UNIVERSITY OF BAGHDAD

MECHANICAL ENGINEERING DEPARTMENT

Heat Transfer Laboratory

NAME: SAMIA KHALID ABD-ALQADER

SEC: 3RD A
EXPERIMENT NAME: PIPE ISULATION
EFFICIENCY STUDY UNIT
Experiment Name: 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 insulating
materials, placed vertically. Steam is fed by means of an
overhead manifold.

Composition: The lagging of piping unit includes:

1- Test pipes covered with materials whose thermal
conductivity coefficient is different.
2- One pipe without covering.
3- Manual control valve on steam inlet.
4- Bourdon pressure gauge on steam inlet.
5- Thermometer in steam inlet.
6- Condensate discharge system.
7- Graduated containers of glass to measure the condensate.
Testing procedure:
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.

Theory: Steam is transferred from a steam plant

element to another by means of pipes, often of
considerable 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.
Calculation of heat flow rate: We can assume that, if
steam passes through a pipe, heat energy will be lost at
constant pressure, thus the enthalpy h, of the steam will be
reduced.
Now:
Now: In case of superheated steam from steam table: ℎ =
𝑓(𝑝, 𝑡)Or for wet steam ℎ = ℎ𝑓 +𝑥. ℎ𝑓𝑔

Where
ℎ𝑓 = liquid enthalpy (from steam table at the steam pressure
(P)
ℎ𝑓𝑔 =condensation/vaporization enthalpy (latent heat) (from
steam table at the steam pressure (P))
𝑥 = dryness fraction, may be determined if the steam supply
system is equipped with a throttling calorimeter.

If 1 and 2 are the conditions at the top and at the bottom of the
pipe respectively (Fig (1)), then:
In case of superheated steam:
ℎ1 =𝑓(𝑝1 ,𝑡1 ) and ℎ2 =𝑓(𝑝2 ,𝑡2 )
Or wet steam: ℎ1 =ℎ𝑓1 +𝑥1 .ℎ𝑓𝑔1 And ℎ2 =ℎ𝑓2 +𝑥2 .ℎ𝑓𝑔2
The rate of heat loss from the pipe: 𝑄̇ =𝑚̇. (ℎ1 -ℎ2 )
In case of wet steam and P2 ≈ P1 Then: ℎ1 -ℎ2 = ( 𝑥1 − 𝑥2 ). ℎ𝑓𝑔
For case study P2= P1 , 𝑥2 =0.0
This means that the steam will condense as it passes through
the pipe, hence:
In case of superheated steam: 𝑄̇ =𝑚̇. (ℎ1 − ℎ𝑓1 )
Where 𝑚̇= (mass of condensate)/ time.
Calculation of thermal conductivity: Heat is
transferred by means of conduction through the lagging and by
means of convection from the outer surface. The rate of heat
transfer is given by:

𝑡 −𝑡
𝑄̇ = 𝑖 𝑎
𝑅𝑡ℎ
Where:
𝑡𝑖 = Steam temperature
𝑡𝑎 = Air temperature
𝑅𝑡ℎ =Total thermal resistance which is giver by:

𝑅 𝑅
ln [𝑅3 ] 1 𝐼𝑛[𝑅2 ]
2 1
+ +
2𝜋. 𝐾𝑖 . 𝑙 2𝜋. ℎ. 𝑅2.𝑙 2𝜋. 𝐾𝑃.𝑙
Where:
𝑅1 =inner radius of pipe.
𝑅2 =inner radius of lagging.
𝑅3 =outer radius of lagging.
𝑙=length of lagged section.
𝑘𝑝 =thermal conductivity of pipe [W/m K].
𝑘𝑖 =thermal conductivity of material [W/m K].
ℎ=surface heat transfer coefficient [W/𝑚2 K].

𝑅 𝑅
ln [𝑅3 ] 1 𝐼𝑛[𝑅2 ]
2 1
As ≫ ≫
2𝜋.𝐾𝑖 .𝑙 2𝜋.ℎ.𝑅2.𝑙 2𝜋.𝐾𝑃.𝑙
 1
So we can get a good approximation by neglecting
2𝜋.ℎ.𝑅2.𝑙
𝑅
𝐼𝑛[ 2 ]
𝑅1
and
2𝜋.𝐾𝑃.𝑙

Thus: (𝑡 −𝑡 ).2𝜋.𝐾
𝑅
𝑖 𝑖 .𝑙 ≅ 𝑄 =
𝑎
̇ 𝑚̇. (ℎ1 -ℎ2 )
ln (𝑅3)
2
Then we can obtain thermal conductivity:
𝑅
𝑄̇ .ln (𝑅3 )
𝑘𝑖 = 2
(𝑡𝑖 −𝑡𝑎 ).2𝜋.𝑙

This thermal conductivity varies linearly with

temperature because of the high temperature. The
variation of thermal conductivity with temperature
is taken as:
𝑏
𝑘𝑖 =𝑘(𝑡)=𝑘𝑜 +𝑘𝑜 (𝑡𝑖 + 𝑡𝑎 )
2
𝑘𝑜 = thermal conductivity at reference temperature (taken from
the apparatus).

𝑏=constant
 Material ∀(ml) 𝑘(𝑤/m.k)
A 240 0.026
B 240 0.037
C 325 0.038

P=3+1=4bar
T=1200 sec
Temp= 155℃
𝑇∞ = 20℃
L= 1.5m
𝑟1 =0.0413m
𝑟2 =0.0445m
𝑟3 =0.095m

Calculating:
For pipe A
At t= 155℃ , from table A-5 at 404kpa
ℎ𝑓2 = 604.73 , ℎ𝑔1 =2755.55 , 𝑣𝑓 =0.0001084
𝑅𝑎𝑜 = 1/𝑣𝑓 = 1/0.00109=922.5011
𝑚̇= (mass of condensate)/ time =
922.5011*240*10−6 /1200=1.845*10−4
𝑄̇ =𝑚̇. (ℎ1 -ℎ2 )= 1.845*10−4 (2755.50-604.73) =0.398w
𝑅
𝑄̇ .ln (𝑅3 )
𝑘𝑖 = 2
(𝑡𝑖 −𝑡𝑎 ).2𝜋.𝑙

=0.398 ln[(0.095/0.0445)]/(155-20)*2𝜋*1.5
=0.0023
𝑘𝑜 =0.026
(0.026/2)*(155+20) =2.275
For pipe B
At t=155℃ , from table A-5 at 404kpa
ℎ𝑓2 = 604.73 , ℎ𝑔1 =2755.55 , 𝑣𝑓 =0.0001084
=1/0.001084=922.5011𝑅𝑎𝑜
𝑚̇ =922.50×290×10^-6/1200=2.229×10−4
=𝑄̇ 2.229×10−4 (2755.50-604.73) =0.4794
= 00.4794 ln[(0.095/0.0445)]/(155-20)×2𝜋 ×1.5= 𝑘𝑖
0.00285
𝑘𝑜 =0.037
= )20+155(×)2/0.037(
=3.2375

For pipe C
At t=155℃ , from table A-5 at 404kpa
ℎ𝑓2 = 604.73 , ℎ𝑔1 =2755.55 , 𝑣𝑓 =0.0001084
𝑅𝑎𝑜 =1/0.001084=922.5011kj/kg
=922.50×325×10−6 /1200= 2.498×10−4 𝑚̇
=2.498×10−4 (2755.50-604.73)=0.5372 𝑄̇
=0.5372ln(0.095/0.0445)/(155-20)×2𝜋×1.5= 0.00282𝑘𝑖
𝑘𝑜 =0.038
(0.038/2)×(155+20) =3.325
b=𝑇𝑎𝑛−1 𝜃

𝜃=46°
𝑇𝑎𝑛−1 46°=88.75

b=𝑇𝑎𝑛−1 𝜃
𝜃=44°
𝑇𝑎𝑛−1 44°=88.69
b=𝑇𝑎𝑛−1 𝜃
𝜃=40°

𝑇𝑎𝑛−1 40°=88.56

Conclusions:
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:

Conserve energy by reducing heat les or gain.

• Control surface temperatures for personnel protection
and comfort.
• Facilitate temperature control of a process.
• Prevent vapor flow and water condensation en cold
surfaces.
• Increase operating efficiency of
heating/ventilating/cooling, plumbing, steam, process and
power systems found in commercial and industrial
installations.
• Prevent or reduce damage to equipment from exposure
to fire or corrosive atmospheres.

Each flow pipe 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.

2- Which material do you consider to

have the best insulating properties?

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
be able to minimize heat transfer. The main downside of
fiberglass is the danger 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.
Mineral Wool
Mineral wool actually refers to several afferent types of
Insulation First, it hay 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, may refer to slag wool which is
produced from the slag from steel mills. The inajority of
mineral wool in the United States is actually slag wool.
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 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.
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 lowing 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/ft3). They have and 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 R-3.6 rating per inch of thickness. Another
advantage of this type of insulation is that it is fire
resistant
Polystyrene
Polystyrene is waterproof thermoplastic foam which is an
excellent sound and temperature insulation material. It
comes in two types, expanded (EPS) and extruded (XEPS)
also known as Styrofoam.

3- Calculate the thermal conductivities of the

materials used and compare these values with
those quoted for the commercial materials.

-The first part was answered.

Cannot compare because of the large difference resulting
from the device.

4 -Comment on discrepancies (if any).

The practical tests are not without errors resulting from
the device and introduction.

5- How could this test carried out with

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