Design Calculations - Insulation Thickness REV-1

Owner
EPC
FO Contractor
MB POWER (Madhya Pardesh) Unit 1 & 2 (2 x 600 MW )

Lanco Infratech Limited
Moser Baer Engineering & Constructions Limited
Design Calculation - INSULATION THICKNESS
LITL - 020 - MEV-213 - R - 41807
O-1107-MBFO-CL-09
Title
Doc No
REV-0
REV-1
DATE
DATE
03.08.2011
14.10.2011
CALCULATIONS FOR INSULATION THICKNESS

HFO LINES
FROM
UNLOADING
AREA TO
STORAGE
TANK
BASIC DATA
HFO
STORAGE
TANK TO
LINE
HEATER
INLET
LINE
BOILER
STEAM AT 3.5 STEAM AT 13 CONDENSATE CONDENSATE HFO STORAGE
HEATER
RETURN TO KG/SQCM(g) KG/SQCM(g)
FROM 3.5
FROM 13
& DRAIN OIL
OUTLET TO STORAGE
KG/SQCM(g)
KG/SQCM(g)
TANK
BOILER
TANK
STEAM
STEAM
Ambient temperature (min)
6.5
6.5
6.5
6.5
6.5
6.5
6.5
6.5
6.5
deg C
Ambient temperature (max)
42.2
42.2
42.2
42.2
42.2
42.2
42.2
42.2
42.2
deg C
60
60
60
60
60
60
60
60
60
deg C
45
43.6
60
51.1
120
81.1
120
81.1
147.2
94.7
360
147.2
360
45
deg C
201.1
94.7
201.1
43.6
deg C
Value of K from IS:8183 for LRB of 81-120

kg/cum density
0.43
0.43
0.52
0.52
0.62
0.73
0.52
0.73
0.43
mW/cm*degC
Value of K from IS:8183 for LRB of 81-120

kg/cum density
0.037
0.037
0.045
0.045
0.053
0.063
0.045
0.063
0.037
kcal/m*degC
Maximum cladding temperature

Fluid temperature
Mean temperature
Insulating material
Light resin bonded mineral wool as per IS:8183
Density
120 kg/cum
Cladding material
Aluminum sheets of 24 gauge thickness
Factor f for aluminum surface

Heat loss per unit area of shell surface
q=
th-tm / {d/2k*ln (d1/d) + 1/ f(d/d1)}
kcal/hr*m2
where
th
deg C
Temp of hot surface
deg C
Ambient temp (min) for worst case
Kcal/hr*m2
Factor for aluminum surface from IS: 7413
Outer dia of pipe
Insulation thickness
Insulation thickness
d1
OD of insulated pipe
kcal/m deg C Thermal conductivity at mean temp
tm
f
4.89
Temp rise over ambient temp

t=
(q*d) / (d1*f)
where
q
kcal/hr*m2
Heat loss per unit area

Outer dia of pipe
d1
OD of insulated pipe
Caldding temperature at min ambient, tc

(min)=
Caldding temperature at max ambient, tc
(max)=
tmin+t
tmax+t
Insulation thickness for HFO LINES FROM UNLOADING AREA TO HFO STORAGE TANK & DRAIN OIL LINES
Pipe size
Thermal
Conductivity
Pipe OD
Thickness of
insulation
Mean dia
NB
OD
th-tm
d / 2k
ln(d1/d)
(d/d1)
1/f(d/d1)
{d/2k*ln (d1/d) +
1/ f(d/d1)}
d1
deg C
Heat loss
Temp rise
Cladding
Cladding
temp at
temp at
minimum
maximum
ambient temp ambient temp
tc (min)
tc (max)
kcal / hr*m2
deg C
deg C
deg C
15
0.037
0.022
0.025
0.047
0.072
38.5
0.297
1.186
0.306
0.669
1.022
37.67
1.68
8.18
43.88
25
0.037
0.034
0.025
0.059
0.084
38.5
0.460
0.904
0.405
0.505
0.921
41.80
2.47
8.97
44.67
50
0.037
0.06
0.025
0.085
0.11
38.5
0.811
0.606
0.545
0.375
0.867
44.42
3.54
10.04
45.74
80
0.037
0.089
0.025
0.114
0.139
38.5
1.203
0.446
0.640
0.319
0.856
44.98
4.21
10.71
46.41
100
0.037
0.115
0.025
0.14
0.165
38.5
1.555
0.361
0.697
0.293
0.855
45.04
4.59
11.09
46.79
150
0.037
0.165
0.025
0.19
0.215
38.5
2.231
0.265
0.767
0.266
0.857
44.93
5.04
11.54
47.24
Insulation thickness for HFO LINES FROM STORAGE TANK TOLINE HEATER INLET
Pipe size
Thermal
Pipe OD
d Thickness of
Mean dia
OD
Conductivity
insulation
d1
NB
th-tm
d/2k
ln(d1/d)
(d/d1)
1/f(d/d1)
{d/2k*ln (d1/d) +
1/ f(d/d1)}
deg C
Heat loss
Temp rise
Cladding
Cladding
temp at
temp at
minimum
maximum
tc (min)
tc (max)
15
0.037
0.022
0.025
0.047
0.072
53.5
0.297
1.186
0.306
0.669
1.022
52.35
2.34
8.84
44.54
25
0.037
0.034
0.025
0.059
0.084
53.5
0.460
0.904
0.405
0.505
0.921
58.09
3.44
9.94
45.64
50
0.037
0.06
0.025
0.085
0.11
53.5
0.811
0.606
0.545
0.375
0.867
61.73
4.92
11.42
47.12
80
0.037
0.089
0.025
0.114
0.139
53.5
1.203
0.446
0.640
0.319
0.856
62.51
5.85
12.35
48.05
100
0.037
0.115
0.025
0.14
0.165
53.5
1.555
0.361
0.697
0.293
0.855
62.59
6.38
12.88
48.58
150
0.037
0.165
0.025
0.19
0.215
53.5
2.231
0.265
0.767
0.266
0.857
62.43
7.00
13.50
49.20
Insulation thickness for HFO LINES FROM LINE HEATER TO BOILER

Pipe size
Thermal
Pipe OD
d Thickness of
Mean dia
Conductivity
insulation
NB
OD
d1
th-tm
deg C
d/2k
ln(d1/d)
(d/d1)
1/f(d/d1)
{d/2k*ln (d1/d) +
1/ f(d/d1)}
Heat loss
Temp rise
Cladding
Cladding
temp at
temp at
minimum
maximum
tc (min)
tc (max)
15
0.045
0.022
0.025
0.047
0.072
113.5
0.246
1.186
0.306
0.669
0.961
118.12
5.28
11.78
47.48
25
0.045
0.034
0.025
0.059
0.084
113.5
0.380
0.904
0.405
0.505
0.849
133.68
7.91
14.41
50.11
50
0.045
0.06
0.025
0.085
0.11
113.5
0.671
0.606
0.545
0.375
0.782
145.23
11.58
18.08
53.78
80
0.045
0.089
0.025
0.114
0.139
113.5
0.995
0.446
0.640
0.319
0.763
148.75
13.92
20.42
56.12
100
0.045
0.115
0.030
0.145
0.175
113.5
1.286
0.420
0.657
0.311
0.851
133.37
12.81
19.31
55.01
150
0.045
0.165
0.030
0.195
0.225
113.5
1.845
0.310
0.733
0.279
0.851
133.37
14.30
20.80
56.50
Insulation thickness for HFO LINES FROM BOILER RETURN TO STORAGE TANK
Pipe size
Thermal
Pipe OD
Conductivity
NB
d Thickness of
insulation
Mean dia
OD
d1
th-tm
deg C
d/2k
ln(d1/d)
(d/d1)
1/f(d/d1)
{d/2k*ln (d1/d) +
1/ f(d/d1)}
Heat loss
Temp rise
15
0.045
0.022
0.025
0.047
0.072
113.5
0.246
1.186
0.306
0.669
0.961
118.12
25
0.045
0.034
0.025
0.059
0.084
113.5
0.380
0.904
0.405
0.505
0.849
50
0.045
0.06
0.025
0.085
0.11
113.5
0.671
0.606
0.545
0.375
0.782
80
0.045
0.089
0.025
0.114
0.139
113.5
0.995
0.446
0.640
0.319
100
0.045
0.115
0.030
0.145
0.175
113.5
1.286
0.420
0.657
150
0.045
0.165
0.030
0.195
0.225
113.5
1.845
0.310
0.733
Cladding
Cladding
temp at
temp at
minimum
maximum
tc (min)
tc (max)
5.28
11.78
47.48
133.68
7.91
14.41
50.11
145.23
11.58
18.08
53.78
0.763
148.75
13.92
20.42
56.12
0.311
0.851
133.37
12.81
19.31
55.01
0.279
0.851
133.37
14.30
20.80
56.50
Insulation thickness for STEAM LINES OF 3.5 KG/SQCM(g) & CONDENSATE LINES
Pipe size
Thermal
Pipe OD
d Thickness of
Mean dia
OD
Conductivity
insulation
d1
NB
th-tm
d/2k
ln(d1/d)
(d/d1)
1/f(d/d1)
{d/2k*ln (d1/d) +
1/ f(d/d1)}
deg C
Heat loss
Temp rise
Cladding
Cladding
temp at
temp at
minimum
maximum
tc (min)
tc (max)
15
0.053
0.022
0.025
0.047
0.072
140.7
0.206
1.186
0.306
0.669
0.914
153.96
6.88
13.38
49.08
25
0.053
0.034
0.025
0.059
0.084
140.7
0.319
0.904
0.405
0.505
0.794
177.29
10.49
16.99
52.69
50
0.053
0.06
0.040
0.1
0.14
140.7
0.563
0.847
0.429
0.477
0.954
147.50
9.24
15.74
51.44
80
0.053
0.089
0.040
0.129
0.169
140.7
0.835
0.641
0.527
0.388
0.924
152.35
11.73
18.23
53.93
100
0.053
0.115
0.040
0.155
0.195
140.7
1.078
0.528
0.590
0.347
0.916
153.57
13.24
19.74
55.44
150
0.053
0.165
0.040
0.205
0.245
140.7
1.547
0.395
0.673
0.304
0.915
153.72
15.14
21.64
57.34
Insulation thickness for STEAM LINES OF 13.0 KG/SQCM(g) & CONDENSATE LINES
Pipe size
Thermal
Pipe OD
d Thickness of
Mean dia
OD
Conductivity
insulation
d1
NB
th-tm
d/2k
ln(d1/d)
(d/d1)
1/f(d/d1)
{d/2k*ln (d1/d) +
1/ f(d/d1)}
deg C
Heat loss
Temp rise
Cladding
Cladding
temp at
temp at
minimum
maximum
tc (min)
tc (max)
15
0.063
0.022
0.040
0.062
0.102
353.5
0.175
1.534
0.216
0.948
1.217
290.49
9.16
15.66
51.36
25
0.063
0.034
0.040
0.074
0.114
353.5
0.271
1.210
0.298
0.686
1.013
348.87
15.21
21.71
57.41
50
0.063
0.06
0.060
0.12
0.18
353.5
0.478
1.099
0.333
0.613
1.138
310.50
15.13
21.63
57.33
80
0.063
0.089
0.100
0.189
0.289
353.5
0.709
1.178
0.308
0.664
1.499
235.84
10.62
17.12
52.82
100
0.063
0.115
0.100
0.215
0.315
353.5
0.916
1.008
0.365
0.560
1.483
238.36
12.72
19.22
54.92
150
0.063
0.165
0.100
0.265
0.365
353.5
1.314
0.794
0.452
0.452
1.496
236.34
15.62
22.12
57.82
Insulation thickness for HFO STORAGE & DRAIN OIL TANK

TANK DIA
Thermal
TANK OD
Thickness of
Mean dia
Conductivity
d
insulation
OD
d1
th-tm
d/2k
ln(d1/d)
(d/d1)
1/f(d/d1)
{d/2k*ln (d1/d) +
1/ f(d/d1)}
deg C
Heat loss
Temp rise
Cladding
Cladding
temp at
temp at
minimum
maximum
tc (min)
tc (max)
16
0.037
16.02
0.040
16.06
16.1
38.5
216.604
0.005
0.995
0.206
1.284
29.97
4.36
10.86
46.56
1.8
0.037
1.812
0.040
1.852
1.892
38.5
24.500
0.043
0.958
0.214
1.272
30.27
4.24
10.74
46.44

Design Calculations - Insulation Thickness REV-1

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Design Calculations - Insulation Thickness REV-1

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MB POWER (Madhya Pardesh) Unit 1 & 2 (2 x 600 MW )

CALCULATIONS FOR INSULATION THICKNESS

Ambient temperature (min)

Ambient temperature (max)

Value of K from IS:8183 for LRB of 81-120

Value of K from IS:8183 for LRB of 81-120

Maximum cladding temperature

Light resin bonded mineral wool as per IS:8183

Aluminum sheets of 24 gauge thickness

Factor f for aluminum surface

th-tm / {d/2k*ln (d1/d) + 1/ f(d/d1)}

Temp of hot surface

Ambient temp (min) for worst case

Factor for aluminum surface from IS: 7413

Outer dia of pipe

kcal/m deg C Thermal conductivity at mean temp

Temp rise over ambient temp

Heat loss per unit area

Caldding temperature at min ambient, tc

Insulation thickness for HFO LINES FROM LINE HEATER TO BOILER

Insulation thickness for HFO STORAGE & DRAIN OIL TANK

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