Fundamentals of insulationFundamentals of insulationFundamentals of insulationFundamentals of insulationKuwait, February 2012
Product Manager Insulation Product Manager Insulation ‐‐MEME, India & Africa, India & Africa
DrDr Laurenţiu PestriţuLaurenţiu Pestriţu MBEMBEDrDr. . Laurenţiu PestriţuLaurenţiu Pestriţu, , MBEMBE
PROGRAM
1717::00 00 ‐‐ 1177::3030
The insulationThe insulation Why should we insulate?Why should we insulate?yy AerofoamAerofoam NBR insulationNBR insulation AerofoamAerofoam XLPE insulationXLPE insulation
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THE INSULATION DefinitionDefinition
InsulationInsulation a material that reduces orInsulationInsulation – a material that reduces orprevents the transmission of heatheat or sound orelectricityelectricity
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THE INSULATION ClassificationClassification
INSULATING MATERIALSINSULATING MATERIALS
Open cell: Closed cell:Open cell:
Rockwool
Closed cell:
polyurethanemineral wool glass wool
p y polystyrene glassg
cork (polyurethane)
g polyethylene elastomeric(p y )
(polystyrene)
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WHY INSULATE? ScopeScope
Refrigeration andRefrigeration and ACACRefrigeration and Refrigeration and ACAC
TargetsTargets: :
11. . Condensation controlCondensation control
22 Minimizing thermal lossMinimizing thermal loss22. . Minimizing thermal loss Minimizing thermal loss
HeatingHeatingTargetTarget:: ‐‐minimizing thermal lossminimizing thermal loss
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Selection criteriaSelection criteriaWHY INSULATE?
Temperature Temperature of the agent of the agent
Thermal conductivity Thermal conductivity (())
Vapor barrier (Vapor barrier () )
Ease of installationEase of installationEase of installationEase of installation(flexible insulation)(flexible insulation)
Fire Fire resistenceresistence‐‐ Class O Class O ‐‐
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Thermal Thermal conductivityconductivityWHY INSULATE?
0,024 Air 0 034 Cross linked PE 0,034 Cross linked PE 0,035 Elastomeric insulaton 0,200 Wood0 550 W 0,550 Water 0,840 Concrete
λ‐value
0 7
0.8
0.9
0.3
0.4
0.5
0.6
0.7
0
0.1
0.2
0.3
Air Aerofoam Aerofoam Wood Water Concrete
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Air Aerofoam XPE
Aerofoam NBR
Wood Water Concrete
Theory Theory ‐‐condensationcondensationWHY INSULATE?
Refrigeration and ACRefrigeration and ACRefrigeration and ACRefrigeration and AC
TargetsTargets: :
11. . Condensation controlCondensation control
22 Minimizing thermal lossMinimizing thermal loss22. . Minimizing thermal loss Minimizing thermal loss
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INSULATION Theory Theory ‐‐condensationcondensation
F HVACF HVACFor HVAC scopesFor HVAC scopes
Can be used only closed‐cell insulation materials:
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Important Important aspects aspects INSULATION
Top Top 5 5 important aspects regarding important aspects regarding l d ll i l til d ll i l ticlosed cell insulationclosed cell insulation
1) Strong water vapor resistance factor ‐
2) Low thermal conductivity – λλ2) Low thermal conductivity λλ
3) Use of right insulation thickness
4) Correct installation – tightness of the glued joints
) h d l d b5) Keeping the minimum distance among insulated objects
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Important Important aspectsaspectsINSULATION
λλ
µµ
Heat flow (λ) and diffusion flow (µ) are caused by thedifference in the line and ambient temperatures
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difference in the line and ambient temperatures
11. . valuevalueINSULATION
11. . STRONG WATER VAPOR BARRIERSTRONG WATER VAPOR BARRIER
Water vapor diffusion resistance factor Water vapor diffusion resistance factor ‐‐
70007000
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11. . valuevalueINSULATIONTline + 6°C RH 0%
There is pressure difference ofThere is pressure difference ofwater vapor between ambientair and closed cell structure ofinsulation (due to temperatureinsulation (due to temperaturedifference between the line and theambient).
The pressure difference isThe pressure difference iscreating a diffusion flow whichis forcing the ambient watervapors into the insulationvapors into the insulation(towards lower temperature).
Tamb +
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Tamb + 22°C RH 70%
11. . valuevalueINSULATIONTline + 6°C RH 0%
For poor quality materials(with low value) insulationillwill get wet.
Therefore one should applyhigh quality insulationhigh quality insulationmaterials (i.e. with high valueof water vapour diffusionresistance factor )resistance factor )
Tamb +
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Tamb + 22°C RH 70%
11. . valuevalueINSULATIONTline + 6°C RH 0%
Thanks to strong value watervapor penetration is very slowand kept at limited level.p
>> 70007000
Tamb +
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Tamb + 22°C RH 70%
11. . valuevalueINSULATION
THE DIFFERENCE BETWEEN HIGH AND LOW THE DIFFERENCE BETWEEN HIGH AND LOW
70007000 << 70007000
iffusion
iffusion
Vapo
rs d
Vapo
rs d
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22. . λ valueλ valueINSULATION22. . LOW THERMAL CONDUCTIVITY LOW THERMAL CONDUCTIVITY
≤≤ 00,,035035
LowLow
Low quality Low quality materialsmaterials
HighHigh
10
High quality High quality materialsmaterials
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10 yrs
33. . IInsulation nsulation thicknessthicknessINSULATION
33. . USING THE CORRECT INSULATION THICKNESSUSING THE CORRECT INSULATION THICKNESS
DependingDepending onon thethe pipepipe diameterdiameterthethe minimumminimum insulationinsulation thicknessthicknessshouldshould bebe calculatedcalculated (other(othershouldshould bebe calculatedcalculated (other(otherinfluencinginfluencing parametersparameters areare:: ambientambienttemperature,linetemperature,line temperature,temperature, relativerelativehumidity,humidity, surfacesurface coefficient,coefficient, thermalthermalconductivity)conductivity)
Φ 114 mm
Thickness: 19 mm Diameter: 15 mm
Thickness: 24,5 mm Diameter: 114 mm
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33. . IInsulation nsulation thicknessthicknessINSULATION
The influence of pipe diameter size towards the The influence of pipe diameter size towards the heat flow heat flow (and towards the insulation thickness) (and towards the insulation thickness)
Plain surface Curved surface
A1 A1 A1
0 0 0 0
A2 A2 A2
A bigger insulation thickness is required for pipes with
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bigger diameters
44. . Correct Correct installationinstallationINSULATION
Installation m st be done ith prod cts hich ass re a goodInstallation m st be done ith prod cts hich ass re a good
44. . TIGHTNESS OF INSULATION GLUINGTIGHTNESS OF INSULATION GLUINGInstallation must be done with products which assure a good Installation must be done with products which assure a good gluing at the joints and on the entire length of the pipe. gluing at the joints and on the entire length of the pipe.
TTlineline 66°°CCRHRH 00%%
Ri idRi id i l ii l i ff
RH RH 00%%
RigidRigid insulationinsulation maymay oftenoftencontaincontain spacesspaces (due(due totowrongwrong cutting)cutting) wherewhere
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condensationcondensation cancan appearappear..
44. . Correct Correct installationinstallationINSULATION
Tight jointsTight joints
The system integrity (tight joints) is assured by following a right installation procedure and by using the right adhesive.
The adhesive glues the insulation surfaces through a chemical reaction which has as result the “cold vulcanization”.
“cold vulcanization” “cold vulcanization” guarantees the guarantees the
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ggrequired tightnessrequired tightness
55. . Surface Surface coefficient (h)coefficient (h)INSULATION
55. . KEEPING THE MINIMUM DISTANCE KEEPING THE MINIMUM DISTANCE AMONG INSULATED OBJECTSAMONG INSULATED OBJECTS
hhrrhh = hhrr + hhcvcv
hcv = convective t ib ti f
rr cvcv
contribution of surface coefficient
hr = radiativecontribution of hhcvcvsurface coefficient
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55. . Surface Surface coefficient (h)coefficient (h)INSULATION
Aerofoamwith steel (flat / mat) cladding Aerofoam
h l
Aerofoampainted
with alu (silver) cladding
A fAerofoamnot painted
W W
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10Wm2 . K 8 W
m2 . K 5,7 W
m2 . K
55. . Surface Surface coefficient (h)coefficient (h)INSULATION
Surface coefficient h
Cladding
Without cladding / With steel
(flat / mat)With alu (silver) Static areaCladding insulation
painted
(flat / mat) cladding
(silver) cladding
Static area
Value of surface coeff. h 10 8 5,7 3[W/m2K]
,InsulationInsulation thickness
(s0)so 1,5 * so 1,9 * so 3,0 * so
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55. . Surface Surface coefficient (h)coefficient (h)INSULATION
Higher probability of forming condensation Higher probability of forming condensation in the static areasin the static areas
Lack of air flow (convection)Lack of air flow (convection)
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55. . Surface Surface coefficient (h)coefficient (h)INSULATION
Recommended distances among theRecommended distances among the insulated objectsinsulated objects
for small objects: 100 100 mmmm
for big objects: 1000 1000 mmmm
100 mm
100 mm
100 mm
100 mm
100 mm
100 mm
100 mm 100 mm100 mm100 mm
1000 mm
1000 mm1000 mm
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55. . Surface Surface coefficient (h)coefficient (h)INSULATION
Especially important for chilled water pipe works
Pipe works in office and hotel buildings
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55. . Surface Surface coefficient (h)coefficient (h)INSULATION
Effects of not keeping the right distance among the Effects of not keeping the right distance among the insulated objectsinsulated objects
Condensation
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THE INSULATION ClassificationClassification
INSULATING MATERIALSINSULATING MATERIALS
Open cell: Closed cell:Open cell:
Rockwool
Closed cell:
polyurethanemineral wool glass wool
p y polystyrene glassg
cork (polyurethane)
g polyethylene elastomeric(p y )
(polystyrene)
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FeaturesFeaturesINSULATIONCross linked PE at Cross linked PE at a glance…a glance…
Almost zero water vapour permeability and waterabsorption – vapour water barrier as per ASHRAE and BritishStandardsStandards
Passed a wide range of fire and smoke tests for buildingt i lmaterials
Passed toxicity levels of combustion gases as perPassed toxicity levels of combustion gases as perISO5659 IMO Resolution MSC61
Safe, fast and easy installation ‐ integrated material
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FeaturesFeaturesINSULATION
No loose fibres that may cause irritations both oninstallation and service
Environmentally friendly:‐ CFC and HCFC free‐ does not contain nor use in its production substances‐ does not contain nor use in its production substancesthat contribute to Ozone Depletion Potential (ODP) andGlobal Warming Potential (GWP)
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ApplicationsApplicationsINSULATIONApplication typesApplication types
Square ducts WallsRound ducts
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Pipes Raised floorsStorage tanks
PropertiesPropertiesINSULATION
1. Thermal Conductivity – defines the thermal performance of
Vital Insulation Properties Vital Insulation Properties y p
the materialThe lower the value, the better the thermal performance.Varies according to mean temperature.Varies according to mean temperature.Symbol: λ, Units: W/mK, Standard: ASTM C518
2 Water Vapour Permeability – the diffusion of water vapors2. Water Vapour Permeability the diffusion of water vaporsinto the insulationThe more permissive is the material , the higher the thermal conductivitywill become over timewill become over time.Varies with temperature and relative humidity.Unit: g/h.m2, Standard: ASTM E96
3. Water Absorption – amount of water a material can absorbMore water absorbed means lower thermal performance of the material
ti
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over time.Varies with density of the material.Standard: BS EN 12087
Water absorptionWater absorptionINSULATIONWater AbsorptionWater Absorption
Water absorption
Cross linked PE: Cross linked PE: 00..33%% Mineral Fiber: Mineral Fiber: 100100%%
Water absorption(% by volume)
90100
5060708090
010203040
0
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Comparative Comparative performanceperformanceINSULATION
Comparison of insulation performanceComparison of insulation performance
Fibreglass NBR XLPE
N Resin bonded Extruded PVC Crossed‐linked Name glass fibers Nitrile Rubber polyethylene foam
Type of material Open cell Closed cell Closed cell
Thermal conductivity [W/mK] 0 036‐0 038 0 035 0 034Thermal conductivity [W/mK] 0.036 0.038 0.035 0.034
Water vapour permeability 75 perm‐in 0.02 perm‐in 0.00 perm‐in
Condensation control No Yes Partial
Integrated product No Partial YesIntegrated product No Partial Yes
Fibre free product No Yes Yes
Reliability in time Low High High
Ease of installationEnvironmentally friendly
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Comparative Comparative costingcostingINSULATION
Condition: Indoor installation of AC ducts
Comparison of installation costsComparison of installation costsCondition: Indoor installation of AC ducts
S/NItem
Description
Estimate for 10,000m2 duct
XLPE (13mm) FIBERGLASS (25mm) ELASTOMERIC (13mm)Description work
1Insulation
Material10,000 m2 18 180,000.00 6.5 65,000.00 14 140,000.00
2 Adhesive Glue 3,000 liters NIL 0.00 10 30,000.00 10 30,000.00
3 1st coat foster 608(4 US
Gallons) NIL 0.00 60 36,480.00 0 0.00
4 canvas cloth 1,186 rolls NIL 0.00 15 17,790.00 0 0.00
5 2nd coat foster 660(4 US
Gallons) NIL 0.00 100 66,000.00 0 0.00Gallons)
6labor and
fabrication1,000 manhours 5.5 5,500.00 16 16,000.00 5.5 5,500.00
Total Cost of Labor and Materials AED 185,500.00 AED 231,270.00 AED 175,500.00
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Cost savings compared to fiberglass 19.79% 24.11%
Comparative Comparative performanceperformanceINSULATION
Comparison of insulation performanceComparison of insulation performance
Condition: Installation of AC ducts in conditioned areasInsulation Thi k
Internal Surface
External Surface
Thermal C d ti it
Tline Tamb ∆T Heat
Fl Q
% Reduction
Insulation MaterialThickness
L (mm)
Surface Coefficient
fi
Surface Coefficient
fo
Conductivity
λ (W/mK)
Tline
(°C)
Tamb
(°C)
∆T
(°C)
Flow Q
(W/m2K)
Reduction of Heat
Flow
XLPE 13 22 5 7 0 034 9 30 21 34 81 79%
l f f b l
XLPE 13 22 5.7 0.034 9 30 21 34.81 79%
NBR 13 22 10 0.036 9 30 21 41.46 75%
Fiberglass 17.5 22 10 0.037 12 25 13 21.021 72%
As per BS5422:
Assuming at least 30% compression of fibreglass
ΔT1/fi + L/λ + 1/fo
As per BS5422:
fi internal surface coefficientfo external surface coefficient
Q =
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Galvanized sheet metal 8 W/m2KBright reflective surface 5.7 W/m2KWhite painted surface 10 W/m2K
Questions?Questions?