Emerging Trends In Insulation By Shahab Z Ahmed (AVP) Shahab Z - - PowerPoint PPT Presentation

ALP Aeroflex India Pvt. Ltd.

Emerging Trends In Insulation

By Shahab Z Ahmed (AVP)

Shahab Z Ahmed -AVP

ALP Aeroflex India Pvt. Ltd.

Presentation Overview

ALP Aeroflex India (P) Ltd – Introduction Energy Consumption and Co2 Emission Definition of Insulation Material Different Type of Insulation Material Parameter to select right Insulation material AAIPL Product Range EPDM Insulation Benefits of EPDM insulation Software Calculation References

ALP Aeroflex India Pvt. Ltd.

ALP NISHIKAW A CO. LTD. ALP OVERSEAS

• PVT. LTD

ALP PLASTICS

• PVT. LTD.

ALP AEROFLEX (I) PVT. LTD. ALP POLYMER PARK PVT. LTD.

GROUP

EPDM & PVC WEATHER STRIPS / SEALLING SYSTEMS EPDM EXTRUSIONS/ MOULDED ARTICLES PVC / TPE / TPR / TPO EXTRUSIONS EPDM / NITRILE INSULATION PRODUCTS NEW CONCEPT POLYMER INDUSTRIES AND TOWNSHIP

About ALP Group – US$ 100MN

ALP Aeroflex India Pvt. Ltd.

ALP Nishikawa Co., Ltd. (ANCO, Gurgaon)

: Production : Sales : Offices + Godown

ALP Nishikawa Co., Ltd. (ANCO, Lalru) ALP Overseas Pvt. Ltd. (ALPO, Gurgaon) ALP Overseas Pvt. Ltd. (ALPO, Rudrapur) ALP Overseas Pvt. Ltd. (ALPO, Noida) ALP Plastics Pvt. Ltd.. (ALPP, Unit-2 Gurgaon ) ALP Aeroflex (I) Pvt. Ltd. ( Rudrapur)

RUDRAPUR (UTTARKHAND) LALRU (PUNJAB) GURGAON (HARYANA) NOIDA (UTTARPRADESH)

MUMB AI PUNE

CHENNA I

HARID WAR AMBA LA SANA ND PITHAMP UR

HOSUR

NA SIK GURGA ON DHAARW AD

ALP Africa (ALPO, South Africa) ALP- GGC (USA)

Our Presence

ALP Aeroflex India Pvt. Ltd.

• Net Worth - US$ 4 million
• Capital Employed : US$ 3.83 million
• Turn Over – US $ 7 Million

Man Power

Financials - AAIPL

• Head Office – Gurgaon
• Factory – Rudrapur , UK

ALP Aeroflex India Pvt. Ltd.

Insulation Thickness mm No Insulation 13 mm 25 mm 38 mm 50 mm 63 mm 75 mm Surface Temperature

• C

5 24.1 26.8 27.9 28.5 28.9 29.1 Prevent Condensation RH % 21 71 83 89 92 94 95 Energy Consumption kw.hr/m/yr 142.8 46.4 30.6 23.6 20.1 17.5 15.8 Energy Cost INR /m/yr 1285.2 417.6 275.4 212.4 180.9 157.5 142.2 CO2 Emission kg/yr 71.4 23.2 15.3 11.8 10.05 8.75 7.9

Energy Consumption & CO2 Emission

Calculation based on 65 mm (NB) pipe , operating temp 5 deg ◦ C, room temp 30 ◦ C, K value -0.037 W/mk in 24 hrs x 365 days , at a cost of Rs 9 /Kw-hr

ALP Aeroflex India Pvt. Ltd.

Is a material or combination of material having relatively high resistance to heat flow Stationary air is common in all the insulating materials providing the insulation effect.

Benefits of Insulation Prevents Energy Gain /Heat Loss Prevents /Reduce Surface Condensation Improves Aircon equipment efficiency Control Surface temperatures

What is Insulation?

ALP Aeroflex India Pvt. Ltd.

Modes of Heat Transfer

ALP Aeroflex India Pvt. Ltd.

Cut Section of Fiber Glass Insulation

ALP Aeroflex India Pvt. Ltd.

Q = KA t Thickness K insulation = K conduction+ K convection+ K radiation

Equation of Heat Transfer

ALP Aeroflex India Pvt. Ltd.

Heat Transfer- Cold Pipe

ALP Aeroflex India Pvt. Ltd.

Heat Transfer- Hot Pipe

ALP Aeroflex India Pvt. Ltd.

Different Type of Insulation Material

ALP Aeroflex India Pvt. Ltd.

• Open cell structure
• Mineral wool
• Glass wool
• Rockwool
• Ceramic wool
• Semi Closed cell structure
• Poly Urethane foam
• Poly Styrene foam
• Polyethylene foam
• Closed Cell structure
• Nitrile foam
• EPDM foam
• Others: Flake(eg Vermiculite); Granular(eg. Cork);Reflective

Insulation – Cell Structure

ALP Aeroflex India Pvt. Ltd.

2.1 OPEN CELL TYPE INSULATION SUCH AS FIBERGLASS, ROCK WOOL AND CALCIUM SILICATE

ALP Aeroflex India Pvt. Ltd.

PENETRATION OF MOISTURE THROUGH FIBERGLASS INSULATION WHEN COVERING CHILLED WATER PIPE LINE (MOISTURE SUCKING MACHINE)

ALP Aeroflex India Pvt. Ltd.

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ALP Aeroflex India Pvt. Ltd.

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ALP Aeroflex India Pvt. Ltd.

ALP Aeroflex India Pvt. Ltd.

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ALP Aeroflex India Pvt. Ltd.

Properties of Good Insulation

ALP Aeroflex India Pvt. Ltd. 1. Low and Stable K Value 2. High Mu Value or Water Vapour ingress resistance 3. Light weight Good Mechanical strength and Flexibility 4. Rot and vermin proof 5. Fire safe Properties 6. FM Approval 7. Green Building Norms adherence

Insulation- Desired Properties

ALP Aeroflex India Pvt. Ltd.

K Value – Low and Stable

ALP Aeroflex India Pvt. Ltd. CLOSED CELL STRUCTURE INSULATION IS THE MOST SUITABLE FOR COLD TEMPERATURE APPLICATION DUE STABLE K. VALUE WHICH NOT VARY DUE TO % RH

ALP Aeroflex India Pvt. Ltd. µ = Poor

Mineral Wool

µ = Low

PUF,XPE, EPS

µ = Good

NBR,EPDM

Mu Value Mu Value – is the resistance to moisture transfer across the walls of insulation , Higher Mu means greater resistance to water vapor

ALP Aeroflex India Pvt. Ltd.

Material

• Max. medium

temperature (°C) Thermal conductivity (W/m.K) at a mean temp. of 10°C Water vapor diffusion resistance (µ) Elastomeric Elastomeric foam (FEF) 115 – 150 (175) 0.033 – 0.038 7000 – 12000 Thermoplastic Polyethylene (PE) 85 – 105 0.035 – 0.038 1000 – 4000 Polystyrene Extruded foam (XPS) 80 0.030 – 0.032 80 - 300 Expanded foam (EPS) 80 0.035 – 0.037 20 - 100 PVC 80 0.35 – 0.38 170 - 320 Duroplastic Phenolic resin foam (PF) 120 - 150 0.032 – 0.035 10 – 50 Other insulation Mineral wool (MW) 200 / 750 0.032 – 0.040 10 - 100 Cellular glass (CG) 430 0.040 – 0.045

K Value/ Mu Value / Operating Temp – Insulation Generics

ALP Aeroflex India Pvt. Ltd.

3000

7000

Mu Value - Comparison

ALP Aeroflex India Pvt. Ltd.

Light Weight and Flexibility

ALP Aeroflex India Pvt. Ltd.

Rigid Foams – Non Flexible

ALP Aeroflex India Pvt. Ltd.

ALP Aeroflex India Pvt. Ltd. In-built anti-microbial protection Elastomeric Insulation contains an anti-microbial additive which actively inhibits mould and bacteria growth. Anti fungal / Anti bacterial – ASTM G21/ ASTM 2180 Dust & fibre free Dusty and fibrous materials are both difficult to work with and create an additional workplace hazard often aggravating respiratory conditions amongst those working with and around them. As nitrile rubber material, is entirely dust and fibre free, making it suitable for use in schools, offices and hospitals.

Anti Microbial Properties

ALP Aeroflex India Pvt. Ltd.

ITCHINESS MOLD/FUNGI/MILDEW PEST/COCKROACH Air borne glass wool fiber is a health hazard – both to the applicators and occupants. Glass wool is prone to settling and sagging Open cell structure allows easy passage & scope for pests , like cockroaches, rats to inhabit and breed. Damp insulation creates breeding ground for mold, fungi & microbes. SAGGING FIRE SAFETY Kraft backed Foil facing burns when exposed to ordinary flame.

Health Hazards

ALP Aeroflex India Pvt. Ltd.

Fire and Smoke Behaviour is governed by Each Countries Fire Codes for the following parameters Surface flame Spread Fire Propagation (Min. Heat Release) Smoke Toxicity Fire Requirements of a Insulation Material.

• Min./Nil Fire surface flame spread ( BS 476 Part 7, Class 1)
• Min Fire heat release ( BS 476 Part 6 & 7, Class O)
• Smoke should be non-toxic. (IMO Res Part MSC 61(67)

Part2)

• Should not produce flaming drips.
• Should be Self Extinguishing

Fire and Smoke Properties

ALP Aeroflex India Pvt. Ltd.

HCN, NO2 , HF HIGHLY FATAL GASES HCl, HNO3, H2SO4 HIGHLY IRRITATE/ CORROSIVE GASES CO, CH2O,CHYOZ LESS TOXIC GASES H2O, CO2 NON TOXIC GASES GASES TYPE

Combustion Gases

ALP Aeroflex India Pvt. Ltd.

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Death after few minutes 50-100 HF Death after few minutes 250 NO2 Danger of lung damage after short exposure 1,000 280 HCl HCN Death by suffocation Death in 3 minutes 200,000 128,000 CO2 CO SYMPTOMS PPM GAS

Toxicity of Gases

ALP Aeroflex India Pvt. Ltd.

Standard Fire Spread Smoke Density Flaming Drips Toxic Gas Self Extinguishing ASTM E 84 Yes Yes

• UL 94 V

Yes

• Yes
• BS 476

Yes

• ASTM D635
• Yes

IMO MSC61(67) Yes Yes

• Yes
• Fire / Smoke Testing Standards

ALP Aeroflex India Pvt. Ltd.

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Flammability Test

ALP Aeroflex India Pvt. Ltd.

Products submitted for certification by FM Approvals shall demonstrate that they meet the intent of the Approval Standard, and that quality control in manufacturing shall ensure a consistently uniform and reliable product.

FM Standards

ALP Aeroflex India Pvt. Ltd.

Products submitted for certification by FM Approvals shall demonstrate that they meet the intent of the Approval Standard, and that quality control in manufacturing shall ensure a consistently uniform and reliable product.

ALP Aeroflex India Pvt. Ltd.

ALP Aeroflex India Pvt. Ltd.

Green Building Codes / Other Building codes IAQ - Should be smooth surface and inhibit build of dirt and possible contaminations. WITHOUT CFCs, HFCs or HCFCs ZERO ODP potential WITHOUT Propane, Butane, pentane and other flammable gases LOW VOC/SVOC content FREE from - formaldehyde , Nitrosamine FREE from Fiber and Dust

Green Building Norms

ALP Aeroflex India Pvt. Ltd.

AAIPL Product Range

ALP Aeroflex India Pvt. Ltd.

Elastomeric EPDM/Nitrile Tubes

“Retrofit” Pre-slit Elastomeric Tubes with self seal.

Tapes Elastomeric EPDM/Nitrile Sheet and Rolls Adhesive Pipe support

Accessories

Paint Aluminium foil faced insulation Flexible duct

Product Offerings

ALP Aeroflex India Pvt. Ltd.

ALP AEROFLEX PRODUCT Nitrile-Insulation EPDM-Insulation Accosound/ Accofoam (Acoustics) Nitrile Sheet Nitrile Tube Nitrile Tape EPDM Sheet EPDM Tube EPDM Tape With Release Paper Without Release Paper Lamination of Release Paper Lamination of Glass Cloth Value addition Slitting of Sheet Lamination of Aluminium foil

ALP Aeroflex India Pvt. Ltd. NBR – Class O ( FM approved), Class 1, Antimicrobial. EPDM- Normal EPDM, High temperature EPDM. Accosound- Normal, Antimicrobial

Technical Classifications

ALP Aeroflex India Pvt. Ltd. Sheets ( Both in EPDM & Nitrile) Both side skin One side skin Both side with out skin One side Aluminium foil & one side skin One side glass cloth & one side skin One side release paper & one side skin One side release paper& one side aluminium foil

Options Available

ALP Aeroflex India Pvt. Ltd. Colour Tubes. Colour Sheet. Low density accosound (140 kg/m3). High tensile sheet.

New Product development

ALP Aeroflex India Pvt. Ltd.

EPDM Insulation (Future Material) Benefits of EPDM insulation

ALP Aeroflex India Pvt. Ltd.

Pendant diene : This double bond will be cured during production processes

• nly to strengthen the product.

Fully saturated backbone chain (no reactive double bonds) Not reactive to HEAT, UV, O3, O2, etc. No toxic components ! Safe for all users ! EPDM Rubber (Ethylene propylene Diene monomer rubber), a type of synthetic rubber ,is an elastomer characterized by a wide range of applications. The material is Non Polar - Does not react with water

EPDM – Sturcture

ALP Aeroflex India Pvt. Ltd.

• For water systems, it is worse if the insulation is POLAR.

Polarity induces water/moisture to penetrate the skin then interacts and absorbs water.

Polar induces Polar NBR/PVC induce water/moisture from its surroundings. Non-Polar DOES NOT induce Polar EPDM Does NOT induce water/moisture from its surroundings.

Polarity

ALP Aeroflex India Pvt. Ltd.

• CHEMICAL STRUCTURE
• MOST OF NITROSAMINE ARE CARCINOGENTS

SUCH AS N - NITROSODIMETHYLAMINE N - NITROSODIETHYLAMINE N - NITROSODIBUTYLAMINE

Nitrosamine Content

ALP Aeroflex India Pvt. Ltd.

_ Non flaming drips _ ASTM E84 (UL 723 or NFPA NO. 255) UL 94 V PASS _ PASS PASS IMO (Fire, Smoke & Toxicity) _ 3 (lowest smoke density) 5 (lowest flame spread) EMPA (Swiss Fire & Smoke Standard) V0 _ Non flaming drips 50 25 Toxic gases Flaming drips Smoke density Flame spread

Note : This table shows the specifications of Aeroflex-Standard product.

Fire Properties –EPDM

ALP Aeroflex India Pvt. Ltd.

ALP Aeroflex India Pvt. Ltd.

EPDM NBR

EPDM vs NBR (Outdoor Installation)

ALP Aeroflex India Pvt. Ltd.

Software Calculation

ALP Aeroflex India Pvt. Ltd.

ALP Aeroflex India Pvt. Ltd.

• 1. Minimum Thickness to Prevent Condensation
• 2. Energy Saving & Economic Thickness

Software Criteria

ALP Aeroflex India Pvt. Ltd.

ALP Aeroflex India Pvt. Ltd.

ALP Aeroflex India Pvt. Ltd.

• Water vapor in the air may form condensation on a cold surface if the

surface temperature is below the dew point temperature.

• Objective: Maintain the temperature of the insulation surface above the

dew point temperature. 6 0C T surf = ~60C

Ambient Conditions T air = 320 C RH = 65% ⇒ Dew Point = 24.6 0C

T surf = ~270C 6 0C

Adding 19mm thick insulation raises the surface temperature, preventing surface condensation

Preventing Surface Condensation

ALP Aeroflex India Pvt. Ltd.

Constant Parameters: Fluid Temperature 6°C Ambient Temperature 32°C Wind Speed Relative Humidity Dew Point 2" 6" % °C Insulation Thickness 50 20.3 3/8" 3/8" 60 23.3 3/8" 1/2" 70 25.8 5/8" 3/4" 80 28.1 1" 1-1/8" 85 29.2 1-1/2" 1-3/4" 90 30.2 2" 2-1/2" Effects of Relative Humidity On Insulation Thickness to Prevent Condensation Pipe Size

Effects of RH% on thickness

ALP Aeroflex India Pvt. Ltd.

SO SHOULD USE MINIMUM INSULATION THICKNESS THAT INSULATION SURFACE TEMPERATURE IS HIGHER THAN DEW POINT DEW POINT VARIES TO % RH (MOISTURE IN THE AIR) NORMALLY USE 85 % RH, 90 % RH FOR CALCULATION THE INSULATION THICKNESS NORMALLY USE HEAT CONVECTION OF AIR VALUE AROUND 7-9 W/M2 K FOR CALCULATION THE INSULATION THICKNESS

Pointers for Correct Selection

ALP Aeroflex India Pvt. Ltd.

• 1. OPERATING TEMPERATURE (TOP) SUCH AS 5O C
• 2. AMBIENT TEMPERATURE (Td b) SUCH AS 32O C
• 3. RELATIVE HUMIDITY (% RH) SUCH AS 85 % RH
• 4. CONVECTION COEFFICIENT (Ha) SUCH AS 8 W/m2K
• 5. PIPES SIZE SUCH AS φ 12 mm. Up to φ 150 mm.
• 6. K VALUE OF THERMAL INSULATION SUCH AS 0.037 W/mK

Input Parameters

ALP Aeroflex India Pvt. Ltd.

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ALP Aeroflex India Pvt. Ltd.

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MOST OF THE ENERGY USED IN THE BUILDING IN TROPICAL AREA IS FROM AIR CONDITIONING SYSTEM

(APPROX. 50-70 % OF TOTAL ENERGY CONSUMPTION)

ALP Aeroflex India Pvt. Ltd.

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Energy Loss = W/m

ALP Aeroflex India Pvt. Ltd.

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Energy Loss – cost $

ALP Aeroflex India Pvt. Ltd.

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Optimum Thickness Selection

ALP Aeroflex India Pvt. Ltd.

24 HRS. 365 DAYS/YEAR AND 0.05 U$/KW•HR SO SIMPLE PAYBACK PERIOD AS FOLLOWS :

Simple Payback Calculation

ALP Aeroflex India Pvt. Ltd.

References

ALP Aeroflex India Pvt. Ltd.

• NATRAJ COLD STORAGE – Kolkata
• SHIMA EDIBLES COLD STORAGE – Kolkata
• GREEN FIELD COLD STORAGE –Tinsukhia
• EVEREST COLD STORAGE – Purnea
• BHABHA ATOMIC RESEARCH CENTRE – Kolkata
• PARAG BREWRIES – Kolkata
• COMPUTER LAND CAPITA –Pune
• PEROT SYSTEM – DLF IT PARK – Chennai
• BARANI SILK – Erode
• CTS – Hyderabad
• FORD – Chennai
• GOA AIRPORT -
• SAHARA PRIME CITY –Mumbai
• Boomerang – Mumbai
• Times Square - Mumbai
• BNP PARIBAS – Kolkata & Mumbai
• MAHINDRA SATYAM IT PARK – Chennai
• HITACHI HOME & LIFE SOLUTIONS – Mehsana
• WESTERN REFREGERATION LTD. –Shahpur
• HOTEL RADISSON – Delhi
• HOTEL TAJ – Delhi
• HOTEL RED FOX – Delhi
• HOTEL ITC Grand CHOLA – Chennai
• HOTEL TRIDENT – Hyderabad
• HEMPTON Hotel – Baroda
• HOTEL HYATT REGENCY – Kolkata
• I TC SONAR BANGLA – Kolkata
• ESI HOSPITAL – Faridabad
• WOCKHARDT HOSPITAL - Mumbai
• APOLLO HOSPITAL – Chennai
• BELLVIEW NURSING HOME – Kolkata
• VEDANT HOSPITAL – Raipur
• PARAS PHARMACEUTICALS – Baddi
• HIMALAYA DRUGs – Ahmadabad
• PANACEA – Baddi
• CHITRA UTSAV -Gurgaon
• MAURYA FOODS PVT LTD –Kolkata
• THACKER DAIRY PRODUCTS PVT LTD – Kolkata
• NEOMACHINE MFG. CO Pvt Ltd. – Kolkata
• HEININ & HOPMAN ENG (I) PVT LTD – Kolkata
• AGROSHINE FOOD PRODUCTS – Kolkata
• NIRVIN COLD STORAGE – Kolkata

Reference List

ALP Aeroflex India Pvt. Ltd.

• Bhaba Atomic Research Centre(BARC)
• Regional Center & Cancer Hospital Tew

Govt.,Medical Hospital

• Infosys Ltd
• DLF Universal ltd
• JCB India Ltd
• JCB India Ltd
• Shiv Nadar University
• Bharti Reality Ltd
• UPAL Universal Mall
• Hitachi Home & Life Solutions(India)ltd
• Hitachi Home & Life Solutions(India)ltd
• Amriprise India Pvt Ltd (Prestige Gp)
• Oracle
• Vardhman Institute of Medical Sciences

(VIMS) (Bihar Govt.)

• Nalasar University of Law
• Karvy Selenium
• Daikin Air Conditioning India Pvt Ltd
• L V Prasad Eye Institute
• IIT Hyderabad Campus
• Institute Of Liver & Biliary Science (ILBS)
• Adobe Systems India Pvt Ltd
• Civil Hospital
• Cancer Hospital
• LG Hospital - Auditorium
• Referral Hospital
• RMZ Galleria
• Indira Gandhi Medical College & Research
• Paul Georges Memorial School C/o St. Georges

School

• Clean Room Technologies
• GAETEC
• AMWAY India Enterprises Ltd
• Data Centre Complex
• Sterling Generators

ALP Aeroflex India Pvt. Ltd.

ALP Aeroflex India Pvt. Ltd.

ALP Aeroflex India Pvt. Ltd.

Thank you