Heat Loss calculation in insulated thermal oil pipes

The program calculates heat loss according to pipe size and length, flow, temperature(s), insulation size and type, in order to select the economical insulation and save energy.

1. System Parameters:

• 8-inch nominal diameter pipe, 1000 feet long
• Thermal oil flowing at 100 lbm/s (45.4 kg/s)
• Oil temperature: 284°F (140°C) inlet
• Ambient air: 60°F (15.6°C), 20 ft/s velocity
• Calcium silicate insulation: 2 inches thick

2. Key Calculations:

• Reynolds number (Re) = 133,126 (turbulent flow)
• Overall heat transfer coefficient (U) = 0.94 W/m²K
• Total heat loss (Q) = 36 kW
• Temperature drop = 0.7°F (inlet to outlet)

The calculation uses:

• Convective heat transfer (air)
• Conductive heat transfer (insulation)
• Mass flow energy balance (Q = mCpDT)