ALP Aeroflex India Pvt. Ltd.
Emerging Trends In InsulationBy Shahab Z Ahmed (AVP)
Shahab Z Ahmed -AVP
ALP Aeroflex India Pvt. Ltd.
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 Aeroflex India Pvt. Ltd.
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 Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
- 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
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
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?
ALP Aeroflex India Pvt. Ltd.
Modes of Heat Transfer
ALP Aeroflex India Pvt. Ltd.
Cut Section of Fiber Glass Insulation
ALP Aeroflex India Pvt. Ltd.
Q = KA t
Thickness
K insulation
= K conduction
+ K convection
+ K radiation
Equation of Heat Transfer
ALP Aeroflex India Pvt. Ltd.
Heat Transfer- Cold Pipe
ALP Aeroflex India Pvt. Ltd.
Heat Transfer- Hot Pipe
ALP Aeroflex India Pvt. Ltd.
�Different Type of Insulation Material
ALP Aeroflex India Pvt. Ltd.
• 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
ALP Aeroflex India Pvt. Ltd.
2.1 OPEN CELL TYPE INSULATION SUCH AS FIBERGLASS, ROCK WOOL AND CALCIUM SILICATE
ALP Aeroflex India Pvt. Ltd.
PENETRATION OF MOISTURE THROUGH FIBERGLASS INSULATION
WHEN COVERING CHILLED WATER PIPE LINE
(MOISTURE SUCKING MACHINE)
ALP Aeroflex India Pvt. Ltd.
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ALP Aeroflex India Pvt. Ltd.
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ALP Aeroflex India Pvt. Ltd.
ALP Aeroflex India Pvt. Ltd.
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ALP Aeroflex India Pvt. Ltd.
�Properties of Good Insulation
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
K Value – Low and Stable
ALP Aeroflex India Pvt. Ltd.
CLOSED CELL STRUCTURE INSULATION IS
THE MOST SUITABLE FOR COLD
TEMPERATURE APPLICATION DUE STABLE K.
VALUE WHICH NOT VARY DUE TO % RH
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
3000 7000
Mu Value - Comparison
ALP Aeroflex India Pvt. Ltd.
Light Weight and Flexibility
ALP Aeroflex India Pvt. Ltd.
Rigid Foams – Non Flexible
ALP Aeroflex India Pvt. Ltd.
ALP Aeroflex India Pvt. Ltd.
� 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
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
HCN, NO2 , HFHIGHLY FATAL GASES
HCl, HNO3, H2SO4HIGHLY IRRITATE/ CORROSIVE GASES
CO, CH2O,CHYOZLESS TOXIC GASES
H2O, CO2NON TOXIC GASES
GASESTYPE
Combustion Gases
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
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Flammability Test
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
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.
ALP Aeroflex India Pvt. Ltd.
ALP Aeroflex India Pvt. Ltd.
� 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
ALP Aeroflex India Pvt. Ltd.
� AAIPL Product Range
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
� NBR –
� Class O ( FM approved), Class 1, Antimicrobial.
EPDM-
� Normal EPDM, High temperature EPDM.
Accosound-
� Normal, Antimicrobial
Technical Classifications
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
� Colour Tubes.
� Colour Sheet.
� Low density accosound
(140 kg/m3).
� High tensile sheet.
New Product development
ALP Aeroflex India Pvt. Ltd.
�EPDM Insulation (Future Material)
�Benefits of EPDM insulation
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
• 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
ALP Aeroflex India Pvt. Ltd.
• CHEMICAL STRUCTURE
• MOST OF NITROSAMINE ARE CARCINOGENTS
SUCH AS
N - NITROSODIMETHYLAMINE
N - NITROSODIETHYLAMINE
N - NITROSODIBUTYLAMINE
Nitrosamine Content
ALP Aeroflex India Pvt. Ltd.
_
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
ALP Aeroflex India Pvt. Ltd.
ALP Aeroflex India Pvt. Ltd.
EPDM NBR
EPDM vs NBR (Outdoor Installation)
ALP Aeroflex India Pvt. Ltd.
�Software Calculation
ALP Aeroflex India Pvt. Ltd.
ALP Aeroflex India Pvt. Ltd.
1. Minimum Thickness to Prevent Condensation
2. Energy Saving & Economic Thickness
Software Criteria
ALP Aeroflex India Pvt. Ltd.
ALP Aeroflex India Pvt. Ltd.
ALP Aeroflex India Pvt. Ltd.
• 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
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
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
ALP Aeroflex India Pvt. Ltd.
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ALP Aeroflex India Pvt. Ltd.
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MOST OF THE ENERGY USED IN THE
BUILDING IN TROPICAL AREA IS FROM
AIR CONDITIONING SYSTEM
(APPROX. 50-70 % OF TOTAL ENERGY CONSUMPTION)
ALP Aeroflex India Pvt. Ltd.
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Energy Loss = W/m
ALP Aeroflex India Pvt. Ltd.
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Energy Loss – cost $
ALP Aeroflex India Pvt. Ltd.
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Optimum Thickness Selection
ALP Aeroflex India Pvt. Ltd.
24 HRS. 365 DAYS/YEAR AND 0.05 U$/KW•HR SO SIMPLE PAYBACK PERIOD AS FOLLOWS :
Simple Payback Calculation
ALP Aeroflex India Pvt. Ltd.
�References
ALP Aeroflex India Pvt. Ltd.
•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
ALP Aeroflex India Pvt. Ltd.
•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
ALP Aeroflex India Pvt. Ltd.
ALP Aeroflex India Pvt. Ltd.
ALP Aeroflex India Pvt. Ltd.
Thank you