Technology of pre-insulated pipe systems: A combination of ... · PDF filemin average max method [2] ... LNG/Gas-Anlagen Excellent insulation performance at ... Erection of a com-pletely

Jabitherm Rohrsysteme AG 1

Jabitherm Rohrsysteme AG

Technology of pre-insulated pipe systems: A combination of ecology and economy

Referees: Thadeus Hoss | Jabitherm Rohrsysteme AG, TroisdorfWilhelm Lindemann | BASF Polyurethanes GmbH, Lemfördethematic support: Degreed Engineer Rainer Trültzsch | Vestocor Protective Coatings GmbH

Special synthetics implemented in pipe construction



Pipelines are an integral part of agile technology!

Pipelines underlie manifold physical influ-ences during their operation at site. Temperature fluctuation in flowing media induce continuously extension and contra-ction acially along the pipe run. Medium pipe, thermal insulation layer andouter jacket are in permanent movement. Wind and low ambient temperatures closeto installation provoke additional heatlosses. Vibration is caused by components installed in line along the process pipe run.

cool

hot



One attempt to „minimise“ heat losses along a pipeline !

effective?

practical?

One opportunity!



Conventional pipe technology

• medium pipe• mineral wool (loose/shells)• pipe jacketing

Initial point for a product development

Properties of popular pipe designs in plant construction.



Prevention of condensation in cavities and inside insulation material (impregnation).

Experience from practice shows:Condensation and ingress of moisture into pipe composit= source for corrosion of medium pipe and reduced insulation ability.

Search for an alternative insulation technology



Aggressive offenders on medium pipe surface

Corrosional defects on medium carrying pipes are provoked by manifold initiations!



Influences effect on medium pipes & surfaces in different ways!

Pitting corrosionStress corrosion

Galvanic corrosion

Intercrystalline corrosion

stainless steel



Conclusion of corrosive attacks:

untight/leaky medium pipes causing a loss of operation characteristics

repair effort and increased maintenance effort during regular pipe operation

without any prevention:



Protective Shield on medium pipe surface:Polyurethane-based coating on pre-insulated pipes

active segment 2nd layer(zinc phosphate & micaceous iron)

active segment 1st layer(zinc phosphate)

steel/stainless steel medium pipe



Protective shield on medium pipe surface:

Corrosion protection material acc. to AGI Q 151

Material: VESTOPUR 2K-DT | ZG 20 TS(primer and hardener)

Density: 1.42 … 1.48 g/mlTemperature stability: max. +130°CFlash point: > +230°CHandling time: 120 minutes

Material basis: polyurethaneorg. solvent content: 21% of weightHeavy metals: lead, cadmium, chromium VIHandling time: 120 minutes



Protective Shield on medium pipe surfacePolyurethane-based coating (VESTOCOR®) employed in all product series

of pre-insulated pipes RAPID & FIRESAFE®

layer paint type sump list [1] dry film thickness (DFT) [3] application

min average max method [2]

1 PC ZG20 60 80 a,s,b,r [4]

2 FC ZG22 60 80 a,s,b,r [4]

total 120 160

Remarks explaining table[1] paint material chpoice from "sump list"

[2] handling: a=airbrush | s=air spray | b=brush | r=roll application

[3] typical DFT is recommended

[4] brush or roll application; multiple coats might be needed to obtain the required DFT

Processing temperatures Surface preparation/consistancycontinuous operation +120°C sweap blasting

peak temperature +180°C pre-fabricated stained pipe



Merchantible components for pipe insulation

Foam shells made of insula-ting material (compressed organic/ inorganic material).

inorganic materials for thermal insulationmineral wool glass wool

Approach for a new technology?



What needs should an alternative technology fulfil?

cavities should becompletely andconsistantly filled

high mechanicalstrength

extreme long-term durability

properties

operating time



Properties which intercede for the employmentof polyurethane foam:

• considerable spreading• long-life performance• chemically neutral


Excellent heat conservation propertyof polyurethane (PU) foam insulation


))

cell diameter:~ 250 µm

cell wall:< 0.5 µm

density: ~ 60 kg/m3

closed cells


total = solid + gas + radiation

matrix blow. agent cell size

Thermal conductivity



Ideal thermal & mechanical properties

Thermal insulation property, λ (W/mK)

Mechanicalstrength

σ (N/mm²)

Foam densityρ (kg/m³)

break-even

60

800,027

0,024

0,10 0,20

70



Furthermore: The extreme adhesiveness and high mechanical strength of polyurethane foam!

The achievement after appliance:

Force-fit connection between medium pipe, thermal insulation and outer protective jacket.

Outer protective jacket

Polyurethane foam

Medium pipe surface




Practical referenceExcursion

Extreme and challenging operating conditions in a LBC Tank Terminal



Basic concept of pre-insulated pipeswith polyurethane foam insulation

a – folded spiral-seam pipejacket (material: metal) - alternatively: plastic plain

b – thermal insulation madeof polyurethane foam

c – medium pipeDN15 … DN800

standard pipe lengths: 6 and 12 meters



Project „LBC Tank Terminal Antwerpen“

Product : CyclohexanApplication : Transfer in pipelinesPipe sizes : 4, 6 and 8 inches

Preculiarity of installation: thermal insulation & pipe design

Conceptual formulation:• diffusion tightness• prevention against condensation• energy efficiency• retention of physical features over installation lifetime• maintenance-free system• high level of installation safety



Practical referenceProject „LBC Tank Terminal Antwerpen“


Design solution:• chemical nature/structure of polyure-

thane foam at volumeric weight be-tween 60 ... 80 kg/m³

• cavity-free foam insulation, continuous insulation inspection during manufac-turing process

• foam contents 85% of gas/air = λ-value between 0.024 … 0.027 W/mK(mineral wool: 0.038 … 0.048 W/mK)

• no material ageing when operated acc. to specification

• step-resistant, corrosion-resistant jacket• self-contained product philosophy





Design solution: Pipe construction

RAPID-CRYO(-195°C)

protective outer jacket

diffusion protection layer (separator)

diffusion protection layer (separator)

Polyurethane foam layers (cavity-free)






Discontinuous production of pre-insulated pipes


Manufacturing process: Pre-insulated pipe(dynamic)

polyurethanefoam



Long-term conservation of thermal insulation properties

Conservation of insulation proper-ties until end of overall transmis-sion time in industry.

Pipes insulated with polyurethanefoam reach a staedy thermal conductivity value short time after start-up on low target.

For comparison:mineral wool: 0.036 … 0.045 W/mK*glass wool : 0.035 … 0.050 W/mK** Influence: Consistance of insulation layer

The

rmal

co

nd

uct

ivit

y

Operation time (y)Thickness: 40mm

Thickness: 80mm



Behaviour of polyurethane foam under cryogen conditions

LNG/Gas-Anlagen

Excellent insulation performance attemperatures between -100°C and-195°C created in case of of single, double and triple layer insulation on pre-insulated pipes.

LNG/gas-complex

The

rmal

co

nd

uct

ivit

y

temperature



Application temperature range: Polyurethane foam used for thermal insulation

0°C

-195°C

+120°C

0°C



Too high working temperature

Overheating of polyurethane foam insulation after exceeding >>+120°C (yellow line, degradation) over a longer time

transition layer:medium pipe to insulation




Polyurethane conditioning: Fire prevention

Product series: FIRESAFE®Modified polyurethane for installationsinside combustible and/or hazardous areas.

Fire protection classes according to DIN 4102-1B1 low flammability (T30/T60/T90)B2 normally inflammable

Fire protection classes according toDIN EN ISO 13501New indications:A … F - s1 … 3 – d0 … 2

Picture, taken from the fire test at MPA (material testing laboratory), Dresden/Germany

testing device

inside

outside~ 1250°C

~ 24°C



Application range of pre-insulated pipes

Breweries

Gasanlagen

Food industry

Cooling complexes

FIRESAFE®

Industry

gas installation



Trace heating for pre-insulated pipes

To protect media in pipelines against frost, to keepmedia on process temperature or to increasetemperature, trace heating can optionally beimplemented.



Trace heating with pre-insulated pipes

Tracer tubes for installations with electrical heating systems, warm water & skin-effect heating solutions

100% surface contact = optimised heat transfer!

medium pipe

thermal insulation

tracing tube

heat-conductiveadhesive



Practical referenceExcursion II

Focus not only on pipelines: Polyurethane foam utilised in fixing points



Focus not only on pipelines: Polyurethane foam utilised in fixing points

polyurethane foam insulation

medium pipefixed-point

medium pipepre-insulated pipe

pipe-to-fixed-point connection



Focus not only on pipelines: Clamps on outer protective jacket

Only one inspection at operation start!No frequent checks during time of opera-tion!



Practical referenceExcursion II



Type testing: Fixed points for pre-insulated pipes

Evidence test for confirmation of force-fit connection.Check of fixed-points about attainable radial, vertical and axial forces.

vertical force axial force tangential force

40


Pipe designs


single-layer insulation double-layer insulation triple-layer insulation

single-layer insulation with trace heating



Product series: Pre-insulated pipes

RAPID-ESP all-purpose pre-insulated pipe with inbuiltenergy saving effect (ESP)maximum allowed operating temperature: +120°C

RAPID-COOL pipe system for operating temperatures between-60°C bis +120°C

RAPID-CRYO pipe system for cryogen operating conditions down tocryogen temperatures of -195°C (Gas/LNG)

FIRESAFE® pre-insulated pipes with special fire-protection system andfocus on installation in hazardous areas.



The company

Foundation: 1984, incorporated companyLocation: Troisdorf/Cologne

2. Location at Bad Lausick/Leipzig, 1990

Objetive of company:Development/manufacture of pre-insulated pipes and pipesystems. Spezialised on modification of insulation materials and thedevelopment of application-orientated products.

Quality Management Systems at both locations: Certified according to DIN EN ISO 9001:2008



Pre-insulated pipes series RAPID and FIRESAFE® installed in international projects

More than 25,000 meters installed in a brewery in South Africa. Erection of a com-pletely new facility ahead of theSoccer World Championships 2010.

Production facility of a brewery located in southern Germany.



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Thank you for your kind attention and interest!

Documents

Technology of pre-insulated pipe systems: A combination of ... · PDF filemin average max method [2] ... LNG/Gas-Anlagen Excellent insulation performance at ... Erection of a com-pletely