· penetration of moisture through fiberglass insulati on when covering chilled water pipe line (moisture sucking machine)

ALP Aeroflex India Pvt. Ltd.

Emerging Trends In InsulationBy Shahab Z Ahmed (AVP)

Shahab Z Ahmed -AVP


Presentation Overview

�ALP Aeroflex India (P) Ltd – Introduction

�Energy Consumption and Co2 Emission

�Definition of Insulation Material

�Different Type of Insulation Material

�Parameter to select right Insulation material

�AAIPL Product Range

�EPDM Insulation

�Benefits of EPDM insulation

�Software Calculation

�References


ALP NISHIKAWA CO. LTD.

ALP OVERSEAS PVT. LTD

ALP PLASTICS PVT. LTD.

ALP AEROFLEX

(I) PVT. LTD.

ALP POLYMER PARK PVT.

LTD.

GROUP

EPDM & PVC WEATHER

STRIPS / SEALLING SYSTEMS

EPDM EXTRUSIONS/

MOULDED ARTICLES

PVC / TPE / TPR / TPO

EXTRUSIONSEPDM / NITRILE

INSULATION PRODUCTS

NEW CONCEPT

POLYMER INDUSTRIES

AND TOWNSHIP

About ALP Group – US$ 100MN


ALP Nishikawa Co., Ltd. (ANCO, Gurgaon)

: Production : Sales : Offices + Godown

ALP Nishikawa Co., Ltd. (ANCO, Lalru)

ALP Overseas Pvt. Ltd. (ALPO, Gurgaon)

ALP Overseas Pvt. Ltd. (ALPO, Rudrapur)

ALP Overseas Pvt. Ltd. (ALPO, Noida)

ALP Plastics Pvt. Ltd.. (ALPP, Unit-2 Gurgaon )

ALP Aeroflex (I) Pvt. Ltd. ( Rudrapur)

RUDRAPUR

(UTTARKHAND)

LALRU

(PUNJAB)GURGAON

(HARYANA)

NOIDA

(UTTARPRADESH)

MUMB

AIPUNE

CHENNA

I

HARID

WAR

AMBA

LA

SANA

ND

PITHAMP

UR

HOSUR

NA

SIK

GURGA

ON

DHAARW

AD

ALP Africa(ALPO, South Africa)

ALP- GGC (USA)

Our Presence


- Net Worth - US$ 4 million

- Capital Employed : US$ 3.83 million

• Turn Over – US $ 7 Million

Man Power

Financials - AAIPL

- Head Office – Gurgaon

- Factory – Rudrapur , UK


Insulation

Thickness mm

No

Insulation 13 mm 25 mm 38 mm 50 mm 63 mm 75 mm

Surface

Temperature ◦ C 5 24.1 26.8 27.9 28.5 28.9 29.1

Prevent

Condensation RH % 21 71 83 89 92 94 95

Energy

Consumption kw.hr/m/yr 142.8 46.4 30.6 23.6 20.1 17.5 15.8

Energy Cost INR /m/yr 1285.2 417.6 275.4 212.4 180.9 157.5 142.2

CO2 Emission kg/yr 71.4 23.2 15.3 11.8 10.05 8.75 7.9

Energy Consumption & CO2 Emission

Calculation based on 65 mm (NB) pipe , operating temp 5 deg ◦ C, room temp 30 ◦ C, K value -0.037 W/mk in 24

hrs x 365 days , at a cost of Rs 9 /Kw-hr


Is a material or combination of material having relatively high resistance to heat flow

Stationary air is common in all the insulating materials providing the insulation effect.

Benefits of Insulation

� Prevents Energy Gain /Heat Loss

� Prevents /Reduce Surface Condensation

� Improves Aircon equipment efficiency

� Control Surface temperatures

What is Insulation?


Modes of Heat Transfer


Cut Section of Fiber Glass Insulation


Q = KA t

Thickness

K insulation

= K conduction

+ K convection

+ K radiation

Equation of Heat Transfer


Heat Transfer- Cold Pipe


Heat Transfer- Hot Pipe


�Different Type of Insulation Material


• Open cell structure

• Mineral wool

• Glass wool

• Rockwool

• Ceramic wool

• Semi Closed cell structure

• Poly Urethane foam

• Poly Styrene foam

• Polyethylene foam

• Closed Cell structure

• Nitrile foam

• EPDM foam

• Others: Flake(eg Vermiculite); Granular(eg. Cork);Reflective

Insulation – Cell Structure


2.1 OPEN CELL TYPE INSULATION SUCH AS FIBERGLASS, ROCK WOOL AND CALCIUM SILICATE


PENETRATION OF MOISTURE THROUGH FIBERGLASS INSULATION

WHEN COVERING CHILLED WATER PIPE LINE

(MOISTURE SUCKING MACHINE)


Home


Home



Home


�Properties of Good Insulation


1. Low and Stable K Value

2. High Mu Value or Water Vapour ingress resistance

3. Light weight Good Mechanical strength and

Flexibility

4. Rot and vermin proof

5. Fire safe Properties

6. FM Approval

7. Green Building Norms adherence

Insulation- Desired Properties


K Value – Low and Stable


CLOSED CELL STRUCTURE INSULATION IS

THE MOST SUITABLE FOR COLD

TEMPERATURE APPLICATION DUE STABLE K.

VALUE WHICH NOT VARY DUE TO % RH


µ = PoorMineral Wool

µ = LowPUF,XPE, EPS

µ = GoodNBR,EPDM

Mu Value

Mu Value – is the resistance to moisture transfer across the walls of insulation , Higher Mu means greater resistance to

water vapor


MaterialMax. medium

temperature (°C)Thermal conductivity

(W/m.K)at a mean temp. of 10°C

Water vapor diffusion resistance (µ)

Elastomeric

Elastomeric foam (FEF) 115 – 150 (175) 0.033 – 0.038 7000 – 12000

Thermoplastic

Polyethylene (PE) 85 – 105 0.035 – 0.038 1000 – 4000

Polystyrene

Extruded foam (XPS) 80 0.030 – 0.032 80 - 300

Expanded foam (EPS) 80 0.035 – 0.037 20 - 100

PVC 80 0.35 – 0.38 170 - 320

Duroplastic

Phenolic resin foam (PF) 120 - 150 0.032 – 0.03510 – 50

Other insulation

Mineral wool (MW) 200 / 750 0.032 – 0.040 10 - 100

Cellular glass (CG) 430 0.040 – 0.045

K Value/ Mu Value / Operating Temp –Insulation Generics


3000 7000

Mu Value - Comparison


Light Weight and Flexibility


Rigid Foams – Non Flexible



� In-built anti-microbial protection

Elastomeric Insulation contains an anti-microbial additive

which actively inhibits mould and bacteria growth.

Anti fungal / Anti bacterial – ASTM G21/ ASTM 2180

� Dust & fibre free

Dusty and fibrous materials are both difficult to work with and

create an additional workplace hazard often aggravating

respiratory conditions amongst those working with and around

them.

As nitrile rubber material, is entirely dust and fibre free, making

it suitable for use in schools, offices and hospitals.

Anti Microbial Properties


ITCHINESS

MOLD/FUNGI/MILDEW PEST/COCKROACH

Air borne glass wool fiber is a health hazard – both to the applicators and occupants.

Glass wool is prone to

settling and sagging

Open cell structure allows easy passage & scope

for pests , like cockroaches, rats to inhabit and

breed.

Damp insulation creates breeding

ground for mold, fungi & microbes.

SAGGING

FIRE SAFETY

Kraft backed Foil facing burns when

exposed to ordinary flame.

Health Hazards


Fire and Smoke Behaviour is governed by Each Countries Fire

Codes for the following parameters

� Surface flame Spread

� Fire Propagation (Min. Heat Release)

� Smoke Toxicity

Fire Requirements of a Insulation Material.

� Min./Nil Fire surface flame spread ( BS 476 Part 7, Class 1)

� Min Fire heat release ( BS 476 Part 6 & 7, Class O)

� Smoke should be non-toxic. (IMO Res Part MSC 61(67)

Part2)

� Should not produce flaming drips.

� Should be Self Extinguishing

Fire and Smoke Properties


HCN, NO2 , HFHIGHLY FATAL GASES

HCl, HNO3, H2SO4HIGHLY IRRITATE/ CORROSIVE GASES

CO, CH2O,CHYOZLESS TOXIC GASES

H2O, CO2NON TOXIC GASES

GASESTYPE

Combustion Gases


Home

Death after few minutes50-100HF

Death after few minutes250NO2

Danger of lung damage after short exposure1,000

280

HCl

HCN

Death by suffocation

Death in 3 minutes

200,000

128,000

CO2

CO

SYMPTOMSPPMGAS

Toxicity of Gases


Standard

Fire

Spread

Smoke

Density

Flaming

Drips

Toxic

Gas

Self

Extinguishing

ASTM E 84 Yes Yes - - -

UL 94 V Yes - Yes - -

BS 476 Yes - - - -

ASTM D635 - - - - Yes

IMO MSC61(67) Yes Yes - Yes -

Fire / Smoke Testing Standards


Home

Flammability Test


Products submitted for certification by FM Approvals shall demonstrate that they meet the intent of the Approval Standard, and that quality control in manufacturing shall ensure a consistently uniform and reliable product.

FM Standards


Products submitted for certification by FM Approvals shall demonstrate that they meet the intent of the Approval Standard, and that quality control in manufacturing shall ensure a consistently uniform and reliable product.



� Green Building Codes / Other Building codes

� IAQ - Should be smooth surface and inhibit build of dirt and possible

contaminations.

� WITHOUT CFCs, HFCs or HCFCs

� ZERO ODP potential

� WITHOUT Propane, Butane, pentane and other flammable gases

� LOW VOC/SVOC content

� FREE from - formaldehyde , Nitrosamine

� FREE from Fiber and Dust

Green Building Norms


� AAIPL Product Range


Elastomeric

EPDM/Nitrile Tubes

“Retrofit” Pre-slit

Elastomeric Tubes

with self seal.

Tapes

Elastomeric

EPDM/Nitrile Sheet and

Rolls

Adhesive Pipe support

Accessories

Paint

Aluminium foil

faced insulation

Flexible duct

Product Offerings

ALP Aeroflex India Pvt. Ltd.ALP AEROFLEX

PRODUCT

Nitrile-Insulation EPDM-InsulationAccosound/ Accofoam

(Acoustics)

Nitrile Sheet

Nitrile Tube

Nitrile Tape

EPDM Sheet

EPDM Tube

EPDM Tape

With Release

Paper

Without Release

Paper

Lamination of

Release Paper

Lamination of Glass

Cloth

Value addition

Slitting of

Sheet

Lamination of

Aluminium foil


� NBR –

� Class O ( FM approved), Class 1, Antimicrobial.

EPDM-

� Normal EPDM, High temperature EPDM.

Accosound-

� Normal, Antimicrobial

Technical Classifications


Sheets ( Both in EPDM & Nitrile)

� Both side skin

� One side skin

� Both side with out skin

� One side Aluminium foil & one side skin

� One side glass cloth & one side skin

� One side release paper & one side skin

� One side release paper& one side aluminium foil

Options Available


� Colour Tubes.

� Colour Sheet.

� Low density accosound

(140 kg/m3).

� High tensile sheet.

New Product development


�EPDM Insulation (Future Material)

�Benefits of EPDM insulation


Pendant diene : This double bond will

be cured during production processes only to strengthen the product.

Fully saturated backbone chain

(no reactive double bonds)

� Not reactive to HEAT,

UV, O3, O2, etc.

No toxic components !

Safe for all users !

EPDM Rubber (Ethylene propylene Diene monomer rubber), a type of synthetic

rubber ,is an elastomer characterized by a wide range of applications. The material

is Non Polar - Does not react with water

EPDM – Sturcture


• For water systems, it is worse if the insulation is POLAR. Polarity induces water/moisture to penetrate the skin then interacts and absorbs water.

Polar induces Polar

NBR/PVC induce water/moisture from its surroundings.

Non-Polar DOES NOT induce Polar

EPDM Does NOT induce water/moisture from its surroundings.

Polarity


• CHEMICAL STRUCTURE

• MOST OF NITROSAMINE ARE CARCINOGENTS

SUCH AS

N - NITROSODIMETHYLAMINE

N - NITROSODIETHYLAMINE

N - NITROSODIBUTYLAMINE

Nitrosamine Content


_

Non flaming

drips_

ASTM E84

(UL 723 or NFPA NO. 255)

UL 94 V

PASS_PASSPASSIMO (Fire, Smoke & Toxicity)

_3

(lowest smoke

density)

5(lowest flame

spread)

EMPA

(Swiss Fire & Smoke

Standard)

V0

_Non flaming

drips

5025

Toxic

gasesFlaming dripsSmoke

density

Flame spread

Note : This table shows the specifications of Aeroflex-Standard product.

Fire Properties –EPDM



EPDM NBR

EPDM vs NBR (Outdoor Installation)


�Software Calculation



1. Minimum Thickness to Prevent Condensation

2. Energy Saving & Economic Thickness

Software Criteria




• Water vapor in the air may form condensation on a cold surface if the

surface temperature is below the dew point temperature.

• Objective: Maintain the temperature of the insulation surface above the

dew point temperature.

6 0C

T surf = ~60C

Ambient Conditions

T air = 320 C

RH = 65%

⇒ Dew Point = 24.6 0C

T surf = ~270C

6 0C

Adding 19mm thick insulation raises the surface

temperature, preventing surface condensation

Preventing Surface Condensation


Constant Parameters: Fluid Temperature 6°C

Ambient Temperature 32°C

Wind Speed 0

Relative

Humidity Dew Point 2" 6"

% °C Insulation Thickness

50 20.3 3/8" 3/8"

60 23.3 3/8" 1/2"

70 25.8 5/8" 3/4"

80 28.1 1" 1-1/8"

85 29.2 1-1/2" 1-3/4"

90 30.2 2" 2-1/2"

Effects of Relative Humidity

On Insulation Thickness to Prevent Condensation

Pipe Size

Effects of RH% on thickness


SO SHOULD USE MINIMUM INSULATION THICKNESS THAT INSULATION

SURFACE TEMPERATURE IS HIGHER THAN DEW POINT

DEW POINT VARIES TO % RH (MOISTURE IN THE AIR)

NORMALLY USE 85 % RH, 90 % RH FOR

CALCULATION THE INSULATION THICKNESS

NORMALLY USE HEAT CONVECTION OF AIR VALUE AROUND 7-9

W/M2 K FOR CALCULATION THE INSULATION THICKNESS

Pointers for Correct Selection


1. OPERATING TEMPERATURE (TOP) SUCH AS 5O C

2. AMBIENT TEMPERATURE (Td b) SUCH AS 32O C

3. RELATIVE HUMIDITY (% RH) SUCH AS 85 % RH

4. CONVECTION COEFFICIENT (Ha) SUCH AS 8 W/m2K

5. PIPES SIZE SUCH AS φ 12 mm. Up to φ 150 mm.

6. K VALUE OF THERMAL INSULATION SUCH AS 0.037 W/mK

Input Parameters


Home


Home

MOST OF THE ENERGY USED IN THE

BUILDING IN TROPICAL AREA IS FROM

AIR CONDITIONING SYSTEM

(APPROX. 50-70 % OF TOTAL ENERGY CONSUMPTION)


Home

Energy Loss = W/m


Home

Energy Loss – cost $


Home

Optimum Thickness Selection


24 HRS. 365 DAYS/YEAR AND 0.05 U$/KW•HR SO SIMPLE PAYBACK PERIOD AS FOLLOWS :

Simple Payback Calculation


�References


•NATRAJ COLD STORAGE – Kolkata

•SHIMA EDIBLES COLD STORAGE – Kolkata

•GREEN FIELD COLD STORAGE –Tinsukhia

•EVEREST COLD STORAGE – Purnea

•BHABHA ATOMIC RESEARCH CENTRE – Kolkata

•PARAG BREWRIES – Kolkata

•COMPUTER LAND CAPITA –Pune

•PEROT SYSTEM – DLF IT PARK – Chennai

•BARANI SILK – Erode

•CTS – Hyderabad

•FORD – Chennai

•GOA AIRPORT -

•SAHARA PRIME CITY –Mumbai

•Boomerang – Mumbai

•Times Square - Mumbai

•BNP PARIBAS – Kolkata & Mumbai

•MAHINDRA SATYAM IT PARK – Chennai

•HITACHI HOME & LIFE SOLUTIONS – Mehsana

•WESTERN REFREGERATION LTD. –Shahpur

•HOTEL RADISSON – Delhi

•HOTEL TAJ – Delhi

•HOTEL RED FOX – Delhi

•HOTEL ITC Grand CHOLA – Chennai

•HOTEL TRIDENT – Hyderabad

•HEMPTON Hotel – Baroda

•HOTEL HYATT REGENCY – Kolkata

•I TC SONAR BANGLA – Kolkata

•ESI HOSPITAL – Faridabad

•WOCKHARDT HOSPITAL - Mumbai

•APOLLO HOSPITAL – Chennai

•BELLVIEW NURSING HOME – Kolkata

•VEDANT HOSPITAL – Raipur

•PARAS PHARMACEUTICALS – Baddi

•HIMALAYA DRUGs – Ahmadabad

•PANACEA – Baddi

•CHITRA UTSAV -Gurgaon

•MAURYA FOODS PVT LTD –Kolkata

•THACKER DAIRY PRODUCTS PVT LTD – Kolkata

•NEOMACHINE MFG. CO Pvt Ltd. – Kolkata

•HEININ & HOPMAN ENG (I) PVT LTD – Kolkata

•AGROSHINE FOOD PRODUCTS – Kolkata

•NIRVIN COLD STORAGE – Kolkata

Reference List


•Bhaba Atomic Research Centre(BARC)

•Regional Center & Cancer Hospital Tew

Govt.,Medical Hospital

•Infosys Ltd

•DLF Universal ltd

•JCB India Ltd

•JCB India Ltd

•Shiv Nadar University

•Bharti Reality Ltd

•UPAL Universal Mall

•Hitachi Home & Life Solutions(India)ltd

•Hitachi Home & Life Solutions(India)ltd

•Amriprise India Pvt Ltd (Prestige Gp)

•Oracle

•Vardhman Institute of Medical Sciences

(VIMS) (Bihar Govt.)

•Nalasar University of Law

•Karvy Selenium

•Daikin Air Conditioning India Pvt Ltd

•L V Prasad Eye Institute

•IIT Hyderabad Campus

•Institute Of Liver & Biliary Science (ILBS)

•Adobe Systems India Pvt Ltd

•Civil Hospital

•Cancer Hospital

•LG Hospital - Auditorium

•

•Referral Hospital

•RMZ Galleria

•Indira Gandhi Medical College & Research

•Paul Georges Memorial School C/o St. Georges

School

•Clean Room Technologies

•GAETEC

•AMWAY India Enterprises Ltd

•Data Centre Complex

•Sterling Generators




Thank you

Documents

· penetration of moisture through fiberglass insulati on when covering chilled water pipe line (moisture sucking machine)