Thermaflex in Tallin - Paper 2
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1) The document discusses heat loss analysis and optimization of flexible pre-insulated piping systems produced by Thermaflex International Holding B.V. 2) It presents results of research measuring the effect of foam cell size, gas content, and density on heat loss, finding that increases in these properties increase heat loss. 3) The research led to process and recipe optimizations that reduced the gap between the pipe and foam and average cell size, lowering heat loss by 16%.
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Thermaflex in Tallin - Paper 2
- 1. Heat loss of a flexible piping system, analysis and optimization E.J.H.M. van der Ven, MSc. Thermaflex International Holding B.V. A new future for flexible pre-insulated piping systems
- 2. What ‘s your idea of a pre-insulated pipe?
- 3. This is our world of pre-insulated pipes
Editor's Notes
- Thermaflex Insulation Training
- Imagine pre-insulated pipe: Type of service pipe Type of foam Type of casing Length Color Etc... Do you have this in mind? I am going to tell about our research to practical heat loss according a new EN standard. I am going to show the most important influence factors and a study for optimization. This lead already to a lowering of our heat loss values of 16 percent. Thermaflex Insulation Training
- Flexible Fast installing time Advantages service pipe of PB [corrosion, homogeneous welding, high creep resistance] Low k-values high flow speeds in system possible Durability systems (minimaal 30 year) Resistance against earth quakes Recycling possible Disadvantages (do not mention): Maximum temperature = 95 degr. C Clean working conditions and accurate working conditions certified employees Service while starting the project Thermaflex Insulation Training
- Thermaflex Insulation Training
- In our own processes In our production We strive for the lowest lambda-values for our products We recycle our own product and have no factory waste Thermaflex Insulation Training
- Flexalen 600 Pre-insulated pipe Couplings (Electrofusion, buttwelding, mechanical) Pre-fabricated branches, risers, etc. Several tools for welding, scrapers, etc. Oxygen barrier products are avaialable The Flexalen system is certified (KIWA/KOMO/CSTB) Thermaflex Insulation Training
- Prefabricated, so no difficulties to connect the T-piece in the field Main branch (2x) Side branch (1x) Saving a lot of time Water tight connection Pre-checked in factory Thermaflex Insulation Training
- Production of Flexalen 600 split into 3 separate parts. These parts are coming together during the production of Flexalen 600 Thermaflex Insulation Training
- Extruder Vacuum cooling equipment Kaliber to adjust the sizes With ultra-sonic measure equipment 100 percent check for dimensions After production: 5 days of curing for cristallinization QC check for the whole product per batch: dimensions, hydrostatic pressure tests, moisture, MFI, etc. Only after complete QC check and 100% approved, the product goes into Flexalen 600 Thermaflex Insulation Training
- PE-Foam Extrusion Physical Foaming proces with a organic blowing agent Picture: head of the extruder with a pin and die to adjust the dimensions of the foam. You see: expansion of the foam The tric is to comine the foam, the PB-pipe and the corrugated outer casing in one step. This step is called the assembly. Of course no pictures of this, but the principle is based on Thermoplastic properties of all products. Thermaflex Insulation Training
- The end result of the assembly is the cooling after production of the end product. Thermaflex Insulation Training
- Thermaflex Insulation Training
- Start with 3 parameters: cell size, gas content and density These result in a kind of optimum. As a result of this research, an optimization of the foam production and process started. It is not just a process that started in 2009/2010, but in fact it is part of our vision, to minimize the waste of energy. Only by the new standard and the equipment it was possible to measure these effects. Thermaflex Insulation Training
- Enlargement of foam cell structure of picture: x60 A cross cutting of the foam is made. The computer calculated the average cell size of the foam in this cross section. Thermaflex Insulation Training
- Almost linear correlation between cross section of surface of the foam and the cell size of the Flexalen 600. The bigger the surface, the bigger the cell size. Thermaflex Insulation Training
- Almost the same correlation as the cell size, there is a correlation between the system lambda value of the Flexalen 600 and the cross section of the foam. The bigger the cross section of the foam, the higher the system lambda-value. Thermaflex Insulation Training
- Picture of a gass chromatograph. With an injection needle, gas is extracted from the foam. The gas is running through a packed column and has a certain retention time in the machine before it is detected. This retention time and the integrated surface, gives information about what type of blowing agent is available and how much. Thermaflex Insulation Training
- Figures measured direct after production. Percentages measured between 50 and 85 percent. Small sizes (outer casing 50 – 125) contain percentages between 50 and 70 percent, big sizes (outer casing 160 – 200) contain percentages between 70 and 85 percent. Thermaflex Insulation Training
- Volumetric density determination. Cut a piece of the foam, measure its mass. Measure the volume of the foam. Density is mass devided by Volume Thermaflex Insulation Training
- Picture left above: insert a probe in the Flexalen 600 product. The probe is built up according the guarded end principle. One measurement section, two section to prevent against leakage. The probes are heated electrically. Picture left bottom: equipment is cured at a temperature of 23 degrees C. Picture right: insert the sample in the equipment, connect the connectors and start the measurment. Results available after 30 minutes for small probes (25 – 40 mm), 60 – 90 minutes for medium probes (50 – 63 mm), 90 – 180 minutes for big probes (75 / 110 mm). Thermaflex Insulation Training
- Heat loss values for flexalen 600 in burried condition. According the standard calculated. Values are for single pipe, without influence of other pipes. Service pipe is 70 degrees C, soil is 10 degrees C. Thermaflex Insulation Training
- The ageing effect is measured by putting the product for a period of 6 months in a curing room of approximately 70 degrees C. After this period the blowing agent was measured (in all cases: 0 percent). The product was cured for two days at room temperature and the heat loss was measured again. Overall result is an increase in heat loss of average 9 percent (5-14 percent). Thermaflex Insulation Training
- It is a result of several years of experience. Thermaflex strives to optimize the heat loss results for all products. Results are measured for a period of approximately 1 year. Thermaflex Insulation Training
- This picture shows the improvement of our product range. Results are known for half a year. Average improvement is 16 percent. These figures are realized, however we think some optimization is possible. Thermaflex Insulation Training
- Thermaflex Insulation Training
- Thermaflex Insulation Training
- Refer to presentation Ivo Smits, Hans Korsman and paper presentations Thermaflex Insulation Training