Pilot Light, Light ONsignifies output

olar esign anual



Legend Abbreviations P ~ a e

Abbreviations and Acronyms for esign Manual

Degree Celsius

Degree Fahrenheit

Inch-Pound

Systeme International

British Thermal Unit

Horsepower

Kilo

Me

Joule

Watt

Hour

Second

Year

Foot

lnch

Millimeter

Meter

Miles Per Hour

Pascal

Gram

Pound

Pounds Per Square Inch Gauge

Pound Per Square lnch

Water Gauge

Cubic Feet Per Minute

Gallon

Gallons Per Minute

Liter

Diameter

Parts Per M illion

Total Dissolved Solids

Percent Relat ive Humidity

NorthfSouth

East /West

Archi tect /Engineer

U

UA

R

uv

Vac

e lev

hor iz

Fc

.FQ

E C

HX

Max

Min

N

NO

DP

ST

TDmSHW

IPH

TC

lrT Stat

DAS

PRV

NPSH

P I D

SOD

SH

EP M

PVC

Overall Heat Transfer Coefficient

Overall Heat Transfer Coefficientfor specific a re a ~ o r evice)

Thermal Resistance Rating

for thermal insulation)

UltraViolet

Voltage-Alternat ing Current

Elevat ion

Hor izontal

FailClose closeon loss of power)

FailOpen (open on loss of power)

Evacuated Tube Collector

Heat Exchanger

Maximum

Minimum

Normally Closed

Normally O pen

ouble Pole

Single Throw

Double Throw

Dvm esticHof Water-

Service Hot W ater

Industrial Process Heat

old Temperature Sensor

Hot Temperature Sensor

Resistance Temperature Detector

Thermostat

Data Acquisition System

Pressure Relief Valve

Net PumpSuction ead

Pipingand instrumentationDiagram

System Design Description

Space Heat

Ethylene Propylene Diene Monomer

Palyvinyl Chtoride

Solar Design Manual



Legend Abbreviations Page vii

Abbreviations and Acronyms for Design Manual

ACEC

ACI

ANSI

ASHRAE

SME

STM

WS

BOCAl

DOE

ETEC

IAPMO

MSS

N S

NWS

SEIA

SF P

SM CN

SR

W

cont inued)

Organizations

American Consulting Engineers Council

American Concrete Institute

American National Standards Institute, Inc

American Society of Heating, Refrigerating and Air-condit ioning Engineers

American Society of Mechanical Engineers

American Society of Testing and Materials

American Welding Society

Building Officials and Code Administrators international

U S Department of Energy

Energy Technology Engineering Center

International Association of Plumbing and Mechanical Officials

Manufacturers Standardization Society of the Valve and Fittings Industry

US Bureau of Standards

National Weather Service

Solar Energy Industries Association

Solar in Federal Buildings ProgramSheet MetalandAir-conditioning ContractorsaNational Association

Solar Rating and Certification Corporation

Tennessee Valley Authority

olarDesign Manual



I

Execufive Summary Page

EXECUTIVE SUMMARY

PURPOSE

This manual was prepared to provide architectdengineers NE s )of large active solarheating systems with the best available design information for large comm ercial-scale solarservice water and space heating systems. t incorporates experience from the solar indus-try and from government-sponsored programs that have demonstrated and advanced thetechnology of active solar heating systems.

The manual is not a stand-alone document. The manual draws on informa tion from bothindustry and government sources. It requires the use of referenced documents to ddress

basic engineering and design practices. Addition or remova l of information to adapt themanual to the individual needs of the architecUengineer is left for the user to do.

The manual is to be used by the A E s of active solar heating systems from concept development through final design. Solar insolation calculations and system configurations areincluded for experienced A/Es of conventional heating systems who may not have a work-ing knowledge of solar energy systems. The manual may also be used by a prospective

owner to follow the progress of solar energy system design, from concept through finaldesign. After the system is built, the manual's design package will provide a record of howandwhy certain design decisions were made for reference during future repair or modifica-tion

Finally, the manual provides information for preparation of system ins tallation, operationand maintenance procedures. The companion volume to this designmanuai, Installation,Operation and Maintenance (IOM) Manual, should be used during preparation of the IOMprocedures for the as-built solar energy system.

S OPE

The manual is for use in designing commercial and industrial solar energy sys tems forservice water heatingand space heating. The systems described in this manual have beendemonstrated to be dependable and efficient to operate. The systems are limited to thoseusing flat plate or evacuated tube collectors, liquid or air cooled, and requiting solar storageof at least 1000gal 3,800 L of water or equivalent or a collector field of at least 700 ft2

(65 m2 . The systems ighest operating temperature is that temperature recommended bythe collector manufacturer.

Solar Design Manual



Executive Summ ary Page

The systems may also be considered for future use in seasonal storage projects wh n hisconcept has been proven for use. The high temperature range of these systems will besuitable for solar space cooling applications when the cost-effectiveness of this applicationhas been improved. The stored solar energy of these systems can be used in existing heat

pump systems. he integration of these solar energy systems with heat pum p systems isnot covered in this manual. All of these systems will add to the overall energy efficiency ofa building that has used passive solar design techniques to reduce the base energy levelneeded for space and water heating.

SYST M CONFIGUR TION

he manual presents optimized liquid collector system configurations for three freezeprotection modes and an optimized air collector system configuration. The drainbackdesign using water in the solar collector loop is suitable for heating service water at any sitewhere the collectors can be mounted high enough above the drainback tank to ensure

positive, complete draining. When drainback is not possible,a design using antifreeze inthe solar collector loop typically, 5 15 propylene glycol/water) can be used. Finally, formild climates with minimum freeze potential, the simple recirculation design is recom-mended. Space heating projects that require a large percentage of fresh air for ventilationare served by the air collector system design.

The systems to be designed by following this m anual are most effective when used for ow

temperature heating of wa ter or air; Le. heating service water for large volume residen tialuse, for commercial buildings, or for industrial processes that can use water up to 180°F82OC).Preheating of fresh air for space heating a large building is also an efficient use of

solar energy.

These systems are also most effective for loads that use the collected solar energy steadilyduring the day as it is collected so that little solar heat has to be stored for later use, mini-mizing or eliminating the need for storage.

DESIGN PROCESS

The manual consists of four interrelated sections that encom pass the design process; i.e.Conceptual Analysis, Feasibility Study, Detailed Design, and esign andConstructionPackages and a fifth section, Lessons Learned, that lists comm on prob lems and solutionsfor solar energy system designs.

A\Es may use all sections in designing a project or may select only those specific sectionsneeded depending on their experience, and size and complexity of the proposed solarenergy system.

olarDesign Manual



Executive Sum mary Page

SECTION SECTION 2 SECTION SECTION 4

PerformFeasibility

Study

CompleteDetailedDesign

SECTION 5

ConstructionPackages

Conceptual nalysis his is a simple analysis to de termine whether a full feasibilitystudy is warranted. his analysis involves simple evaluations based on ru les of thumbcharts and typical performance results from existing systems. This analysis allows for thedetermination of the type of sol r energy system to be used a rough estimate of the loadand where the collectors could be placed; size of collector field and system cost are esti-

mated. The results are summarized in a concep tual analysis summary.

If this study shows reasonable cost-effectiveness the design process proceeds to thefeasibility study.

easibilityStudy his study estimates the cost-effectiveness of the pro posed project.The first subsection presents p rocedures for determining the site data ne eded to design thesystem: energy conservation measures sizing and timing of the heating loads to be satis-fied site and building characteristics interface with existing heating systems and selectionof system configuration.

The sscon d subsection presen ts procedures for sizing the collector field estimating thesystem cost and determining system cost-effectiveness. he results of this section aresummarized in a solar energy system design description.

f his study shows th t the sol r n rgy system will be cost-effective the design processproceeds to detailed system design. At this point a contractual commitment for th e designeffort may be made.

So la r Design Manual



Executive Summary Page

Detailed Design he first step in detailed design is to verify the design requirementsand collec tor field sizing from the feasibility study. A system schematic (or pipinglinstru-mentation drawing) is prepared to establish the optimum syst m configuration. Collectorand storage subsystems design can then proceed in parallel with the electrical, instrumen-tation, nd control design. Design review at 40 of the task completion confirms that thesystem configuration is still optimum or directs an iteration to improve the fit with theproject sgoals. A final design review at 90 to100 of task com pletion confirms that thedesign details are correct and complete. A final check of collector performance calculationsis made to account for any design changes that were made, and a firm final cost estimate isprepared.

Output from the detailed design includes system performance calculations; economic

evaluation; piping, structural, mechanical, thermal, and other design analyses; subsystemdrawings; and component requirements.

Design and Construction ackages he design analyses, design and installationdrawings, cost estimate, economic evaluation, and th solar energy syst m design descrip-tion generated in Section 3 are compiled into a design package. The construction packageincludes all design and installation drawings, component specifications,and constructionspecifications. It is ready for construction b ids when bidding procedures are added.

Lessons Learned roblems commonly found in solar energy syst m design, potentialeffects of these problems, and ways to avoid them are presented. Problems found in

' construction and operation, caused by design mistakes, are describedand solutions explained.

This section provides a quick reference by specific component for design problems corn-monly found that must be avojded these lessons have been incorporated in the manual sdesign procedures. Review of this section can prevent the inadvertent inclusion of a designprocedure that has been shown by accumulated field experience to be dysfunctional.

The sketch that follows illustratesthe flow of work in the design process, as it is presentedin the manual, with the major work packages and decision poin ts identified.

Solar Design Manual



Executive Summary Page

SOLAR SYSTEM DESIGN PROCESS

Per formFe a s i b i l i t y

Study

Completeetailed Design

I

Subsystem

lDei.L

Construction

DesignPPokago h

Installation

n example of the design of a solar energy service water heating system following this

design process is in luded s Example System Design nd follows Section of this

manual.

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