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Pipeline PPT General

The document discusses insulation surveys conducted for pipelines and vessels. It includes measuring surface temperatures, calculating heat loss savings, determining economic thickness of insulation, and methodology for identifying damaged insulation using thermography. Key focus areas are surface temperature measurement, insulation thickness calculation, heat loss calculation, and identifying savings from replacing damaged portions.

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Lương Hồ Vũ
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130 views

Pipeline PPT General

The document discusses insulation surveys conducted for pipelines and vessels. It includes measuring surface temperatures, calculating heat loss savings, determining economic thickness of insulation, and methodology for identifying damaged insulation using thermography. Key focus areas are surface temperature measurement, insulation thickness calculation, heat loss calculation, and identifying savings from replacing damaged portions.

Uploaded by

Lương Hồ Vũ
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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Scope of Work

 The main focus areas of study are:


 Measurement of Surface Temperature of all
Insulated Pipelines & Vessels.
 Calculation of economic thickness of insulation
for different operating temperatures.
 Calculation of Heat loss and savings for pipe
lines
 Calculation of Heat loss and savings for vessels

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Methodology for Pipe Line Insulation Survey

 Surface Temperature for all the Insulated Pipelines has been


measured with calibrated contact type Surface Temperature Meter.
Markings have been done with permanent marker on all concerned
pipelines.
 Surface Temperature of all Insulated Vessels has been checked by
Thermal Image Camera. Pictures of Vessels have been taken from
various angles and thermal images are generated.
 Insulation has been assumed to be damage where the surface
temperature is equal to more than 20 deg C higher than ambient
temperature.
 Total monitory savings by replacing the damaged insulation is
Rs 10772364 and the total investment is Rs 8805763.

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METHODOLOGY FOR VESSELS INSULATION SURVEY

 The thermographic images along with optical images of different portions of the vessels
have been provided incorporating damaged insulation portion and heat loss. Total
monitory savings by replacing the damaged insulation is Rs 15542866 and the total
investment is Rs 6840974. Vessel wise details have been provided in subsequent
chapters

 Damaged insulation has been identified with the help of thermpgraphy.

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1.Calculation of economic thickness of insulation for different
operating temperatures:

As the thickness of insulation is increased the heat loss is reduced but the
cost of insulation is also increased with the increase in insulation thickness.
With the help of software economic thickness of insulation has been
calculated for different operating temperatures and diameters of pipeline.
Economic thickness of insulation is the thickness where the sum of cost of
insulation and cost of savings in heat loss is minimum. It is suggested that
damaged insulation should be replaced by proposed thickness of insulation
for minimum investment.

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The determination of economic thickness

Factors required
i. Cost of fuel
ii. Annual hours of operation
iii. Heat content of fuel
iv. Boiler efficiency
v. Operating surface temperature
vi. Pipe diameter/thickness of surface
vii. Estimated cost of insulation.
viii. Average exposure ambient still air temperature

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Determination of economic thickness

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Note that the total cost in lower when using 2” insulation, hence is the economic insulation thickness.

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Following method has been used for calculating the heat loss.
H = [10+(Ts – Ta)/20]* [Ts – Ta]
H = Heat loss in kcal/hr/m2
For pipe line total heat loss
HT= H*3.14*D*L*T
HT= Annual heat loss
D = Diameter
T = Time in hours
L = Length of damaged insulation

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THERMOGRAPHIC IMAGE OF PIPE LINE

S02
°C
130
120
110
100
90
S01
80
70
60
50
40
30
20
10

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THERMOGRAPHIC IMAGE OF VESSELS

°C
110

S02 100

90

80
S01
70

60

50

40

30

20

10

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Problem Surface
Classificat Temperatur Comments
ion e

Intermedia Repair in the near future (2-4 weeks). Inspect for


55º C
te physical damage.

Repair in immediate future (1-2 weeks). Replace


Serious 75º C component and inspect the surrounding components
for probable damage.

above 100º Repair immediately (overtime). Replace component,


Critical
C inspect surrounding components.

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HEAT LOSS CALCULATION SHEET FOR PIPE LINE

PLANT - AMMONIA 2 Diameter(inch) 16

Address - E3203B TO E3203A

AT ST OT W L P.T SHL AHL EHL SAVING ET Rate INVESTMENT

Pipe Per Year Per

Marking (M) (cm) RS. Unit RS

1-1 32 85 435 `0.5 6 16 220 670 450 39400 17 1600 9600

2-2 32 65 435 0.5 15 16 220 384 164 35961 17 1600 24000

3-3 32 53 435 0.5 20 16 220 232 12 3513 17 1600 32000

41 78874 65600

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HEAT LOSS CALCULATION SHEET FOR VESSELS

OFFSITES (VESSELS)

S.NO. EQUIPMENT DESCRIPTION


DAMAGED
AREA TOTAL SAVING RATE/m2
(m2) (RS.) (RS.) INVESTMENT (RS.)

1 Ammonia Tank -2301 546 1,748,132.00 1,400.00 764,400.00

2 Ammonia Tank -3301 546 1,748,132.00 1,400.00 764,400.00

TOTAL 1092 3,496,264.00 1,528,800.00

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Insulation material
Insulation materials can also be classified into organic and inorganic types. Organic insulations are based on
hydrocarbon polymers, which can be expanded to obtain high void structures
Example: Thermocol (Expanded Polystyrene) and Poly Urethane Form(PUF).
Inorganic insulation is based on Siliceous/Aluminous/Calcium materials in fibrous, granular or powder forms.
Example: 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.

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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.

Use of Moulded Insulation


Lagging materials can be obtained in bulk, in the form of moulded sections; semi - cylindrical for
pipes, slabs for vessels, flanges, valves etc. The main advantage of the moulded sections is the ease
of application and replacement when undertaking repairs for damaged lagging.

The thermal conductivity of a material is the heat loss per unit area per unit insulation thickness per
unit temperature difference. The unit of measurement is W-m2/m°C 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.

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