A Report On STUDY OF THERMAL INSULATION FOR AIR CONDITIONING SYSTEMS By Faraz Ahmed 2007A4PS124U At Mechanical

BITS, Pilani Dubai Campus Dubai International Academic City, Dubai UAE

Second Semester 2010-11

A Report On STUDY OF THERMAL INSULATION FOR AIR CONDITIONING SYSTEMS By Faraz Ahmed 2007A4PS124U Mechanical

Prepared in Partial Fulfillment of the Project Course: BITS C323 Study oriented project

At

BITS, Pilani Dubai Campus Dubai International Academic City, Dubai UAE Second Semester 2010-11

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BITS, Pilani Dubai Campus Second Semester 2010-11

Course Name: Study Oriented Projects Course No: BITS C323 Duration: 30th January, 2011 16th May 2011 Date of Start: 30/01/2011 Date of Submission: 16/05/2011 Title of the Report: Study of Thermal Insulation for Air Conditioning Systems ID No. / Name of the student: 2007A4PS124U /Faraz Ahmed Discipline: Mechanical Name of the Project Supervisor: Dr. A. M. Surendra Kumar Key Words: Thermal Insulation, Ducting, Air Conditioning, Glass Wool Insulation Project Area: Mechanical Engineering/ Refrigeration / Air conditioning/ Ducting and insulation

Abstract:

The basic function of air conditioning is to guarantee the ambient comfort of a

buildings occupants. To achieve this, the designer selects the appropriate air conditioning system, guided by several criteria, such as the type of the building, acoustic requirements, cost, maintenance etc. Air duct systems enjoy several advantages over other air conditioning systems, including such factors as insulation thickness, power savings, and high quality interior air. All of these can be achieved if the designer ensures that there is minimal loss of energy.

Signature of Student Date:

Signature of Supervisor Date:

ACKNOWLEDGEMENT
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My deepest thanks to faculty Dr. A. M. Surendra Kumar .He has given his precious time, which plays a key role in guiding and correcting various documents of mine with attention and care. He has taken pain to go through the project and make necessary correction as and when needed. I express My, thanks to the Director of, BITS Pilani Dubai, for his encouraging works and providing all facilities to use, the colleges resources as library, lab, computers etc for the completion of my project work.

TABLE OF CONTENTS
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ABSTRACT.......................................................................................................................iii ACKNOWLEDGEMENT........................................................................................................iv LIST OF FIGURES...................................................................................................................viii LIST OF TABLES.....................................................................................................................viii

CHAPTER 1 INTRODUCTION

1.1 FOREWORD...............................................................................................1 1.2 SCOPE........................................................................................................1 1.3 LAYOUT OF REPORT.................................................................................2

CHAPTER 2 INSULATION

2.1 THEORY.....................................................................................................3 2.2 BENEFITS...................................................................................................5 2.2.1 FUNCTION...............................................................................................5 2.2.2 SIGNIFICANCE........................................................................................5 2.2.3 GEOGRAPHY...........................................................................................5 2.3 PROPERTIES..............................................................................................6 2.4 APPLICATION............................................................................................7 2.5 MATERIALS ..............................................................................................8 CHAPTER 3 AIR DUCTS AND INSULATION SOLUTIONS 10

3.1 AIR DUCTS AND INSULATION..............................................................................10

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3.2 METAL DUCTS..........................................................................................................10 3.3 GLASSWOOL DUCTBOARDS.................................................................................12 3.4 PLASTIC DUCTS.......................................................................................................14 3.5 FLEXIBLE DUCTS.....................................................................................................14

CHAPTER 4 THERMAL INSULATION

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4.1 THERMAL INSULATION IN HVAC DUCT WORK..............................................15 4.2 INTRODUCTION ON HVAC....................................................................................15 4.3 INSULATION THICKNESS......................................................................................17 4.3.1 HEAT CONDUCTION ............................................................................................17 4.3.5 SURFACE HEAT TRANSFER................................................................................19 4.4 THERMAL INSULATION OF DUCTS ....................................................................20 4.4.1 HEAT TRANSFERS IN DUCTS.............................................................................20 4.4.5 COMPARATIVE ANALYSIS.................................................................................22 4.4 CONDENSATION......................................................................................................23

CHAPTER 5 DESIGN FOR THICKNESS

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5.1 HOT INSULATION...................................................................................................25 5.2 COLD INSULATION.................................................................................................27

CHAPTER 6 FIRE PROTECTION

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6.1 REACTION TO FIRE................................................................................................29

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6.2 FIRE RESISTANCE...................................................................................................30

CHAPTER 7 CONCLUSION AND FUTURE SCOPE

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7.1 CONCLUSION...........................................................................................................31 7.2 FUTURE SCOPE........................................................................................................31

REFERENCES...................................................................................................................32 APPENDIX........................................................................................................................33

LIST OF FIGURES

Fig 1.1 Heat transfer through insulation........................................................................... 3

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Fig 1.2 Heat flow through bulk and reflective insulation..................................................4 Fig 3.1 Major components in Air-conditioning................................................................16 Fig 4.1 Transmittance Vs Air velocity of metal duct with and without insulation...........21 Fig 4.2 Psychometric chart................................................................................................23 Fig 5.1 Heat loss Vs Insulation thickness.........................................................................26

LIST OF TABLES

Table 3.1 Classification according to maximum pressure................................................11 Table 3.2 Thickness the thermal resistance for wrapped insulation and duct liner..........11 Table 3.3 Isover products description...............................................................................13 Table 4.1 Comparative analysis........................................................................................22

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CHAPTER 1 INTRODUCTION

1.1 FOREWORD An HVAC installation is designed to ensure the thermal and acoustic comfort of a buildings occupants, use energy efficiently and comply fully with safety requirements. Installation design takes into account the air exchange rates in the building, the number of its occupants and their activities, its interior characteristics and the materials from which it is constructed. The basic function of air conditioning is to guarantee the ambient comfort of a buildings occupants. To achieve this, the designer selects the appropriate air conditioning system, guided by several criteria, such as the type of the building, acoustic requirements, cost, maintenance etc. Air duct systems enjoy several advantages over other air conditioning systems, including such factors as centralized maintenance, power savings, and high quality interior air.

1.2 SCOPE In air conditioning systems, the duct is considered a static component of the installation through which air flows within the building, connecting all parts of the system and via which used or exhaust air is discharged. Some thermal losses in HVAC installations are due to temperature differentials between the fluid (air or water) inside the duct or the pipe and the surrounding ambient air. Heat transfer between the two air masses causes a loss of efficiency and increases energy costs; this can be minimized by using insulation.

1.3 LAYOUT OF REPORT 1

The following chapters emphasizes on; The second chapter comprises with the definition of thermal insulation its properties, applications, weather conditions, benefits and material used for manufacturing. The third chapter , will deal with air ducts and insulation solutions as well as alternative types of ducting like metal, glass wool , plastic and flexible ducting . The fourth chapter, design for thermal insulation with a brief introduction on HVAC and equations to calculate thermal insulation thickness, thermal resistance and transmittance there by also considering condensation risks, have quality insulation to help reduce energy consumption. The fifth chapter, considering two broad types of insulation i.e. hot and cold taking input parameters and calculating the thickness as well as plotting a graph between heat loss and thickness. The sixth chapter, deals with reaction of the insulating material with fire and methods in which the material can resist from getting burnt easily. The report ends with a conclusion and future scope.

CHAPTER 2
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INSULATION

2.1 THEORY

High crude oil prices underline the increasing need to curb consumption of energy, which happens to be a major component of industry and commercial building operations. The building sector accounts for approx 30-35% of the total energy consumption in the country. According to estimates, this sector alone can reduce energy consumption by at least 40% by choosing proper energy efficient equipments and thermal insulation A thermal insulator is any material that slows the transfer of heat. This means that the insulator reflects heat and does not emit much heat. Common insulators use vacant space as their insulation. Gases such as air are excellent insulators because they are not very dense. Most insulators, such as fiberglass and Styrofoam have large pockets of air. This is what makes them such great insulators. A vacuum also makes an excellent insulator.

Fig 1.1 heat transfer through insulation Heat travels through the movement of atoms in a substance. When there is a greater space between atoms, heat has a harder time getting through the substance. Of course, there are other factors in heat transfer. However, the space between the atoms in air is very large, which makes it very hard for the heat to transfer through the air. This means that the heat from the outside of the refrigerator has a hard time heating up the inside of the refrigerator. If it were not for insulation, refrigerators would have to use much more energy to keep their contents cool. 2.1.1 Insulation products work in two different ways:
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1.

REFLECTIVE this type of insulation works by reflecting large amounts of heat from its polished metallic surface. It works in conjunction with a still air layer for maximum effectiveness. The still air provides an insulating layer that increases the resistance of heat flow to other materials. Dust free and clean surfaces ad on to better performance ,it is better during summer by reducing heat gain rather than slowing heat loss in winter.

2.

BULK - pockets of still air are trapped within the structure of the wall. Resistance to heat flow is provided by these air pockets. Examples are blankets or batts.

Fig 1.2 Heat flow through bulk and reflective insulation

2.2 BENEFITS

Materials that provide significant resistance to the movement of heat are known as insulation, the heat flow both into and outside of a building is reduced by installing insulation in the ceilings, floors and walls of a building. During summer, insulation minimizes the amount of heat entering through ceilings and walls thus keeping the room cleaner. During winter, it helps in keeping warmth inside the building.

2.2.1 Function Thermal insulation helps maintain more uniform temperatures throughout the interior space, eliminating drafts and heat pockets. Insulation thus plays a vital role in improving cooling conditions inside the building, which definitely reflects on the power consumption involved in the construction process. 2.2.2 Significance The use of air conditioning during the scorching summer heat is said to raise the power consumption in the UAE during this period to 75to 85 per cent of the total power generated. better yet, unlike very expensive heating and cooling equipment modern insulation has no maintenance cost and no recurring expenses 2.2.3 Geography The ever-increasing demand for economical and comfortable living especially in the hot and humid climate conditions. The government with regard with the application of thermal insulation issued an administrative decree.

In the fight against global warming, thermal insulation is critical to energy conservation and serves as a barrier to heat during warmer temperatures and the cold in cooler months.

2.3 PROPERTIES

Thermal insulators are meant to reduce the rate of heat transfer by conduction, convention and radiation -- the standard methods by which heat transfers. This can be either in order to prevent heat loss or to keep heat out. In order to do this, all insulators share certain properties.

2.3.1

Thermal Conductivity

The best thermal insulators have the lowest thermal conductivity; this is the property of a material that measures how well it can conduct heat through its mass. The lower the conductivity measure, the less well a material is able to conduct heat, thus enabling it to trap heat or protect contents from outside heat.

2.3.2

Heat Resistance

Thermal insulators should also be resistant to heat, since they will likely be subject to heat on their surfaces because of the inability of heat to move through them. A thermal insulator without a high heat resistance quotient runs the risk of melting or burning. 2.3.3 Air Permeability Air permeability is the property of a material to allow air to pass through its weave or pores. It is often attributed to materials such as those used in the manufacture of clothing. High air permeability means a lower level of thermal conductivity. 2.3.4 Thermo-Insulating Materials Based mainly on thermal conductivity, some of the best and most common thermal insulation materials include fiberglass, which is made of spun threads of melted and fluffed glass, and foam, which has pockets of gas that do not conduct heat well

2.4 APPLICATIONS

Backed by the understanding of changing trends, new-age requirements, and state-of-the-art technology, thermal insulation division develops customized insulation solutions for various industries. It offers new generation alternative products to replace conventional materials including glass, rubber, metals, wood etc. for cost effectiveness Insulation products offer solutions in the following areas:
1. Duct insulation in various hospitals, shopping malls, airports, etc. 2. Piping insulation used in split, package, A/C tubes, chiller-piping, drain pipes, and

chilled water plants etc. 3. Floor insulation in the server rooms, data centers, medical & diagnostic centers, and control rooms for petrochemicals.
4. Under deck insulation is installed in, textile industries, airports, malls etc. 5. Over deck and wall insulation are in commercial high rise buildings, residential buildings,

cold storages etc.

2.5 MATERIALS Broadly classified into Hot and Cold insulation: 2.5.1 Hot Insulation: The Insulation is required for environment temperature. Exceeding 60 the type of Insulation comes under Hot Insulation. The materials required and generally applied for the Hot Insulation are as under
1. 2. 3. 4. 5.

Unbounded Glass wool with Handmade Mattresses Up to 400 Unbounded Mineral wool with Handmade Mattresses Up to 500 Lightly Resin Bonded (LRB) Mattresses with Handmade Mattresses Up to 550 Calcium Silicate Powder / Slabs: Up to 800 Ceramic Fiber Blankets: Up to 1000

2.5.2 Cold Insulation: The Insulation is required for environment temperature. Below ambient the type of Insulation comes under Hot Insulation. The materials required and generally applied for the Hot Insulation are as under.
1. 2. 3. 4.

Thermopolis: Both in ND and TF quality Up to -20 Polyurethane Foam: Up to - 200 Phenolic Foam: Up to - 180 Nitrile Rubber: Up to - 200

It is interesting to note that the Polyurethane Foam Item B can also be applied in Block and Pipe Sections by Manual Application process.

Insulation can be prepared by machine, providing cavity of the required thickness and dispensing the PU Chemicals in defined proportion through dispensing machine where the isothermal reaction takes place and foam is formed. The job can be prepared at site and the process is called as Pouring In-Situ.

2.5.3 Dual Insulation: This is a combination of Hot & Cold Insulation where the process demands are for Hot & Cold Insulation, and the process lines and equipments are used for both purposes.

2.5.4 Acoustic Insulation: The Application is required for reducing Sound Abuse. This is mainly for providing comforts and cozy working atmosphere. The main application is on buildings Malls, Theaters, Hotels, Studios and Hospitals where simultaneous activities are going on.

2.5.5 Underground Piping Insulation: The Pipe lines laid under earth for the flow of fuel oil, Chemicals etc, are requires to be given a treatment to provide resistance to formation of corrosion on the pipe surface. The Insulation process is known as Wrapping and Coating.

2.5.6 Furnace and Ovens Insulations: It is The Thermal Insulation provided to prevent and minimize heat losses through female walls. 2.5.7 Building Insulation: The latest phenomenon in building insulation provided to conserve heat losses and at the same time providing cozy and comfortable economic insulation to minimize heat losses and reduce load on the system. 2.5.8 HVAC Insulation: The Insulation provided on HVAC systems comes under category. The Ducts used to circulate Hot / Cold Air / Gasses etc. are provided with insulation to minimize heat losses and reduce load on the system.

CHAPTER 3
AIR DUCTS AND INSULATION SOLUTIONS

3.1 AIR DUCTS AND INSULATION

Air ducts are the elements of an installation through which air is distributed, including the air supply, air processing units, diffusers, air return, extraction, etc. The properties of ducts determine largely, the quality of the installation, as they have a key influence on certain factors such as energy savings or the acoustic properties of the system. This chapter looks at four alternative types of ducting. 1. Metal ducts 2. Glass wool duct boards 3. Plastic ducts 4. Flexible ducts

Air ducts are the elements of an installation through which the air is distributed,

including the air supply, air processing units, diffusers, air return, extraction, etc.

The properties of ducts determine to a large extent the quality of the installation,

as they have a key influence on certain factors such as energy savings or the

3.2

METAL DUCTS

acoustic properties of the system.

This chapter looks at four alternative types of ducting in some detail.

Since metal is a good thermal conductor, such ducts require thermal insulation, the commonest material for which is glass wool, usually in roll form (known as wraps or wrapped insulation), wrapped around the outer duct wall. Wraps incorporate an aluminum foil facing that acts as a vapor barrier. Insulation can also be installed on the inner wall of the duct (duct liners), as glass wool duct wraps or duct slabs faced with a glass matting or mesh providing acoustic insulation and strengthening the inner face of the duct.

Metal ducts 1.

Glass wool ductboards 2.

Plastic ducts 3.

4.

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3.2.1 Metal Duct Classification

Maximum Pressure The metal sheet ducts are classified in Table 3.1 according to the maximum pressure they can withstand. Maximum pressure (Pa) 500 Pa (1) 1000 Pa (2) 2000 Pa (2) 2000 Pa (2) (2) Positive pressure

(1) Positive or negative pressure.

Table 3.1 Classification according to maximum pressure

Insulation For Metal Ducts Depending on thickness the thermal resistance for wrapped insulation and duct liner are shown in Table 3.2 Application Products Glass wool blanket faced with an aluminum vapor barrier, generally reinforced with a glass fiber mesh. Blanket (can be also faced with reinforced aluminum).This product should be applied if fire resistance is required in addition to thermal and acoustic insulation. Glass wool blanket or board, faced on the airstream side with a glass mesh or fabric. Thermal resistance

Wrapped insulation for metal ducts

Depending mainly on thickness, can vary from 0.80 to 1.3 (m2/KW) Depending mainly on thickness, can vary from 0.7 to 1.3 (m2/KW)

Duct liner

Table 3.2 Thickness the thermal resistance for wrapped insulation and duct liner

3.3 GLASS WOOL DUCT BOARDS

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These are ducts made from high-density glass wool board. Ducts are shaped from boards, by cutting and folding in order, to obtain the required geometry required. The Face of the original board in contact with the air stream when assembled as a duct is called the internal face, i.e. inside the duct. The other surface of the original board is called the external face. Panels are supplied with double facing such that: The external face of the duct is faced with a robust reinforced aluminum foil that acts as a vapor barrier and confers air tightness on the duct. Depending on the properties required on the duct, the internal face of the duct has an aluminum coating or a glass mat or fabric layer.

3.3.1 Duct boards

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Air conditioning needs of an installation can vary depending on its type, users, etc. ISOVER has developed a wide range of products to meet this diversity. Table 3.3 shows the working conditions based on the description of product

Working conditions Products High density glass wool duct board offering thermal and acoustic insulation Description Thermal resistance Maximum static pressure Maximum air speed Max air temp

PlusR

Outer lining of aluminum reinforced with a glass fiber mesh, Kraft paper and a glass veil to ensure rigidity. Inner lining with aluminum foil, Kraft paper and glass mesh.

Neto

Enhanced acoustic insulation

Outer lining of aluminum reinforced with a glass fiber mesh, Kraft paper and a glass Mesh to ensure rigidity. Inner lining: woven black glass cloth,neto Similar to Plus R, avoiding the use of Kraft paper

R 0.75 m2 K/W

< 80 mm c.a

18 m/s

90C

A2

Enhanced fire reaction Enhanced acoustic insulation and fire reaction Enhanced acoustic insulation

A2 Neto

Similar to Neto, avoiding the use of Kraft paper

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Outer lining of aluminum, inner lining with a glass mesh

Table 3.3 Isover products description

3.4 PLASTIC DUCTS

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This category includes ducts made from plastic or foam boards, shaped by cutting and folded to produce the required cross-sectional geometry. Boards are faced usually with an aluminum coating both internally and external. The main drawback of this type of ducting is their fire classification. Even if they comply with local standards, when exposed to fire they often exhibit poor performance in terms of the production of both smoke and flaming droplets.

3.5 FLEXIBLE DUCTS

These usually consist of two aluminum and polyester concentric tubes. A glass wool layer is inserted between the two tubes as thermal insulation. Their use is generally limited to short lengths, due to high-pressure drop-off and the acoustic problems they create: they are mainly used to connect main air duct and terminal units (diffusers, grids) their use is in lengths not greater than 1.5 m.

CHAPTER 4
THERMAL INSULATION
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4.1 THERMAL INSULATION IN HVAC DUCT WORK

Thermal loss is due to the temperature of the air in the duct may not be same as that of the surrounding ambient air. Heat transfer between the two air masses can represent a loss of efficiency and increase energy costs. Ductwork and pipe work also represent a condensation risk, caused by localized cooling of air and a rise in relative humidity. Regulations define a minimum thickness for the thermal insulation in pipes and ducts to minimize the danger of condensation.

4.2 INTRODUCTION ON HVAC

The term HVAC comprises of Heating, Ventilation, and Air-Conditioning. 4.2.1 Heating A closed space can be heated by using electrical heaters, or by directly heating the space by radiation for e.g. ceiling, floor, radiant panels or wall radiation. 4.2.2 Ventilation It controls smell, and removes noxious waste from occupied spaces and helps in keeping an adequate mixture of gases in the air that we breathe i.e. not excess of CO2. Ventilation are of two types active through mechanical distribution systems powered by fans or passive through natural ventilation.

4.2.3 Air-conditioning The basic function of air conditioning is to guarantee the ambient comfort of a buildings occupants. To achieve this, the designer selects the appropriate air conditioning system,
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guided by several criteria, such as the type of the building, acoustic requirements, cost, and maintenance. A refrigerant with very low boiling point is first compressed in a compressor and then the latent heat is removed in the condenser from where the refrigerant is throttled ,the throttled refrigerant is passed over cooling collies where heat is taken up from the surroundings.

Fig 3.1 Major components in Air-conditioning

The thermodynamic properties of the air-conditioning unit have to be transferred to the space required to be cooled and this is done through ducting, piping etc. Therefore, to ensure that these properties of the fluid do not change the role of insulation takes a very important step in maintaining the thermodynamic properties of the fluid.

4.3 INSULATION THICKNESS

4.3.1 Heat Conduction

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If two areas in contact are at different temperature, then heat tends to flow from the area of higher temperature to the one with lower temperature. If a physical body separates these two areas, heat transfer depends on:

the geometry of the physical element the thermal conductivity of the material

Fouriers law gives the heat flow through such an element:

4.1 With: q: heat passing perpendicularly through the separating element (W/m2) : the thermal conductivity of the material (W/m.K) grad T: is variation of temperature with material thickness (K/m) Different expressions of Fourier's law are used for different geometries of separating (insulating) elements (flat walls, cylindrical elements or rectangular elements).

4.3.2 Flat Walls Fouriers law is written as:

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4.2 Where: si: surface temperature of the warmer side (K) se: surface temperature of the cooler side (K) R: total thermal resistance (m2.K/W)

4.3 Where: dj: thickness of the layer j (m) j: thermal conductivity of the layer j (W/m.K) 4.3.3 Cylindrical Elements Fouriers law is written as:

4.4

With R: total thermal resistance (m.K/W)

4.5 Where: Dej: internal diameter Dij: external diameter

4.3.4 Rectangular Elements The following expression describes linear heat flow through an element of rectangular cross-section (applicable for a duct of rectangular section):
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4.6 Rd is the linear thermal resistance of this element and can be evaluated using the following approximation:

4.7 Where: Pi: internal perimeter of the duct (m) Pe: external perimeter of the duct (m) d: insulating layer thickness (m) 4.3.5 Surface Heat Transfer In addition to heat transfer by conduction through the separating element between two areas at different temperatures, heat transfer also occurs at the surface delimiting this separating element. Heat flow passing through the element must be equal to heat flow emitted by the warmer side and equal to the heat flow received by the colder side. Heat transfer on the surface of the element is defined as:

4.8 Where: hi: surface heat transfer rate of the environment i (W/m2.K) he: surface heat transfer rate of the environment e (W/m2.K) 4.4 THERMAL INSULATION OF DUCTS

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Heat transferred through the duct network represents a loss of energy, and in turn increased operating costs. Moreover, thermal losses can lead to fluctuations in the desired airconditioned temperature of the building. Therefore, it is necessary to know the relationship between calorific transfer and air temperature variation for the geometric characteristics of the duct network and internal airflow. 4.4.1 Heat Transfers In Ducts Thermal transmittance between two environments is defined as the amount of heat that passes from one to the other per unit of area, divided by the temperature difference. The transmittance, U, is the inverse of the total thermal resistance of the system, including surface resistances h.

In flat walls (ducts with rectangular cross-section), transmittance U is expressed per unit surface area

4.9 In pipes (or ducts of circular cross-section), expressed in per unit length:

4.10

The ASHRAE graph shows experimental values of U based on air speed and different materials used for ducts .It also indicates that U values are relatively independent of air velocity when glass wool duct boards are used, or when insulation are installed for metallic ducting (wrapped insulation).
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This is due to the airflow inducing movement of the air contained within the glass wool that creates an increase of l value for the material. This side effect diminishes with increased material density, so that in rigid glass wool duct boards this factor is virtually negligible

Fig 3.1 Transmittance Vs Air Velocity of metal duct with and without insulation

4.4.5 Comparative Analysis Using the formulae described in equations 4.9 and 4.10 .It is possible to make comparative analyses of heat loss for different types of insulation.
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This general case can be simplified, especially for he and hi. For example, systems with internal liquids have very low 1/hi values which is negligible compared to U values. The following formulae apply for internal installations in a building: Horizontal pipes: he = CA+ 0.05 W/(m2.K) Vertical pipes and flat walls: he = CB+ 0.05 W/(m2.K) Depending on the facing material used, the appropriate values can be selected from table 4.1: Material Polished aluminum Oxidized aluminum Galvanized steel duct (clean) Galvanized steel duct (dirty) Austenitic Steel Zinc-aluminum board Non metallic materials Table 4.1 Comparative analysis The previous equations are applicable for horizontal pipes of diameters from 0.25 m to 1 m, and for vertical pipes of any diameter. CA and CB are approximate values and applicable only if < 100 C and if radiation is negligible, as the temperature difference between the external surface of the equipment and the surrounding air is negligible. CA 2.5 3.1 4.0 4.0 3.2 3.4 8.5 CB 2.7 3.3 4.2 5.4 3.4 3.6 8.7

4.5 CONDENSATION

If an air mass with a given temperature and relative humidity (Hr) cools, condensation occurs if the "dew point" is reached (tr), corresponding to Hr = 100%. This is important when the temperature inside the equipment or the duct is lower than that of the surroundings: The temperature of the outer air falls and Hr increases, resulting in a risk of condensation.

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If the separating element is metallic or a good thermal conductor, usually the risk of condensation is high, even with low temperature differences between inner and outer air, and particularly in environments with high humidity (Hr).

Fig 4.1 Psychometric chart Condensation might occur when there is a localized cooling of air and a rise in humidity. Insulation of pipes and ducts will minimize condensation risks. When the temperature of the fluid inside a duct or pipe is lower than the temperature of the surroundings, and there is inefficient insulation, then the temperature of the external surface might also decrease. If the humidity in the outer fluid increases, then there is a condensation risk. 4.5.1 Reducing Condensation Mineral wool is used for the insulation of HVAC systems, a vapor barrier must be included to prevent the condensation occurring inside the insulation material itself. This is the reason why insulation products for ducts and pipes have an outer facing that acts as vapor barrier. In any case, it is essential to work from the worst possible set of conditions when considering the insulation for equipment, including conditions under which condensation is likely.
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CHAPTER 5 DESIGN FOR INSULATION

5.1 HOT INSULATION 5.1.1 Calculation of heat loss for 50, 75 and 100 mm of glass mineral fiber insulation with a density of 24 kg/m3 can be performed to establish the heat losses at the various insulation thicknesses.
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Input parameters; Process temperature: Difference Temp: 1500C T= 150 20= 130 0C Ambient Temperature: 200C

From Appendix 4 thermal conductivity (k) at a mean temperature of 93.30C (closest value not exceeding 1300C) is 0.053 W/(m0C). The thermal resistance (R) can be calculated for the various insulation thicknesses using the equation. R = t/k Where, t- Thickness in (m) k- Thermal conductivity in W/(m0C). R50= 0.050/0.053 = 0.943 (m2 0C)/W. R75= 0.075/0.053 = 1.415 (m2 0C)/W R100= 0.100/0.053= 1.887 (m2 0C)/W The surface area will remain constant for the insulation since this is a flat surface.

Heat loss can be evaluated for a typical one-m2 area for each insulation thickness. Heat loss in one hour Heat loss; (50 mm insulation) in one hour = (130* 1)/ .943 = 137.86 Wh = (T * A)/R

(75 mm insulation) in one hour

= (130* 1)/ 1.415 = 91.873 Wh

(100 mm insulation) in one hour = (30* 1)/1.88 = 68.89 Wh

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Heat loss Vs Insulation Thickness

0.16 0.14 0.12

Heat Loss (kWh)

0.1 0.08 0.06 0.04 0.02 0 50 75 100 125

Thickness (mm)

Fig 5.1 Heat loss Vs Insulation thickness The graph shows that as the thickness of insulation increases, the heat loss is reduced drastically until it reaches its minimum. As seen in figure when thickness is 50 mm heat loss is maximum and when thickness is 125 mm heat loss is negligible.
5.2

COLD INSULATION

5.2.1 A duct network placed between the framework and a suspended ceiling has the following characteristics: Cross section 400 x 400 mm, length 20 m Air flow speed: 8 m/s Air temperature in the inflow air: 14 C Air temperature of the surrounding air: 26 C
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Using this basic construct, the aim is to compare heat transfer when different materials are used in this example; un- insulated metallic ducts versus glass wool duct boarding. Galvanized sheet metal duct: R= .00855 m2 K/W Q = (26-14)/.00855 = 1403.3 W . But R=t/k Thermal conductivity k= 18 W/mK Thickness t=R/k = .00855/18 =.000475 m or .5 mm Appendix1 EQN 4.6

Glass wool duct boards: R= .029 m2 K/W Q = (26-14)/.029 = 413 W EQN 4.6

Thermal conductivity k= .046 W/mK Thickness t=R/k = .029/.046 = 0.63 m or 63 mm

Appendix1

Q (Galvanized steel duct)

= 1,403.2 W 415.0 W

Q (Glass wool duct boards) =

% Reduction = 1403.2 415 = .704 or 70.4 % 1403.2 Heat loss from a glass wool duct board network can be 70.4 % lower than from un-insulated galvanized sheet metal ducting. If metal ducting is insulated, then, depending on the insulation thickness and the air leakages in the joints, duct boards can save up to 30% thermal losses when compared to insulated metal ducting.
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CHAPTER 6 FIRE PROTECTION

Fire is one of the greatest risks for the occupants of any building. This is why fire protection regulations are becoming more and more stringent worldwide. Incorrect or poorly designed duct networks may contribute to the spread of fire and smoke throughout a building, as they offer direct physical access by which the fire can travel. Many different protection methods are available to avoid or minimize fire propagation: passive
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methods (where the fire propagation is minimized by the correct choice of building materials) and active (using mechanisms that try to reduce fire risks to a pre-designed level.

6.1 REACTION TO FIRE When a material reaches its ignition temperature, it can start to burn, and this is therefore considered the starting point of a fire. From this moment, as combustion is an exothermic process, the temperature increases in the area around the starting point of the fire and the surrounding area may also start to burn. As long as combustible material is available, the relationship between time and temperature becomes exponential

6.2 FIRE RESISTANCE The fire resistance of a building component is defined as the time during which this component is able to fulfill conditions of stability, display an absence of flammable gases, provide no passage to flames and minimize the temperature of the unexposed face. Ducts can be designed to meet the fire resistance requirements of the regulation. For example, when ducts pass through separating walls designed to function as firebreaks, they must also be designed with a minimum level of fire resistance. Two solutions are available:
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 Fire resistant ducts. Fire dampers. Fire resistant ducts can be created by in several different ways. The most common method is to insulate metal ducts with a mineral wool that, making it resistant, in addition to providing thermal and acoustic insulation. The range of products designed for this application is U Protect and can achieve the following fire resistance in ducts:
1. Rectangular ducts up to 2 hours fire resistance for fires located inside or outside

of the duct, both horizontally and vertically. The U Protect Slab is used for rectangular ducts.
2. Circular ducts up to 2 hours fire resistance for fires located inside or outside of

the duct, both horizontally and vertically. U Protect Wired Mat is used for circular ducts.

CHAPTER 7 CONCLUSION
7.1 CONCLUSION The energy consumption of ductwork can be reduced drastically by using adequate thermal insulation, not only in the building itself but also in the ductwork and pipe work which are used to distribute fluids (air and water) throughout the building. Thermal insulation in a duct network is dependent on the insulation material, its thickness and air leakage these three effects are the designers main point of calculation.

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After doing the design on the thickness of the insulating material with different materials we can observe the amount of heat loss with inadequate insulation. 7.2 FUTURE SCOPE OF WORK Nanotechnology is the future for thermal insulation materials for buildings having higher thermal resistivity and would probably have small thickness with high insulation effect, the combination of different materials and their effect on thermal resistance would be a vast field for research and development for the study of thermal insulation.

REFERENCES

1. Brumbaugh, James E, Audel HVAC fundamentals , Wiley Publishing, Inc, 2004,

Vol. 4,pp. 361-370.

2. Khurmi, R.S. and Gupta, J.K. A Textbook Of Refrigeration and Air Conditioning, Tata McGraw Hill, 3rd ed., 2009, pp. 729-740.

3. Rydberg J. and P. Norbac, Air distribution and draft, ASHVE Transactions, Vol. 55,

1949, p. 225.
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4. Saint Gobain, Technical insulation Handbook, Isover Publishing , Vol. 2, 2004,

pp. 15-45.

5. Reuters, A. (2011, April 18). Thermal Insulation. Khaleej Times, pp. 18-20.

APPENDIX 1

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APPENDIX 2
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APPENDIX 3

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APPENDIX 4

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APPENDIX 5

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