Figure 4-1: Steam pipe sizing The following table also summarises the recommended pipe sizes for

steam at various pressure and mass flow rate.

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Table 4-1: Recommended pipe sizes for steam Capacity (kg/hour) Steam Pressure Speed 15 20 25 (bar) (m/s) 0.4 15 7 14 24 25 40 0.7 15 25 40 1 15 25 40 2 15 25 40 3 15 25 40 4 15 25 40 5 15 25 40 6 15 25 40 7 15 25 40 8 15 25 40 10 15 25 40 14 15 25 40 10 25 40 7 16 25

Pipe Size (mm) 32 37 62 40 72 43 72 70 40 52 92 59 50 99 162 109 65 145 265 403 166 287 428 182 300 465 280 428 385 632 432 80 213 384 250 430 260 445 410 100 394 675 431 716 470 730 715 125 648 972 1670 680 1145 1715 694 1160 1800 1125 1755 2925 1505 2480 4050 1685 2925 4940 2105 3540 5400 2525 4250 6475 2765 4815 7560 3025 5220 8395 3995 6295 9880 5215 8500 150 917 1457 2303 1006 1575 2417 1020 1660 2500 1580 2520 4175 2040 3440 5940 2460 4225 7050 2835 5150 7870 3400 6175 9445 3990 6900 4540 7120 5860 8995 7390 200 1606 2806 4318 1708 2816 4532 1864 3099 4815 2814 4815 7678 3983 6779 4618 7866 12661 5548 8865 6654 250 2590 4101 6909 2791 4629 7251 2814 4869 7333 4545 7425 6217 300 368 5936 9500 3852 6204 10323 4045 6751 10370 6277 10575 8743

17 35 64 102 142 265 12 25 45 8 17 29 100 182 65 112

576 1037

18 37 68 106 167 298 12 26 48 12 25 45 100 193 100 182

630 1108

19 39 71 112 172 311 19 43 70 112 162 195 30 64 115 178 275 475 16 37 60 93 127 245 26 56 100 152 225 425 19 42 70 108 156 281 30 63 115 180 270 450 22 49 87 128 187 352 36 81 135 211 308 548 26 59 105 153 225 425

640 1150 656 1215 535 925

745 1010 1895 910 1580 635 1166

11997 16796 10269 14316 7121 1963 8586 10358 27816 11947

41 87 157 250 357 595 1025 1460 2540 742 1080 1980 526 770 1295

10479 16470 22950 12225 17304

49 116 197 295 456 796 1247 1825 3120 885 1265 2110 632 925 1555

14268 20051 10297 14328

59 131 225 338 495 855 1350 1890 3510 43 97 162 253 370 658 1065 1520 2530 71 157 270 405 595 1025 1620 2270 4210 29 63 110 165 260 445 705 952 1815 49 114 190 288 450 785 1205 1750 3025 76 177 303 455 690 1210 1865 2520 4585 32 70 126 190 285 475 800 1125 1990 54 122 205 320 465 810 1260 1870 3240 84 192 327 510 730 1370 2065 3120 5135 41 95 155 250 372 626 1012 1465 2495 66 145 257 405 562 990 1530 2205 3825 104 216 408 615 910 1635 2545 3600 6230 50 121 205 310 465 810 1270 1870 3220 85 195 331 520 740 1375 2080 3120 5200

13761 23205 32244 10629 17108 24042 16515 27849 38697 7390 12015 16096 12288 19377 27080 8042 12625 17728

10880 19141 30978 43470 13140 21600 33210 9994 16172 22713

12470 21247 33669 46858 15966 25860 35890 12921 20538 29016

14390 26621 41011 57560 12560 21720 34139 47128

126 305 555 825 1210 2195 3425 4735 8510 13050 18630 35548 54883 76534

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4.4

Piping Installation
1. All underground steam systems shall be installed a minimum of 10 feet from plastic piping and chilled water systems. All plastic underground piping must be kept at a 10 foot distance from steam/condensate lines. 2. Install piping free of sags or bends and with ample space between piping to permit proper insulation applications. 3. Install steam supply piping at a minimum, uniform grade of 1/4 inch in 10 feet downward in the direction of flow. 4. Install condensate return piping sloped downward in the direction of steam supply. Provide condensate return pump at the building to discharge condensate back to the Campus collection system. 5. Install drip legs at intervals not exceeding 200 feet where pipe is pitched down in the direction of the steam flow. Size drip legs at vertical risers full size and extend beyond the rise. Size drip legs at other locations same diameter as the main. Provide an 18-inch drip leg for steam mains smaller than 6 inches. In steam mains 6 inches and larger, provide drip legs sized 2 pipe sizes smaller than the main, but not less than 4 inches. 6. Drip legs, dirt pockets, and strainer blow downs shall be equipped with gate valves to allow removal of dirt and scale. 7. Install steam traps close to drip legs.

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5
5.1

WATER DISTRIBUTION SYSTEM

Recommended Velocities
As a rule of thumb, the following velocities are used in design of piping and pumping systems for water transport: Table 5-1: Recommended velocities Pipe Dimension Velocity Inches mm m/s 1 25 1 2 50 1.1 3 75 1.15 4 100 1.25 6 150 1.5 8 200 1.75 10 250 2 12 300 2.65 If you want to pump 14.5 m /h of water for a cooling application where pipe length is 100 metres, the following table shows why you should be choosing a 3 pipe instead of a 2 pipe.
Table 5-2:Calculation of System Head Requirement for a Cooling Application (for different pipe sizes)
3

Description Water flow required Water velocity Size of pipe line (diameter) Pressure drop in pipe line/metre Length of cooling water pipe line

units m /hr m/s mm m m

3

Header diameter, inches 2.0 14.5 2.1 50 0.1690 100.0 15.0 2.6 117.6 19.9 5 5 29.9 2.2 3.0 14.5 0.9 75 0.0235 100.0 22.5 3.9 126.4 3.0 5 5 13.0 1.0 6.0 14.5 0.2 150 0.0008 100.0 45.0 7.8 152.8 0.1 5 5 10.1 0.9

Equivalent pipe length for 10 nos. m bends Equivalent pipe length for 4 nos. valves m Total equivalent length of pipe m Total frictional head loss in pipes/fittings m Pressure drop across heat exchanger, m assumed Static head requirement, assumed m Total head required by the pump Likely motor input power m kW

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If a 2 pipe were used, the power consumption would have been more than double compared to the 3 pipe. Looking at the velocities, it should be noted that for smaller pipelines, lower design velocities are recommended. For a 12 pipe, the velocity can be 2.6 m/s without any or notable energy penalty, but for a 2 to 6 line this can be very lossy. To avoid pressure losses in these systems: 1. 2. 3. First, decide the flow Calculate the pressure drops for different pipe sizes and estimate total head and power requirement Finally, select the pump.

5.2

Recommended water flow velocity on suction side of pump

Capacity problems, cavitation and high power consumption in a pump, is often the result of the conditions on the suction side. In general - a rule of thumb - is to keep the suction fluid flow speed below the following values: Table 5-3: Recommended suction velocities Pipe bore inches 1 2 3 4 6 8 10 12 Water velocity m/s ft/s 0.5 1.5 0.5 1.6 0.5 1.7 0.55 1.8 0.6 2 0.75 2.5 0.9 3 1.4 4.5

mm 25 50 75 100 150 200 250 300

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6
6.1 Introduction

THERMAL INSULATION

There are many reasons for insulating a pipeline, most important being the energy cost of not insulating the pipe. Adequate thermal insulation is essential for preventing both heat loss from hot surfaces of ovens/furnaces/piping and heat gain in refrigeration systems. Inadequate thickness of insulation or deterioration of existing insulation can have a significant impact on the energy consumption. The material of insulation is also important to achieve low thermal conductivity and also low thermal inertia. Development of superior insulating materials and their availability at reasonable prices have made retrofitting or re-insulation a very attractive energy saving option. The simplest method of analysing whether you should use 1 or 2 or 3 insulation is by comparing the cost of energy losses with the cost of insulating the pipe. The insulation thickness for which the total cost is minimum is termed as economic thickness. Refer fig 6.1. The curve representing the total cost reduces initially and after reaching the economic thickness corresponding to the minimum cost, it increases.

Figure 6-1: Economic insulation thickness However, in plants, there are some limitations for using the results of economic thickness calculations. Due to space limitations, it is sometimes not possible to accommodate larger diameter of insulated pipes. A detailed calculation on economic thickness is given in section 6.5.

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6.2

Heat Losses from Pipe surfaces

Heat loss from 1/2" to 12" steel pipes at various temperature differences between pipe and air can be found in the table below. Table 6-1: Heat loss from Fluid inside Pipe (W/m) Nominal bore (mm) (inch) 15 1/2 20 3/4 25 1 32 1 1/4 40 1 1/2 50 2 65 2 1/2 80 3 100 4 150 6 200 8 250 10 300 12 Temperature Difference ( C) 50 30 35 40 50 55 65 80 100 120 170 220 270 315 60 40 50 60 70 80 95 120 140 170 250 320 390 460 75 60 70 90 110 120 150 170 210 260 370 470 570 670 100 90 110 130 160 180 220 260 300 380 540 690 835 980 110 130 160 200 240 270 330 390 470 5850 815 1040 1250 1470 125 155 190 235 290 320 395 465 560 700 970 1240 1510 1760 140 180 220 275 330 375 465 540 650 820 1130 1440 1750 2060 150 205 255 305 375 420 520 615 740 925 1290 1650 1995 2340 165 235 290 355 435 485 600 715 860 1065 1470 1900 2300 2690 195 280 370 455 555 625 770 910 1090 1370 1910 2440 2980 3370 225 375 465 565 700 790 975 1150 1380 1740 2430 3100 3780 4430 280 575 660 815 1000 1120 1390 1650 1980 2520 3500 4430 5600 6450
o

The heat loss value must be corrected by the correction factor for certain applications: Application Single pipe freely exposed More than one pipe freely exposed More than one pipe along the ceiling Single pipe along skirting or riser More than one pipe along skirting or riser Single pipe along ceiling Correction factor 1.1 1.0 0.65 1.0 0.90 0.75

Typical heat losses in a steam distribution system are quantified below. Table 6-2: Steam piping heat losses

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The above data can be used to estimate the cost of heat loss in a piping system, while calculating the economic thickness. Heat losses can also be estimated from empirical equations as explained in next section.

6.3

Calculation of Insulation Thickness

The most basic model for insulation on a pipe is shown below. r1 show the outside radius of the pipe r2 shows the radius of the Pipe+ insulation.

Figure 6-2: Insulated pipe section

Heat loss from a surface is expressed as H = h X A x (Th-Ta) ---(4) Where 2 h = Heat transfer coefficient, W/m -K H = Heat loss, Watts Ta = Average ambient temperature, K Ts = Desired/actual insulation surface temperature, C Th = Hot surface temperature (for hot fluid piping), C & Cold surface temperature for cold fluids piping) For horizontal pipes, heat transfer coefficient can be calculated by: h = (A + 0.005 (Th Ta)) x 10 W/m -K For vertical pipes, h = (B + 0.009 ( Th Ta)) x 10 W/m -K Using the coefficients A, B as given below.
2 2

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Table 6-3: Coefficients A, B for estimating h (in W/m -K) Surface Aluminium , bright rolled Aluminium, oxidized Steel Galvanised sheet metal, dusty Non metallic surfaces Tm = 0.05 0.13 0.15 0.44 0.95 A 0.25 0.31 0.32 0.53 0.85 B 0.27 0.33 0.34 0.55 0.87

(Th + Ts )
2

k = Thermal conductivity of insulation at mean temperature of Tm, W/m-C tk = Thickness of insulation, mm r1 = Actual outer radius of pipe, mm r2 = (r1 + tk) Rs = Surface thermal resistance =

1 h

C-m /W

Rl = Thermal resistance of insulation =

The heat flow from the pipe surface and the ambient can be expressed as follows H = Heat flow, Watts =

tk 2 C-m /W k

(Th Ta ) = (Ts Ta ) ---(5) (Rl + Rs ) Rs

(r1 + tk ) (r1 + tk) ln r1

From the above equation, and for a desired Ts, Rl can be calculated. From Rl and known value of thermal conductivity k, thickness of insulation can be calculated. Equivalent thickness of insulation for pipe, Etk.=

6.4

Insulation material
Insulation materials are classified into organic and inorganic types. Organic insulations are based on hydrocarbon polymers, which can be expanded to obtain high void structures. Examples are thermocol (Expanded Polystyrene) and Poly Urethane Form(PUF). Inorganic insulation is based on Siliceous/Aluminous/Calcium materials in fibrous, granular or powder forms. Examples are Mineral wool, Calcium silicate etc. Properties of common insulating materials are as under: Calcium Silicate: Used in industrial process plant piping where high service temperature and compressive strength are needed. Temperature ranges varies from 40 C to 950 C. Glass mineral wool: These are available in flexible forms, rigid slabs and preformed pipe work sections. Good for thermal and acoustic insulation for heating and chilling system pipelines. Temperature range of application is 10 to 500 C Thermocol: These are mainly used as cold insulation for piping and cold storage construction.

29

Expanded nitrile rubber: This is a flexible material that forms a closed cell integral vapour barrier. Originally developed for condensation control in refrigeration pipe work and chilled water lines; now-a-days also used for ducting insulation for air conditioning. Rock mineral wool: This is available in a range of forms from light weight rolled products to heavy rigid slabs including preformed pipe sections. In addition to good thermal insulation properties, it can also provide acoustic insulation and is fire retardant. The thermal conductivity of a material is the heat loss per unit area per unit insulation thickness 2 per unit temperature difference. The unit of measurement is W-m /mC or W-m/C. The thermal conductivity of materials increases with temperature. So thermal conductivity is always specified at the mean temperature (mean of hot and cold face temperatures) of the insulation material. Thermal conductivities of typical hot and cold insulation materials are given below. Table 6-3: Thermal conductivity of hot insulation Mean Temperature C 100 200 300 400 700 1000 Specific heat(kJ/kg/C) Service temp, (C). 3 Density kg/m Calcium Silicate 0.07 0.08 0.08 0.96 (at 40C) 950 260 Resin bonded Mineral wool 0.04 0.06 0.08 0.11 0.921 (at 20C) 700 48 to144 Ceramic Fiber Blankets 0.06 0.07 0.09 0.17 0.26 1.07 (at 980C) 1425 64 to 128

Table 6-4 Specific Thermal Conductivity of Materials for Cold Insulation MATERIALS Mineral Or Glass Fiber Blanket Board or Slab Cellular Glass Cork Board Glass Fiber Expanded Polystyrene (smooth) - Thermocole Expanded Polystyrene (Cut Cell) - Thermocole Expanded Polyurethane Phenotherm (Trade Name) Loose Fill Paper or Wood Pulp Sawdust or Shavings Minerals Wool (Rock, Glass, Slag) Wood Fiber (Soft) Thermal Conductivity W/m-C 0.039 0.058 0.043 0.036 0.029 0.036 0.017 0.018 0.039 0.065 0.039 0.043

30