MANUAL

NAIMA
3EPLUS Program Registration

Version 2.12
You must complete and return this form for technical support, information regarding
updates, and new products.
Company:
Name:
Title:
Dept:
Address:
Country:
Phone:
Fax:
Email:
Thank you for completing this registration form and returning it promptly. We welcome any
constructive suggestions or comments you may have after working with the program.
Please mail the form to:

SofTech2
PO Box 55232
Grand Junction, CO 81505
or fax this page to 970-241-4107
i
Table of Contents
License Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Chapter I
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3EPLUS Program Operation . . . . . . . . . . . . . . . . . . . . . . 5
Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter II
3EPLUS Users Manual . . . . . . . . . . . . . . . . . . . . . . . . . 13
Project Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fuel Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Economic Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Report Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Insulation Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Insulation Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Surface Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installed Cost Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Program Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Example 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Chapter III
Thermal Insulation Materials . . . . . . . . . . . . . . . . . . . . . 45
Chapter IV
Heat Flow Calculations . . . . . . . . . . . . . . . . . . . . . . . . . 47
Thickness for Maximum Surface
Temperature or Thickness for
Condensation Control Using 1
Insulation Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Example 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Example 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Thickness for Maximum Surface
Temperature or Thickness for
Condensation control Using 2
Insulation Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Example 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ii
Heat Loss (Gain) Calculations
for up to 10 Selected Layers
of Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Example 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Example 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Heat Loss (Gain) Tables for
Multiple Surfaces in 5 Temperature
Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Surface Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Chapter V
Mathematical Model for Determination of
the Economic Thickness for
Hot or Cold Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . 69
Insulation related Costs . . . . . . . . . . . . . . . . . . . . . . . . 70
Heat Related Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Tax Savings for Hot Surfaces . . . . . . . . . . . . . . . . . . . . 72
Discounted Payback Period . . . . . . . . . . . . . . . . . . . . . 74
Heat Gain Related Costs . . . . . . . . . . . . . . . . . . . . . . . 76
Tax Savings for Cold Surfaces . . . . . . . . . . . . . . . . . . . 78
Discounted Payback Period for
Cold Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
List of Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Appendix A - Present Worth Factor . . . . . . . . . . . . . . . 83

Appendix B - Heat Flow Model . . . . . . . . . . . . . . . . . . . 85
Appendix C - Dew Point Model . . . . . . . . . . . . . . . . . . . 92
Appendix D - Thermal Conductivity Equations . . . . . . . 93
Appendix E - Carbon Dioxide Reduction . . . . . . . . . . . 95
Appendix F - Program History Documentation . . . . . . . 96
Appendix G - References . . . . . . . . . . . . . . . . . . . . . . . 98
Appendix H - Sample Input Data Forms . . . . . . . . . . . 101
iii
North American Insulation
Manufacturers Association (NAIMA)
NAIMA Program License Agreement
YOU SHOULD CAREFULLY READ THE FOLLOWING TERMS AND CONDITIONS

BEFORE INSTALLING THIS DISKETTE PACKAGE. INSTALLING THESE PROGRAMS
ON YOUR COMPUTER INDICATES YOUR ACCEPTANCE OF THESE TERMS AND
CONDITIONS.
The programs contained in this package are copyrighted. Any attempt to copy the
programs or alter them in any way is a violation of this agreement and US copyright laws.
NAIMA provides these programs and licenses their use. The user assumes the
responsibility for the selection of the program to achieve the intended results, and for the
installation, use, and results obtained from the program. The user assumes all risk and
liability resulting from the installation and use of the programs, whether used singly or in
combination with other programs, services, or goods. NAIMA neither assumes nor
authorizes any person to assume for NAIMA any other liability in connection with the sale
or use or installation of the programs, and there are no oral agreements or warranties
collateral to or affecting this agreement.
LICENSE
You may:
1. use the programs on a single machine. The network version allows you to use the
programs on only the machines registered.
2. transfer the programs and license to another party if the other party agrees to
accept the terms and conditions of this Agreement. If you transfer the programs,
you must at the same time transfer all program materials and manuals.
DISCLAIMER OF WARRANTIES
THE PROGRAMS ARE PROVIDED "AS IS" AND "WITH ALL FAULTS". NAIMA MAKES
NO WARRANTY OF ANY KIND WHATEVER, EITHER EXPRESSED OR IMPLIED, AND
EXPRESSLY DISCLAIMS ANY AND ALL IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE ENTIRE
RISK AS TO THE QUALITY AND PERFORMANCE OF THE PROGRAMS ARE WITH THE
PURCHASER. SHOULD EITHER PROGRAM PROVE DEFECTIVE, YOU AND NOT
NAIMA, ASSUME THE ENTIRE COST OF ALL NECESSARY SERVICING, REPAIR, OR
CORRECTION.
iv
SOME STATES DO NOT ALLOW THE EXCLUSION OF IMPLIED WARRANTIES, SO
THE ABOVE EXCLUSION MAY NOT APPLY TO YOU. IN THAT EVENT, ANY IMPLIED
WARRANTIES ARE LIMITED IN DURATION TO NINETY (90) DAYS FROM THE DATE
OF DELIVERY OF THE SOFTWARE AND NAIMA'S ENTIRE LIABILITY AND YOUR
EXCLUSIVE REMEDY SHALL BE THE REPLACEMENT OF ANY DISKETTE WHICH IS
RETURNED TO NAIMA THAT HAS NOT BEEN TAMPERED WITH AND WITH THE
PROGRAMS RECALLED.
IN NO EVENT WILL NAIMA BE LIABLE TO YOU FOR ANY DAMAGES, INCLUDING ANY
LOST PROFITS, LOST SAVINGS, OR OTHER INCIDENTAL OR CONSEQUENTIAL
DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE EITHER PROGRAM
EVEN IF NAIMA OR ITS AUTHORIZED DISTRIBUTOR HAVE BEEN ADVISED OF THE
POSSIBILITY OF SUCH DAMAGES, OR FOR ANY CLAIM BY ANY OTHER PARTY.
SOME STATES DO NOT ALLOW THE LIMITATIONS OR EXCLUSION OF LIABILITY

FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE LIMITATIONS OR
EXCLUSION MAY NOT APPLY TO YOU.
The laws of the Commonwealth of Virginia govern this agreement . Should you have any
questions concerning this Agreement, contact NAIMA 44 Canal Center Plaza, Suite 310,
Alexandria, VA, 22314.
By installing the program:
YOU ACKNOWLEDGE THAT YOU HAVE READ THIS AGREEMENT, UNDERSTAND IT,
AND AGREE TO BE BOUND BY ITS TERMS AND CONDITIONS. YOU FURTHER
AGREE THAT IT IS THE COMPLETE AND EXCLUSIVE STATEMENT OF THE
AGREEMENT BETWEEN US WHICH SUPERSEDES ANY PROPOSAL OR PRIOR
AGREEMENT, ORAL OR WRITTEN, AND ANY OTHER COMMUNICATIONS BETWEEN
US RELATING THE SUBJECT MATTER OF THIS AGREEMENT.
v
FOREWORD
As we all know, energy has a long term effect on every individual. It is the concern of
virtually every individual and business organization in our nation. It also is a major
concern of the North American Insulation Manufacturers Association (NAIMA). NAIMA
represents a large producing segment of an industry dedicated to the conservation of
energy. As a result of the oil embargoes, political unrest in the oil-producing countries,
and other factors, NAIMA has refined economic thickness determination to accommodate
the new and higher costs and again later to adapt the procedures to insulating existing
facilities. Now there is an updated method to meet today's economic realities. This report
finalizes and documents research performed by Louisiana Tech University for NAIMA from
April l979 to August l979 and work contracted to Tutco Scientific from 1989 to 1991. The
report documents two new computer programs for determining the economic thickness for
thermal insulation for hot and cold surfaces and the calculation of heat loss and surface
temperature. It examines the mathematics of determining the economic thickness for a
given application and presents a user's manual for the utilization of the programs. We are
indebted to many people who assisted in the research and preparation of this manuscript.
The original economic thickness program was prepared by:

Dr. B. F. Blackwell and D. E. McConnell
Louisiana Tech University, Mechanical Engineering Department
Ruston, L.A. February, 1980
The original heat loss program was prepared by:

SofTech²
Grand Junction
CO 81521 March 1991
The previous releases of the economic thickness program were to provide the user with
an easy method to determine economic thicknesses. The objective was to provide a
program that could be run on a personal computer at the convenience of the user. Several
users have made suggestions on the user interface and what they really needed from the
program. This release incorporates many of those suggestions. The new release is
designed to provide a table that summarizes the economic thicknesses for the given
information. The heat loss calculation technique has been changed to agree with the
method adopted by ASTM Committee C16 on Thermal Insulations. A separate heat loss
program has been incorporated to allow the casual user to calculate heat losses and
surface temperatures without having to enter all the economic data.
1
CHAPTER I
INTRODUCTION
The oil embargo of 1973 and recent unrest in the oil-producing countries of the Middle
East have stimulated renewed interest on a variety of alternative energy sources.
However, studies have indicated that energy conservation can be more cost effective than
the utilization of energy from one of the newly emerging alternate energy sources.
Thermal insulation is certainly an effective means of conserving energy. The question to
be addressed by this program is how much insulation can one economically justify in
today's changing fuel market.
Reference 1 reviews the work done on the determination of the economic thickness of
industrial insulation. An outgrowth of the Reference 1 work was the development by
Ranck of several computer programs for the determination of the economic thickness of
insulation (Reference 2). The primary differences between this work and work by Ranck
are in the following areas:
a) fuel inflation rate

b) equipment maintenance
c) insulation maintenance
d) equipment investment
e) tax savings
f) carbon dioxide reduction
The economic analysis procedure that was adopted for this program is an after-tax annual
cost method. All costs associated with owning insulation are expressed on an equivalent
uniform annual cost basis. Each commercially available thickness is analyzed, and the
thickness with the lowest annual cost is the economic thickness (ETI). For situations in
which condensation (sweating) is a problem, calculations will be performed to determine
the condensation control thickness. Depending on the fuel source, the program will
estimate the reduction in Carbon Dioxide emissions due to the use of additional insulation.
Chapter II describes the input procedure for both hot surface and cold surface
applications. Chapter III discusses the thermal conductivity data maintained by the
program. It describes how to remove and add insulation materials. Chapter IV describes
the method used for simple heat loss calculation. This part of the program can be used
to do surface temperature calculations, condensation control calculations and print heat
loss tables. Chapter V presents a detailed description of the mathematical model for the
3EPLUS program. The manual is organized in a manner that would allow the person who
is primarily interested in utilizing the computer results to skip the details of Chapter V.
2
GETTING STARTED
Throughout this manual, information that the user must type is printed in BOLD ITALICS.
When typing commands, type the command as shown then press the ENTER key.
The economic thickness of insulation program is named 3EPLUS.
The installation instructions assume that the user is using drive A. If drive B is to be used,
substitute the appropriate letter in the commands below. The normal procedure will install
the program to drive C: and subdirectory NAIMA. To change either of these parameters,
use the alternate installation command. Technical support is available from the company
that provided this program package. To get support, call the company contact on the
business card provided with the program package.
NETWORK USERS
The program is not network compatible. It may or may not function correctly. It is not
designed to communicate with a remote printer.
Standard Program Installation
Users who have older versions of the Economic Thickness, Heat Loss, or 3EPLUS
programs should remove these programs since the older version cannot use the files from
the new version.
For normal installation, insert the 3EPLUS disk into the diskette drive and type:
A:INSTALL
A subdirectory will be created on drive C and all the programs copied to it. If you have an
older version, the directory may already exist. If it exists, you will see an error message
on the display, neglect the message.
3
Custom Program Installation
To install the program and files to your own subdirectory, type the install command as
below.
INSTALL FROM: TO: SUB
where FROM: is the floppy drive ID letter that contains the

original 3EPLUS disk
TO: is the hard disk drive ID that will contain the

3EPLUS program and its data files.
SUB is the subdirectory on the hard disk where the

program will be stored.
To put the commands on the screen for easier use, type INSTALL ?. This will display all
the required information to install the program.
During the installation process, the user will be asked to enter his name and address. This
information will be saved by the program and printed on all reports. This identifies the
owner of the program.
The 3EPLUS program is copyrighted, you cannot use the program on more than one
machine unless you purchase additional programs.
The 3EPLUS disk is compressed, therefore you must use the installation commands as
shown. If you decide to use the program on a different computer, you can erase the
programs and then install it on the other computer. In any case, the original program
diskette must be used.
INSTALLATION PROBLEMS
If you encounter any problems during installation and you see errors displayed on the
screen during the copying, retry the installation procedure. This may occur if you type an
invalid name for the directory or do not separate the drive ID names from the directory
name.
In some cases, certain TSR (Terminate and Stay Resident) programs may not work
properly with this program. Since this program frequently uses and updates disk files,
some anti-virus and disk monitoring programs can cause the 3EPLUS programs to fail.
4
Program Verification
To verify that the programs have been properly installed, go through the following steps:
1. Change the directory to the NAIMA directory by typing CD \NAIMA. If the program
was installed to a different directory, use the correct directory name.
2. Type the name of the program, 3EPLUS.
3. The program will load into memory then display a menu.
4. Select Retrieve the information from a PREVIOUS 3EPLUS JOB by using the
arrow keys to highlight the choice then press ENTER.
5. Use the arrow keys to select the example 1 file, EX1.ETI, then press ENTER.
6. When the program displays the first screen, press the F3 function key to begin
preparing the report.
7. The program should print a report. The output report can be compared to Example
1 at the end of Chapter I.
3EPLUS PROGRAM OPERATION
First go to the NAIMA directory, or use an appropriate PATH statement. Refer to the
User's Manual that accompanied your computer for information about the Change
Directory (CD\) command or the PATH statement.
Type 3EPLUS then press ENTER.
The program will start by loading all the required data files and then display a menu. Use
the arrow keys to select the choice. The default option for the 3EPLUS program is to Start
NEW 3E ECONOMICS JOB and type new information about that job. Chapter II describes
the 3EPLUS program operation when this option is selected.
Start NEW 3E ECONOMICS JOB

Retrieve the information from a PREVIOUS 3EPLUS JOB
HEAT FLOW calculations only
Update the THERMAL CONDUCTIVITY file
Change SCREEN COLORS
5
The second option is to Retrieve the information from a PREVIOUS 3EPLUS JOB. This
option allows the user to make changes to the data or to begin printing a report
immediately. You do not have to go through all the questions to start the report. Select
the file name using the arrow keys then press ENTER.
The third option is to run HEAT FLOW Calculations only to determine heat losses or
gains from piping, tanks, or flat surfaces. Use this option where you are not interested in
economics. Chapter IV describes this selection and how to determine the amount of
insulation to use for condensation control or a maximum surface temperature specification.
The fourth option is Update the THERMAL CONDUCTIVITY file. This option allows the
user to add, delete, or print a list of insulation materials from the program. After selecting
this option, a new menu will be displayed. Chapter III describes this option and how to
change insulation materials.
The next option is to Change SCREEN COLORS. This option allows the user to
customize the colors used in the program. If the computer is a laptop with an LCD screen,
this allows the user to pick the best combination for his computer type.
The last option is QUIT and Return to DOS. This choice stops the program.
IMPORTANT
When starting a new job, be careful when typing the file name. File names are very
important. Invalid file names can result in the loss of valuable data. Consult the PC-DOS
or MS-DOS manual about how to name a file. Do not use periods, commas, blanks, or any
other punctuation marks in the name. Names are limited to eight characters. Choose
names that mean something to the user such as the job name, etc. This will help reduce
confusion on systems that have many files. It is also helpful to keep a log of file names
and a brief description of the job. This will allow the user to locate a particular file when
the need arises. If the user needs disk space, copy older files to a floppy disk and store
for future reference.
HELP
Help screens are available at any time to provide additional information and typical
answers. To get help, locate the cursor on the question of interest and press the F1
function key. The program will display HELP information. Press any key to return to your
original place.
6
PAGE UP AND PAGE DOWN
You may use the Page Up [Pg Up] or Page Down [Pg Dn] keys to accept the information
displayed on most screens. The Page Down key displays the next screen while the Page
Up key displays a previous screen.
7
EXAMPLE 1 - File EX1.ETI
NORTH AMERICAN INSULATION MANUFACTURERS ASSOCIATION (NAIMA)
NAIMA 3EPLUS ECONOMIC THICKNESS ANALYSIS REPORT, Version 2.12
Project Name = Example #1

Project Number = 123-45
System = Production Steam Boiler
Location = Central Plaza
Date = 12-01-1995
Engineer = Plant
Contact =
Phone = ext 3765
All the information printed in this report is based on the given input
information. Actual values will vary depending on the actual service
conditions. The system of mathematical heat flux equations used in this
analysis has been accepted by ASTM as applicable for most systems
normally insulated with bulk-type insulations. The thermal performance
equations are based on laboratory conditions and may not represent
actual system performance. NAIMA makes no warranty of any kind, either
expressed or implied, as to performance of the actual system and
expressly disclaims any and all implied warranties of merchantability
and fitness for a particular purpose.
Entry date 12-01-1995 Report date 04-12-1996

File Name = EX1.ETI Page 1
8
Fuel Type = Liquid

First Year Price = 0.64 $ per gallon
Heating Value = 91000 Btu per gallon
Efficiency = 75.0%
Annual Fuel Inflation Rate = 6.0%
Annual hours of operation = 8320 hours
ECONOMIC DATA
Interest rate or Return on investment = 10.0%
Effective Income Tax Rate = 30%
Physical Plant Depreciation Period = 7 years
New Insulation Depreciation Period = 7 years
Incremental Equipment Investment Rate = 3.47 $/MMBtu/hr
Percent of New Insulation Cost for
Annual Insulation Maintenance = 2%
Percent of Annual Fuel Bill for
Physical Plant Maintenance = 1%
Ambient temperature = 75 F
Emittance of outer jacketing = 0.10
Wind speed = 0 mph
Emittance of existing surface = 0.90
Reference thickness for
payback calculations = 0.0 inches
Insulation material = 1200F MIN.FIBR BOARD ASTM C612-93

9
Surface or Pipe Number 1

Top of Tank - Steel
Complexity factor = 1.00
Performance Service factor = 1.00
Insulation costs estimated by FEA method

Labor rate = 38.35 $/hr
Productivity factor = 100
Price of 2x2 pipe insulation = 4.97 $/ln ft
Price of 2 inch block = 1.71 $/sqft
Operating Temperatures
200 300 400 500 600 700 F
ECONOMIC
THICKNESS 1.0 4.0 4.0 6.0 6.0 6.0 in
HEAT LOSS 26 16 25 25 35 46 Btu/sqft/hr

SURF TEMP 105 95 104 104 113 123 F
PAYBACK 0.35 0.21 0.10 0.10 0.10 0.10 yr
ANNUAL COST 1.81 2.89 3.55 4.33 4.99 5.77 $/sqft/yr
TOTAL SAVINGS 20 46 79 123 178 248 $/sqft/yr
CARBON DIOXIDE
REDUCTION 419 985 1692 2615 3768 5212 Lbs/sqft/yr

10

Vertical Flat Surface - Steel

200 300 400 500 600 700 F
ECONOMIC
THICKNESS 1.0 3.0 3.0 3.0 4.0 4.0 in

SURF TEMP 110 104 118 133 136 152 F
PAYBACK 0.38 0.29 0.14 0.10 0.10 0.10 yr
CARBON DIOXIDE

11

Bottom of Tank - Steel

200 300 400 500 600 700 F
ECONOMIC
THICKNESS 1.0 4.0 4.0 4.0 6.0 6.0 in

SURF TEMP 118 106 120 137 134 150 F
PAYBACK 0.57 0.33 0.16 0.10 0.10 0.10 yr
CARBON DIOXIDE

12
CHAPTER II
3EPLUS USERS MANUAL
INTRODUCTION
The 3EPLUS program calculates the economic thickness of industrial insulation for a wide
variety of operating conditions. There are five different fuel types and five different surface
orientations. Several different generic insulation materials have built-in thermal
performance relationships, plus the user has the option of supplying conductivity data for
other materials. The large number of possible combinations of program options gives a
great deal of flexibility to the computer program. Typical program output includes annual
cost of owning the insulation (per unit area or foot of pipe length), payback period, surface
heat loss and the surface temperature for each insulation thickness considered. The
economic thickness is the thickness that gives the minimum annual cost over the
designated insulation life. The analysis can be described as an after-tax, annual-cost
procedure.
A detailed description of the economic analysis procedure used in the 3EPLUS program
is presented in Chapter V. For the user that desires a better understanding of the
computational procedure for determining the economic thickness, it is strongly
recommended that Chapter V be studied. For the person primarily concerned with using
the program and its output, it is not necessary to consider Chapter V in great depth.
The remainder of this chapter will be devoted to describing the input information and the
proper format for typing information into the program.
The input data are broken up into several screens. Each screen is described below. To
begin, select Start NEW 3EPLUS ECONOMICS JOB from the main menu.
Start NEW 3E ECONOMICS JOB

Retrieve the information from a PREVIOUS 3EPLUS JOB
HEAT FLOW calculations only
Update the THERMAL CONDUCTIVITY file
Change SCREEN COLORS
QUIT and return to DOS
13
SCREEN 1 - PROJECT DATA
This screen consists of eight questions of descriptive information that can be used to
identify the particular job. A blank line is acceptable. The information entered will be
printed in the heading of the report.
The last two questions on this page are to select a Hot or Cold surface analysis and to
select a new or retrofit application. The default is a Hot surface analysis for a New
surface.
NORTH AMERICAN INSULATION MANUFACTURERS ASSOCIATION

Owner Name
Project Name =
Project Number =
System =
Location =
Date = 12-01-1993
Engineer =
Contact =
Phone =
Analysis of Hot or Cold surface (H or C) = H
SCREEN 2 - FUEL SELECTION
Any one of five types of fuel can be selected by using the arrow keys to highlight the
appropriate choice. The different fuel types have different units for both price and heating
value.
Liquid ($/gal)
Gas ($/mcf)
Solid ($/ton)
Electricity ($/kWh)
14
SCREEN 3 - FUEL DATA
This screen is used to enter economic information about the fuel chosen in the last screen.
The user can change the defaults displayed or can type new information.
Fuel Data
First year price ($ per gallon) = 0.640
Heating Value (Btu per gallon) = 91000
Efficiency (%) = 75.0
Annual Fuel Inflation Rate (%) = 6.0
First Year Price: Type the price in dollars per unit as shown on the screen. This is the
price at the start or beginning of the project. This price will be inflated throughout the
duration of the project.
Default values are included in the program and may be used by the operator. The values
were obtained from the US Department of Energy and were the most recent data available
when this manual was written. The user should be aware that the actual cost may vary
considerably. The user should strive to get cost data that is specific for the job at hand.
Updated information may be available from the Department of Energy.
Manufacturing Energy Consumption Survey, 1988
Coal 1.72 $/MMBtu

Natural Gas 2.52
Distillate 4.66
LPG 5.27
Electricity 13.44
DOE weighted average 4.68
For example, if the user selects coal as the fuel, the default values for the heating value
and cost per ton equal the DOE value of $1.72/MMBtu will be displayed. The user should
use these values only if he does not have access to any other cost information. The same
applies to the other fuel types.
Heating Value: Type the amount of heat that one unit of the fuel can give off. This number
will be corrected by the efficiency of conversion in the next question.
15
SOME TYPICAL HEATING VALUES
LIQUIDS #2 OIL 134000 - 146000 Btu/Gallon

#4 OIL 138000 - 152000
#6 OIL 140000 - 155000
LIQUID BUTANE 102000
LIQUID PROPANE 91000
GASES NATURAL 960 - 1100 Btu/Ft3

BUTANE 3200
PROPANE 2500
PRODUCER 150 - 200
SOLIDS LIGNITE 8000 Btu/Lb

SUB-BITUMINOUS 8300 - 13000
BITUMINOUS 11000 - 14000
ANTHRACITE 12000 - 15000
WOOD 4800 - 6300
PEAT 7600 - 10000
ELECTRICITY 3412 Btu/kW
Efficiency: Type the conversion efficiency of the equipment. This is the efficiency from
converting one unit of fuel into the heating medium used in the process, such as steam or
hot air.
Annual Fuel Inflation Rate: This is the annual rate at which fuel prices are inflating. Since
this quantity is assumed to be constant over the insulation life, it should be representative
of what is expected over the long term. Although there are instances where fuel prices
escalated very rapidly or even reversed, it is extremely unlikely that one could expect such
rates to continue for 10-20 years into the future. Although this is a very speculative
quantity, it will certainly be greater than zero. The default value is 6%.
If the job is for cold surfaces, the following questions will also be displayed.
Cost of Condenser Make-Up Water: This represents the current price of the make-up
water evaporated at the condenser, in $/1000gal.
Annual Condenser Water Inflation Rate: This is the estimated annual rate of increase in
the price of make-up water.
16
SCREEN 4 - ECONOMIC DATA
This screen consists of seven or eleven items that specify the economic and general
parameters that remain fixed for all of the operating conditions. Each item will be
discussed in the order it is displayed on the screen. There are seven questions for a Hot
surface analysis and eleven questions for a condensation control analysis.
ECONOMIC DATA
Interest rate = 10.0 %
Effective Income Tax Rate = 30.0 %
New Insulation Depreciation Period = 7 yrs
Annual Insulation Maintenance = 2 %
Physical Plant Maintenance = 1 %
Interest Rate or Return on Investment: This is the best estimate of the average cost of
money over the financial life of the project. You may also consider using a minimum
required return on investment. After corporate taxes have been paid, this represents the
minimum acceptable rate of return on investment required by management. This variable
has a large effect on the economic thickness. The default is 10%.
Effective Income Tax Rate: This represents the effective corporate tax rate(%) for local,
state, and federal income tax. Since state income tax is deductible from the federal return,
the effective tax rate(%) can be calculated from
TR = (STATE TAX RATE + FEDERAL TAX RATE) -

((STATE TAX RATE X FEDERAL TAX RATE)/100)
The default is 30%.
Physical Plant Depreciation Period: The incremental cost of the heating or cooling plant
is depreciated over the equipment life by the straight line method. For a job where there
is no incremental physical plant cost, then the depreciation period has no significance.
The minimum acceptable value is 1 year if you type an incremental cost. If you type 0,
then type 0 for the incremental physical plant cost below. The default is 7 years.
17
Economic Life of New Insulation: In addition to the new insulation life, this quantity
represents the period of economic analysis for the problem. All costs are uniformly
distributed over the insulation life. The default is 20 years.
Incremental Physical Equipment Investment: The addition of insulation can cause a

reduction in the physical plant load. For the design of a new plant, the increased
insulation should be given credit for a smaller physical plant. This quantity represents the
cost of adding an increase in the physical plant capacity of 1,000,000 Btu/hr. Two plant
sizes and their corresponding costs are necessary to calculate this quantity. It is assumed
that the relationship is a straight line between cost and the plant capacity range of interest.
Plot the rated capacity (MMBtu/hr) on the X axis versus physical plant cost($) on the Y
axis. The incremental investment is the slope of the line. This has a very small effect on
the economic thickness.
If these data are unavailable, suggested values are

Oil Gas Electric
Water Boiler 10.49 10.62 5.04
Steam Boiler 7.68 3.47 7.29
The default is 3.47.

Source: Means Construction Cost Data 1991, 49th Edition
For jobs that have an existing physical plant, the plant size is already fixed and the
addition of insulation should not be given credit for a reduction in size, therefore type zero.
Percentage of New Insulation Cost for Annual Insulation Maintenance: The first year's
insulation maintenance is proportional to the initial insulation cost. Each succeeding year,
the insulation maintenance is allowed to inflate at the same rate as fuel.
Percentage of Annual Fuel Bill for Physical Plant Maintenance: The physical plant
maintenance is assumed to be proportional to the cost of the heat loss or gain. The plant
usage increases with increased heat loss or gain for a fixed load. Each succeeding year,
the plant maintenance is allowed to inflate at the same rate as fuel.
The following prompts will appear if the user selected a cold surface analysis.
Water Operated Condenser Factor: If the condenser rejects heat to water, an amount of
water must be evaporated to the atmosphere. The quantity represents the required
gallons of make-up water per ton of capacity per hour of operation. An electric driven
compression system has a factor of 3.2. An absorption system has a factor of 6.2. These
are typical values reported by ASHRAE in the Handbook of Fundamentals. The default
is 6.2.
18
Coefficient of Performance: This is the coefficient of performance of the chiller system,
and should always be expressed as a decimal. This information is available from the
manufacturer or may be included with the equipment literature.
Design Wet Bulb Temperature: Condensation will occur on a cold surface if the
temperature is below the dew point. The design wet bulb temperature and the relative
humidity are used to determine the design dew point. If the cold line is outside, then the
design wet bulb can be considerably above the annual average temperature that was used
to determine the annual heat loss. The design wet bulb temperature should be a worst
case condition whose annual occurrence rate is relatively infrequent while the annual
average temperature is representative of an average of what happens over the entire year.
For cold lines located indoors, the design wet bulb may or may not be the same as the
annual average ambient temperature. It may be necessary to consider a worst case
situation for which the design wet bulb is greater than the annual average ambient
temperature.
Design Relative Humidity: The design relative humidity along with the design wet bulb
temperature is used to determine the design dew point. Typical data for the relative
humidity and design temperatures are available in the ASHRAE Handbook of
Fundamentals or from the National Weather Service publications on monthly weather
information by state.
SCREEN 5 - OPERATING INFORMATION
This screen is used to indicate fixed conditions concerning the operation of the job. The
user can accept the default numbers or type in new information.
OPERATING INFORMATION
Wind = 0 mph
19
Ambient Temperature: The average annual temperature on the exterior of the insulated
pipe or surface. For outdoor applications, this information is available from a variety of
sources, such as the National Weather Service, or sometimes the local Chamber of
Commerce. This variable has a moderate effect on the calculated heat losses, and a small
effect on the economic thickness. The default is 75oF representing indoor conditions.
Average Annual Wind Speed: This influences the convective heat loss from the insulation
surface that is exposed to the air. For indoor applications where natural convection is
prevalent, use zero. The item has a moderate effect on the calculated heat losses and a
large effect on the surface temperatures. The wind speed has a small effect on the
economic thickness. The default is 0 mph representing indoor conditions.
Emittance of Surfaces: This data is required to calculate the surface heat transfer film
coefficient. Typical values are available by pressing the F1 function key to get HELP. For
the best accuracy, data should be obtained from the manufacturer of the external jacket.
This data has a large effect on the insulation surface temperature but only a small effect
on the calculated heat losses. The emittance has a very small effect on the economic
thickness. The default is 0.1 representing an average of reported values for aluminum
jacket.
Some typical emittance values include:

Aluminum, new, bright 0.04
Aluminum, oxidized, in service 0.1
Stainless Steel, new, cleaned 0.13
Stainless Steel, dull, in service 0.3
Iron or Steel 0.8
Painted metal 0.8
Galvanized steel, new, bright 0.1
Galvanized steel, dipped or dull 0.28
All Service Jacket 0.9
Aluminum Paint 0.5
Canvas 0.9
Roofing felt and black mastic 0.9
Colored mastic 0.9
Plastic pipe or jacket (PVC or FRP) 0.9
Sources: Mark's Handbook for Mechanical Engineers, 8th Edition
Malloy, J.F., Thermal Insulations, 1969
Reference Thickness: This number specifies the starting thickness used for calculating
the reference heat loss which is in turn used to calculate the energy savings for the
discounted payback period. The most common case is zero indicating a bare pipe or
surface as the reference condition. This option might be used when a company's
20
insulation thickness specification is smaller than the economic thickness, and the
discounted payback period of the economic thickness in relation to the specification
thickness is desired. For this situation, the discounted payback period is the time required
for the present value of the energy savings to exactly balance the present value of the cost
differential between the economic thickness and the company specification. The default
is zero representing a bare surface.
Annual Hours of Operation: The time in hours that the system is in operation each year.
The default is 8320. This represents 90% of the number of hours in a year.
SCREEN 4 - REPORT FORMAT
The program is designed to produce one of two styles of reports. The majority of the time,
the summary table report will be the most useful. It generates a table of economic
thicknesses for a range of operating temperatures and a range of pipe sizes. This is
useful in developing insulation standards for a particular job. The other style is for those
situations where the user is more interested in detailed financial and engineering data.
This option prints an individual table for each surface and each temperature. If the job has
many surfaces and many different operating temperatures, this option will require a large
amount of printer time and paper. The default is a summary table style report.
Summary Table
Detailed Report
Depending on the user choice, one or two questions will be displayed. If the user selects
a Detailed Report, then one question will be displayed, the operating temperature. For a
Summary Report, the user will be asked to type the starting temperature and temperature
step size.
Starting Temperature: For the economic thickness summary table report, this is the
temperature in the first column of the table. There will be 5 columns in the table. The
starting temperature must be at least 25oF above or below the ambient temperature.
Temperature Step: For the tables report, this is the step size between each of the columns
in the table. The program will not allow the table to go from below ambient to above
ambient due to the calculation technique. For cold surfaces, it is best to use a negative
step size to avoid the problem. It the user attempts to cross the ambient, the step size will
be reduced automatically.
21
Operating Temperature: For the detailed report, this is the operating temperature of the
hot or cold surface. In either case, the operating temperature must be at least 25oF above
or below the ambient temperature.
SCREEN 5 - INSULATION TYPE
The user will be given a choice of selecting an insulation material that has been stored in
the program, or be allowed to enter a new insulation material.
Thermal Conductivity Insulation File

New Material That Has Not Been Previously Saved
The default is to use the Thermal Conductivity Insulation File. This contains default
insulation choices plus any other insulation materials that have been previously entered.
The default file provided with the program includes several generic insulation materials
and the thermal conductivity curves of those materials as provided by the ASTM material
specification. Notice in the table below, the material is listed and also the ASTM
specification number, class (if any), and the specification date.
If the choice was to enter a new material then the user can type the thermal performance
characteristics for a new material. If the user selects to use a material that is already in
the program, a list of those materials will be displayed in the next screen.
SCREEN 6 - INSULATION MATERIAL
Insulation Type: If the selection from the previous menu is Thermal Conductivity
Insulation File then the user can select from a list of materials maintained by the program.
Use the arrow keys to select the material, then press ENTER. The materials and their
respective thermal conductivity equations are shown in Appendix D. The thermal
conductivity equations are derived from ASTM material specifications.
22
1800F MIN.FIBR BLOCK ASTM C612-93
1200F MIN.FIBER BORD ASTM C612-93
850F MIN.FIBER BOARD ASTM C612-93
450F MIN.FIBER BOARD ASTM C612-93
CALCIUM SIL PIPE+BLK ASTM C533-95
PERLITE PIPE & BLOCK ASTM C610-95
CELLULAR GLASS BLOCK ASTM C552-91
1200F MIN.FIBER PIPE ASTM C547-95
850F MIN. FIBER PIPE ASTM C547-95
Up to this point, all the information types is fixed for the entire analysis. The program will
allow the user to analyze 25 surfaces. The surfaces will be numbered from 1 to 25. For
each surface, the programs will redisplay screens 7 and 8 until the user has completed
typing all the information.
SCREEN 7 - SURFACE TYPE

The program will display a list of typical surface types. Select a surface type that best
represents the major type of surface. Pipe and tank diameters larger than 36 inches are
considered flat surfaces for this program.
Horizontal Pipe
Vertical Pipe
Vertical Flat Surface
Top of Tank or Duct
Bottom of Tank or Duct
Use the arrow keys to select the most appropriate choice for each surface to be analyzed,
then press ENTER.
SCREEN 8 - INSTALLED COST DATA
If the user selected, a horizontal or vertical pipe, then the program will prompt for the pipe
size. If the user selected a flat surface, then skip the next question.
Pipe Size: If a horizontal or vertical pipe was selected above, then the program will prompt
for the diameter of the pipe. Type a valid US Iron Pipe size from 0.5 to 36 inches.
23
A. Previous data
B. F.E.A. default costs
C. Type data in each column
Next the user will be prompted for thickness and cost data. The program will display a
menu prompting the user about the source of the cost data. An explanation will be shown
under the three choices. For choice A, the program remembers the last time the user
entered data for the chosen pipe size and the chosen insulation material. If the user has
not selected the pipe size or insulation material before, then the data will all be zeros. For
the FEA procedure (choice B), the user will need to supply the installed cost of a piece of
2 inch thick insulation on a 2 inch pipe and a piece of 2 inch thick block measuring 1
square foot. This cost includes jacketing. The FEA procedure is an alternate procedure
developed by the Federal Energy Administration in 1970. This is a ratio method and
should be used only as a last resort. If the user has a limited number of installed cost
values, one suggestion would be to request estimated cost data, then change the
individual values to use the correct data.
Then a table that represents single, double, and triple layer construction will be displayed.
The program allows the user to type up to a maximum of 18 pairs of thickness and cost
data for each particular surface. Generally there are fewer than 18 thicknesses available.
If the thickness is typed, then a price will be required. The price should be the installed
cost including jacket, bands, butt straps, etc. The installed cost data has the largest
effect on the program output. The user should strive to provide data as accurate as
possible. When the cost data for the surface has been typed, press the Page Down key
to go to the next surface or the Page Up key to return to a previous surface.
There are two basic cost elements that determine the installed insulation prices:
1. Material prices
2. Labor to install the material.
Material prices are directly related to the volume and cost of insulation, jacket securement,
finishing, and structural support material required to meet the specification. Also included
are the costs to the contractor for storage, shipping, and handling these materials.
Although material prices vary with geographic area, the ratio of material price for a given
insulation thickness and pipe size to that for another thickness and pipe size does not
change appreciably from contractor to contractor.
24
Material price ratios have been included in the program to provide the user a method to
estimate unit material prices. Included are tables for each of the following materials
finished with 0.016 Aluminum jacket:
Mineral Fiber Pipe and Block

Calcium Silicate Pipe and Block
Cellular Glass Pipe and Block
To use the FEA estimating procedure, obtain a material price for 2 inch insulation for a 2
inch pipe, and 2 inches of insulation for flat surfaces, both including 0.016 Aluminum
jacket. Material prices for other pipe sizes and thicknesses can be estimated from the
factors provided in the program. Where possible, obtain several prices from different
contractors and use the average of these prices. Another good source of insulation cost
data is the Means Construction Cost File. The defaults for the estimating procedure were
obtained from the 1991 Means file. Since this is an estimating technique, the user should
be aware that individual prices can vary significantly from those supplied by the program.
To check the accuracy of the procedure, the user can get installed estimates from
contractors covering several pipe sizes and insulation thicknesses. Compare these with
the estimates supplied by the program. Where possible, use quotes supplied by
contractors or distributors instead of estimated prices.
Labor for Installation
The labor cost for installing insulation varies considerably nationally and is influenced by
1. Local labor wage rate ($/man-hour)

2. Worker productivity (man-hours per linear foot or square foot of insulation)
3. Job size support force costs.
The local labor rate has a significant effect on determining the level of labor prices for
various insulation thicknesses and pipe sizes. Labor rates are dictated by such factors as
local labor availability, whether or not union labor is employed, and whether overtime work
in involved. The labor rate includes the base labor wage, fringe benefits, per diem and
travel expenses, and may also include elements of the job size support force costs.
Worker productivity is the most variable element comprising unit labor price. The man-
hours required to insulate increases with large pipe sizes, inaccessibility to piping, and
equipment and job complexity. Other factors which are known to influence worker
productivity are:
25
1. Type of material used,
2. Working conditions,
3. Local worker productivity,
4. Overtime loss of worker efficiency.
The job size support force costs is the third element of the fixed final unit labor costs. Job
size support force costs increase with the magnitude of the job. Although each contractor
may treat this cost differently, some of the major factors it includes are:
1. Preparation costs such as scaffolding, etc.

2. Clean-up and tear-down costs,
3. Supervision costs,
4. General overhead.
Average worker productivity factors for insulating piping and flat surfaces are included in
the program. The factors are expressed in man-hours per 100 linear feet of piping or 100
square feet of flat surface. These were derived from a large sampling of insulation
productivity across the United States and Eastern Canada. The data was published in
Reference 1.
26
REGIONAL LABOR PRODUCTIVITY FACTORS
City City City
or State or State or State
Alabama 80 Kentucky 100 Ohio 100

Alaska 140 Louisiana 90 Oklahoma 90
Arizona 110 Maine 110 Oregon 120
Arkansas 90 Maryland 120 Pennsylvania 100
California 100 Massachusetts 110 Rhode Island 110
Colorado 100 Michigan 100 Carolina 100
Connecticut 110 Minnesota 100 S. Dakota 100
Delaware 90 Mississippi 90 Tennessee 100
Florida 90 Missouri 100 Texas 80
Miami 100 St. Louis 120 Utah 100
Georgia 80 Montana 120 Vermont 110
Atlanta 100 Nebraska 100 Virginia 90
Hawaii 120 Nevada 120 Washington 120
Idaho 100 New Hampshire 110 Washington DC 120
Illinois 110 New Jersey 100 W. Virginia 100
Chicago 120 New Mexico 80 Wisconsin 100
Indiana 110 New York 110 Wyoming 100
Iowa 100 New York City 120 Ontario 120
Kansas 100 N. Carolina 100 Maritime
N. Dakota 100 Provinces 140
The user can change the complexity factor for each surface if required. Use the function
keys to select a new complexity factor or service performance factor.
Complexity Factor: The complexity factor is a multiplier used to escalate the input cost
data. The program will display a menu of choices. Use the arrow keys to select the
appropriate description. An example of the use of this factor might be when there are two
lines that have the same diameter and number of fittings per foot but one line is at ground
level and the other is 50 feet off the ground. If the actual installed costs are determined
for the ground level line, then the piping complexity factor for the line would be VERY
SIMPLE. One way of obtaining an estimate of the installed cost for the raised line might
be to use the same basic cost data as for the ground level line and use a piping complexity
factor that is more complex. The program users should be cautioned that the above
approach is certainly not as desirable or accurate as determining the actual installed cost
data for the specific job at hand. The default is AVERAGE. The definitions are:
27
COMPLEX - 30-40 flanged fittings every 100 feet of pipe
AVERAGE - 15-20 flanged fittings every 100 feet of pipe
SIMPLE - 10-15 flanged fittings every 100 feet of pipe
The factors above apply only to welded piping with flanged valves and line flanges. For
welded piping with no flanges, use VERY SIMPLE as the complexity factor. If the flanges
and valves are not to be insulated, then use VERY SIMPLE.
The cost multipliers in the program are:

Pipe Size, in COMPLEX AVERAGE SIMPLE
½ to 1 ½ 1.60 1.30 1.20
2 to 3 1.35 1.20 1.15
4 to 6 1.25 1.15 1.10
8 to 12 1.28 1.15 1.12
14 and above 1.30 1.20 1.15
If the user is going to type cost data, be sure to set the complexity factor correctly. Since
the program defaults to AVERAGE, it could effect the results without the knowledge of the
user. If the data you are typing is a typical selling price, then AVERAGE would be an
appropriate choice. But if the user has specific cost data that takes the installation into
account, then select VERY SIMPLE so the program will not change the data you typed.
When the cost data for the surface has been typed, press the Page Down key to go to the
next surface or the Page Up key to return to a previous surface.
Once all the cost and thickness information has been typed, press the F3 function key to
proceed with the analysis. The program is designed to save the cost and thickness
information and update it's cost files for future reference. As the user types information
for different materials.
28
EXAMPLE 2 - FILE EX2.ETI

Project Number = 23L-7-0
System = Storage Tank Tops
Location =
Date = 12-01-1995
Engineer = Corporate Engineering
Contact =
Phone =

29
Fuel Type = Electricity

First Year Price = 0.05 $ per kwh
ECONOMIC DATA
Wind speed = 0 mph
Insulation material = CALCIUM SIL PIPE+BLK ASTM C533-95

30

Top of Tank - Steel

200 300 400 500 600 700 F
ECONOMIC
THICKNESS 4.0 6.0 6.0 6.0 8.0 8.0 in

SURF TEMP 77 81 89 97 97 104 F
PAYBACK 0.32 0.23 0.14 0.10 0.10 0.10 yr
CARBON DIOXIDE
The economic thickness is the thickest insulation you supplied

data for. The true ETI may be greater.

31

Horizontal Pipe - Steel
Pipe Size = 2 inch

200 300 400 500 600 700 F
ECONOMIC
THICKNESS 1.0 3.0 4.0 4.0 4.0 4.0 in
HEAT LOSS 35 39 51 70 90 113 Btu/ft/hr

SURF TEMP 100 88 90 99 108 117 F
PAYBACK 0.99 0.67 0.48 0.29 0.19 0.13 yr
ANNUAL COST 5.06 7.91 10.47 13.16 16.11 19.32 $/ft/yr
TOTAL SAVINGS 12 29 55 92 142 208 $/ft/yr
CARBON DIOXIDE
REDUCTION 110 291 541 883 1349 1965 Lbs/lnft/yr

32

Pipe Size = 12 inch

200 300 400 500 600 700 F
ECONOMIC
THICKNESS 4.0 4.0 6.0 6.0 6.0 6.0 in
HEAT LOSS 54 98 115 157 204 254 Btu/ft/hr

SURF TEMP 80 93 93 102 112 122 F
PAYBACK 0.50 0.23 0.23 0.15 0.10 0.10 yr
ANNUAL COST 14.13 20.55 27.68 33.75 40.39 47.63 $/ft/yr
TOTAL SAVINGS 108 237 413 650 958 1353 $/ft/yr
CARBON DIOXIDE
REDUCTION 1065 2267 3954 6157 9028 12708 Lbs/lnft/yr

33
EXAMPLE 3 - File EX3.ETI
COLD SURFACE

Project Number = 1233-4
System = Cold Storage
Location =
Date = 12-01-1995
Engineer = RSL - Field Service
Contact =
Phone =

34
Fuel Type = Electricity

First Year Price = 0.05 $ per kwh
Cost of make-up water = 0.001 $ per gallon
Inflation rate of make-up water = 1%
ECONOMIC DATA
Water Operated Condenser Factor = 6.20
Coefficient of Performance = 0.60
Design Wet-Bulb Temperature = 80 F
Design Relative Humidity = 95%
Wind speed = 0 mph
Insulation material = CELLULAR GLASS BLOCK ASTM C552-91

35

Pipe Size = 12 inch
Average Installation

Operating Temperature -30 F
Insulation Annual Payback Pres Value Heat Surf

Thick Cost Cost Period Heat Saved Gain Temp
Inches $/ft $/ft Years $/ft Btu/ft F
Bare 124.08 483 -30
1.5 24.79 20.29 0.7 287.12 61 53
2.0 29.06 18.47 0.8 294.07 51 58
2.5 32.87 17.42 0.9 298.74 44 61
3.0 36.67 16.86 1.0 302.11 39 64
4.0 44.28 16.57 1.2 306.66 32 67
Double layer
3.0 41.99 17.86 1.2 302.11 39 64
4.0 54.21 18.44 1.5 306.66 32 67
5.0 66.43 19.62 1.8 309.63 28 69
6.0 78.65 21.20 2.2 311.53 25 71
Triple layer
6.0 114.90 28.01 3.3 311.53 25 71
7.0 126.65 29.63 3.7 313.10 23 72
8.0 138.41 31.38 4.1 314.32 21 73
The Economic Thickness is single layer 4.0 inches.
The savings for the economic thickness is 107.51 $/ln ft/yr and
the reduction in Carbon Dioxide emissions
is 601 lbs/ln ft/yr
The Condensation Control Thickness for this surface is 1 inches.

36

Pipe Size = 2 inch


Bare 14.83 58 -30
1.0 9.71 7.32 3.6 24.72 21 53
1.5 11.57 6.64 3.9 27.42 17 60
2.0 13.70 6.47 4.5 28.94 15 65
2.5 15.46 6.43 5.0 29.93 14 67
3.0 17.28 6.49 5.6 30.66 13 69
4.0 22.93 7.16 7.8 31.72 11 72
Double layer
3.0 21.57 7.30 7.5 30.66 13 69
4.0 28.66 8.23 10.9 31.72 11 72
5.0 35.81 9.33 16.1 32.37 10 73
6.0 42.76 10.48 25.4 32.78 10 74
Triple layer
is 59 lbs/ln ft/yr
The Condensation Control thickness exceeded

the maximum thickness entered by the user.
The dew point temperature is 78.4

37

Pipe Size = 24 inch


Bare 292.03 1138 -30
1.5 42.27 36.71 0.5 696.97 112 50
2.0 48.52 32.56 0.6 711.06 91 55
2.5 55.28 30.31 0.6 720.38 78 59
3.0 62.04 29.08 0.7 727.02 68 62
4.0 75.56 27.97 0.8 736.69 54 66
Double layer
3.0 73.90 31.31 0.8 727.02 68 62
4.0 92.63 31.18 1.0 736.69 54 66
5.0 111.35 32.90 1.3 741.46 47 68
6.0 129.46 34.72 1.5 745.64 40 70
Triple layer
6.0 194.50 46.96 2.3 745.64 40 70
7.0 215.54 49.82 2.5 748.52 36 71
8.0 235.66 52.76 2.8 750.75 33 72
is 1443 lbs/ln ft/yr
The Condensation Control thickness exceeded

the maximum thickness entered by the user.
The dew point temperature is 78.4

38
PROGRAM OUTPUT
After the user has completed typing the cost data for all the surfaces, press the F3 function
key to start the calculations and prepare the report. If the user has just typed new
information, the information will be saved in a JOB FILE for future retrieval. If the user has
retrieved a previous job and made any changes, the program will allow the information to
be saved under a different name.
The user is presented with a screen asking where to send the report. The options are P
for printer and D for disk. The default is "P" for printer. To save the job and print the
results of the calculations on the system printer, press the ENTER key.
The other option is to print the report to a disk file that can be imported by a word
processor such as WordPerfect or Microsoft Word. To use this option, type the letter D.
The job file containing all the information the user typed will be saved for future retrieval.
The program will save the results of the calculations in an ASCII file. The file name will
be the same as the job name, with the extension .PRN. In either case, the job file will be
saved with the user's information.
To abandon the program and return to the Main Menu, press the Escape key. CAUTION,
this causes the program to lose all the information typed by the user.
The program generates a report based on the information typed by the operator.
Examples 1 and 3 demonstrate the difference between the detailed report and the
summary report.
The first two pages are a synopsis of the information typed by the operator. Each following
page details the results of the calculations. The report shows the heat loss or gain and the
surface temperature. Also listed are the discounted payback period and annual cost. The
use of the discounted payback period is discussed in Chapter 5. The annual cost includes
not only the cost of energy, but also all the costs associated with owning the insulation.
The economic thickness is the thickness with the lowest annual cost.
The savings is also listed. The savings is the difference between the annual cost of the
reference thickness and the annual cost at the economic thickness condition. This savings
includes more than the cost of saved energy. It also includes all the other factors included
in the annual cost. Since the reference cost is usually the bare surface, the annual cost
represents the inflating cost of the lost heat over the life of the project. If the operator
types a reference thickness, then the annual cost of this thickness is used to determine the
savings.
39
Depending on the fuel choice, the program can estimate the reduction in the Carbon
Dioxide (CO2) emissions. This applies to all fuel types except OTHER. The program uses
US Environmental Protection Agency (EPA) data to calculate the reduction in Carbon
Dioxide emissions. The basic data was supplied by the Global Change Division of EPA
to NAIMA in a private letter. The data is:
Natural Gas 113 lbs per million Btu

Oil 173
Coal 215
Electricity 1.6 lbs per KWhr
The mathematics are shown in Appendix E.
The report may also contain error messages about maximum use temperature. The
program checks all surface temperatures against the material maximum use temperature.
If the hot surface on any underlayer temperature exceeds the maximum, the program alerts
the operator and puts a warning message on the report. The program will also print
warning messages if the mean temperature used in any calculation exceeds the limits of
the data used to determine the thermal conductivity equation. If the program has to
extrapolate the mean temperature more than 50oF, then it will print a warning message.
Another instance where the program may issue a warning is when it can not calculate the
heat loss or gain properly. As the operating temperature approaches the ambient
temperature, the heat loss calculation requires increasingly more iterations to calculate the
heat flow. When the temperature difference is less than 25oF, the number of iterations
may exceed the maximum number allowed by the program. Calculations for this surface
will be suspended and a message is displayed and printed on the report. To correct the
problem, change the operating temperature such that it is more than 25o away from the
ambient.
Other warnings are issued when the user has not entered sufficient thermal conductivity
to cover the range of temperatures used by the operator. It the user specifies a
temperature and thickness combination that exceeds or falls below the mean temperature
range used to generate the thermal conductivity curve, then an error message will be
printed on the report.
40
EXAMPLE 4
RETROFIT APPLICATION

Project Number = Retrofit
System = Main Boiler Header
Location =
Date = 12-01-1995
Engineer = Plant Maint. Dept
Contact =
Phone =

41
Fuel Type = Gas

First Year Price = 3.36 $ per mcf
Heating Value = 1000 Btu per cf
Efficiency = 75.0%
ECONOMIC DATA
Wind speed = 0 mph
Existing insulation material = 1200F MIN.FIBER PIPE ASTM C547-95

Existing insulation thickness = 2.0
Retrofit / New Insulation material = 1200F MIN.FIBER PIPE ASTM C547-95

42

Pipe Size = 4 inch

Operating Temperature 1050 F

Thick Cost Cost Period Heat Saved Loss Temp
Do Nothing 16.13 472 286
1.5 15.37 15.38 5.7 96.79 334 209
2.0 18.55 15.36 5.8 113.94 310 195
2.5 21.44 15.44 6.1 127.70 290 184
3.0 24.43 15.58 6.3 140.50 272 174
4.0 29.86 16.15 7.0 157.68 248 160
Double layer
3.0 27.92 16.49 7.5 140.50 272 174
4.0 35.96 17.72 9.0 157.68 248 160
5.0 43.75 19.03 10.4 171.93 227 149
6.0 51.79 20.72 12.7 179.79 216 143
Triple layer
6.0 81.38 28.35 9.8 179.79 216 143
7.0 93.29 31.01 10.5 188.11 204 137
8.0 104.14 33.47 11.0 194.96 194 132
is 161 lbs/ln ft/yr

43

Pipe Size = 8 inch

Operating Temperature 1050 F

Thick Cost Cost Period Heat Saved Loss Temp
Do Nothing 26.58 778 315
1.5 19.35 22.91 3.7 177.81 525 231
2.0 23.40 22.41 3.8 209.39 480 215
2.5 26.99 21.84 3.8 240.31 436 200
3.0 30.54 21.80 4.0 259.89 408 190
4.0 37.73 22.17 4.5 290.19 365 174
Double layer
3.0 34.61 22.85 4.6 259.89 408 190
4.0 44.37 23.89 5.4 290.19 365 174
5.0 53.88 25.23 6.2 312.91 332 163
6.0 63.40 26.95 7.2 327.87 311 154
Triple layer
6.0 96.99 35.61 13.3 327.87 311 154
7.0 109.73 38.19 15.4 342.20 291 146
8.0 122.97 41.04 18.3 353.93 274 140
is 367 lbs/ln ft/yr

44
CHAPTER III
THERMAL INSULATION MATERIALS
This chapter describes the method used to change the thermal conductivity information
stored by the program. This is the second option on the main menu. The user can add
new insulation materials or delete an existing material. A menu will be displayed showing
the default selection. To add a new material, press ENTER. Use the arrow keys to
change the selection bar, then press ENTER.
ADD AN INSULATION MATERIAL
The program will ask for the name of the material. Type the name and press ENTER. The
program will prompt for the information it needs. Type the maximum operating temperature
of the material. Next the program will present a table to allow the user to type thermal
conductivity data on the material. Be careful when typing the data. Type mean
temperatures and thermal conductivities that span the temperature of interest. Do not
expect the program to calculate reliable high temperature conductivities if the user only
provides information for low temperatures. Type data that covers the entire temperature
range of use. The program allows the user to type up to 10 pairs of mean temperature and
conductivity data. The more pairs type by the user, the more accurate the calculations will
be. After typing the data, the program will save the data for future reference.
REMOVE AN INSULATION MATERIAL
Select this option to delete an insulation material from the file. This option is useful to
remove unused materials that the user never uses or to update the thermal conductivity
of an existing material. To update the conductivity, delete the material and add it using the
new data.
DISPLAY INSULATION MATERIALS
Select this option to display a list of materials in the program. This can be used to verify
if an insulation material has been previously entered. Press any key to return when you
are ready. Use the Up or Down or Page Up or Page Down keys to scroll through the
complete list of materials.
PRINT INSULATION MATERIALS
Select this option to print a complete list of the insulation materials in the program. The
printed report will also include the thermal conductivity equation and a brief table of
comparative values.
45
CHAPTER IV
STANDARD HEAT FLOW CALCULATIONS
This is the third option on the main 3EPLUS menu. The program will start by displaying
a menu to allow the user to select from one of four calculation types. The default is the
screen setup for the Maximum Surface Temperature Using 1 Insulation Material.
HELP
To get HELP on any question, press the F1 function key. A message box will display more
information about the question. As you move the cursor around the screen, you can press
F1 to get help on the input variable where the cursor is located. The user can request
HELP at any time in the program. In some cases, typical values will be suggested. After
reading the HELP screen, press ENTER to return to the original point of departure.
MAIN MENU
To display the main menu, press the F2 function key. A pulldown menu will appear. Use
the left and right arrow keys to change menus. There are three topics on the top row of
the menus, they are:
DO WHAT REPORT SURFACE TYPE
DO WHAT
The program will do four different types of calculations. The four types are:
Maximum Surface Temperature Using 1 Insulation Material

Maximum Surface Temperature Using 2 Insulation Materials
Standard Heat Loss or Gain Calculations
Heat Loss or Gain Tables
Each type of calculation is explained briefly below. To choose a calculation type, use the
Up or Down arrow key to move the selection bar, then press the ENTER key.
REPORT
When requested, the program will print a report on the printer unless the user changes the
report location to a disk file. To select a disk file, use the Up or Down arrow keys to select
Disk, then press the ENTER key. The program output will be written to a disk file that can
be imported into a word processor. This allows the user to include the report in a
proposal, bid, or other document.
46
SURFACE TYPE
The program will allow one of 5 surface types. The five types are:
Horizontal piping or tanks

Vertical piping or tanks
Vertical flat surface
Top or bottom of tank or duct
The program assumes a horizontal pipe unless the user changes to another surface type.
To choose a surface type, use the Up or Down arrow keys to move the selection bar, then
press the ENTER key.
CALCULATION TYPES
This is a brief description of each of the 4 calculation types.
THICKNESS FOR MAXIMUM SURFACE TEMPERATURE OR THICKNESS FOR

CONDENSATION CONTROL USING 1 INSULATION MATERIAL
Use this calculation type to determine the amount of insulation to use for personnel
protection or any other specification requiring a maximum surface temperature or a
condensation control thickness. The program will display a screen of questions. Answer
any or all the questions depending on the applications. The program will display a table
of insulation thicknesses from ½ inch to 10 inch and allow the user to quickly determine
the amount of insulation required.
To change any value displayed on the screen, move the cursor to the question using the
Up or Down arrow keys, then type a new value. You can use the arrow keys to move the
cursor to any question on the screen. You may also press the ENTER key without typing
any new information and the cursor will go to the next question without changing the
information.
The first question is the process temperature. This may be above ambient for a hot
surface or below ambient for a cold surface. The screen will change if you type a cold
surface temperature. Type the process temperature in degrees Fahrenheit(oF). This
should be an average temperature for normal calculations. To determine the heat loss and
surface temperature for an abnormal situation, type an extreme temperature that
represents the lowest or highest possible temperature the process could encounter.
Next type the ambient temperature. This should be the average ambient temperature for
normal calculations. To see the possible variation from night to day or from month to
47
month, type different ambient temperatures representing the extreme conditions the
process could be exposed to. Good sources of average temperatures are the US Weather
Service or a local Chamber of Commerce. If the piping or equipment is indoors, then type
an average temperature representing the indoor conditions. In some situations, such as
underground piping, the ambient may be considerably different than expected. Changing
the ambient temperature has a large effect on the calculated surface temperature and a
smaller effect on the heat loss or gain.
Next type the emittance of the bare surface. This will be used to calculate the heat loss
or gain of the uninsulated surface. This heat flow can be used as the basis for efficiency
calculations. The default emittance represents a weathered steel surface. Press the
HELP key to display other possible values. This number has a very large effect on the
calculated heat losses and on the insulation efficiency calculation.
Type the surface emittance of the insulation outer surface. This value is very important
and has a large effect on the calculated surface temperature. The default value of 0.1
represents Aluminum jacketing that has some oxidation and has been exposed to the
weather for a few years. The type of outer jacketing should be carefully chosen depending
on the application. For hot surface application, chose a material that has a higher
emittance to reduce the surface temperature. This is illustrated in Examples 5 and 6.
If the operating temperature is above the ambient, then the next question is for the
maximum allowable surface temperature. At the time this manual was written, no actual
government or consensus standard existed for a personnel protection standard. The
number 140oF is the most popular temperature used by manufacturing companies. The
maximum surface temperature for personnel protection is largely dependent on the type
of surface, such as metal or painted cloth. Type a new temperature or use the existing
temperature by press an arrow key or pressing the ENTER key.
If the operating temperature is below the ambient, the next question displayed is the
relative humidity. This number is used to calculate the dew point temperature and will be
used to calculate the condensation control thickness. Type a relative humidity that best
represents the average for the summer months. To estimate the worst case situation, type
a number that represents the extreme humidity the insulation will be exposed to. The
relative humidity the insulation is exposed to may not necessarily be the relative humidity
furnished by the weather service. If the equipment is below ground, the humidity may be
different than expected, especially if the equipment is enclosed in an unheated space.
The design relative humidity should be given some attention to prevent future insulation
problems.
The last question is for the insulation material. To change the insulation material, locate
the cursor on the insulation material displayed on the screen and press the ENTER key.
48
A list of insulation materials will be displayed. Select a new material by using the Up or
Down arrow keys to move the selection bar then pressing ENTER. If you have many
insulation materials stored in the program, you will need to use the Page Up or Page Down
keys to display more materials.
The cursor will return to the top question. If you are satisfied with the information you have
typed into the program and are ready to display the results, press the F3 function key to
start the calculations. The screen will change to display the information you typed into the
program and a table of heat flows and surface temperatures at different insulation
thicknesses.
If the operating surface temperature was hotter than the ambient, then the display will also
show the thickness required to meet the maximum surface temperature you typed. If the
operating temperature was below the ambient, then the display will show the thickness of
insulation required to keep the insulation surface temperature above the condensation
temperature.
If your printer is ready, a message will appear at the bottom of the screen allowing you to
make a printed report. To print the report, press the F3 key again. If the printer is not
ready, then the message will tell the user to press any key to continue.
49
EXAMPLE 5
Emittance 0.1 (Aluminum)
NAIMA 3EPLUS HEAT LOSS (GAIN) AND SURFACE TEMPERATURE COMPUTER ANALYSIS, Ver2.12
Thickness for Maximum Surface Temperature for One Material
Horizontal Pipe
Steel
Nominal pipe size = 4.0 in
Actual pipe diameter = 4.5 in
Process temperature = 350 F
Average ambient temperature = 75 F
Average wind velocity = 0.0 MPH
Outside surface emittance = 0.10
Bare surface emittance = 0.80
Maximum Surface Temperature = 140 F
Heat Flow Calculations Performed According

to the Method Described in ASTM C680
expressed or implied, as to performance of the actual systems and
Page 1 of 2
50
Material = 850F MIN. FIBER PIPE ASTM C547-95
Thickness Surface Heat Efficiency
Temp (F) Loss %
Bare 350 686
0.5 190 156 77.2
1.0 146 100 85.4
1.5 128 78 88.7

2.0 117 65 90.5
2.5 110 57 91.7
3.0 104 50 92.7

3.5 101 46 93.3
4.0 98 43 93.8
4.5 95 40 94.2
5.0 93 38 94.5
5.5 93 37 94.7
6.0 91 35 94.9
6.5 90 34 95.1
7.0 89 32 95.3
7.5 88 31 95.4
8.0 87 30 95.6
8.5 87 29 95.7
9.0 86 29 95.8
9.5 85 28 95.9
10.0 85 27 96.0
Heat loss units are Btu/hr/linear foot.
Efficiency is the reduction in heat flow from the bare surface.
Thickness required for the surface temperature

to be below 140 is 1.5 inches.
Page 2 of 2
Time 18:59:10 Date 03-24-1995
51
EXAMPLE 6
Emittance 0.9 (Dark Mastic)
Thickness for Maximum Surface Temperature for One Material
Horizontal Pipe
Steel
Bare surface emittance = 0.80

Page 1 of 2
52
Material = 850F MIN. FIBER PIPE ASTM C547-95
Thickness Surface Heat Efficiency
Temp (F) Loss %
Bare 350 686
0.5 146 189 72.4
1.0 114 111 83.8
1.5 103 84 87.7

2.0 95 66 90.4
2.5 92 60 91.3
3.0 89 53 92.3
3.5 87 48 93.0
4.0 85 44 93.5
4.5 84 41 94.0
5.0 83 39 94.4
5.5 82 38 94.5
6.0 82 36 94.8
6.5 81 34 95.0
7.0 81 33 95.2
7.5 80 32 95.3
8.0 80 31 95.5
8.5 79 30 95.6
9.0 79 29 95.7
9.5 79 28 95.9
10.0 79 28 96.0
Heat loss units are Btu/hr/linear foot.
Efficiency is the reduction in heat flow from the bare surface.
Thickness required for the surface temperature

Page 2 of 2
Time 19:05:38 Date 03-24-1995
53
THICKNESS FOR MAXIMUM SURFACE TEMPERATURE OR THICKNESS FOR
CONDENSATION CONTROL USING 2 INSULATION MATERIALS
Use this calculation type to determine the amount of insulation to use for personnel
protection or any other specification requiring a maximum surface temperature or a
condensation control thickness when there are two insulation types. This calculation will
allow the user to calculate the amount of additional insulation to add to existing piping or
equipment to reduce the surface temperature and heat flow. The program will display a
screen of questions. The questions are similar to the questions discussed above. Answer
any or all the questions depending on the applications.
To change the value displayed on the screen on any question, move the cursor to the
question using the Up or Down arrow keys, then type a new value. You can use the arrow
keys to move the cursor to any question on the screen. You may also press the ENTER
key without typing any new information and the cursor will go to the next question without
changing the information.
surface temperature. Type a process temperature in degrees Fahrenheit (oF).
process could be exposed to.
Next type the emittance of the bare surface. This will be used to calculate the heat loss
or gain of the uninsulated surface. This heat flow can be used as the basis for efficiency
calculations. The default emittance represents a weathered steel surface. Press the F1
key to display other possible values.
weather for a few years.
If the operating temperature is above the ambient, then the next question is for the
maximum allowable surface temperature. Type a new temperature or use the existing
temperature by press an arrow key or pressing the ENTER key.
If the operating temperature is below the ambient, the next question displayed is the
relative humidity. This number is used to calculate the dew point temperature and will be
54
used to calculate the condensation control thickness. Type a relative humidity that best
represents the average for the summer months.
The next questions relate to the insulation material. To change the insulation material,
locate the cursor on the insulation material displayed on the screen and press the ENTER
key. A list of insulation materials will be displayed. Select a new material by using the Up
or Down arrow keys to move the selection bar then pressing ENTER. If you have many
insulation materials stored in the program, you will need to use the Page Up or Page Down
keys to display more materials.
Type the thickness of the first, or inside, layer of insulation. This thickness is fixed and will
not change. The thickness of the outer layer will change from ½ inch to 10 inches in half
inch increments.
The cursor will return to the top question. If you are satisfied with the information you have
typed into the program and are ready to display the results, press the F3 function key to
start the calculations. The screen will change to display the information you typed into the
program and a table of heat flows and surface temperatures at different insulation
thicknesses.
If the operating surface temperature was hotter than the ambient, then the display will also
show the thickness required to meet the maximum surface temperature you typed. If the
operating temperature was below the ambient, then the display will show the thickness of
insulation required to keep the insulation surface temperature above the condensation
temperature.
ready, then the message will tell the user to press any key to continue.
Example 7 is a report from this type of calculation. The process temperature was changed
to 600oF.
55
EXAMPLE 7
Two Different Insulation Materials
Thickness for Maximum Surface Temperature for Two Materials
Vertical Flat Surface

Stainless Steel

Page 1 of 2
56
Thickness of inner layer is 1.5 inches
Inner layer material 1 = CALCIUM SIL PIPE+BLK ASTM C533-95
Outer layer material 2 = 450F MIN.FIBER BOARD ASTM C612-93
Thickness Temperature(F) Heat Efficiency
(inches) Inside Outer Loss %
0.0 215 142
0.5 320 188 109 24
1.0 376 172 89 37
1.5 412 160 76 47
2.0 438 151 66 54

2.5 458 144 59 59
3.0 473 138 53 63
3.5 485 134 48 66

4.0 495 130 44 69
4.5 503 127 41 71
5.0 510 124 38 73

5.5 516 121 35 75
6.0 522 119 33 77
6.5 526 117 31 78

7.0 530 115 30 79
7.5 534 113 28 80
8.0 537 112 27 81

8.5 540 110 25 82
9.0 543 109 24 83
9.5 546 108 23 84

10.0 548 107 22 84
Heat loss units are Btu/hr/sqft.
Efficiency is the percent reduction in heat flow

from the inner layer of insulation.
Thickness required for surface temperature

The operating temperature exceeded the maximum allowable temperature

of the insulation.
The surface temperature and heat loss calculations were completed

but the results are very questionable!
Page 2 of 2
Time 19:08:02 Date 03-24-1995
57
HEAT LOSS (GAIN) CALCULATIONS FOR UP TO 10 SELECTED LAYERS OF
INSULATION
This calculation is used to evaluate different insulation types and thickness combinations.
The user is allowed up to 10 layers of insulation materials. The layers can be any
insulation type and any valid insulation thickness. The program will show the heat loss or
gain, the external surface temperature, and all the intra layer temperatures. This allows
the user to choose the optimum insulation type and thickness for the application.
surface temperature. Type a process temperature in degrees Fahrenheit (oF). This should
be an average temperature for normal calculations. To determine the heat loss and
surface temperature for an abnormal situation, type an extreme temperature that
represents the lowest or highest possible temperature the process could encounter. The
operating temperature may be above or below the ambient temperature. If you type an
operating temperature below the ambient temperature, then some questions on the display
will change.
weather for a few years. The type of outer jacketing should be carefully chosen depending
on the application. For hot surface application, chose a material that has a higher
emittance to reduce the surface temperature.
58
The lower portion of the screen allows the user to type the number of layers, layer
thickness, and insulation material. Type the number of layers in the system. The screen
will change to display the thickness and the insulation type for each layer. To type the
layer thickness, use the arrow keys to move the cursor to the thickness, then type in a new
thickness. To change the insulation material, locate the cursor on the insulation material
displayed on the screen and press the ENTER key. A list of insulation materials will be
displayed. Select a new material by using the Up or Down arrow keys to move the
selection bar then pressing ENTER. If you have many insulation materials stored in the
program, you will need to use the Page Up or Page Down keys to display more materials.
If you are satisfied with the information you have typed into the program and are ready to
display the results, press the F3 function key to start the calculations. The screen will
change to display the information you typed into the program and a table of heat flows and
surface temperatures. The top line of the table will be the process operating temperature.
Each additional line will show the intra layer temperature and the calculated thermal
conductivity of the insulation material. At the bottom will be the external surface
temperature and the heat flow. It the surface is a flat surface, the heat flow will be reported
in terms of Btu per hour per square foot of surface area. If the surface is a pipe or a tank,
then the heat flow will also be reported as Btu per hour per linear foot of length.
ready, then the message will tell the user to press any key to continue. Example 8 is a
report from the Standard Heat Flow Calculation. The process temperature was set at
600oF and the number of layers set to 3. Notice by changing one of the 3 layers to a
different material, the heat loss and surface temperature changes. Example 9 is the same
as Example 8 except the first layer was changed to a different material.
59
EXAMPLE 8
Multiple Layer System
Heat Loss Calculations for Multiple Layers of Insulation
Vertical Pipe
Steel
Number of layers = 3

Page 1 of 2
60
Layer Thick Material Temp Cond
Process temperature 600F
1 1.5 CALCIUM SIL PIPE+BLK ASTM C533-95 448 0.62
2 1.5 850F MIN. FIBER PIPE ASTM C547-95 304 0.48
Outside surface temperature = 125 F
Total heat loss per square foot = 36.9 (Btu/sqft/hr)
Page 2 of 2
Time 19:09:55 Date 03-24-1995
61
EXAMPLE 9
Multiple Layer System Using Different Materials
Heat Loss Calculations for Multiple Layers of Insulation
Vertical Pipe
Steel
Number of layers = 3

Page 1 of 2
62
Layer Thick Material Temp Cond
Process temperature 600F
1 1.5 PERLITE PIPE & BLOCK ASTM C610-95 448 0.75
Outside surface temperature = 117 F
Total heat loss per square foot = 31.6 (Btu/sqft/hr)
Page 2 of 2
Time 19:11:21 Date 03-24-1995
63
HEAT LOSS (GAIN) TABLES FOR MULTIPLE SURFACES IN 5 TEMPERATURE
RANGES
Use this calculation type to print a table of heat flows and surface temperatures. This
calculation will print a table with five (5) columns of temperatures across the top of the
report. The user is allowed to select either a flat surface or piping. If the user selects
piping, then he can chose some or all the pipe sizes between ½ and 48 inch. The program
will display a screen of questions. Answer any or all the questions depending on the
applications.
The first question is the starting temperature. This may be above ambient for a hot surface
or below ambient for a cold surface. Type the starting temperature in degrees Fahrenheit
(oF).
Next type the temperature increment between columns. The report will begin with the
starting temperature then add the temperature increment for the next column. You may
use a large increment to cover a wide temperature range, or a small increment to evaluate
a small range of temperatures.
Type the emittance of the insulation outer surface. This value is very important and has
a large effect on the calculated surface temperature. The default value of 0.1 represents
Aluminum jacketing that has some oxidation and has been exposed to the weather for a
few years. The type of outer jacketing should be carefully chosen depending on the
application. For hot surface applications, chose a material that has a higher emittance to
reduce the surface temperature.
64
If you are satisfied with the information you have typed into the program and are ready to
display the results, press the F3 function key to start the calculations. The screen will
change to display a short message indicating the computer is printing the report. The user
has the option of sending the report to a disk file. This disk file can be imported into a
word processor to make presentation quality tables. Another possibility is to include the
table in a report or specification.
SURFACE TYPE
This menu selection describes the type of surface the program is working on. There are
four type of surfaces to select from, they are:
HORIZONTAL PIPE
VERTICAL PIPE
VERTICAL FLAT
TOP OR BOTTOM OF TANK OR DUCT
To choose the surface type, use the Up or Down arrow key to move the selection bar, then
press the ENTER key.
HORIZONTAL PIPE
This is the default surface. Use this surface type for piping or tanks running horizontally.
The diameter range is from ½ inch and larger. The heat flow will be reported as Btu per
hour per square foot of outer surface and Btu per hour per running foot of length.
VERTICAL PIPE
Use this surface type for piping and tanks that have most of their outer surfaces primarily
vertical. The diameter range is from ½ inch and larger. The heat flow will be reported as
Btu per hour per square foot of outer surface and Btu per hour per running foot of length.
VERTICAL FLAT
Use this surface type for surfaces that are primarily vertical and have very little curvature.
The heat flow is reported as Btu per hour per square foot of outer surface.
TOP OR BOTTOM OF TANK OR DUCT
Use this surface type if the heat flow is coming from the top or bottom of a flat surface.
The heat flow is reported as Btu per hour per square foot of surface.
65
REPORT
The program will display a report on the display. The user has the option to print a report
on the printer or a disk file. The disk file can be imported into a word processor or printed
at a later date. After the program has displayed a report, a message will be printed near
the bottom of the report if the printer is ready. To print to a disk file, select REPORT TO
DISK from the main menu.
SURFACE TEMPERATURE CALCULATIONS
One of the more popular uses of the program is to calculate the amount of insulation
required to meet a maximum surface temperature specification.
There are many variables that have a large effect on surface temperature. The choice of
the insulation material and the insulation thickness are the most important.
The surface emittance and ambient conditions can also change the surface temperature.
Changing the surface emittance of an insulated steam pipe from a low number such as 0.2
to a higher number such as 0.7 will decrease the surface temperature by many degrees
but there will only be a small change in the heat loss.
For example:
Start the 3EPLUS program and select run heat flow calculations.
Select all the defaults from the menus as they appear. This will set the program for
1 insulation material, report to printer, and a horizontal pipe.
Press F3 to calculate the surface temperature using the defaults. This will then
display a report showing the heat losses and surface temperatures for a horizontal
4 inch pipe operating at 350oF
Notice the surface temperature and heat loss, press F3 again to get a printed
report.
Press ENTER to return to the Data Entry screen.
Use the Up or Down arrow key to move the cursor to the emittance value.
Change the emittance to 0.7
Press F3 twice to get another printed report.
66
Notice the difference in the surface temperatures and heat losses. The surface
temperature has dropped significantly.
A cold surface example:
Now use the arrow keys to return the cursor to the Pipe Temperature and type -50.
The emittance is 0.7 from the previous calculation.
Press F3 twice to get a printed report and notice the surface temperature and heat
gain.
Again use the arrow keys to move the cursor to the emittance value and change it
back to 0.1
Press the F3 key twice and compare the surface temperatures.
Notice that the higher emittance now increases the surface temperature toward the
ambient temperature. The higher emittance changes the surface temperature
toward the ambient temperature.
These examples demonstrate that designing an insulation system is more than just
selecting an insulation. The designer must give careful consideration to the selection of
jacketing materials.
67
CHAPTER V
MATHEMATICAL MODEL FOR
DETERMINATION OF THE
ECONOMIC THICKNESS FOR
HOT OR COLD SURFACES
The list of factors that influence the economic thickness of industrial insulation is extremely
long. In order to develop a realistic model that contains a tractable number of input
parameters, a limited number of factors will be considered. The factors considered in the
model of this report can be divided into three general categories:
INSULATION RELATED COSTS

INSULATION COST
INSULATION MAINTENANCE
HEAT LOSS OR GAIN RELATED COSTS

EQUIPMENT COST
ENERGY COST
EQUIPMENT MAINTENANCE
CONDENSER MAKE-UP WATER COST
TAX SAVINGS
INSULATION DEPRECIATION
INSULATION MAINTENANCE
EQUIPMENT DEPRECIATION
EQUIPMENT MAINTENANCE
ENERGY COST
CONDENSER MAKE-UP WATER COST
Other factors such as property taxes on the increased value of insulation and plant
equipment, investment tax credits, and tax savings on interest on borrowed money are
specifically ignored. There may also be other factors that certain companies or analysts
would add to this list. However, it is felt that the factors given above certainly represent
the major contributions to the total cost of owning a piece of insulation, and that the
computer economic thickness from this model is well within the uncertainty associated with
a more sophisticated model.
The factors that influence the economic thickness are similar for either the hot or cold
surface models. While heating plant equipment costs were important for hot surfaces, the
chiller cost is the corresponding cost for cold surfaces. The only cold surface factor that
68
does not have an analogous hot surface term is the condenser make-up water cost. For
a water driven condenser, the water evaporated into the atmosphere must be replenished.
The total cost of owning a piece of insulation can be written as the sum of heat loss and
insulation related costs less any tax savings. Symbolically, this can be written as:
Insulation Related Cost

Total Cost ' % Heat Flow Related Costs (1)
&Tax Savings
The economic thickness is defined as the insulation thickness that yields the minimum total
cost of owning insulation. Since money obviously has a time value, one must choose a
particular time at which costs are evaluated. The procedure adopted on this model is the
Equivalent Uniform Annual Cost (EUAC) method in which all costs are converted to an
equivalent uniform annual cost by use of the appropriate interest discount factors. This
procedure is mathematically equivalent to the Present Value or Future Value methods
provided the time period chosen is the least multiple of the insulation life and plant
equipment life. Hereafter, the EUAC method will be referred to simply as the annual cost.
The remainder of this chapter will be devoted to a discussion of the equations used to
calculate the annual cost of the various factors that influence the economic thickness.
INSULATION RELATED COSTS
Insulation Cost: The unit cost of insulation CI ($/ft or $/ft2) is already expressed as a
present value. This cost can be uniformly distributed over the life of the insulation by use
of the series present worth factor, (P/A,i,nI).
CI
A'
P (2)
( ,i,nI)
A
Throughout this practice, the symbol A will represent any equivalent uniform annual cost.
For those readers unfamiliar with the concept of the series present worth factor, it can be
thought of conceptually as an "effective" life that considers the time value of money. For
example, if money does not have a time value, the (P/A,0,nI) = nI: it is obvious that the
insulation cost has been divided into nI equal parts. In general, (P/A,i,nI)< nI with the
difference between the two terms increasing as the interest rate increases.
Insulation Maintenance: First year's insulation maintenance is assumed to be proportional

to the initial insulation cost. In each succeeding year the maintenance is allowed to inflate
69
at the same rate as fuel. It is probable that maintenance charges will not inflate at the
same rate as fuel. However, it should be closer to the fuel inflation rate than to zero.
Rather than introduce a general inflation rate as an additional input parameter, the fuel
inflation rate was chosen as representative of the rate at which insulation maintenance
inflates. The resulting annual cost of insulation maintenance is
P
( ,i,nI,iF)
A0
A'C IfMI (3)
P
( ,i,n I)
A
The term (P/A0,i,nI,iF) is the series present worth factor that converts the annual (inflating)
cost to a present value and can also be thought of as an effective life. If the fuel inflation
rate is zero, then (P/A,i,nI,0) = (P/A,i,nI). If both interest rates are zero, then both series
present worth factors are equal to nI, and they simply cancel out. Additional information
on this factor can be found in APPENDIX A.
HEAT RELATED COSTS
For any specified thickness, the heat loss Q (Btu/hr-ft or Btu/hr- sqft) can be calculated.
The heat producing equipment can have a life nE that is different from the insulation life
nI.
Incremental Equipment Cost (Heating): The cost of adding an increment in heating

capacity is specified by the parameter mE, which represents the dollar investment in adding
a 1,000,000 Btu/hr increase in capacity. Since this quantity is already in present value
terms, the series present worth factor must be applied to convert this to an annual cost.
m EQ
A'
P (4)
( ,i,nE)
A
Note that the equipment life nE is used instead of the insulation life. Every effort should
be made to obtain a value that is representative for the particular project being analyzed.
Since we have used an incremental equipment cost equation, the total annual cost cannot
be used in an absolute sense.
70
Energy Cost: Fuel prices are assumed to be inflating at a fixed annual rate of iF. If the
present day fuel price is CFo ($/1,000,000Btu), the system operates H hours each year, and
0E is the thermal efficiency at which fuel is converted to heat, then the annual cost of the
lost energy is
P
(
,i,nI,iF)
QH A0
A'CF0 (5)
0E P
( ,i,n I)
A
Equipment Maintenance: The annual equipment maintenance is assumed to be

proportional to the cost of the annual heat loss or gain. Since the fuel cost is inflating at
an annual rate of iF, the equipment maintenance also inflates at the same rate.
P
(
,i,nI,iF)
Cf0QH A0
A'fME (6)
0E P
( ,i,nI)
A
TAX SAVINGS FOR HOT SURFACES
Maintenance, fuel costs, and depreciation all produce a savings from the point of view of
federal income taxes. Operating expenses for a business are subtracted from the gross
income in order to determine the taxable income.
TAXABLE INCOME = GROSS INCOME - EXPENSES
The reduction in federal income tax due to expenses is simply the effective tax rate times
the expenses.
INCOME TAXES = (TR)(GROSS INCOME - EXPENSES)
Insulation Depreciation: Straight line depreciation will be assumed. This procedure allows
an annual deduction of CI/nI from gross income for a tax savings of
CI
A'(TR) (7)
nI
71
Insulation Maintenance: The annual insulation maintenance cost is simply multiplied by
the effective tax rate.
P
( ,i,n I,iF)
A0
A'(TR)CIfMI (8)
P
( ,i,nI)
A
Equipment Depreciation: Assuming straight line depreciation, this becomes

Q
A'(TR)m E (9)
nE
Equipment Maintenance: The annual equipment costs are multiplied by the effective tax
rate.
P
(
,i,nI,iF)
QH A0
A'(TR)fMECf0 (10)
0E P
( ,i,n I)
A
Energy Cost: The annual energy costs are multiplied by the effective tax rate
P
,i,nI,iF)
(
QH A0
A'(TR)Cf0 (11)
0E P
( ,i,n I)
A
As can be readily seen, the tax rate has a very strong effect. For example, with a tax rate
of 48%, natural gas at $2.00/MMBtu effectively costs only (1 - 0.48) X $2.00 or
$1.04/MMBtu. The federal income tax structure discourages the application of insulation.
If the tax savings are subtracted from the insulation and heat loss related costs, the net
annual cost can be written as
72
P
( ,i,n I,iF)
A A0 TR
A'CI[( ,i,nI)%(1&TR)fMI & ]
P P nI
( ,i,nI)
A
(12)
A TR
%Q(mE[( ,i,nE)& ]
P nE
H P A
%Cf0 ( ,i,nI,iF)( ,i,nI)(1&TR)(1%fME))
0E A0 P
The above equation can be written more compactly as

A'aCI%bQ (13)
where the factors a and b are independent of insulation thickness.
The procedure for determining the economic thickness is to evaluate the annual cost for
each discrete insulation thickness (including zero thickness) and choose the thickness that
gives the minimum annual cost. Since most commercial and industrial insulations are only
available in nominal thickness increments of one-half inch, there appears to be little value
in attempting to determine the precise insulation thickness that minimizes Equation (12)
because (a) this thickness is not commercially available and (b) the cost versus thickness
relationship is not known analytically. The most important terms which contribute the
greatest amount to the total annual cost, are (a) insulation cost and depreciation, (b)
energy cost and its tax savings, (c) insulation maintenance, and (d) equipment
maintenance, with the latter two terms being an order of magnitude smaller than the first
two terms.
DISCOUNTED PAYBACK PERIOD
The concept of payback period is often used in judging the merits of an economic venture.
In its simplest form, payback period is the time required for the savings resulting from an
investment to repay the cost of the investment. For the case of thermal insulation, the
savings is the economic value of the reduction in heat loss or gain due to increased
insulation, while the cost of the investment is the insulation cost. If one ignores the time
value of money and any inflation, the resulting payback period is termed simple payback
period. The discounted payback period considers the time value of money and any
anticipated inflation costs. Some care is necessary in precisely defining the energy
savings and insulation cost. For the model presented in this report, all costs and savings
73
will be expressed in present value terms. The present value of the savings is the
difference between the present value of the cost for two different alternatives, A and B.
PV SAVINGS'(PV COST)A&(PV COST)B (14)
Alternative A will generally be the "bare pipe" condition for a new job. However, there may
be instances where this is not true. Alternative B will be whatever insulation thickness is
under consideration. Therefore, one can calculate a savings for each thickness of
additional insulation that is greater than the reference thickness.
The annual cost equations used to develop the economic thickness model can be used as
a guide for the payback period model. To convert a uniform annual cost to a present
value, multiply by the series present worth factor (P/A,i,np) where np is the payback period
in years. Realizing that the insulation cost increment is CI = CI - CR and that Q is the heat
savings due to insulation, then the present value of the savings can be written as
P
( ,i,nP)
A
PV SAVINGS')Q[m E(1&TR )
nE
C H P
%(1&fME)(1&TR) f0 ( ,i,nP,iF)] (15)
0E A0
P
( ,i,nP)
P A
&)CI[1%(1&TR)fMI( ,i,nP,iF)&TR ]
A0 nI
The payback period will be the value of np that produces the Present Value of the Savings
(PV SAVINGS) equal to zero. In other words, the present value of the heat loss related
savings equals the present value of the insulation related costs. Note that all of the tax
savings appear as reductions in both the heat loss related savings and insulation related
savings. The equipment and insulation life appear only in the depreciation terms.
The unknown discounted payback period np appears in the various series present worth
factors. Since Equation (15) is non-linear in the payback period, some type of iterative
procedure is necessary in order to solve for np. A bisection method for solving non linear
algebraic equations was chosen for this procedure. The method requires an initial guess
of the payback period and is obtained from the simple payback period. For I = iF = 0, both
of the series present worth factors in Equation (15) are equal to np. Solving for the value
of np that yields PV SAVINGS = 0, one obtains
74
)CI&mEQ
nP'
TR H TR (16)
)Q[m E %(1%fME)(1&TR)Cf0 ]&CI[(1&TR)fMI& ]
nE 0E nI
If income tax, maintenance, and incremental plant equipment are ignored, the simple
payback period reduces to the familiar
)C I
nP'
H
)QCf0
0
A problem occurs when the operating temperature approaches the ambient temperature.
In some cases, the iteration procedure will not converge. In this case, the program
substitutes the simple payback period. Typically this number is longer than the project life.
It must be realized that equation (15), in general, plots as a quadratic. Since a negative
payback period has no physical meaning, the program sets it equal to zero if it is found to
be negative. The discounted payback period and the simple payback period are very
close for situations in which the payback period is relatively short or the time value of
money is relatively unimportant for short time periods.
The payback period generally increases with increasing insulation thickness. This might
suggest trying to minimize the payback period. However, this is an erroneous concept.
The payback period concept ignores any benefits that occur after the initial investment has
been repaid. Although payback period has some uses, it should never be used as the sole
indicator of how much insulation to apply.
The present value of the fuel savings for the life nI is often of interest. This quantity can
be calculated from Equation (15) if replaced by nI and set CI = 0.
HEAT GAIN RELATED COSTS
Cold surfaces are different from hot surfaces in that condensation control must be
considered in addition to the economic thickness. If the outer surface temperature of the
insulation system is below the design dew point temperature, then condensation can
occur. Since water degrades the thermal performance of insulation and reduces its
expected life, this condition must be avoided. If the condensation control thickness
exceeds the economic thickness, then the condensation control thickness should be
applied. If the condensation control thickness is smaller than the economic thickness, then
75
the economic thickness should be applied. See Appendix B for a discussion about dew
point calculations.
Incremental Equipment Cost (Cooling): In the design of new systems, the addition of
insulation can cause a reduction in the required chiller capacity. The cost model of this
practice assumes that the chiller incremental costs varies linearly with the heat gain of the
cold line.
Since we are always comparing the total annual cost of two different insulation
thicknesses, any costs that are independent of insulation thickness will simply cancel out
in the analysis. Therefore, the chiller cost will be the cost of adding an increment in chiller
capacity.
Q
A'm c
P (17)
( ,i,nC)
A
where mc is the incremental cost of increasing the chiller capacity. The computer input will
be in the form of $/1,000,000Btu/hr. For example, suppose that a 100 ton unit costs
$70,000 and a 150 ton costs $100,000. The incremental chiller cost will be
100,000&70,000 50
m c' '$
(150&100)(12) MMBtu/hr
If an absorption type chiller is used instead of an electric driven chiller, then mc should also
include the incremental heating plant cost if applicable.
Energy Cost: For the most general case of an absorption chiller, the efficiency of the heat
source (0E) and the chiller coefficient of performance (COP) influence the energy
consumption. If today's fuel price (Cfo) is inflating at an annual rate of iF, the annual cost
is
P
( ,i,nI,IF)
QH A0
A'Cf0 (18)
0ECOP P
( ,i,nI)
A
Chiller Maintenance: The annual chiller maintenance is assumed to be proportional to the

cost of the annual heat gain. Since fuel costs are inflating at an annual rate of iF, the
chiller maintenance also inflates at the same rate.
76
P
(
,i,nI,iF)
QH A0
A'(TR)fMECf0 (19)
0E P
( ,i,n I)
A
Condenser Make-Up Water (Incremental): The condenser make-up water requirements

are assumed to be proportional to the chiller capacity. Since we are looking at incremental
costs, the incremental make-up water costs can be written as
P
( ,i,nI,iW)
A0
A'BQHCW0 (20)
P
( ,i,nI)
A
The 1976 ASHRAE Systems Handbook recommends B = 3.2 gal/ton-hr for electric driven
systems and 6.2 gal/ton-hr for absorption systems. Note that the water costs are allowed
to inflate at an annual rate of iw.
TAX SAVINGS FOR COLD SURFACES
All maintenance, fuel cost, water cost, and depreciation factors produce a tax savings of
the effective tax rate times the appropriate costs.
Insulation Depreciation:
CI
A'(TR) (21)
nI
Insulation Maintenance:
P
( i,n I,iF)
A0
A'(TR)CIfMI (22)
P
( ,i,nI)
A
77
Chiller Depreciation:
Q
A'(TR)m C (23)
nC
Chiller Maintenance:
P
( ,i,nI,iF)
QH A0
A'(TR)fMCCf0 (24)
0ECOP P
( ,i,n I)
A
Energy Cost:
P
( ,i,nI,iF)
QH A0
A'(TR)Cf0 (25)
0ECOP P
( ,i,n I)
A
Condenser Water Make-Up Cost:

P
( ,i,nI,iW)
A0
A'(TR)BQHCW0 (26)
P
( ,i,nI)
A
The net annual cost is obtained by subtracting the tax savings from the sum of the
insulation and heat loss related cost:
78
P
(,i,n I,iF)
A A0 TR
A'CI[( ,i,nI)%(1&TR)fMI & ]
P P nI
( ,i,nI)
A
A TR
%Q(mC[( ,i,nC)& ] (27)
P nC
H P A
%Cf0 (1&TR)(1%fMC)( ,i,nI,iF)( ,i,n I)
0ECOP A0 P
P A
%(1&TR)CW0BH( ,i,nI,iW)( ,i,nI))
A0 P
The above equation can be written more compactly

A'aCI%bQ (28)
where the factors a and b are independent of insulation thickness.
DISCOUNTED PAYBACK PERIOD FOR COLD SURFACES
The discounted payback period is significant only for the economic thickness condition;
if the condensation control thickness exceeds the economic thickness, then payback
period has no meaning.
If the reference condition is bare pipe for a new job or heat gain through existing insulation
for a retrofit job, the present value of the savings can be written as:
P
( ,i,nP)
A
PV SAVINGS')Q[m C(1&TR )
nC
Cf0H P
%(1&TR)(1&fMC) ( ,i,nP,iF)
0ECOP A0
(29)
P
%(1&TR)CW0BH( ,i,nP,iW)]
A0
P
( ,i,nP)
P A
&CI[1%(1&TR)fMI( ,i,nP,iF)&TR ]
A0 nI
79
Zero additional insulation thickness may be an acceptable engineering solution for hot
surface conditions, provided personnel protection is not important. However, for cold
surfaces the minimum allowable thickness is the condensation control thickness. If the
condensation control thickness exceeds the economic thickness, then the payback period
is not defined. Using this concept, the present value of the savings can be written as:
P
( ,i,nP)
A
PV SAVINGS')Q[m C(1&TR )
nC
Cf0H P
%(1&TR)(1%fMC) ( ,i,nP,iF)
0ECOP A0
(30)
P
%(1&TR)CW0BH( ,i,nP,iW)]
A0
P
( ,i,nP)
P A
&)CI[1%(1&TR)fMI( ,i,nP,iF)&TR ]
A0 nI
where ªCI = CI-CIR. If the reference condition is bare pipe then CIR = 0 and Equation (30)
reduces to Equation (29).
In some cases, some thickness may have zero payback periods! At first glance this may
seem to indicate that all of the thicknesses will pay for themselves immediately. In reality,
by defining the discounted payback period as we have, we have allowed a mathematical
quirk to occur. There may be cases where the correct value for nP in equation 28 is
actually negative. This quantity then has no physical meaning, but is mathematically
correct. If this occurs the computer program automatically sets the payback period to zero.
A negative value for nP can be caused when the costs associated to energy are much
greater than the costs associated with insulation. It must be realized that equation 30 plots
as a quadratic. The relative costs of energy and insulation will determine where the curve
crosses the time axis.
80
LIST OF SYMBOLS
nE Life of heating plant, years or remaining life if retrofit

mI Life of insulation, years
Q Heat loss, Btu/ft-ft, or Btu/hr-ft2
mE Dollar investment in adding a 1,000,000 Btu/hr increase in physical capacity,
$/1,000,000 Btu/hr
Cfo Present day fuel price, $/1,000,000 Btu
if Fuel inflation rate, (% per year)
nE Efficiency of conversion in heat plant, %
H Annual hours of operation, hours
fME Percentage of fuel cost which is spent each year for physical plant
maintenance, %
I After tax rate-of-return, %
TR Effective income tax rate, %
a, b Constants independent of insulation thickness
Q Heat savings due to additional insulation, Btu/unit area
ªCI Increment in insulation cost, $/unit area
np Payback period, years
k Thermal conductivity, Btu-in/hr-ft2-oF
, Emittance
A Annual Cost
B Water operated condenser factor, gal/ton-hr
CI Initial installed cost of insulation, $/ft or $/ft2
COP Coefficient of performance of the refrigeration system
Cwo Present day cost of condenser make-up water, $/Mgal
fMI Fraction of initial insulation cost spent each year on insulation maintenance
%
iw Inflation rate of the cost of condenser make-up water, %
mc Dollar investment in adding a 1,000,000 Btu/hr increase in capacity of the
chiller, $/1,000,000 Btu/hr
RH Relative humidity, %
(A/P, I, nI) Capital recovery factor
(P/A, in nI, iF) Series present worth factor accounting for inflation
(P/A, I, nI) Series present worth factor not accounting for inflation
PV Savings Present Value of Savings, $
81
APPENDIX A
SERIES PRESENT WORTH FACTOR FOR FUEL INFLATION
In the cost model for determining the economic thickness of insulation, it is necessary to
convert a sequence of annual fuel payments into a uniform annual amount. For the model
adopted in this report, the fuel costs are allowed to inflate at a constant annual rate of iF.
If today's fuel price is C0, then the fuel price for any arbitrary year j can be written as
Cj'C0(1%iF)j, j'1,2,&&&,n&1,n (A-1)
In order to convert the above sequence of payments to an equivalent uniform annual cost,
one first converts each annual payment to a present value, determines the sum of all the
individual present value terms, and then converts the total present value to a uniform
annual cost by use of the capital recovery factor. Assuming a time value of money of I, the
present value of all the fuel payments can be written as:
PV'j Cj( ,i,j)

n
P
j&1 F
'j Cj(1%i)&j
n
(A-2)
j&1
j
'C0j
n (1%iF)
j&1 (1%i)
The above series can be written in simpler form by using the geometric series results:
n
1%iF
&1
1%iF 1%i
PV'C0 (A-3)
1%i 1%iF
&1
1%i
It is convenient to define an inflating series present worth factor by:

n
(1%iF)
(1%iF) &1
P (1%i)
( ,i,n,iF)' (A-4)
A0 (1%iF)
(1%i) &1
(1%i)
The subscript "0" on A0 denotes that today's fuel price is used instead of the end of the
year fuel price. If the end of year fuel price were given, Equation (A-4) would have to be
82
modified; see White, Agee, and Case for details. If fuel is inflating at the same rate as the
time value of money, their effects simply cancel and one obtains:
P
( ,i,n,i)'n (A-5)
A0
If the fuel inflation rate is zero, Equation (A-4) reduces to the familiar series present worth
factor:
P P
( ,i,n,0)'( ,i,n) (A-6)
A0 A
For those readers unfamiliar with the series present worth factor, it can be thought of
conceptually as an "effective life" that considers the time value of money. If there is no
inflation or time value of money, then:
P P
( ,0,n,0)'( ,0,n)'n (A-7)
A0 A
In general,
P
( ,i,n,IF)#n (A-8)
A0
for all values of I. For the inflating series present worth factor,
P
( ,i,n,iF)#n for iF#i (A-9)
A0
or
P
( ,i,n,iF)$n for iF$i (A-10)
A0
The present value of fuel costs is converted to a uniform annual amount by dividing by the
capital recovery factor or equivalently dividing by the series worth factor.
P
( ,i,n,iF)
A0
A'C0 (A-11)
P
( ,i,n)
A
83
APPENDIX B
HEAT LOSS EQUATIONS
The equations used for calculating the heat flow and various temperatures for block or
pipe insulation are presented here.
Block Insulation
The heat flow through the insulation is given by:
Q (t P&tA)
' (B-1)
A (R%RS)
where:
R'j
n Xj 1
; R S' (B-2)
j'1 kj h0
The conductivity is evaluated at the mean temperature of each layer. It is assumed that
the surface resistance on the process temperature side is sufficiently small in comparison
to the other resistances that is can be neglected.
The surface resistance RS represents the combined effects of radiation and convection
heat loss. To calculate RS, a variation of the Heilman equations is used. The equation is
presented in ASTM C680 relates to the surface resistance of the insulated surface only.
Q (tS&t A)
'
A RS
4 4
'gF(TS &TA )
0.181
(B-3)
1 0.266
%0.5296C (tS&tA) 1%1.277V
1
(TS%TA)
2
where tP= process temperature, 0F

tA= ambient temperature, 0F
tS= outer surface temperature of insulation, 0F
T = temperature in 0R (t + 460)
V = wind velocity, mph
C = constant depending on surface orientation
, = outer surface emittance
F = Stefan-Boltzman constant
84
The following values of C are included in the program:
1.394 Vertical surface
1.79 Top of hot tank for bottom of cold tank
0.89 Bottom of hot tank or top of cold tank
Since the surface resistance depends on surface temperature in a non-linear manner,

some type of iteration process is necessary. A back substitution method is used until the
routine converges. Within the iteration loop, the thermal conductivity of the insulation
material is continuously updated.
For the bare surface case, the surface temperature is calculated using the thermal
conductivity of the metal and the surface resistance is calculated using correlations
presented by Holman, McAdams, and Incopera and DeWitt. In general, the correlations
of Incopera and DeWitt are preferred. Modern correlations of convection heat transfer are
presented in terms of the dimensionless Nusselt (NU), Reynolds (Re), Rayleigh (Ra), and
Prandtl (Pr) numbers. These correlations have been accepted by DOE (Oak Ridge
National Lab) and are being presented to ASTM for inclusion in the next revision of ASTM
C680.
For forced convection with fluid flow normal a cylinder, the correlations are:
4/5
5/8
0.62Re 1/2Pr 1/3 Re
Nu ' 0.3 % 1%
2/3
1/4 282,000 (B-4)
0.4
1%
Pr
and
1/2
0.62Re 1/2Pr 1/3 Re
Nu ' 0.3 % 1%
2/3
1/4 282,000 (B-5)
0.4
1%
Pr
According to Churchill and Bernstein (15), Equation B-4 apples to Re between 100 and
20,000 and between 400,000 and 107. Equation B-5 is a better representation for Re
between 20,000 and 400,000.
85
For natural convection from horizontal cylinders, Churchill and Chu (16) give the following
two equations:
1/4
Ra
Nu ' 0.36 % 0.518
16/9
0.559
9/16) (B-6)
1%
Pr
and
1/6
1/2 Ra
Nu ' 0.60 % 0.387
16/9
0.559
9/16) (B-7)
1%
Pr
Equation(B-7 applies to any value of Ra; however, Equation B-6 is considered more
accurate for Ra less than 109.
When a heated surface is exposed to flowing fluid, the convective heat transfer will be a
combination of forced and free convection. For this mixed convection condition, Churchill
(17) recommends the following equation fro the overall Nu for horizontal cylinders:
4 4
(Nu & Nu0)4 ' Nuforced % Nunatural (B-8)
where Nuforced and Nunatural are calculated separately from their respective correlations. The
parameter Nu0 ensures a non-zero value for the overall Nu when Nuforced and Nunatural both
approach zero (for example, fine wires in still air). Since Equations B-4 through B-8 have
a non-zero value of 0.3 to 0.36 when Ra or Re go to zero, 0.3 should be subtracted from
both Nuforced and Nunatural before substitution into Equation(B-8, and that a value of 0.3 be
used for Nu0.
Equation B-8 simply states that if the Nu for forced convection is much larger that the Nu
for natural convection, then the overall Nu is equal to the Nu for forced convection.
Likewise, if Nu for natural convection is much larger than Nu for forced convection, then
the overall Nu is equal to Nu for natural convection. It is only when the Nu’s for forced and
natural convection are of the same magnitude that an additional formula is needed. If the
two Nu’s in equation B-8 are equal, then the overall Nu would be 19 percent greater than
86
either of them. The overall Nu would not be twice as large as either one of them, as would
be obtained by simply adding the two Nu’s together.
For forced convection from flat surfaces, Churchill and Ozoe (18) recommend the following
equation for the laminar range (RePr greater than 100 and Re less than 5 x 105);
0.6774 Re 1/2 Pr 1/3
Nu '
1/4
0.0468
2/3 (B-9)
1 %
Pr
For turbulent forced convection (Re greater than 5 x 105) from flat surfaces, Incropera and
DeWitt recommend
Nu ' (0.037 Re 4/5 & 871) Pr 1/3 (B-10)
Churchill (19) gives more complicated equations that would be preferred at very low Re
and that provide a smooth connection between equations B-9 and B-10 for the region near
the transition from laminar to turbulent flow. However, the equations involve other
parameters that are difficult to evaluate and are not used in this report.
For natural convection from vertical flat surfaces, Churchill and Chu (20) recommend the
following two equations:
0.670 Ra 1/4
Nu ' 0.68 %
4/9
0.492
9/16 (B-11)
1 %
Pr
and
0.387 Ra 1/6
Nu ' 0.825 %
8/27
0.492
9/16 (B-12)
1 %
Pr
Equation B-11 is to be used for Ra less than 109, and equation B-12 is to be used for Ra
greater than 109.
For mixed convection from a vertical plate, Churchill (17) recommends combining the
separately calculated Nuforced and Nunatural by
87
3 3
Nu3 ' Nuforced % Nunatural (B-13)
For all the correlations for a vertical surface, the characteristic dimension is taken as the
vertical height.
For horizontal plates with heat flow up, Incropera and DeWitt recommend the following two
equations, where the first applies to laminar flow and the second to turbulent flow:
Nu ' 0.54 Ra 1/4 (B-14)
Nu ' 0.15 Ra 1/3 (B-15)
Use equation B-14 for Ra less than 107, and equation B-15 for Ra greater than 107. These
equations were adapted from McAdams, but Incropera and DeWitt recommend the
characteristic length to be used for horizontal plates by taken as the area divided by the
perimeter. Thus for a square of side L, the characteristic length is L/4. Since Ra is
proportional to the cube of L and Nu is proportional to L, the convection coefficient, h0
given by equation B-15 is independent of L, and h0 given by equation B-14 varies inversely
with the fourth root of L.
Natural convection coefficients for horizontal plates with heat flow down are dependent on
the details of fluid flow around the edges of the plate. For this case, Incropera dn DeWitt
adopt McAdam’s recommendation that the Nu for heat flow down is about one-half that for
laminar flow with heat flow up, or
Nu ' 0.27 Ra 1/4 (B-16)
The characteristic length is again the area divided by the perimeter.
For mixed convection from horizontal plates, Churchill (13) recommends

n n
Nu ' Nuforced ± Nunatural (B-17)
where n is 3 for vertical plates, 3.5 for horizontal plates, and 4 for horizontal cylinders.
When the forced and natural coefficients are equal, the difference between a power of 3
88
or 4 amounts to only about 6% difference in the overall convection coefficient. Use the
plus sign where heat flow is up and use the minus sign where heat flow is down.
The radiation heat transfer coefficient is calculated from:

hrad'1.714x10&9,[(Ts%459.67)2%(Ta%459.67)2]
(B-18)
x (Ts % Ta % 919.34)
The thermal conductivity k is calculated by integrating the thermal conductivity equation

from the hot face temperature to the surface temperature. This requires an initial guess
of the surface temperature. Each time the program goes through the iteration, the surface
temperature is recalculated and a new thermal conductivity is calculated.
Pipe Insulation
The heat loss per unit of outside surface area is given by

Q (t P&tS)
' (B-4)
A (R%RS)
where:
r2
ln( )
r1 1 (B-5)
R'r2 , RS'
k h0
Again, the surface resistance on the process temperature side of the insulation is assumed
to be small in comparison to the other resistances. The conduction resistance R is a
function of temperature because k is temperature dependent. The combined convection
and radiation heat loss from the pipe surface is calculated from:
Q (tS&tA)
'
A RS
4 4
'gF(T S &T A )
0.181
(B-6)
0.2
1 1 0.266
%C (t S&tA) 1%1.277V
D 1
(TS%TA)
2
89
where D is the outside diameter of the last insulation layer, expressed in inches. For D >
24 inches, use D = 24. The constants has two values depending on geometry.
1.016 Horizontal pipe
1.235 Vertical pipe
For the bare pipe case, the resistance of the pipe walls is not neglected. Geometrical data
for standard weight pipe and the conductivity of the two metals are stored in the program.
This program calculates the resistance of the pipe walls and then iterates on the surface
energy balance.
The detail with which the convective heat loss is calculated may give the false impression
that on of the objectives is to calculate the heat loss with great precision. This is definitely
not the case. An accurate determination of the annual heat loss is much more complicated
than, for example, assuming a horizontal pipe with a constant wind speed blowing
perpendicular to the axis of the pipe and a constant ambient temperature. This is the
difference between the real world and the laboratory conditions under which the empirical
convection equations were determined. The wind is not constant in either speed or
direction and the ambient temperature is continuously changing.
If a pipe is insulated with a thickness near the economic thickness, the surface resistance
is not a large percentage of the total resistance. This implies that the economic thickness
should be relatively insensitive to changes in surface resistance. This being the case, one
might ask why a constant value of surface resistance is inadequate. First, the bare pipe
heat loss is extremely sensitive to surface resistance. Second, for a given value of heat
loss, the surface temperature is very sensitive to changes in surface resistance. Third,
since the cost of one insulation thickness is compared directly with the cost of another
thickness, the relative effects of wind speed, emittance, surface geometry, etc., are much
better represented by the equations of this program than with a constant surface
resistance. The use of the equations presented by Malloy has been accepted by ASTM
Committee C16 on Thermal Insulation as being the accepted method of calculating heat
flows.
90
APPENDIX C
DEW POINT CALCULATION
The dew point for an air-water vapor mixture is defined as the temperature at which the
water vapor condenses when cooled at constant pressure. The dew point can easily be
determined from the relative humidity and the design ambient temperature. The relative
humidity is the ratio of the partial pressure of the water vapor as is exists in the mixture (Pv)
to the saturation pressure at the same temperature (Pg).
PV
r H' (C-1)
PG
The variation of the saturation pressure with temperature must be determined

experimentally. A convenient empirical relationship is the Goff equation, as presented in
the ASHRAE Handbook of Fundamentals.
LOG P ' 10.79586(1&1)%5.02802(LOG 1)
1
&8.29692( )
&4 1&1
% 1.0574x10 1&10 (C-2)
% 0.42873x10 &3 104.76955(1&1)&1
& 2.2195983
where P is the vapor pressure in atmospheres and È= 273.16/T with T in 0K. This
relationship is valid over the temperature range of 58oF to 212oF. In terms of temperature
(0F):
È = 273.16/[(5(T-32)/9)+273.16] (C-3)
The calculation procedure is as follows:
1. Determine Pg corresponding to ta from Equation (C-2)

2. Determine Pv from pv = (RH)Pg
3. Determine tdp corresponding to Pv using Equation (C-3)
Step 3 requires the iterative solution of a non-linear equation. A variation of Newton's

method is used to accelerate convergence. This procedure converges quite rapidly
because log P is very nearly a linear function of temperature over the practical range of
interest.
91
APPENDIX D
THERMAL CONDUCTIVITY EQUATIONS
The thermal conductivity file supplied with the 3EPLUS program and the HL program
include the thermal conductivity equations of several generic types of thermal insulations.
These equations were derived from ASTM material specifications. The maximum thermal
conductivity at various mean temperatures was curve fitted using standard statistical least
squares techniques. The equations are shown below:
Material and Maximum

equation temperature (F)
850F MINERAL FIBER PIPE C547-95

k = 0.208 + 2.94x10-4 tm + 1.143x10-6 tm2 850
1200F MINERAL FIBER PIPE ASTM C547-95

k = 0.2143 + 3.179x10-4 tm + 6.786x10-7 tm2 1200
1800F MINERAL FIBER BOARD ASTM C612-93

k = 0.193 + 7.17x10-4 tm + 26196x10-7 tm2 1800

k = 0.2114 + 3.184x10-4 tm + 6.85510-7 tm2 1200

k = 0.215 + 4.293x10-4 tm + 1.065x10-6 tm2 850

k = 0.214 + 5.565x10-4 tm + 8.734x10-7 tm2 450
ELASTOMERIC TUBE & SHEET ASTM C534-94

k = 0.280 + 1.556x10-4 tm + 1.482x10-6 tm2 200
POLYSTYRENE 1.6 PCF ASTM C578-92

k = 0.174 + 2.779x10-4 tm + 1.234x10-6 tm2 165
CALCIUM SILICATE PIPE AND BLOCK ASTM C533-95

k = 0.355 + 4.586x10-4 tm + 7.142x10-8 tm2 1200
CELLULAR GLASS BLOCK ASTM C552-91

k = 0.302 + 5.240x10-4 tm + 8.692x10-7 tm2 800
92
PERLITE PIPE & BLOCK ASTM C610-95
k = 0.452 + 4.246x10-4 tm + 2.679x10-7 tm2 1200
INSULATING & FINISHING CEMENT ASTM C449-95

k = 1.413 - 1.203x10-3 tm + 1.825x10-6 tm2 1200
93
APPENDIX E
CARBON DIOXIDE REDUCTION
The program determines the heat loss for the reference surface and the heat loss of the
surface insulated with the economic thickness. The units are Btu/hr/unit surface area or
length. The difference is then multiplied by the EPA factor for the fuel chosen. If the user
has selected OTHER as the fuel type, then no calculations are performed. The EPA value
is converted to pounds emitted per Btu.
)Q Btu
hr
CO2 ' (E-1)
REDUCTION EPA VALUE Lbs
Btu
The basic data on Carbon Dioxide emissions for different energy sources was obtained
from the Office of Global Change of the United States Environmental Protection Agency.
Energy Source Carbon Dioxide Reduction

July 15, 1991
Natural Gas 113 Lbs per million Btu
Fuel Oil 173 Lbs per million Btu
Coal 215 Lbs per million Btu
Electricity 1.6 Lbs per Kilowatt hour
which calculates to
160 Lbs per million Btu
The national average heat rate for electricity is 10,000 Btu per Kilowatt hour sold.
94
APPENDIX F
PROGRAM HISTORY
This computer program was originally named "Economic Thickness of Industrial Insulation
for Hot and Cold Surfaces". The program was developed in 1980 and sold to the public.
The program was written in Fortran IV and was sold as a card deck or a paper tape. The
user was responsible to compile the program and maintain the card deck or the paper
tape.
In 1986, the Thermal Insulation Manufacturers Association (TIMA) developed a version of

the program that could be used on a personal computer.
In 1988, the program was modified to use the ASTM C680 method of calculating the heat
loss and surface temperature. The nominal dimensions used for the insulation thickness
were changed to use the insulation thickness specified in ASTM C585. Some changes
were made to improve the way the operator typed data into the program.
In 1990, the program was again modified to make the program more user friendly and
provide two output reports. These changes were made in response to customer
comments. A heat loss program was included to allow the user to do routine heat loss and
surface temperature calculations without having to type all the financial information.
In 1992, the program was renamed 3E - Energy, Environment, and Economics. The output
report was changed to include an estimate of Carbon Dioxide reduction based on the
amount of insulation used. The Thermal Insulation Manufacturers Association changed
its name to the North American Insulation Manufacturers Association (NAIMA).
Release Date
7-7-92 Change in screen display to improve user data entry.
10-92 Correction in heat loss calculation. Surface geometry factor was not correct
for all surfaces.
11-16-92 Changed screen display to show typed cost and not cost*complexity. Users
having trouble not seeing actual data typed on display.
5-7-93 Change in screen displays to add more menus. Added Service Factor to
allow user to correct for outside factors that influence carbon dioxide
emissions. Added more information to printed report to show defaults used
to estimate installed costs. Added Retrofit for applications with existing
insulation.
95
12-01-93 Changed name to 3EPLUS. Changed screen displays to make easier to
use. Changed main menu to allow execution of Heat Loss program. Heat
Loss program completely revised to allow more surfaces and options. Old
data files do not work and must be changed.
5-15-96 After throughly reviewing the program source code, the US Department of
Energy (DOE) requested several changes to the program. They asked that
the surface resistance equations for the bare surface be updated to use
modern correlations. These were incorporated for the bare surface and the
request was forwarded to ASTM to revise C680 to use the same correlations
in the next revision. The program was renamed 3EPLUS to indicate the
version upgrade.
The thermal conductivity of steel was changed to be a function of

temperature and the thermal conductivity of stainless steel as a function of
temperature was added.
A correction was made in the retrofit section to correct a problem in the

calculated cost of the installed insulation. The program was not selecting
the correct diameter on which to base the costs. A change in the printed
report was made to indicate a “DO NOTHING” choice instead of the bare
surface as was printed.
The thermal conductivity file was updated to use current thermal values as
published in 1995 ASTM material standards.
2-1-98 A correction was made to the surface heat transfer equations for flat
surfaces. The program did not correctly calculate the direction of heat flow
when the ambient temperature was greater than the process temperature.
96
APPENDIX G
REFERENCES
1. Economic Thickness for Industrial Insulation, Federal Energy Administration,

Department of Energy, August 1976, Reprinted by Fairmont Press, 1983
2. Malloy, John F. Thermal Insulation, New York, NY. Van Nostrand Reinhold Co.,
1969
3. Ranck, Bruce A., User's Guide and Program Documentation Manual for
ECONOMIC THICKNESS FOR INDUSTRIAL INSULATION COMPUTER
PROGRAMS, York Research Corporation, Stamford, CT. May 1978
4. White, J. A., Agee, M. H., and Case, K. E., Principles of Engineering Economic
Analysis, New York, NY., John Wiley, 1977
5. Standard Practice for DETERMINATION OF HEAT GAIN AND THE SURFACE

TEMPERATURES OF INSULATED PIPE AND EQUIPMENT SYSTEMS BY THE
USE OF A COMPUTER PROGRAM, ASTM C680, Available from ASTM,
Philadelphia, PA
6. Standard Recommended Practice for INNER AND OUTER DIAMETERS OF RIGID

THERMAL INSULATION FOR NOMINAL SIZES OF PIPE AND TUBING (NPS
SYSTEM), ASTM C585, Available from ASTM, Philadelphia, PA
7. Mark's Standard Handbook for Mechanical Engineers, 8th Edition, McGraw Hill
Book Co.
8. Langmuir, I., Convection and Radiation of Heat, Transactions of the American

Electrochemical Society, Vol 23, pp 299-332, 1913
9. Rice, C.W., Free Convection of Heat in Gases and Liquids - II, Transactions
A.I.E.E., Vol 43, pp 131-144, 1924
10. Heilman, R.E., Surface Heat Transmission, Transactions A.S.M.E., Vol 1, Part 1,
FSP-51-91, pp 289-301, 1929
11. Langmuir, I., Physical Review, Vol 34, pp 401, 1912
12. Hagen, E., and Rubens, H., Metallic Reflection, Ann. Phys., Vol 1, No. 2, pp 352-
375, 1900
97
13. Lorenz, L., Ann. Phys., Vol 13, p 582, 1881
14. Kennelly, A.E., Wright, C.A., and Van Bylevelt, J.S., The Convection of Heat from
Small Copper Wires, Transactions A.I.E.E., Vol 28, pp 363-397, 1909
15. Griffiths, E., and Davis, A.H., The Transmission of Heat by Radiation and
Convection, Food Investigation Board, Special Report 9, Department of Scientific
and Industrial Research, Published by His Majesty’s Stationery Office, London,
England.
16. McAdams, WH., Heat Transmission, 3rd ed., McGraw-Hill, New York, 1954
17. Holman, J.P., Heat Transfer, 5th ed., McGraw-Hill, New York, 1981
18. Incropera, F.P., and DeWitt, D.P., Fundamentals of Heat and Mass Transfer, 3rd
ed., John Wiley & Sons, 1990
19. Hilsenrath, J., et. al, Tables of Thermodynamic and Transport Properties of Air,
Argon, Carbon Dioxide, Carbon Monoxide, Hydrogen, Nitrogen, Oxygen, and
Steam, NBS Circular 564, U.S. Dept of Commerce, 1960
20. Churchill, S.W., and Bernstein, M., A Correlating Equation for Forced Convection
from Gases and Liquids to a Circular Cylinder in Crossflow, J. Heat Transfer, Vol
99, pp 300-306, 1977
21. Churchill, S.W., and Chu, H.H.S., Correlating Equations for Laminar and Turbulent
Free Convection from a Horizontal Cylinder, Int. J. Heat and Mass Transfer, Vol 18,
pp 1049-1053, 1975
22. Churchill, S.W., Combined Free and Forced Convection Around Immersed Bodies,
Heat Exchanger Design Handbook, Section 2.5.9, Hemisphere Publishing Co.,
1983
23. Churchill, S.W., and Ozoe, H., Correlations for Laminar Forced Convection in Flow
Over an Isothermal Flat Plate and in Developing and Fully Developed Flow in an
Isothermal Tube, J. Heat Transfer, Vol 95, pp 78, 1973
24. Churchill, S.W., A Comprehensive correlating Equation for Forced convection from
Flat Plates, AiChE Journal, Vol 22, No. 2, pp 264-268, 1976
98
25. Churchill, S.W., and Chu, H.H.S., Correlating Equations for Laminar and Turbulent
Free Convection from a Vertical Plate, Int. J. Heat and Mass Transfer, Vol 18, pp
1323-1329, 1975
99
APPENDIX H
3EPLUS INPUT WORKSHEET
For Insulation to be installed on bare surfaces or insulated surfaces
Send printed report to:___________________________________________ Company:_________________________________
Street or PO Box:_________________________________________________ City:_________________________________
State & Zip:______________________________________________________
Project:__________________________________________________________
Location:_________________________________________________________
Project Number:___________________________________________________
Date:_____________________________________________________________
System:___________________________________________________________
Engineer:_________________________________________________________
All surfaces in this job must be either Hot or Cold (Circle one) HOT COLD
All the surfaces in this job must be either new insulation installed on bare surfaces (NEW) or new insulation installed over existing insulation
(RETRO). Circle one
NEW RETROFIT
FUEL OR ENERGY COSTS FOR THIS PROJECT
Oil $__________________/gal ______________________ Btu/gal
Gas $__________________/Mft3 ______________________ Btu/ft3
Coal & Solid Fuel $__________________/ton ______________________ Btu/ton
Conversion efficiency (fuel to heat) ______________ %
Electricity $__________________/KWH
Purchased energy $__________________/MMBtu
Expected fuel cost inflation rate ____________________ %/year
Capital Investment rate for cooling plant (includes all associated equipment) $___________________/MMBtu/hr
Cooling plant depreciation period ____________ yr Chiller coefficient of performance ________________
Price of cooling makeup water $_____________/gal Expected water price inflation rate ________________ %/year
S value (ASHREA Handbook of Fundamentals, electric motor driven=3.2 absorption chiller=6.2) ______________
OTHER PROJECT INFORMATION
Interest rate or minimum rate of return on investment ______________________ %
Income tax rate (combined federal and state and local) ____________________ %
Average annual ambient temperature ______________oF Average annual wind speed ____________ mph
Annual hours of operation ______________ hrs/year
Annual cooling plant maintenance (% of annual fuel bill) _____________ %
100
Annual insulation maintenance (% of total installed cost) ____________ %
Design relative humidity ________________________ % Design wet bulb temperature _______________ oF
Report type (circle one) Detailed Summary
For Detailed report, enter process operating temperature ___________________ oF
For Summary report, there will be six columns of temperatures across the top of the page
Starting temperature __________ oF Temperature step between columns _________ oF
INSULATION COST INFORMATION
Insulation depreciation period or service life ____________________________ yr
New Insulation Material _________________________________________________________________
For retrofit:
Old Insulation Material __________________________________________________
Old Insulation Thickness ___________________________ in
Jacket emittance or Jacket type __________________________________________________________
INSTALLED INSULATION PRICE
Surface Number ( 24 maximum) __________________________________________________________
Surface type: (Circle one)

Horizontal pipe or tank Vertical pipe or tank Vertical flat
Top of tank Bottom of tank
Complexity factor (Circle one)

Very simple Simple Average Complex
Pipe or tank diameter ________________________________ in
Installed costs:
Single layer Double layer Triple layer
Thickness (in) Cost ($/ft or $/ft2) Thickness (in) Cost ($/ft or $/ft2) Thickness (in) Cost ($/ft or $/ft2)
__________ ____________ __________ ____________ __________ ____________
__________ ____________ __________ ____________ __________ ____________
__________ ____________ __________ ____________ __________ ____________
__________ ____________ __________ ____________ __________ ____________
__________ ____________ __________ ____________ __________ ____________
__________ ____________ __________ ____________ __________ ____________
To have the program estimate the installed cost of the insulation, supply the following information
This is not as accurate as using actual information supplied above.
Cost of 2x2 inch section of pipe insulation, with jacket, $_________________/foot

Cost of 2 inch thick block, with jacket $_______________________________/ft2
Cost of local labor, including supervision, $____________________________/hr
Local productivity rate (see instructions) ______________________________
101

MANUAL

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NAIMA

3EPLUS Program Registration

Please mail the form to:

or fax this page to 970-241-4107

Appendix A - Present Worth Factor . . . . . . . . . . . . . . . 83

YOU SHOULD CAREFULLY READ THE FOLLOWING TERMS AND CONDITIONS

SOME STATES DO NOT ALLOW THE LIMITATIONS OR EXCLUSION OF LIABILITY

By installing the program:

The original economic thickness program was prepared by:

The original heat loss program was prepared by:

a) fuel inflation rate

The economic thickness of insulation program is named 3EPLUS.

Standard Program Installation

INSTALL FROM: TO: SUB

where FROM: is the floppy drive ID letter that contains the

TO: is the hard disk drive ID that will contain the

SUB is the subdirectory on the hard disk where the

2. Type the name of the program, 3EPLUS.

3. The program will load into memory then display a menu.

3EPLUS PROGRAM OPERATION

Type 3EPLUS then press ENTER.

Start NEW 3E ECONOMICS JOB

NAIMA 3EPLUS ECONOMIC THICKNESS ANALYSIS REPORT, Version 2.12

Project Name = Example #1

Entry date 12-01-1995 Report date 04-12-1996

Fuel Type = Liquid

Insulation material = 1200F MIN.FIBR BOARD ASTM C612-93

Entry date 12-01-1995 Report date 04-12-1996

Surface or Pipe Number 1

Insulation costs estimated by FEA method

HEAT LOSS 26 16 25 25 35 46 Btu/sqft/hr

TOTAL SAVINGS 20 46 79 123 178 248 $/sqft/yr

Entry date 12-01-1995 Report date 04-12-1996

Surface or Pipe Number 2

Insulation costs estimated by FEA method

HEAT LOSS 25 20 32 47 50 67 Btu/sqft/hr

TOTAL SAVINGS 18 41 72 113 165 232 $/sqft/yr

Entry date 12-01-1995 Report date 04-12-1996

Surface or Pipe Number 3

Insulation costs estimated by FEA method

HEAT LOSS 23 15 24 35 34 45 Btu/sqft/hr

TOTAL SAVINGS 13 30 56 91 138 199 $/sqft/yr

Entry date 12-01-1995 Report date 04-12-1996

Start NEW 3E ECONOMICS JOB

NORTH AMERICAN INSULATION MANUFACTURERS ASSOCIATION

Analysis of Hot or Cold surface (H or C) = H

SCREEN 2 - FUEL SELECTION

Manufacturing Energy Consumption Survey, 1988

Coal 1.72 $/MMBtu

DOE weighted average 4.68

LIQUIDS #2 OIL 134000 - 146000 Btu/Gallon

GASES NATURAL 960 - 1100 Btu/Ft3

SOLIDS LIGNITE 8000 Btu/Lb

ELECTRICITY 3412 Btu/kW

TR = (STATE TAX RATE + FEDERAL TAX RATE) -

The default is 30%.

Incremental Physical Equipment Investment: The addition of insulation can cause a

If these data are unavailable, suggested values are

The default is 3.47.

SCREEN 5 - OPERATING INFORMATION

Some typical emittance values include:

SCREEN 4 - REPORT FORMAT

SCREEN 5 - INSULATION TYPE