Softener Sizing - yourkinetico.com · Water softener system sizing is an exercise that must be ... Calculation: A) ... A conservative design would limit softener system flow to between

Softener Sizing

TABLE OF CONTENTS

1.0 INTRODUCTION....................................................................................................... 3

2.0 SIZING CONSIDERATIONS ................................................................................ 4 2.1 Time Between Regenerations ....................................................................................4 2.2 Daily Demand – Grains of Hardness Removed ........................................................4

3.0 HYDRAULIC LOADING & SIZING ...................................................................... 5 3.1 Hydraulic Loading.......................................................................................................5 3.2 Hydraulic Sizing ..........................................................................................................6 Engineering Factor .................................................................................................................6 3.3 Sizing Work Sheet .......................................................................................................7 3.4 System Diagram................................................................................................................9

4.0 Flow ................................................................................................................... 10 4.1 Engineering Reference to Flow................................................................................10 4.2 Hotels and Motels......................................................................................................10 4.3 Schools ......................................................................................................................12 4.4 Apartments ................................................................................................................13 4.5 Plumbing Fixture Values ..........................................................................................15 4.6 Pressure.....................................................................................................................16 4.7 Water Usage Guide ...................................................................................................19

5.0 Steam Boiler Water Volume Requirements......................................................... 22

6.0 Misc. Capacities .................................................................................................... 24

1.0 INTRODUCTION

Water softener system sizing is an exercise that must be broken into segments. Often there is more than one system that will serve to fulfill an application and care must be taken to determine the optimal configuration ensuring the most salt efficient and reliable design. Before you can begin to size a system there is a significant amount of data that must be collected. The absence of data can result in the misapplication of equipment. Assumptions should not be made; rather an investigation of each application must be undertaken. Often the customer does not have all the required data and as the supplier you may have to turn to equipment suppliers, site trades people or industry statistical information prior to making a system proposal. Below is a list of considerations that should be examined. There may be other site specific considerations that should be examined in addition to the items below.

Absence of any information will result in a wrong choice so be thorough in your assessment of the site, customer’s needs and expectations.

Softener Sizing 3 Revision (1)


2.0 SIZING CONSIDERATIONS

There are multiple softener system configurations that can fulfill an application. Before proceeding any further refer to the sizing section of the Kinetico Hydrus owner’s water softener installation manual for the system you believe to be appropriate. The charts in the owner’s manual reflect the maximum capacity of different Hydrus systems based on regeneration salt dosage. Keep referring back to that section as you go forward from here. First identify the hydraulic requirements of the system. In order to do this you must know the minimum flow, anticipated average flow and have confirmation of the maximum flow rate requirements. Many business owners will not be able to determine their maximum flow therefore an examination of pipe size, pipe length, fixture count and understanding of the process will be required. The final water use calculations must be presented to the customer and they must agree to those values. Should you, as supplier of the softener system make warranties around the flow capacity of the proposed system the future financial costs in rectifying a system that was designed too small could be your’s. See the sizing and fixture guide at the end of this document to assist in determining flow rates and average water uses for various applications.

2.1 Time Between Regenerations When sizing a system care must be taken to ensure that units do not regenerate too often. If an online softener tank were to exhaust before a second unit finished regenerating the system would fail due to lack of available water. A system design pushed to its limit may having a run time as short as 6 hours per vessel. A system that exhausts in 6 hours can be used where the maximum water demand over 6-8 hours per day is a rare occurrence. A 24 hour per day system should run at least 8 hours between regenerations. The ideal system would regenerate once or twice per 24 hour period giving the owner some flexibility in flow rate demands. To examine demand first you must determine the total amount of hardness to be removed per day.

2.2 Daily Demand – Grains of Hardness Removed Calculation: A) Flow rate in gpm x total number of minutes per day of operation x grains per gallon of hardness to

be removed = total number of grains to be removed per day (24 hour period). OR B) Total water use per day in gallons per day (from customer or water meter) x grains per gallon of

total hardness to be removed = total number of grains to be removed per day. At this point you can choose the volume of resin required to achieve a specific run time between regenerations. In most applications it is desirable to not regenerate a single tank more than twice in a 24 hour period. I.e. 5000 gallons per day x 20 grains per gallon = 100,000 grains removal per 24 hours. In theory a 100,000 grains per day single tank with 100,000 grains capacity will regenerate once per 24 hours. A duplex system, each tank having 50,000 grains capacity would result in each tank regenerating once in a 24 hour period. A system must have other design factors calculated in and these factors will be discussed later in this document. All systems should be sized so they operate at the lowest salt dose (highest efficiency) settings, unless the feed has significant iron concentration. If the feed water iron concentration is above 0.25 mg/L, the higher capacity salt setting should be used. By selecting a highly efficient system you may have a slightly larger system than lower efficiency configurations but the salt savings due to regeneration efficiency will easily offset any additional system costs. Remember to compensate iron into your total hardness


calculations. Each ppm of iron (ferrous) is equivalent to 3.0 grains per gallon ppm of total hardness as CaCO3. At this point you only know how many grains of hardness per day removal capacity you require. This is not all of the data required to select the exact configuration. Next you must examine the hydraulic capacity and ion exchange capacity of the system.

3.0 HYDRAULIC LOADING & SIZING

3.1 Capacity Loading and Hydraulic Loading The maximum flow of a softener system is governed by many factors. The flow is influenced by mechanical factors, such as pipe size, valve restrictions, and tank internals. Resin specifications, specifically service flow in gallons per minute per cubic foot (gpm/ ft3) also determine hydraulic loading. Variation in hydraulic loading design is one of the single largest variables when comparing competitive technologies. Once the maximum capacity is determined for a Hydrus system an appropriate safety factor can be applied. The volume between regenerations data in the owner’s manual is based on the theoretical resin capacity for a given salt setting, and the volume used for regeneration. The maximum capacity assumes intermittent flow and some hardness leakage at exhaustion; the engineering factor is applied depending on the specific application. A conservative design would limit softener system flow to between 6.0 and 10 us gpm per cubic foot (ft3) of resin in the tank. Therefore a softener vessel with 10 ft3 of resin would ideally be configured to treat up to 60 gpm. Pushing more water through less resin will reduce the size and cost of the system, but the increased flow rate per ft3 of resin will result in shorter runs and higher hardness leakage due to reduced efficiency of the process. Criteria:

Continuous flow and exceptional and consistent effluent quality ~1.0 ppm hardness = 5 gpm/ft2

Continuous flow and average effluent quality ≤1.0 gpg = 6.0 to 10.0 gpm/ft2

Intermittently high flow (<30% of the time) effluent quality ≤ 1.0 gpg = 10.0 to 15.0 gpm/ft2

Examples of typical average to peak hydraulic loadings per ft3 of resin: - Selection varies depending on desired effluent quality (as above): Boiler Feed = 4 - 5 gpm/ft3

Restaurant = 8 – 10 gpm/ft3

Municipal Treatment (for compliance) = 4 - 5 gpm/ft3

Continuous Flow = 4 – 10 gpm/ft3 depending on required effluent quality.

RO Feed = 6 – 10 gpm/ft3

Residential = 8 – 10 gpm/ft3

Car Wash = 8 – 10 gpm/ft3

Apartment = 8 – 12 gpm/ft3

Hotel / Motel = 8 – 12 gpm/ft3

Laundry = 8 - 10gpm/ft3 Kinetico system literature and manuals indicate flow for at a given pressure loss across the system in psi. (delta-p or ∆-P) This pressure differential takes into consideration the pressure loss attributed to the control valve, riser tube, resin, under drain etc. Ideally you will select a system that, when all tanks are on line, meets the maximum required flow rate in gpm across the system at a 10 psi loss or less. All Hydrus


softener units run at less than 10.0 gpm per ft3 of resin at a 15 psi pressure loss across the unit (from inlet of the valve to outlet of the valve). Sizing a Hydrus softener system for less than 15 psi pressure loss will result in a reasonably conservative design based on mechanical and resin specifications. These pressure loss values do not take into consideration installation plumbing.

3.2 Hydraulic Sizing In a multi-tank system the flow is split into the tanks that will simultaneously be in service. When one tank goes off line to regenerate the remaining tanks must increase their throughput and process all the flow without a significant loss in outlet system pressure. The flow through the remaining tanks must be adequate to maintain outlet header pressure enough to supply demand and fulfill regeneration of the off line tank. Kinetico multi tank designs also use treated water to regenerate the off line tank, therefore this hydraulic load must be considered. In a triplex system when one tank goes into regeneration the remaining two tanks continue to provide water to the system while simultaneously provided treated water for the counter current regeneration. The hydraulic demand to the off line tank is relatively small except for the brief backwash cycle. Multi tank system sizing: Total flow required for process in gpm, plus (+) backwash flow rate for off line tank in gpm = total hydraulic demand place on remaining on line units. Example – Process Flow Required = 125 gpm: An HS324s OD triplex 24” tank system can process 65 gpm per tank, or 195 gpm when all three tanks are in service. When one tank is off line for regeneration, the other tanks are required to process the 125 gpm service flow and up to 15 gpm backwash flow, or 140 gpm. This flow exceeds the 65 gpm service flow per tank. The system size should be increased to an HS330s OD triplex 30” tank system, which can produce the 125 gpm process flow when one tank is in backwash. Using larger tanks also extends the run time between regenerations. Another way to maintain process flow is to use a larger number of smaller tanks. An HS330s OD, with three 30” tanks has as much resin as an HS236s OD with two 36” tanks. When the HS330s OD is in regeneration more resin remains in service and the single tank backwash requirement is lower.

Engineering Factor All systems, once sized based on a list of empirical data require some safety margin incorporated into the design. The “engineering factor” is a percentage of capacity that gets added to the design to offset the potential for process variation and accounts for variation between theoretical (stated) resin capacities and “real” capacities as encountered in actual applications. Engineering factor can vary from 10% to as much as 25% conservatism added to the design. This variable, while increasing system size can result in the difference between success and failure of a system. Competitive pressure can result in minimization of engineering factor making the risks around sizing increase. The biggest influence is the expectation of quality and flow rates variations in an application. The lower the critical nature of the application and the lower the expectation around water quality the lower the engineering factor that is applied. As a rule of thumb: Continuous flow and exceptional and consistent effluent quality ~1.0 ppm = engineering factor 35%

Continuous flow and moderate effluent quality <1.0 gpg = engineering factor 15% - 20%

Intermittently high flow (<30% of the time) moderate effluent quality ≤ 1.0 gpg = 10 %

The engineering factor is typically taken off the volume capacity of the system once implemented. This results in the regeneration meter setting being reduced by the requisite amount.

Examples of typical engineering factor (multiplier): Residential = 0.85

Car Wash = 0.85

Apartment = 0.85 – 0.9

Hotel / Motel = 0.85 – 0.9

Laundry = 0.85

Boiler Feed = 0.75 – 0. 85

Restaurant = 0.9

Municipal Treatment = 0.85

Continuous Flow = 0.6 – 0.85 depending on desired effluent quality

RO Feed = 0.8 – 0.85

3.3 Sizing Work Sheet Step 1.

WATER ANALYSIS

a) Total Hardness __________ gpg as CaCO3b) Iron __________ ppm (mg/L)c) Compensated Hardness __________ gpg as CaCO3d) TDS __________ ppm (mg/L)e) Temperature __________ (estimated)f) Turbidity ______________________________ NTU

Step 2.

WATER USAGE a) No. of People ______X _____gallons/person (a)__________________

b) Other Water Usage As Provided by Customer (b)__________________ c) (a) + (b) Total (c) __________________

Step 3.

FLOW RATE a) Maximum Flow per Minute (a)_______________gpmb) Or use fixture count in appendix to calculate the

approximate flow rates. Fixture counts are not absolute values and should be used as estimates only. (b)_______________gpm

Step 4.

WATER PRESSURE a) Inlet Pressure to System at Location with No Water

Flowing in System (a)_________________psi

b) Vertical height of piping from softener inlet to highest point in system _____feet x 0.5 = psi loss

(b)_________________psi

c) Operating Pressure equals (a) minus (b) (c) ________________psi Note: Listen for signs of water hammer in system

All CP, Mach & Hydrus valves require constant pressure at the outlet port for proper operation, refer to installation manual for pressure requirements.



Step 5.

WATER SOFTENER SELECTION a) Compensated Hardness (1.c) x water usage (2.c) (a)________ grains capacity per dayb) Subtract un-metered water used for regeneration from

system capacity (multi-tank only) (b)________ grains capacity per day

c) Required capacity (5.a – 5.b) x 1.15 (c)________ softener capacity per dayd) Peak flow rate (3.a) or estimated flow (3.b) (d)________ softener capacity in gpme) Number of anticipated regenerations per day per 24 hour

period (e)________ regenerations per day

f) Total daily capacity (5.c) divided (÷) by number of regenerations (5.e) = grains capacity per tank for each tank in the system • 15% safety factor is being added for example - use correct Engineering Factor At this point make an initial selection of a softener system.

Step 6.

REFINE SELECTION a) Pressure loss of 1st choice at peak flow rate with one

tank in regeneration (if multi tank system) (a)______psi loss

Note: In a multi-tank system, remember to add the regeneration flow rate required by an off line tank using backwash flow rate value.

b) Available working press = _____inlet (4.c) minus (-) pressure loss (6.a) = available psi c) If available working pressure on outlet is < 30 psi select again.

Step 7.

AVAILABLE INSTALLATION SPACE a) Length __________b) Depth __________c) Height __________d) Max: Door Opening __________ Note: If softener tank diameter is too large, then go with multiple smaller tanks. Ensure brine

tank(s) will also fit. Step 8.

OPERATING REQUIREMENTS a) Power availability __________b) Volumetric delay (regenerate at night) __________c) Immediate demand regeneration __________d) Manual regeneration __________e) Continuous operation (multiple tanks) __________f) Central Brine __________

Step 9.

ADDITIONAL CONSIDERATIONS a) Access to drain and drain capacity for regeneration waste during peak (backwash) cycle. b) Floor load capacity for system & brine tank when filled with water c) Frequency of brine tank filling (larger brine tanks require less frequent topping up) d) Remember to compensate each ppm of iron to equal 3.0 gpg hardness as CaC03

3.4 System Diagram When commencing with system design always start by drawing a rough schematic of the system working from the water inlet on the left with the outlet of the softeners converging on the right. This method allows you to identify flows and pressures in a graphic representation. When putting together a schematic it is not necessary to capture the actual installed dimensions or layout but rather it should be drawn to facilitate calculating various flows and pressures.

A.) System Flow Requirement in GPMB.) System Pressure Requirements in PSI

D.) Inlet Pressure in PSIE.) Available water in GPM

C.) Drain requirement of one tank in backwash

Bypass Valve

TA

TB

TC

While drawing the system assists in working out the hydraulic configuration of the system it also forms the basis for an installation materials list. Some simple calculations for the Hydrus softener system depicted are as follows: At the maximum design flow rate: (A+C) must be ≤ E (A+C) must be < (TA +TB flow capacity at < 10 psi ∆P)


4.0 Flow

4.1 Engineering Reference to Flow The information within this document has been taken from field experiments, utility surveys and a number of technical publications all of which are assembled into a condensed explanation of customer water demand and how to determine the maximum flows that can be expected in a given application. Most types of fixtures and uses are listed in this publication to permit the estimating of the probable gallon per minute demand in residential, public buildings, motels and hotels, offices, schools, shopping centers, and other customers. The following information which the AWWA assembled in the estimating of flows, is also in part, data that has been published from the National Bureau of Standards, using plumbing manual report BMS-66. This method includes a list of fixtures and a table of values for each fixture, as well as a value for the fixture if it is in public use. In order to properly select water conditioning equipment it is essential to determine flow demands. The recording of actual water use by the use of water meters, special meters or recording charts is ultimately the most reliable way to obtain data. Always obtain water use records if possible.

4.2 Hotels and Motels Hotels and motels are subject to wide fluctuations in water use, with peak periods of short duration. The example of a 216 room hotel had a maximum demand of 150 GPM, or 0.7 GPM/unit, which occurred at one time during the 24 hour period. The graph below represents the result of a recorded survey on a Texas hotel.



HOTELS – estimating flow rate 180 gallons per hour base, plus:

Showers or Tubs 12 gph for each Lavatories only 10 gph for each

Barber Shop 10 gph for each fixture Beauty Salon 10 gph for each fixture

Soda Fountain 60 gph for each fixture. If automatic dishwasher is used, determine actual requirements.

Restaurants 1½ gph for each meal served during peak period. If automatic dishwasher is used, determine actual requirements.

MOTELS – estimating water use Theoretical Peak

NUMBER OF ROOMS (2

ADULTS PER) 45 GAL./PERSON

GALLONS per DAY — FULL

LINE (no Laundry or Restaurant)

GALLONS per MINUTE PEAK TOILETS with

FLUSH VALVES

GALLONS per MINUTE PEAK TOILETS with FLUSH TANK

GAL./DAY HOT ONLY

HOT WATER PEAK FLOW G.P.M.

10 900 60 35 300 15

20 1,800 120 65 575 30

30 2,700 165 90 850 40

40 3,600 220 115 1,100 50

50 4,500 270 140 1,230 60

60 3,400 320 165 1,320 68

70 6,300 365 180 1,400 75

80 7,200 410 200 1,500 82

90 8,100 450 220 1,580 88

100 9,000 490 235 1,660 95

Should a Restaurant and Laundry be a part of this water supply, refer to the related table and add to above. If toilets are by-passed, estimate less 40% on water usage, 35% on peak flow rate, less on flush valve toilet rate, 10% less on tank type toilets. The above flow rates and water requirements are suggestions. Each installation has variations, so this table should be used as a guide only.

As a rule of thumb only 60% of theoretical peak flow requires treatment as only 60% of patrons will use water simultaneously.


4.3 Schools Flush valves with high flow requirements are normally used for sanitary purposes, and schools usually operate with uniform recess periods, both of which produce high water-flow-rate demands. Test results from a South Texas modern high school with 1390 students demonstrated the need to properly size equipment for these types of applications. In this particular application flows of 150 GPM were common, with peak demands reaching 210 GPM on many occasions. Keep in mind that most installations will have pressure type expansion storage tanks providing buffer capacity for peak use. Water treatment devices are usually on the inlet side to the expansion tanks therefore the treatment equipment should not see these peak values if such tanks are installed.

SCHOOLS Estimated at 25 Gal. per Day per Student

HOT ONLYNUMBER OF

STUDENTS

ALL WATER

SOFTENED

GAL. per DAY

(no lawn sprinkling)

PEAK DEMAND

with

FLUSH VALVE

TOILETS G.P.M.

PEAK DEMAND

TANK TYPE

TOILETS

in G.P.M

TOILETS

BY-PASSED

GAL. PER

DAY

PEAK

FLOW

GALLONS

6 PER

100 2,500 60 30 1,500 15 600

200 5,000 90 50 3,000 23 1,200

300 7,500 120 80 4,500 30 1,800

400 10,000 150 90 6,000 40 2,400

500 12,500 180 100 7,500 50 3,000

800 20,000 250 130 12,000 60 4,800

1,000 25,000 300 160 15,000 70 6,000

Elementary: Hot and Cold = 13 gallon/student/day Hot only = 5 gallons/student/day Jr. High: Hot and Cold = 20 gallons/student/day Hot only = 10 gallons/student/day High Hot and Cold = 25 gallons/student/day Hot only = 15 gallons/student/day Estimates assume there is a cafeteria and showers. With cafeteria, no showers reduce the daily water use by 25% for Jr. High and High School applications.


4.4 Apartments

Estimating GPM Flow Apartments, like hotels have wide variations in flow rates as shown below. The survey conducted illustrates the flows throughout a one week period.

GPM PEAK RECORDINGS Sun M Tues W Th F Sat Midnight 10 10 10 10 10 10 10 6:00 a.m. 25 50 30 30 45 35 30 Noon 35 90 45 80 90 85 35 6:00 p.m. 30 40 45 30 30 30 30

99 Unit Apartment Complex 140 Baths, 99 Dishwashers, 8 Washing Machines

Most sizing calculations for Apartments are founded on: Assumes 3 persons per apartment Hot & Cold = 150 gal/unit/day Hot only = 60 gal/unit/day Average Water Requirements for various types of activities within an apartment complex (total hot and cold). For tank-less Heaters (use as listed) APARTMENT HOUSES – flow rates 180 gph base, plus:

Apartments or baths 12 gph for each Barber Shop 10 gph for each fixture

Beauty Parlor 10 gph for each fixture *Soda Fountain 60 gph for each fixture. If automatic dishwasher is

used, determine actual requirements. *Restaurant or Tavern 1½ gph for each meal served during peak period. If

automatic dishwasher is used, determine actual requirements.

Laundry Washing Machines 30 gph for each


APARTMENTS & MOBILE HOMES

CENTRAL LAUNDRY INCLUDED Estimate three people per home

60 Gal. per person

each Day

Units

All Soft

Peak Flow Flush Tanks

(no lawn sprinkling)

G.P.M.

Hot Water Soft Only Gal. Per

Day

Hot Water Peak Flow Gal. Per

Minute

Toilets By-Passed

Estimate 35 Gal. Per Day

Each Person

4 720 22 240 12 430 17

5 900 25 300 15 525 20

6 1,000 30 360 20 600 23

8 1,440 40 480 26 864 28

10 1,800 50 600 30 1,050 35

15 2,700 75 900 45 1,575 45

20 3,600 90 1,200 55 2,100 55

30 5,400 110 1,800 65 3,150 67

40 7,200 125 2,400 75 4,200 78

50 9,000 140 3,000 85 5,250 90

100 18,000 220 6,000 110 10,500 150

The above information is for estimating only. Each installation varies with design and local conditions and must be evaluated individually.


4.5 Plumbing Fixture Values The following represents each individual fixture value as if each fixture was operated independently at 35 PSI inlet pressure. A bathtub for example flows at a rate of 8 GPM without any interference from other fixtures. As more fixtures are present, the probability of flow decreases. When encountering devices or fixtures not listed, the demand in gallons per minute should be determined and added to the total fixture count.

Fixture Value Based on 35 psi Inlet

Fixture Type

Fixture Value Based on 35 psi inlet

pressure Bathtub Arrangement 8

Bedpan Washers 10 Combination Sink and Tray 3 Dental Unit 1 Dental Lavatory 2 Drinking Fountain (cooler) 1 Drinking Fountain (public) 2 Kitchen Sink: 1/2 in. connection 3 3/4 in. connection 7 Lavatory: 3/8 in. connection 2 1/2 in. connection 4 Lavatory Tray: 1/2 in. connection 3 3/4 in. connection 7 Shower Head (shower only) 4 Service Sink: 1/2 in. connection 3 3/4 in. connection 7 Urinal: Pedestal Flush Valve 35 Wall or Stall 12 Wash Sink: (each set of faucets) 4 Water Closet: Flush Valve 35 Tank Type 3 Dishwasher: 1/2 in. connection 4 3/4 in. connection 10 commercial (nominal) 15 Washing Machine: 1/2 in. connection 5

3/4 in. connection 12

1 in. connection 25

1-1/4 in. connection 35

1-1/2 in. connection 50

Hose (50 ft. length- wash down): 1/2 in. 6

5/8 in. 9

3/4 in. 12

1 in. 25


4.6 Pressure Water pressure available has a significant influence on the gallon per minute flow of the application. To illustrate this all important factor, the chart below provides evidence that the water pressure factor must be included in your sizing. Variations in Flows with a 50 Foot 5/8” Garden Hose

Water pressure at hose outlet - PSI Flow - GPM

10 7

20 9

30 11

40 13

50 15

70 18 100 22

Due to the variation illustrated above, compensation must be applied when calculating the fixture value flow demand of any application. Multiplication factors must be applied upon completion of converting fixture value to probable GPM flow. The chart in Figure A should be used for this important adjustment. Example: A probable demand of 50 GPM was determined. The application has an inlet pressure of 60 PSI. Using the chart below, a multiple factor of 1.34 should be used. 50 GPM x 1.34 = 67 GPM compensated flow demand.

Figure A

Pressure - PSI Factor

20 0.74

30 0.92

35 1.00

40 1.07

50 1.22

60 1.34

70 1.46

80 1.57

90 1.68

100 1.78


*Fixture Value Conversion Charts

Chart I Chart II Country Clubs, Hospitals, Nursing Homes, Hotels,

Office Buildings, Schools, Shopping Centers, Restaurants

Apartments, Condominiums, Dormitories, Trailer Parks, Homes, Motels

Fixture Value Probably gpm Flow Fixture Value Probably gpm Flow 10 - - - 10 10 20 - - - 20 18 25 - - - 25 20 40 - - - 40 21 50 35 50 22 75 43 75 23 100 50 100 24 125 55 125 26 150 57 150 28 200 62 200 30 250 67 250 33 300 72 300 37 350 77 350 39 400 82 400 42 450 86 450 44 500 90 500 46 550 94 550 50 600 98 600 52 650 102 650 54 700 106 700 56 750 110 750 58 800 112 800 59 900 117 900 61

1,000 122 1,000 62 1,100 127 1,100 64 1,200 131 1,200 66 1,300 133 1,300 68 1,400 136 1,400 69 1,500 138 1,500 70 2,000 140 2,000 72 3,000 156 3,000 76 4,000 162 4,000 82 5,000 168 5,000 88 6,000 174 6,000 94 7,000 180 7,000 100 8,000 186 8,000 108 9,000 192 9,000 116 10,000 198 10,000 122 11,000 204 11,000 128 12,000 210 12,000 134 13,000 216 13,000 140


The following is an example of estimating the probable gpm demand for an apartment complex. Customer: 160 unit apartment complex - pressure at meter: 50 psi.

Fixture Fixture Value Extended Fixture Values 205 tank water closets X 3 = 615 259 lavatories: 3/8 in. X 2 = 518 138 dishwashers: ½ in. X 4 = 552 10 washing machines: ½ in. X 5 = 50 165 kitchen sinks: ½ in. X 3 = 495 162 bathtubs X 8 = 1,296

Total Fixture Value: 3,526 Charts are based on inlet pressure of 35 psi. For other pressures, adjust by use of Figure A. Fixture value: 3,526 Conversion from Figure B, Chart II: 80 gpm Adjustment to 50 psi inlet water pressure: 80 gpm x 1.22 = 97.6 gpm or 98 gpm The probable peak demand therefore, in this example of a 160-unit apartment, would be 98 gpm.


4.7 Water Usage Guide In determining water consumption of any application it is more desirable to obtain the actual water meter history. Generally a six month history will be representative of the applications requirements. If no water use records are available you may be able to get the information by contacting the water service supplying the application. Such requests are considered public information. Many of these services record usage in cubic feet. To convert volume given in cubic feet to gallons, multiple by 7.5. Example: 50 cubic feet x 7.5 = 375 gallons. Another procedure in determining consumption, and in particular when a meter reading is not available such as on a well system, is the use of a clock recording method. Upon determining the GPM rating of a well pump, connect an inexpensive clock to the pump circuit. Set at 12:00 o’clock and record daily the number of minutes the pump ran. Multiply these minutes recorded by the GPM rate and the average total daily consumption can then be estimated more realistically. A third method that can lend credibility to an estimated daily usage is through comparison. By obtaining an actual meter recording usage of a similar operation, the customer will have more confidence in your projections. When it is not practical to utilize any of the methods thus far described, the estimating of usage can be achieved through the preceding fixture count or by using the chart below.

Water Usage Table: Airports 3 -5 gallons per day per passenger Barber Shops 180 gallons per hour base, plus 10 gph for each fixture

55 gal/day/chair daily usage Beauty Salons 180 gallons per hour base, plus 10 gph for each fixture

or 270 gallons/day/station Boilers (see boiler feed pages that follow)

To Determine Daily Make-up in Gallons: 1) Multiply boiler h.p.. by 4.25 2) Then multiply by hours per day of operation 3) Then multiply by the % operating rating 4) The subtract the % condensate returns

Note: When ratings are given in pound of steam per hour, divide by 500 to obtain GPM requirement. When ratings are given in BTU’s, divide by 12,000. For every 12,000 BTU’s, there is an equivalent of 1 h.p.

Camps Days (no meals) = 15 gallon/day/person Resorts = 15 gallons/day/person Tourist = 35 gallon/day/person

Construction Camps 50 gallons per day per worker Cooling Tower To determine daily makeup in gallons:

1) Multiply the tonnage by four (this includes 2 gallons/day/hour/ton bleed off).

2) Then multiply by the number of hours per day of operation.

Clubs 180 gallons per hour base, plus: Business and Residence** Showers 60 gph for each

Lavatories 10 gph for each Restaurants 1½ gph for each meal served during peak period. If

automatic dishwater is used, determine actual requirements.

Dentist 4,000 gallons/month/chair


Dormitories Hot and Cold = 40 gallons/person/day Hot Only = 16 – 20 gallons/person/day

Factories Process flow is widely variable, for personnel use : **Showers 120 gph for each Lavatories 10 gph for each

*Restaurants 1½ gph for each meal served during peak period. If


**Bradley Wash fountains 54” circular 260 gph **Bradley Wash fountains 54” semi-circular 180 gph

**Bradley Wash fountains 36” circular 180 gph **Bradley Wash fountains 36” semi-circular 125 gph

Golf Clubs 180 gallons per hour base, plus: **Showers 120 gph for each Lavatories 10 gph for each

*Restaurants1½ gph for each meal served during peak period. If


Gymnasiums 180 gallons per hour base, plus: ** Showers 120 gph for each Lavatories 10 gph for each

For Storage Heaters Omit 180 gph base Hospitals * meter readings preferred 180 gallons per hour base, plus:

**Showers or Tubs 60 gph for each Lavatories 10 gph for each

Laundry Tubs 120 gph for each

Dishwashers1½ gph for each meal served during peak period. If


Laundry tubs 120 gph for each

Daily usageMeter reading preferred Hot and Cold = 250 gallons/bed/day Hot Only = 170 gallons/bed/day

Laundry Hot and Cold – 2.5 lb. capacity is equivalent to gallons per cycle

Livestock and Poultry People = 50 gallons/day/person Cow, beef = 10 gallon/day/cow = 20 gallons/animal/day with drinking cup Dairy = 15 gallons/animal/day = 30 gallons / animal /day with drinking cup Goat = 2 gallons/animal/day Hog = 10 gallon/animal/day Horse = 10 gallon/animal/day Mule = 12 gallon/animal/day Sheep = 2 gallon/animal/day Chickens – 10 gallons/each 100/day Turkeys = 18 gallons/each 100/day

Nursing Homes Hot and Cold = 100 gallons/bed/day Hot Only: = 50 gallons/bed/day

Estimate 75 gallons per day per bed (Total Water Usage) or estimate 50 gallons per day per bed (Hot Only)

Office Buildings 180 gallon per hour base plus: 10 gph for each fixture 1½ gph for each meal served during peak period. If



Office Buildings cont… Hot and Cold = 15 -20 gallons/person/day Hot only= 3 – 16 gallons/person/day

Picnic Areas (with toilets) 10 gal / picnicker Restaurants or Taverns 180 gph for each

1½ gph for each meal served during peak period. If automatic dishwasher is used, determine actual requirements.

Food Preparation

Water Use Per Seat

Hot and Cold = 15 gallons/meal/day Hot only = 7 gallons/meal/day Hot & cold = 20 gallons/person/day Hot only = 3 gallons/person/day

Restaurant owners generally have good water use records. Estimate 8 gallons per person per day (Total Water Usage)

or 3 gallons per person per day (Hot Only). Add 30% water usage for 24 hour restaurants, add 2 gal/person/day for cocktail bar facilities.

Shopping Centers 300 gallons/day/1,000 square feet *Soda Fountain 60 gph for each fixture. If automatic dishwasher is used,

determine actual requirements. Stores (Convenience) 400 / day / toilet Theaters 5 gallons / day / seat Trailer Parks 150 gallons/trailer/day

*Some communities require a 180° F. sterilize-rinse for dishes and pots. To obtain this high temperature, steam is generally used as the heating medium. ** These requirements are based on shower heads regulated for a maximum flow of hot water of 2 G.P.M. This is particularly important for clubs, schools and gymnasiums.


5.0 Steam Boiler Water Volume Requirements Useful Equations: 1 Boiler HP / hour = 4.3 gallons of water evaporated per hour. 1 lb. evaporation per hour – 0.12 gallons of water evaporated per hour 1 gallon evaporated per hour = 8.34 lbs. of water evaporated per hour Steam boiler requires four gallons of water per hour for each horsepower rating of the boiler. (Example) A 50 H.P. boiler would require 200 gallons (50 X 4 = 200). Many boilers have a condensate return and this percentage should be subtracted from the full demand to determine actual requirement. Example 50% condensate return is one half full demand (1/2 of 200 = 100) so make up is only 100 gallons per hour. The condensate return water does not require further softening. Multiply total make up by % of operation rating. Example for a boiler that only runs 45 minutes per hour or 75% of each hour. 75% rating x 100 gallons = 75 gallons per hour makeup. Multiply this times hours of day operation to determine total daily requirement. The following equations are useful in calculating boiler requirements. All calculations are made in pounds per hour (lbs/hr). 1.0 Evaporation rates:

o Evaporation in gal/hr. = Boiler H.P. x 4.3 x (% of full boiler rating the unit is running at as

a decimal) If a boiler is running at 50% of its full rated horsepower use 0.5 factor etc.

o Evaporation in lbs/hr = gal/hr x 8.34 2.0 Lbs/hr = gpm 500 3.0 % condensate return = lbs of condensate returned per hour. X 100 Lbs of evaporation per hour 4.0 % make-up = 100 – (% condensate returned) 5.0 % blow down = (dissolved solids in feed water) x (%make up) (total solids in boiler drum) 6.0 Lbs. total feed water per hour. = (evaporation rate in lbs. per hour)

1.0 – (% blow down expressed as a decimal) 7.0 Lbs/hr actual make up water required = (Lbs. total feed water per hr) – (Lbs actual condensate returned per hour) 8.0 Lbs./hr. blow down = % blow down X (lbs. of feed water per hour) 100


Steam Boiler Feed Water Quality Requirements Below are both recommended feed water qualities for boilers operating at various boiler pressures as well as the drum water quality. Drum water quality represents the maximum or threshold values. As the values rise over the stated limits the boiler would blow down to drain (intake make up boiler feed water) to reduce the boiler water values through dilution with make up water.

ASME Guidelines for reliable operation of modern industrial steam boilers

Boiler Feed-water Boiler Water

Drum Pressure

(psig)

Iron (ppm of

Fe) Copper

(ppm of Cu)

Total Hardness ppm as CaC03

Silica (ppm Si02)

Total Alkalinity (ppm as CaC03)

Specific Conductance

(µmho/cm)

0-300 0.100 0.050 0.300 150 700 7000 (3500) 301-450 0.050 0.025 0.300 90 600 6000 (3000) 451-600 0.030 0.020 0.200 40 500 5000 (2500) 601-750 0.025 0.020 0.200 30 400 4000 (2000) 751-900 0.020 0.015 0.100 20 300 3000 (1500) 901-1000 0.020 0.015 0.050 8 200 2000 (1000)

1001-1500 0.010 0.010 0.000 2 0 150 (75) 1501-2000 0.010 0.010 0.000 1 0 100 (50)

6.0 Misc. Capacities Approximate flow through pipe under pressure listed by pipe diameter and pressure at various lengths. This does not factor in the pressure loss due to fittings, elbows, tees etc. Assumptions: - straight pipe, with no valves or bends - open flow, with no backpressure – smooth pipe. Discharge in US gallons per minute

Approximate Carrying CapacitGallons per minute through

Pipe Size 1” in 100' 1” in 75

4" 71 816" 225 2608" 495 585

10" 900 1,08012" 1,575 1,800

Softener Sizing

Length in Feet Pipe Size psi 25 50 100 200 4003/4" 20 23 16 11 8 5

40 34 24 16 11 8 60 43 29 20 14 10 80 50 34 24 16 11

1" 20 44 31 21 14 10 40 65 44 31 21 14 60 81 55 38 26 18 80 94 65 44 31 21

11/4" 20 121 84 58 39 27 40 177 121 84 58 39 60 220 151 104 72 50 80 257 177 121 84 58

11/2" 20 137 94 65 45 31 40 200 137 94 65 45 60 250 170 117 81 56 80 290 200 137 94 65

2" 20 265 183 126 86 59 40 385 265 183 126 86 60 480 330 227 156 105 80 560 385 265 183 126

4" 20 1,435 1,070 725 495 340 40 2,225 1,535 1,070 725 495 60 2,780 1,910 1,315 900 625 80 3,250 2,225 1,535 1,070 725

ies of Drain Pipes tile pipe

Slope of Pipe ' 1” in 50' 1” in 40' 1” in 30' 1” in 20' 1” in 10' 1” in 6'

101 114 128 158 224 289315 360 405 495 720 950675 765 900 1,125 1,575 2,050

1,350 1,465 1,680 2,050 2,900 3,8002,200 2,450 2,850 3,475 4,850 6,300

24 Revision (1)


Capacity of Vertical Tanks

Tank diameter Area Ft2 Gallons per foot

Depth (side sheet only)

8” 0.35 2.63

10” 0.55 4.13

12" 0.79 5.86

14” 1.07 8.03

16” 1.40 10.44

18" 1.77 13.22

20” 2.18 16.32

22” 2.64 19.75

24" 3.14 23.50

28” 4.28 32.07

30" 4.9 36.72

36" 7.1 52.88

42" 9.6 71.97

48" 12.6 94.00

54" 15.9 119.0

60" 19.6 147.0

72" 28.3 211.0

Copper Pipe Friction Pressure loss Chart

Pressure loss in psi. per foot of tube length Flow GPM 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4

1 0.118 0.023 0.008 0.001 2 0.084 0.03 0.005 0.001 3 0.177 0.062 0.011 0.003 0.001 4 0.106 0.018 0.005 0.002 0.001 5 0.161 0.027 0.007 0.003 0.001 10 0.098 0.027 0.01 0.004 0.001 15 0.057 0.02 0.009 0.002 0.001 20 0.096 0.035 0.015 0.004 0.001 0.001 25 0.052 0.022 0.006 0.002 0.002 30 0.073 0.031 0.008 0.003 0.001 35 0.042 0.011 0.004 0.002 40 0.054 0.014 0.005 0.002 0.001 45 0.017 0.006 0.003 0.001 50 0.021 0.007 0.003 0.001 60 0.029 0.01 0.004 0.001 70 0.039 0.014 0.006 0.001 80 0.017 0.007 0.002 90 0.022 0.009 0.002

100 0.026 0.011 0.003 120 0.016 0.004 140 0.021 0.005 160 0.026 0.007 180 0.008 200 0.01 250 0.015

L Copper Pipe listed (M pipe will have slightly less drop) Info from the Copper Development Association Shaded zone is pipe velocities between 5 to 8 ft/sec Friction shown do not exceed 8 ft/sec Fluid velocities of greater than 8 ft/sec are not recommended


Friction loss in Copper fittings & valves in equivalent feet of straight pipe friction losses equivalent per foot Example: A standard 1", 900 elbow has the same pressure loss as 2.5 feet of 1" pipe - refer to the pipe pressure loss sheet for value

Fittings ValvesNominal or Standard Size,

inch Standard

Elbow 90 Tee Coupling Ball Gate Butterfly Check

90 45 Side Branch Straight Run

3/8 0.5 1.5 1.5 1/2 1 0.5 2 2 5/8 1.5 0.5 2 2.5 3/4 2 0.5 3 3

1 2.5 1 4.5 0.5 4.51 1/4 3 1 5.5 0.5 0.5 0.5 5.5 1 1/2 4 1.5 7 0.5 0.5 0.5 6.5

2 5.5 2 9 0.5 0.5 0.5 0.5 7.5 9 2 1/2 7 2.5 12 0.5 0.5 0 1 10 11.5

3 9 3.5 15 1 1 1.5 15.5 14.5 3 1/2 9 3.5 14 1 1 2 12.5

4 12.5 5 21 1 1 2 16 18.5


Friction Loss Chart for PVC pipe Friction Loss Per 100 Feet of Pipe of plastic pipe (Schedule 40 pipe is white and schedule 80 pipe is gray).

Pipe Diameter 1 in. 1 1/2 in. 2 in. 2 1/2 in. 3 in. 4 in

SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH SCH US gpm 40 80 40 80 40 80 40 80 40 80 40 80

2 0.55 0.88 0.07 0.1 - - - - - - - - 5 1.72 2.75 0.22 0.3 0.066 0.1 0.038 0.05 0.015 0.02 - - 7 3.17 5.04 0.38 0.55 0.11 0.15 0.051 0.07 0.021 0.028 - -

10 6.02 9.61 0.72 1.04 0.21 0.29 0.09 0.12 0.03 0.04 - - 15 12.77 20.36 1.53 2.2 0.45 0.62 0.19 0.26 0.07 0.09 - - 20 21.75 34.68 2.61 3.75 0.76 1.06 0.32 0.44 0.11 0.15 0.03 0.04 25 32.88 52.43 3.95 5.67 1.15 1.6 0.49 0.67 0.17 0.22 0.04 0.06 30 46.08 73.48 5.53 7.95 1.62 2.25 0.68 0.94 0.23 0.31 0.06 0.08 35 - - 7.36 10.58 2.15 2.99 0.91 1.25 0.31 0.42 0.08 0.11 40 - - 9.43 13.55 2.75 3.83 1.16 1.6 0.4 0.54 0.11 0.14 45 - - 11.73 16.85 3.43 4.76 1.44 1.99 0.5 0.67 0.13 0.17 50 - - 14.25 20.48 4.16 5.79 1.75 2.42 0.6 0.81 0.16 0.21 60 - - 19.98 28.7 5.84 8.12 2.46 3.39 0.85 1.14 0.22 0.3 70 - - - - 7.76 10.8 3.27 4.51 1.13 1.51 0.3 0.39 75 - - - - 8.82 12.27 3.71 5.12 1.28 1.72 0.34 0.45 80 - - - - 9.94 13.83 4.19 5.77 1.44 1.94 0.38 0.5 90 - - - - 12.37 17.2 5.21 7.18 1.8 2.41 0.47 0.63 100 - - - - 15.03 20.9 6.33 8.72 2.18 2.93 0.58 0.76 125 - - - - - - 9.58 13.21 3.31 4.43 0.88 1.16 150 - - - - - - 13.41 18.48 4.63 6.2 1.22 1.61 175 - - - - - - - - 6.16 8.26 1.63 2.15 200 - - - - - - - - 7.88 10.57 2.08 2.75 250 - - - - - - - - 11.93 16 3.15 4.16 300 - - - - - - - - - - 4.41 5.83 350 - - - - - - - - - - 5.87 7.76 400 - - - - - - - - - - 7.52 9.93


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Softener Sizing - yourkinetico.com · Water softener system sizing is an exercise that must be ... Calculation: A) ... A conservative design would limit softener system flow to between