Department of Mechanical Engineering

Bangladesh University of Engineering and Technology

ME 310
Thermo-Fluid System Design
1.5 Credit Hours

THERMAL INSULATION
 What is Thermal Insulation?
The term thermal insulation is most commonly
used to describe the process that is used to
keep something at a stable temperature.

It may refer to the steps taken to insulate

buildings or objects to reduce the
transmission or loss of heat, and it can also
mean the material that is used to protect an
area or object from heat - either loss or
entrance - in the form of conduction, convection
or radiation.
 Reasons for Thermal Insulation

The primary reasons for insulation are many and varied, the main ones being:

❑ To conserve energy
❑ To reduce heat loss or gain
❑ To maintain a temperature condition
❑ To maintain the effective operation of equipment or chemical reaction
❑ To assist in maintaining a product at a constant temperature
❑ To prevent condensation
❑ To create a comfortable environmental condition
❑ To protect personnel
 Economic Insulation Thickness
Economic thickness is the thickness of insulation, which will result in the
minimum total cost of energy losses plus the cost of the erected
insulation.
The economic thickness calculation has to be prepared by the user and is
usually NOT the function of the insulation contractor. It includes salient
factors such as:
❑ Cost of the energy losses, which include capital cost of installed
equipment to generate/extract heat
❑ Expected price movement in the cost of fuel
❑ Capital cost of installed insulation
❑ Payback period that the user requires for capital investments
❑ Various other accounting factors
Economic Insulation Thickness
 Critical Insulation Thickness
Consider an insulated pipe -

Adding more insulation will

increase heat transfer rate
Heat flux, q

Critical Radius:
𝑘
𝑟2 = 𝑟2 𝑐𝑟 =
Outer radius, r2 ℎ0
 Critical Insulation Thickness
Consider an insulated pipe -

Adding more insulation will

decrease heat transfer rate
Heat flux, q

Critical Radius:
𝑘
𝑟2 = 𝑟2 𝑐𝑟 =
Outer radius, r2 ℎ0
 Factors Needed to be Considered

1. Surface Operating Temperature 12. Moisture Resistance & Water

2. Surface Size and Shape Repellency
3. Heat Transfer and Thermal Conductivity 13. Mechanical Properties Durability
4. Process Control Requirements 14. Environmental and Biological Aspects
5. Economic Thickness of Insulation 15. Installed Cost
6. Personnel Protection 16. Cladding Selection
7. Condensation Control 17. Original Equipment Manufacturing
8. Noise Control 18. Health & Safety
9. Minimization of Stress Corrosion Cracking
Risk
10. Punking of Thermal Insulation
11. Fire Protection
 Basic heat transfer equation

Define: Overall Heat Transfer Coefficient, U

1 1 ∆𝑥 1 1 1 ∆𝑥 1
= + + = + +
𝑈𝐴 ℎ1 𝐴 𝑘𝐴 ℎ2 𝐴 𝑈𝑖 𝐴𝑖 ℎ𝑖 𝐴𝑖 𝑘𝐴𝐿𝑀 ℎ𝑜 𝐴𝑜

1 1 ∆𝑥 1
= + +
𝑈𝑜 𝐴𝑜 ℎ𝑖 𝐴𝑖 𝑘𝐴𝐿𝑀 ℎ𝑜 𝐴𝑜

Relationship between the two:

1 1
=
𝑈𝑖 𝐴𝑖 𝑈𝑜 𝐴𝑜
 Basic heat transfer equations

Define: Overall Heat Transfer Coefficient, U

−∆𝑇
𝑄= 𝑄 = 𝑈𝑖 𝐴𝑖 𝑇𝑖 − 𝑇𝑜 = 𝑈𝑜 𝐴𝑜 𝑇𝑖 − 𝑇𝑜
1
𝑈𝐴
 Critical Insulation Thickness

Consider an insulated pipe:

Conduction resistance across insulation:

∆𝑟 ln 𝑟2 Τ𝑟1
𝑅𝑐𝑑 = =
𝑘𝐴𝐿𝑀 2𝜋𝑘𝐿

Convection resistance:

1 1
𝑅𝑐𝑣 = =
ℎ0 𝐴0 ℎ0 2𝜋𝑟2 𝐿
 Critical Insulation Thickness

Consider an insulated pipe:

Writing the heat flux 2𝜋𝐿 𝑇1 − 𝑇0
𝑄=
in series: ln 𝑟2 Τ𝑟1 1
+
𝑘 ℎ0 𝑟2

∆𝑟 ln 𝑟2 Τ𝑟1
𝑅𝑐𝑑 = =
𝑘𝐴𝐿𝑀 2𝜋𝑘𝐿
1 1
𝑅𝑐𝑣 = =
ℎ0 𝐴0 ℎ0 2𝜋𝑟2 𝐿
 Critical Insulation Thickness

Consider an insulated pipe:

*When Q was plotted against r2,
notice that the heat flux plateaus at a
certain thickness of insulation.
Heat flux, q

2𝜋𝐿 𝑇1 − 𝑇0
𝑄=
ln 𝑟2 Τ𝑟1 1
+
𝑘 ℎ0 𝑟2
Outer radius, r2
 Critical Insulation Thickness

Consider an insulated pipe:

2𝜋𝐿 𝑇1 − 𝑇0
Taking the derivative with respect to outer radius and 𝑄=
equating to 0: ln 𝑟2 Τ𝑟1 1
+
𝑘 ℎ0 𝑟2

𝑑𝑄 −2𝜋𝐿 𝑇1 − 𝑇0 1 1
= 2 − 2 =0
𝑑𝑟2 ln 𝑟2 Τ𝑟1 1 𝑟2 𝑘 ℎ0 𝑟2
+
𝑘 ℎ0 𝑟2
Critical Radius
1 1
= 𝑘
𝑟2 𝑘 ℎ0 𝑟22 𝑟2 = 𝑟2 =
𝑐𝑟
ℎ0
 Work out Problem-1
8-inch piping system, operating at 400°F with a 60°F ambient
temperature and insulated with calcium silicate. Determine the
Critical Thickness of Insulation.

Step-1: Read the chart for the K of Calcium silicate

Step-2: Use the basic heat transfer equation to find h

Step-3: use the equation for the critical thickness

Work out Problem-1
 Hot Surfaces which we insulate
✓ Surfaces of piping and equipment normally operating at temperatures above
100°F where heat conservation is desirable should be insulated for
economic reasons.

✓ Valves, piping and vessel flanges, and manway covers in most services with
operating temperatures above 100°F should be insulated for heat
conservation. For the same reason, most large normally operating hot pumps
and turbines should also be insulated.
✓ Piping operating at temperatures over 140°F and easily accessible to
personnel must be insulated or otherwise guarded for personnel protection.

✓ Equipment may require insulation for fire protection regardless of its normal
operating temperature.

✓ Piping and equipment should be insulated as required for process control.

 Hot Equipment We Normally Don’t Insulate

✓ Equipment and piping where heat loss to the atmosphere is a design requirement.
✓ Equipment and piping that are refractory lined. Use metal cages for personnel
protection.
✓ Cooling water lines.
✓ Water side of coolers and condensers.
✓ Steam traps.
✓ Bellows expansion joints.
✓ Nameplates, code data plates, etc.
✓ Bearing housings of pumps.
✓ Seals pots, vent chambers, and drip pots should be insulated only if steam
traced.
 Problems with Insulation

✓ Corrosion Under Insulation

✓ High-temperature, Waxy Serfaces

✓ Un-equal thermal expansion if different materials are used in

flanges
 How to choose proper insulation material

The process of selecting an appropriate insulation system involves three steps.

These steps are:

1. Select candidate materials based on the requirements of the equipment to be

insulated. These requirements basically include temperature limits and physical
strength.

2. Calculate the most economical thickness for each candidate material.

3. Estimate the price of those candidate materials at thicknesses calculated in

Step 2. A more expensive material may be less costly to install, making it overall
the least expensive candidate
 How to choose proper insulation material

Calcium Silicate

High vibration areas should not be treated with calcium silicate.

 How to choose proper insulation material
Perlite: Perlite can be used for insulating piping, vessels, etc., up to 1200°F and is an
acceptable alternative to calcium silicate.
 How to choose proper insulation material
Mineral Wool: Mineral wool contains an average of 75% post-industrial recycled
content. It doesn't require additional chemicals to make it fire resistant, and it can be used
in two different insulation forms
Fiberglass:

2 types:
❑ Batt
❑ Blown-in
 How to choose proper insulation material
Refractory Ceramic Fiber (RCF)
For very high temperature above 1100°F and up to 2300°F, RCF insulation is used. Very few refinery services
except furnaces require insulation in this temperature range.
 How to choose proper insulation material
Polyurethane
 How to choose proper insulation material
Polyisocyanurate Rigid Foam
This polyisocyanurate is often used for cold insulation and can also be used up to 300°F
 Different Insulation Materials
Expanded Polystyrene
 How to choose proper insulation material
Icynene:
Icynene is a foaming agent that uses a
mixture of carbon dioxide and water. Though
it does not have polyurethane's HCFC-
related environmental problems, it also has a
lower insulation rating (R-value). Like
polyurethane, Icynene is foamed into wall
cavities, but the resultant open-cell foam is
soft, not rigid.
 How to choose proper insulation material
Cellular Glass Block (Foamglas):

Its use has been restricted primarily to cold insulation because of high cost. Foamglas has
a thermal efficiency similar to calcium silicate and can be used to 350°F without concern
for thermal cracks.
 How to choose proper insulation material
Calcium Carbonate and Insulating Cement:
 How to choose proper insulation material
Aerated concrete block:
 How to choose proper insulation material
Straw

Bales of straw have been used for exterior wall insulation. Of course, precautions need to
be taken to prevent insect infestation and well as moisture intrusion.
 Cellulose: How to choose proper insulation material

Cellulose insulation is made from recycled paper that is applied as either loose fill into attics and closed
wall cavities or damp-sprayed into open wall cavities. Due to its recycled content and potentially higher
energy and acoustic performance, cellulose is an environmentally preferable product.
 Different Insulation Materials
R-Value per inch Material
R/
Inch Material
R/
Inch
Insulation Materials

Fiberglass Batt 3.14 Vermiculite 2.13

Fiberglass Blown 2.20 Air-entrained Concrete 3.90

(attic)
Fiberglass Blown 3.20 Urea terpolymer foam 4.48
(wall)
Rock Wool Batt 3.14 Rigid Fiberglass (> 4.00
4lb/ft3)
Rock Wool Blown 3.10 Expanded Polystyrene 4.00
(attic) (beadboard)

Rock Wool Blown 3.03 Extruded Polystyrene 5.00

(wall)
Cellulose Blown 3.13 Polyurethane (foamed- 6.25
(attic) in-place)

Cellulose Blown 3.70 Polyisocyanurate (foil- 7.20

(wall) faced)
 Weather Jackets
Weather jackets must be applied over insulation to prevent entry of water under
normal operating conditions. Typical weather jacketing is aluminum with a
moisture barrier.
 Priming
Priming of steel under insulation is very important in the prevention of corrosion once the
insulation gets wet. Polyamide epoxy is used for equipment running under 200°F. For
equipment running over 200°F, an organic zinc is recommended
 Procedure for determining the Economic Thickness of Insulation

Economical thickness is determined primarily by the value of heat, installed cost of

insulation, payout period and to a lesser extent by ambient temperature, thermal
conductivity and operating factor. Other factors to consider are: the thickness
needed to protect personnel from hot surfaces and what thicknesses are
commercially available.
 Procedure for determining the Economic Thickness of Insulation

Step 1: Collect the information needed regarding the insulation cost.

Step 2: Calculate the heat loss for various insulation thicknesses for the
payout period specified.
Step 3: Calculate the financial value of heat loss for the various insulation
thicknesses.
Step 4: Calculate the money saved by the incremental insulation.
Step 5: Compare the results of Step 4 to the incremental insulation cost.
The most economical thicknesses are those at which the incremental insulation
cost is less or equals the incremental value of heat saved.
 Workout-2
8-inch piping system, operating at 400°F with a 60°F ambient
temperature and insulated with calcium silicate. Determine the
economic thickness of Insulation.
A1½" = 2.65 sq ft/lineal ft
Step-1: A2" = 2.76 sq ft/lineal ft
A2-1/2" = 2.87 sq ft/lineal ft
Assume: C1½" = $15.07/lineal ft for 1½" insulation
H = $6/MMBtu = heat value C2" = $18.40/lineal ft for 2" insulation
O = 0.9 = operating factor C2½" = $22.43/lineal ft for 2½" insulation
L = Use nominal insulation thickness, inches
P = 2 years = payout period before taxes
T1 = 400°F
T3 = 60°F
k = 0.46 (Btu)(in)/(sq ft)(hr)(°F)
Calculate Step 2 and 3:
Workout-2

If values of L/kA are now computed for various pipe sizes and insulation thicknesses, it is
found that 1/hAo is only 3 to 11% of the corresponding value of L/kA. By taking a mean
value of 7%, and introducing it as a constant

The actual heat loss over the payout period in MMBtu per lineal foot is:
Calculate Step 4 and 5:
Workout-2
 Workout-3

8-inch piping system, operating at 400°F with a 60°F ambient

temperature and insulated with calcium silicate. Determine the insulation
thickness where outer surface temperature is required to be less than
215oF.
Workout-3
Introduction to 3E Plus Software
 Workout-4
8-inch piping system, operating at 400°F with a 60°F ambient
temperature and insulated with calcium silicate. Determine the economic
thickness of Insulation. Solve the problem using 3E plus software
Workout-5

Gas ducting in a power station operates at a maximum temperature of 420°C. The

insulation system consists of an inner layer of 75mm Fibertex 450 plus an outer
layer of 100mm Fibertex 350 with aluminum cladding.

Determine the heat loss and surface temperature for an ambient temperature of
30°C, basing calculations on still air conditions.
Code and Standard for Insulation
Workout-6
Consider an ANSI Class 300 valve on an 8-in. NPS pipe line. The service temperature
is 600°F and, for the purposes of the calculations, we are given a standard outdoor
temperature of 40°F and a wind speed of 5 mph. The valve has a dark, low
reflectance surface.

Estimate the heat loss from the valve.

 ASSIGNMENT-3

1. A horizontal steel tank of 2.5m diameter and length of side 6.5m has two dished
ends of radius equal to the diameter of the tank. It is to be used as a holding tank for
asphalt which will be pumped in at a temperature not less than180°C.
Insulation is required to ensure that the drop in temperature is no greater than 1.5°C
per hour. The density of the particular grade of asphalt over the temperature range
in question will average 930 kg/m3 and the specific heat capacity will average 2.28
kJ/kg.K.
The worst expected climatic conditions are 0°C and a wind velocity of 25 km/h.
On the basis that the lowest level at which the contents of the tank will be held for
prolonged periods of time is 30% of its capacity, what thicknesses of the
recommended insulation will be required. Aluminium cladding is to be used.
.

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 ASSIGNMENT-3

2. A furnace is required to sinter powder-metal parts. It operates continuously at

650ºC while the parts are fed through on a moving belt. You are asked to select a
material for furnace insulation to minimize heat loss and thus to make the furnace as
energy-efficient as possible. For reasons of space the insulation is limited to a
maximum thickness of x = 0.2 m. List the function, constraints, objective and free
variable.

3. A cold room has to be design for an industry. The room would be of 20 ft * 20 ft

*10 ft in size and has to maintain a temperature of -20 deg-C to store the fish for
export. Design the insulation system of the cold and estimate the cost of maintaining
the indoor environment. Assume appropriate value for the design.

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Thank You!

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