BACK TO BASICS:

PIPE INSULATION

INDUSTRIAL REFRIGERATION CONSORTIUM

RESEARCH & TECHNOLOGY FORUM
MAY 2-3, 2012

Todd Jekel, Ph.D., P.E.

Assistant Director, IRC
Overview

1 • Basics of insulation & insulation systems

2 • Industry insulation recommendations

3 • Annual energy simulation

4 • Conclusions
INSULATION BASICS
Why do we insulate piping?
• Preserve the refrigerant state by limiting heat
loss or gain
• Limit temperatures of jacketing to
– protect personnel (high temperature)
– protect product/space/system (low temperature)
from free water (condensation) or weight (ice
formation)
• Protect the underlying piping from corrosion by
keeping the piping cold & dry (vapor retarder)
How Insulation Works
• Uses low thermal conductivity materials
• Material manufactured
with trapped bubbles of
low thermal conductivity
blowing agents
• Reduction of surface temperature
relative to ambient further reduces
convection & radiation and inhibits
condensation & ice growth
 d2 TS,2
Heat Transfer TS,1
d1

• One-dimensional, steady-state, conduction

heat transfer in cylindrical coordinates
2𝜋𝜋𝜋 ∙ 𝑇𝑠,1 − 𝑇𝑠,2
𝑄̇ =
ln 𝑑2 ⁄𝑑1
• 𝑘 is a property of the insulation chosen
• 𝑑2 = 𝑑1 + 2 ∙ 𝑡
• 𝑄̇ is a heat rate, i.e. units of Btu/hr, tons, kWt
 TS,2
Heat Transfer, continued 𝑄𝑐̇

h
• Convection k

𝑄𝑐̇ = ℎ ∙ 𝐴2 ∙ 𝑇𝑠,2 − 𝑇𝑜
– ℎ is a property of the orientation, diameter,
velocity, and temperatures
– 𝐴2 = 𝜋 ∙ 𝑑1 + 2 ∙ 𝑡 ∙ 𝐿
– 𝑄𝑐̇ is a heat rate, i.e. units of Btu/hr, tons, kWt
Heat Transfer, continued
• Radiation
𝑄𝑟̇ = 𝜀 ∙ 𝜎 ∙ 𝐴2 ∙ 𝑇𝑠,2 4 − 𝑇𝑜 4
– 𝑄𝑟̇ is a heat rate, i.e. units of Btu/hr, tons, kWt
– 𝜀 is the surface emittance
– 𝜎 is the Stefan Boltzmann constant
– 𝐴2 = 𝜋 ∙ 𝑑1 + 2 ∙ 𝑡 ∙ 𝐿
Heat Transfer, cont.
• Increasing the insulation thickness
– increases the conduction resistance, reducing
heat transfer & surface temperature relative to
surroundings
– increases the area over which convection &
radiation acts, increasing relative heat transfer
– Does an “optimum” exist?
• Energy Balance on jacket surface
𝑄̇ = 𝑄𝑐̇ + 𝑄𝑟̇
Design Analysis
• Assumptions:
– Ambient conditions: quiescent, 95°F, outdoors
– Pipe at uniform temperature
– Insulation 𝑘 = 0.0195 Btu/hr-ft2-°F
– Aluminum jacket (weathered) 𝜀= 0.3
𝑇𝑜 𝑄𝑟̇ 𝑄𝑐̇
𝑇𝑠,2

𝑄̇
𝑇𝑠,1 𝑑1

𝑑2
Analysis (Load v. 8” Pipe Temperature)
Analysis (Load v. 4” Pipe Temperature)
Analysis (Load v. Pipe Size @ -40°F)
Analysis (Surface Temperature)
Analysis
Observations
• Used NAIMA’s 3EPlus (v. 4) to verify the
analysis with good agreement
• For the range of insulation thicknesses in our
industry, an “optimum” insulation thickness
doesn’t occur
INDUSTRY
RECOMMENDATIONS
Industry Recommendations
• Outdoor horizontal piping
– 100°F dry bulb, 90% relative humidity,
wind velocity 7.5 mph, metal jacket
• Indoor horizontal piping
– 90°F dry bulb, 80% relative humidity,
wind velocity 0 mph, PVC jacket, or
– 40°F dry bulb, 90% relative humidity,
wind velocity 0 mph, PVC jacket
IIAR Recommended Thickness
Table 7-3 IIAR Ammonia Refrigeration Piping Handbook
Extruded Polystyrene insulation on outdoor piping

Nominal Service Temperature (°F)

Pipe Size
(in) -40 -20 0 +20 +40
2 3.5 3 3 2.5 2
2-½ 3.5 3 3 2.5 2.5
3 4 3.5 3.5 3 2.5
4 4.5 3.5 3.5 3 2.5
5 4.5 4 3.5 3 2.5
6 4.5 4.5 3.5 3 2.5
8 5 4.5 4.5 3 2.5
10 5.5 5 4.5 3.5 3
12 5.5 5 4.5 3.5 3
IIAR Recommended Thickness
Table 7-4 IIAR Ammonia Refrigeration Piping Handbook
Extruded Polystyrene insulation on indoor piping (90°F)

Nominal Service Temperature (°F)

Pipe Size
(in) -40 -20 0 +20 +40
2 2.5 2 2 1.5 1.5
2-½ 2.5 2 2 1.5 1.5
3 2.5 2.5 2 2 1.5
4 3 2.5 2 2 1.5
5 3 2.5 2.5 2 1.5
6 3 2.5 2.5 2 1.5
8 3 2.5 2.5 2 1.5
10 3 3 2.5 2 1.5
12 3.5 3 2.5 2 1.5
IIAR Recommended Thickness
Table 7-5 IIAR Ammonia Refrigeration Piping Handbook
Extruded Polystyrene insulation on indoor piping (40°F)

Nominal Service Temperature (°F)

Pipe Size
(in) -40 -20 0 +10
2 4 3 2 2
2-½ 4 3 2 2
3 4 3.5 2.5 2
4 4.5 3.5 2.5 2
5 4.5 3.5 2.5 2
6 4.5 4 3 2
8 5 4 3 2.5
10 5 4 3 2.5
12 5.5 4.5 3 2.5
SIMULATION
Energy Analysis
• Previous analysis was for design conditions,
but what about the energy impact over the
year?
• To estimate that, will need
– Weather data, including wind & solar
– Model that accounts for the solar gain
– Refrigeration system efficiency
Weather Values
• Data excerpt for Madison, WI TMY2 data
Month Day Hour GHR DB DP WS
Btu/hr-ft2 °F °F mph
1 1 6 0.00 34.0 28.9 13.87
1 1 7 0.00 33.6 29.7 13.20
1 1 8 2.54 33.4 30.2 12.30
1 1 9 12.05 33.1 30.0 11.63
1 1 10 26.31 33.4 30.9 10.74
1 1 11 43.11 33.6 31.5 10.07

• Descriptions
– GHR = Global Horizontal Radiation (solar),
Btu/hr-ft2-F
– DB = Dry bulb temperature, deg F
– DP = Dewpoint temperature, deg F
– WS = Wind speed, mph
Model Description
• Split insulation in half
– Upper half is exposed to solar radiation
– Lower half is not
– Both halves get the same convection coefficient
• Horizontal cylinder in cross-flow or natural convection
depending on wind speed
• Hourly calculation to determine the total load
on the piping due to heat gain through
insulation
Model 𝐺𝐺𝐺

̇
𝑄𝑟,𝑢 𝑇𝑜
̇
𝑄𝑐,𝑢
𝑇𝑠,𝑢

𝑄𝑢̇
𝑇𝑠,1 𝑑1
WS
𝑑2
̇
𝑄𝑐,𝑙
𝑄̇𝑙

𝑇𝑠,𝑙

̇
𝑄𝑟,𝑙
Refrigeration System Efficiency
Results for Piping @ -40°F
Properly Maintained Insulation Estimate
Pipe Size [in] Insulation
Thickness
Annual Heat Annual Cost
Gain [ton-hrs per 100 ft
Assumptions
[in] per 100 ft] • Madison, WI
8” 5” 1,014 $180
8” 3” 1,456 $260
• 2.4 HP/ton
4” 4.5” 707 $125 • $0.10/kWh
4” 3” 907 $160
2” 3.5” 562 $100
2” 3” 610 $110

Failed Insulation Estimate†

Pipe Size [in] Insulation Annual Heat Annual Cost
Thickness Gain [ton-hrs per 100 ft † Factor of 2 loss of insulation
[in] per 100 ft] thermal conductivity on top,
factor of 6 on the bottom
8” 5” 3,730 $670
Results for Piping @ +20°F
Properly Maintained Insulation Estimate
Pipe Size [in] Insulation
Thickness
Annual Heat Annual Cost
Gain [ton-hrs per 100 ft
Assumptions
[in] per 100 ft] • Madison, WI
8” 3” 540 $36
4” 3” 224 $22
• 0.9 HP/ton
2” 2.5” 165 $16 • $0.10/kWh

Failed Insulation Estimate†

Pipe Size [in] Insulation Annual Heat Annual Cost
Thickness Gain [ton-hrs per 100 ft † Factor of 2 loss of insulation
[in] per 100 ft] thermal conductivity on top,
factor of 6 on the bottom
8” 3” 1,826 $120
Results for Piping @ -40°F
Properly Maintained Insulation Estimate
Pipe Size [in] Insulation
Thickness
Annual Heat Annual Cost
Gain [ton-hrs per 100 ft
Assumptions
[in] per 100 ft] • Tampa, FL
8” 5” 1,340 $240
8” 3” 1,920 $340
• 2.4 HP/ton
4” 4.5” 935 $170 • $0.10/kWh
4” 3” 1,200 $215
2” 3.5” 740 $135
2” 3” 805 $145

Failed Insulation Estimate†

Pipe Size [in] Insulation Annual Heat Annual Cost
Thickness Gain [ton-hrs per 100 ft † Factor of 2 loss of insulation
[in] per 100 ft] thermal conductivity on top,
factor of 6 on the bottom
8” 5” 4,900 $880
Results for Piping @ +20°F
Properly Maintained Insulation Estimate
Pipe Size [in] Insulation
Thickness
Annual Heat Annual Cost
Gain [ton-hrs per 100 ft
Assumptions
[in] per 100 ft] • Tampa, FL
8” 3” 1,010 $68
4” 3” 625 $42
• 0.9 HP/ton
2” 2.5” 465 $31 • $0.10/kWh

Failed Insulation Estimate†

Pipe Size [in] Insulation Annual Heat Annual Cost
Thickness Gain [ton-hrs per 100 ft † Factor of 2 loss of insulation
[in] per 100 ft] thermal conductivity on top,
factor of 6 on the bottom
8” 3” 3,460 $230
Conclusions
• IF insulation system is properly maintained
the parasitic load is relatively low
• Failed insulation systems NOT ONLY effect
the heat load, BUT ALSO put the underlying
piping at increased risk for corrosion
Resources
• IIAR Ammonia Refrigeration Piping
Handbook, Chapter 7
• ASHRAE 2010 Refrigeration Handbook,
Chapter 10
• NAIMA 3EPlus (http://www.pipeinsulation.org/)
QUESTIONS?