University of Baghdad

Engineering college
Mechanical Department

Report Title
PIPE INSULATION EFFICIENCY
STUDY UNIT

Name : zeena kareem azeez

Group: A | Date : 29-6-2020
PIPE INSULATION EFFICIENCY STUDY UNIT
Experiment Aim:
The study unit for the assessment of thermal insulation efficiency allows
investigating the effect of thermal insulation of steam pipes .

the unit consists of a set of four pipes, three of which are covered with insulation
materials, placed vertically . steam is fed by means of an overhead manifold.

composition:
the lagging of piping unit includes :

1) 3 test pipes covered with material whose thermal

conductivity coefficient is different.
2) One pipe without covering .
3) Bourdon pressure gage on steam inlet.
4) Thermometer in steam inlet.
5) Manual control valve on steam inlet.
6) Condensate discharge system .
7) Graduated containers of glass to measure the
condensate .

Theory :
Steam is transferred from a steam plant element to another by means
of pipes, often of considering length, As the steam is obviously at a
much higher temperature than atmosphere, the heat energy is lost all
around. Pipes must be insulated to minimize this loss: this is the
purpose of the covering with a suitable low conductivity material. This
process is known as lagging .

Testing procedure ;-

PAGE 1
1.Connect the study unit to the boiler plant,

2. Verify that steam arrives at the study unit,

3. Open the discharge valves and let the condensate flow down

4. Open the steam inlet valve

5. Wait until the study unit reaches thermal steady conditions,

6. Start the test: allow the steam to pass for a suitable time,

7. Weigh the containers to measure the mass of condensate

CALCULATION:
p = 1.5 bar
T = 130 cₒ

o at: p1 = 1.5 bar , T1 = 130 cₒ

p1 = 1.5 ×105 +1× 105 = 250 kpa

T1 = 130 cₒ → (from table B.1.1 ) psat= 270.1 kpa > p1
S.H.V→B.1.3
h1= 2722.21 KJ/Kg
at p= 250 kpa →h1= hf = 535.35 KJ/Kg (sat. liquid)
at p= 250 kpa → (table B1.2 ) v=vf =0.001067
ρ1 = 1/vf → ρ1 = 1/0.001067 = 937.2071 kg/m3

PAGE 2
o at: p2 = 2.5 bar , T2 = 182 cₒ
p2 = 2.5 ×105 +1× 105 = 350 kpa
T2 = 182 cₒ → (from table B.1.1 ) psat= 1050.4 kpa > p2 (by interpolation )
S.H.V→B.1.3
H2= 2825.87 KJ/Kg
at p= 350 kpa →h2= hf = 584.311 KJ/Kg
at p= 350 kpa → (table B1.2 ) v=vf =0.001079
ρ2 = 1/vf → ρ2 = 1/0.001079 = 926.784 kg/m3

o at: p3 = 3 bar , T3 = 190 cₒ

p3 = 3 ×105 +1× 105 = 400 kpa
T2 = 190 cₒ → (from table B.1.1 ) psat= 1254.4 kpa > p3
S.H.V→B.1.3
h3= 2839.92 KJ/Kg
at p= 400 kpa →h3 =hf = 604.723 KJ/Kg
at p= 400 kpa → (table B1.2 ) v=vf =0.001084
ρ3 = 1/vf → ρ3 = 1/0.001084 = 922.509 kg/m3

pipe A1:

PAGE 3
 v= 340 mm3
ρ= 937.2071 kg/m3
t= 1200 sec
mₒ = ρ (v/t)
340∗10−6
=937.2071 ( 1200 ) = 2.655 ×10-4 kg/sec

Q1 = m' (h1 – h2)

= 2.655×10-4 ( 2722.21 – 535.35 )
= 0.58061133 m3 / sec
T 1−T a T 1−T a
Q1 = R2 → R2 = Q1

r3
Q1∗ln ⁡( )
Kins= r2
( T 1 −T a )∗2 πL
0.095
Kins =
ln ( 0.0445 )∗0.5806 = 3.737×10 -4
w/m.c'
(130−5)2 π∗1.5

k0
X= 2
(t1+ta)

= 0.037 /2 (130+5) = 2.4975

K(t)= k0+ k0 (b/2)(t1+ ta) (θ=tan-1 θ = 0.859)

= 0.037+0.037(0.859/2)(130+5) =2.1823

PAGE 4
pipe A2:
v= 385 mm3
ρ= 926.784 kg/m3
t= 1200 sec
mₒ = ρ (v/t)
385∗10−6
= 926.784 ( 1200 ) = 2.983 ×10-4 kg/sec

Q2 = m' (h1 – h2)

= 2.983 ×10-4 ( 2825.87 - 584.311 )
= 0.6686 m3 / sec
T 2−T a T 2−T a
Q2 = R2 → R2 = Q2

r3
Q2∗ln ⁡( )
Kins= r2
( T 12−T a )∗2 πL
0.095
Kins =
ln ( 0.0445 )∗0.6686 = 3.039×10 -4
w/m.c'
(182−5)2 π∗1.5

k0
X= 2
(t1+ta)

= 0.037 /2 (182+5) = 3.4595

K(t)= k0+ k0 (b/2)(t1+ ta) (θ=tan-1 θ = 0.859)

= 0.037+0.037(0.859/2)(182+5)

PAGE 5
 =3.0087

pipe A3:
v= 425 mm3
ρ= 922.509 kg/m3
t= 1200 sec
mₒ = ρ (v/t)
−6

= 922.509 ( 425∗10
1200
) = 3.267 ×10 -4
kg/sec

Q3 = m' (hf – h2)

= 3.267 ×10-4 ( 2839.92 - 604.723 )
= 0.730 m3 / sec
T 3−T a T 3−T a
Q3 = R2 → R2 = Q3

r3
Q3∗ln ⁡( )
Kins= r2
( T 13−T a )∗2 πL
0.095
Kins =
ln ( 0.0445 )∗0.730 = 3.175×10 -4
w/m.c'
(190−5)2 π∗1.5

k0
X= 2
(t1+ta)

PAGE 6
 = 0.037 /2 (190+5) = 3.6075

K(t)= k0+ k0 (b/2)(t1+ ta) (θ=tan-1 θ = 0.859)

= 0.037+0.037(0.859/2)(190+5)
=3.1358

pipe B1:
v= 300 mm3
ρ= 937.2071 kg/m3
t= 1200 sec
mₒ = ρ (v/t)
300∗10−6
= 937.2071 ( 1200 ) = 2.343×10-4 kg/sec

Q1 = m' (h1 – h2)

= 2.343×10-4 ( 2722.21 – 535.35 )
= 0.5123 m3 / sec
T 1−T a T 1−T a
Q1 = R2 → R2 = Q1

r3
Q1∗ln ⁡( )
Kins= r2
( T 1 −T a )∗2 πL

PAGE 7
 0.095
Kins =
ln ( 0.0445 )∗0.5123 = 3.297×10 -4
w/m.c'
(130−5)2 π∗1.5

k0
X= 2
(t1+ta)

= 0.038 /2 (130+5) = 2.565

K(t)= k0+ k0 (b/2)(t1+ ta) (θ=tan-1 θ = 0.759)

= 0.038+0.038(0.759/2)(130+5)
=1.9843

pipe B2:
v= 330 mm3
ρ= 926.784 kg/m3
t= 1200 sec
mₒ = ρ (v/t)
330∗10−6
= 926.784( 1200 ) = 2.548 ×10-4 kg/sec

Q2 = m' (h1 – h2)

=2.548 ×10-4 ( 2825.87 - 584.311 )
= 0.5711 m3 / sec

PAGE 8
 T 2−T a T 2−T a
Q2 = R2 → R2 = Q2

r3
Q2∗ln ⁡( )
Kins= r2
( T 12−T a )∗2 πL
0.095
Kins =
ln ( 0.0445 )∗0.5711 = 2.596×10 -4
w/m.c'
(182−5)2 π∗1.5

k0
X= 2
(t1+ta)

= 0.038 /2 (182+5) = 3.553

K(t)= k0+ k0 (b/2)(t1+ ta) (θ=tan-1 θ = 0.759)

= 0.038+0.038(0.759/2)(182+5)
=2.7347

pipe B3:
v= 325 mm3
ρ= 922.509 kg/m3
t= 1200 sec
mₒ = ρ (v/t)
325∗10−6
= 922.509 ( 1200 ) = 2.498 ×10-4 kg/sec

Q3 = m' (hf – h2)

PAGE 9
 = 2.498 ×10-4 ( 2839.92 - 604.723 )
= 0.5583 m3 / sec
T 3−T a T 3−T a
Q3 = R2 → R2 = Q3

r3
Q3∗ln ⁡( )
Kins= r2
( T 13−T a )∗2 πL
0.095
Kins =
ln ( 0.0445 )∗0.5583 = 2.428×10 -4
w/m.c'
(190−5)2 π∗1.5

k0
X= 2
(t1+ta)

= 0.038 /2 (190+5) = 2.565

K(t)= k0+ k0 (b/2)(t1+ ta) (θ=tan-1 θ = 0.759)

= 0.038+0.038(0.759/2)(190+5)
=2.8500

pipe C1:
v= 740 mm3
ρ= 937.2071 kg/m3
t= 1200 sec

PAGE 10
mₒ = ρ (v/t)
740∗10−6
= 937.2071 ( 1200 ) = 5.779×10-4 kg/sec

Q1 = m' (h1 – h2)

= 5.779×10-4 ( 2722.21 – 535.35 )
= 1.2637 m3 / sec
T 1−T a T 1−T a
Q1 = R2 → R2 = Q1

r3
Q1∗ln ⁡( )
Kins= r2
( T 1 −T a )∗2 πL
0.095
Kins =
ln ( 0.0445 )∗1.2637 = 8.134×10 -4
w/m.c'
(130−5)2 π∗1.5

k0
X= 2
(t1+ta)

= 0.026 /2 (130+5) = 1.755

K(t)= k0+ k0 (b/2)(t1+ ta) (θ=tan-1 θ = 1.145)

= 0.026+0.026(1.145/2)(130+5)
=2.0354

PAGE 11
pipe C2:
v= 633 mm3
ρ= 926.784 kg/m3
t= 1200 sec
mₒ = ρ (v/t)
633∗10−6
=926.784 ( 1200 ) = 4.888 ×10-4 kg/sec

Q2 = m' (h1 – h2)

=4.888 ×10-4 ( 2825.87 - 584.311 )
= 1.0956 m3 / sec
T 2−T a T 2−T a
Q2 = R2 → R2 = Q2

r3
Q2∗ln ⁡( )
Kins= r2
( T 12−T a )∗2 πL
0.095
Kins =
ln ( 0.0445 )∗1.0956 = 4.980×10 -4
w/m.c'
(182−5)2 π∗1.5

k0
X= 2
(t1+ta)

= 0.026 /2 (182+5) = 2.431

K(t)= k0+ k0 (b/2)(t1+ ta) (θ=tan-1 θ = 1.145)

PAGE 12
 = 0.026+0.026(1.145/2)(182+5)
=2.8094

pipe C3:
v= 260 mm3
ρ= 922.509 kg/m3
t= 1200 sec
mₒ = ρ (v/t)
260∗10−6
= 922.509 ( 1200 ) = 1.998 ×10-4 kg/sec

Q3 = m' (hf – h2)

= 1.998 ×10-4 ( 2839.92 - 604.723 )
= 0.4465 m3 / sec
T 3−T a T 3−T a
Q3 = R2 → R2 = Q3

r3
Q3∗ln ⁡()
Kins= r2
( T 13−T a )∗2 πL
0.095
Kins =
ln ( 0.0445 )∗0.4465 = 1.9420×10 -4
w/m.c'
(190−5)2 π∗1.5

PAGE 13
 k0
X= 2
(t1+ta)

= 0.026 /2 (190+5) = 1.755

K(t)= k0+ k0 (b/2)(t1+ ta) (θ=tan-1 θ = 1.145)

= 0.026+0.026(1.145/2)(190+5)
=2.9285

Plot between Kins & k0/2(ti+ta) for A:

0.03

0.03

0.02
kins

0.02

0.01

0.01

0
2.4 2.6 2.8 3 3.2 3.4 3.6 3.8

k0/2(ti+ta)

0.025−0.01
Slope = 3.5−2.54 = 0.015

θ=tan-1 θ = 0.859

PAGE 14
Plot between Kins & k0/2(ti+ta) for B:

0.03

0.02

0.02
kins

0.01

0.01

0
2.4 2.6 2.8 3 3.2 3.4 3.6 3.8

k0/2(ti+ta)

0.0153−0.01
Slope = 3.5−3.1 = 0.01325

θ=tan-1 θ = 0.759

PAGE 15
Plot between Kins & k0/2(ti+ta) for C:

0.02

0.02

0.02

0.01

0.01
kins

0.01

0.01

0.01

0
1.7 1.8 1.9 2 2.1 2.2 2.3 2.4 2.5 2.6

k0/2(ti+ta)

0.016−0.008
Slope = 2.5−2.1 = 0.02

θ=tan-1 θ = 1.145

PAGE 16
CONCLUSION:

1. Comment the heat flow rate for each pipe and comment
about the advantages of insulation for steam piping.
Steam pipes are very important in engineering application and are widely used.
The main applications include household boilers, industrial steam generating
plants, locomotives, steam engines, different building works, etc. to name but a
few. Lack of proper insulation results in large energy losses which in turn cost a lot
of money over time. Without proper insulation, the amount of energy lost can be
10 times greater than the energy being delivered through those pipes. Insulation is
defined as those materials or combinations of materials which retard the flow of
heat energy by performing one or more of the following functions:

1. Conserve energy by reducing heat loss or gain

2. Control surface temperatures for personnel protection and comfort

3. Facilitate temperature control of a process

4. Prevent vapor flow and water condensation on cold surfaces

5. Increase operating efficiency of heating/ventilating/cooling, plumbing, steam,

process and power systems found in commercial and industrial installations

6. Prevent or reduce damage to equipment from exposure to fire or corrosive

atmospheres.

Note that each flow pipe is different from the other because of the process of
insulation in the process of insulation depends on the coefficient of insulation K
The lower the amount of this coefficient was excellent insulation process and this
is what is included in the experiment

PAGE 17
2. Which material do you consider to have the best insulating
properties?

1. Fiberglass : Fiberglass is the most common insulation used in modern

times. Because of how it is made, by effectively weaving fine strands of
glass into an insulation material, fiberglass is able to minimize heat
transfer. The main downside of fiberglass is the danger of handling it.
Since fiberglass is made out of finely woven silicon, glass powder and tiny
shards of glass are formed. These can cause damage to the eyes, lungs,
and even skin if the proper safety equipment isn’t worn. Nevertheless,
when the proper safety equipment is used, fiberglass installation can be
performed without incident.
2. Mineral Wool : Mineral wool actually refers to several different types of
insulation. First, it may refer to glass wool which is fiberglass
manufactured from recycled glass. Second, it may refer to rock wool
which is a type of insulation made from basalt. Finally, it may refer to
slag wool which is produced from the slag from steel mills. The majority
of mineral wool in the United States is actually slag wool.

3. Cellulose: Cellulose insulation is perhaps one of the most eco-friendly

forms of insulation. Cellulose is made from recycled cardboard, paper,
and other similar materials and comes in loose form. Cellulose has an R-
value between R-3.1 and R-3.7. Some recent studies on cellulose have
shown that it might be an excellent product for use in minimizing fire
damage. Because of the compactness of the material, cellulose contains
next to no oxygen within it. Without oxygen within the material, this
helps to minimize the amount of damage that a fire can cause.

4. 4. Polyurethane Foam While not the most abundant of insulations,

polyurethane foams are an excellent form of insulation. Nowadays,
polyurethane foams use non-chlorofluorocarbon (CFC) gas for use as a blowing
agent. This helps to decrease the amount of damage to the ozone layer. They
are relatively light, weighing approximately two pounds per cubic foot (2
lb/ft^3). They have an R-value of approximately R-6.3 per inch of thickness.
There are also low density foams that can be sprayed into areas that have no
insulation. These types of polyurethane insulation tend to have approximately

PAGE 18
 R-3.6 rating per inch of thickness. Another advantage of this type of insulation
is that it is fire resistant.

4- Comment on discrepancies (if any).

The practical tests are not without errors resulting from the device or
the process of dealing with the experience in taking readings and
calibrating the measuring devices. Measuring the temperature and
pressure and calculating the volume of water with time. The process is
not accurate.

5. How could this test carried out with greater accuracy?

Through the development of the laboratory device and the introduction of
electronic sensors for reading the temperature and flow rate meters for water and
periodic maintenance of the device and the process of continuous calibration and
attention to safety aspects because we deal with high temperatures and pressures

PAGE 19