Sample Problem – Insulation thickness

calculation for a pipe

Sample Problem Statement

Calculate insulation thickness (minimum value) required for a pipe carrying steam at 1800C. The
pipe size is 8" and the maximum allowable temperature of outer wall of insulation is 500C.
Thermal conductivity of the insulation material for the temperature range of the pipe can be
taken as 0.04 W/m·K. The heat loss from steam per meter of pipe length has to be limited to 80
W/m.

Solution

Solution to this sample problem is quite straightforward as

demonstrated below.

As per EnggCyclopedia's heat conduction article,

For radial heat transfer by conduction across a cylindrical wall, the

heat transfer rate is expressed by following equation,

For the given sample problem,

T1 = 500C
T2 = 1800C
r1 = 8" = 8 × 0.0254 m = 0.2032 m
k = 0.04 W/m·K
N = length of the cylinder

Q/N = Heat loss per unit length of pipe

Q/N = 80 W/m

Hence, inserting the given numbers in the radial heat transfer rate equation from above,

80 = 2π × 0.04 × (180-50) ÷ ln(r2/0.2032)

ln(r2/0.2032) = 2π × 0.04 × (180-50) / 80 = 0.4084

Hence, r2/= r1 × e0.4084

r2/= 0.2032 × 1.5044 = 0.3057 m
Hence, insulation thickness = r2 - r1
thickness = 305.7 - 203.2 = 102.5 mm

Some margin should be taken on the insulation thickness because if the conductive heat transfer
rate happens to be higher than the convective heat transfer rate outside the insulation wall, the
outer insulation wall temperature will shoot up to higher values than 500C. Hence conductive
heat transfer rate should be limited to lower values than estimates used in this sample problem.
The purpose of this sample problem is to demonstrate radial heat conduction calculations and
practical calculations of insulation thickness also require consideration of convective heat
transfer on the outside of insulation wall.
 Calculation of Insulation Thickness for Pipes
As fluid passes through pipe, it loses its heat to surround atmosphere if its temperature is higher than
surrounding air. If temperature of pipe is lower than surrounding air, it gains heat from it. As pipe are
generally made from metals like steel, copper etc. which are very good conductor of heat, heat loss will
be substantial and very costly. So it is essential to provide cover of a material which is very poor
conductor of heat like mineral wool, hemp etc.

Total heat transferred (Q) from pipe through such insulating material depends on following
factors :
1. N : Length of Pipe.
2. Tp : Operating temperature of fluid inside pipe.
3. Ti : Maximum temperature allowed on the outside surface of insulation. Typically 50°C.
4. Rp : Radius of Pipe.
5. Ri : Radius of Insulation.
6. k : Thermal conductivity of insulating material.

Formula for Steady state heat transfer through insulating material wrapped around a pipe is as
follows :

Above equation is derived from Fourier’s equation for heat conduction, for steady state heat
transfer for radial heat conduction across hollow cylinder.

Example Calculation

Suppose we have a pipe of Diameter 12″ with hot oil at a temperature of 200°C flowing through
it. Maximum allowed insulation temperature at the outer wall is 50°C. Allowed heat loss per
meter of pipe is 80 W/m. Insulation used is Glass Mineral Wool with thermal conductivity for
that temperature range of 0.035W/m.K. Now we have to find out required insulation thickness.

Thermal conductivity is expressed in Watts per meter per Kelvin (W/m.K) which is essentially
same as Watts per meter per degree celsius (W/m.C) (There is no multiplier in conversion from
Kelvin to degrees. So incremental change in Kelvin is same as incremental change in Celsius.)

In above formula, Q is total heat loss and N is length of pipe. So Q/N becomes our allowed heat
loss per meter of pipe which is 80W/m.

Q/N = 80W/m.
Pipe Dia is 12″ hence radius is 6″.

Radius in meters : (6″ X 25.4)/1000 = 0.1524 meters.

So:
80 = 2π × 0.035 × (200-50) ÷ ln(Ri/0.1524)

ln(Ri/0.1524) = 2π × 0.035 × (200-50) / 80 = 0.4123

Hence, Ri = Rp × e0.4123
Ri = 0.1524 × 1.5103 = 0.2302 m

Hence, insulation thickness = Ri – Rp = 0.2302 – 0.1524 = 0.0777

Insulation thickness = 77.7 mm

Extra margin must be taken on insulation thickness as sometimes conducting heat transfer
through insulation may become higher than convective heat transfer due to air on outside wall of
insulation. In that case, temperature of outer surface of insulation may increase to more than
50°C. The purpose of this sample problem is to demonstrate radial heat conduction calculations
and practical calculations of insulation thickness also require consideration of convective heat
transfer on the outside of insulation wall.