Hydronic cooling systems (also known as chilled water systems) are closed-loop, tempered water systems that convey heat away from a conditioned space or process, using water as the heat transfer medium.
These systems use standard compressed refrigerant in tubes or coils, or evaporative cooling, to cool the water. The cooled water is pumped through the system piping to an end-point heat exchanger/cooling coil. The heat-exchanging coil surface is cooled by the chilled water.
Air-to-air heat exchange
In an air-to-air heat exchange, a fan moves air across the coil, removing heat from the air, and providing cooled air to the building’s space or to the process being chilled.
In a direct exchange chilled water cooling process, heat is removed from the process by the direct contact of the heat exchanger with the product being cooled, whether a liquid or solid material.
Fiberglass insulation
Insulating these systems is important to satisfactory operation. Fiberglass insulation has a long and successful history of being the most selected insulation material for chilled water systems.
The areas of a chilled water cooling system that typically need to be insulated are the chiller barrels and heads, pumps, piping, and piping specialties. Insulating these components delivers:
- Energy savings equaling reduced operating costs.
- Reduced machine usage and wear equaling reduced operating costs.
- Increased system effectiveness equals happier occupants.
- Condensation control equaling reduced moisture-induced problems.
The Science of Condensation Formation
The warmer water vapor molecules lose energy to the colder surface
Ever-present water vapor molecules in the atmosphere are attracted to any colder surfaces, where they cohere to form liquid water. The warmer water vapor molecules lose energy to the colder surface.
These water molecules gather on the cold surface in enough quantity to form a liquid that sits on the surface of any construction that will not allow water vapor to pass.
The Basics of Condensation Control
Two key parameters in an installation must be met to control condensation formation on mechanical systems, including piping, duct, and equipment.
- First, the total amount of insulation used must have enough resistance to the flow of heat energy to hold the surface temperature of the insulation system higher than the atmospheric dew point, no matter what the atmosphere temperature, relative humidity, and dewpoint (the temperature at which condensation forms).
- Second, the insulation system must include a material that is classified as a vapor retarder, either a separate system solely meant as the vapor retarder or an insulation material that has vapor retarding properties. A vapor retarder is a material that resists all or a significant amount of water molecule penetration, in the form of vapor. If the insulation system does not offer both a sufficiently low thermal conductance and a low water vapor permeance, condensation can still form.
Control Condensation Options for Ducts & Pipes
Fiberglass insulation has differing rates of heat energy flow, depending on the density and thickness
Different combinations of two key insulation system components, the insulation, and the finishing system, can be used to achieve the goal of impeding condensation formation on the surface of insulated mechanical systems.
Fiberglass insulation has differing rates of heat energy flow, depending on the density and thickness of the product. A denser, thinner fiberglass insulation may deliver as much insulating value as a thicker less dense fiberglass insulation.
- Levels of emissivity
The finish systems used for mechanical insulation have different levels of emissivity, changing the rate of energy flow of the system. Highly-reflective finishes require thicker fiberglass for the system to work than non-reflective finishes.
This is an important consideration when selecting system components, in conjunction with site conditions that may restrict selections.
Drawbacks of Ineffective Chilled Water Insulation Installation
Ineffective chilled water insulation system installation can result in negative impacts such as:
- Yields damaged assets, including damage to architectural finishes and the development of moisture in building assemblies, requiring corrective costs.
- Contributes to excessive energy consumption increasing operational expense.
- Causes excessive machine wear increasing repair expense.
- This may lead to mold and mildew growth in facilities requiring remediation costs.
- Duplicate costs to prematurely remove and replace insulation installations.
Keys to an Effective Installation
Correct thickness for the worst expected temperatures, relative humidity, and air movement combinations
There are a few key details to watch for in an insulation installation for chilled water systems: Correct thickness for the worst expected temperatures, relative humidity, and air movement combinations. Many times, the wrong thickness is chosen for a multitude of reasons.
Longitudinal seam/joints, butt joints/seams, fitting insulation, hanger insulation, and vapor sealing are the most common features of an insulation system that need special focus.
Satisfactory performance
Proper completion of each of these details is as important as the others.
Details for completing installations that will deliver satisfactory performance can be found in the North American Insulation Manufacturers’ Association GUIDE TO INSULATING CHILLED WATER PIPING SYSTEMS WITH MINERAL FIBER PIPE INSULATION or the North American Commercial and Industrial Insulation Standards Manual.
Importance of Vapor Retarder and Correct Installation
Water vapor finds the smallest entry points through compromised vapor retarding materials or systems. The vapor retarder system on an insulation installation is key to making a successful installation.
As previously mentioned, the correct insulation thickness combined with a well-executed vapor retarder makes the use of fiberglass insulation on chilled water highly preferred.
- ASJ vapor retarder jacketing
Knauf refers to this as All Service Jacketing (ASJ+), a flexible laminate composite of multiple layers
Higher-performance, premium ASJ vapor retarder jacketing being supplied on Knauf fiberglass pipe insulation products provides a water vapor permeance of 0.01 perm.
Knauf refers to this as All Service Jacketing (ASJ+), a flexible laminate composite of multiple layers typically consisting of foil, paper, film, and reinforcements. ASJ+ or ASJ butt strip tape completes the jacketing system to seal the joints between sections of pipe insulation.
- Vapor retarder treatment
Appropriate vapor dams or vapor seals must be installed, including all terminations. Fitting insulation must have vapor retarder treatment applied as part of or before applying protective finishes.
Seal the throat seam and circumferential edges of PVC fitting covers with PVC vapor seal or adhesive/solvent to all joints. Any damage or voids in the vapor retarder materials must be repaired.
Principles and Practices Apply
Many industrial processes use chilled water as well to cool products or maintain a process temperature
When thinking of chilled water installations, most think of commercial building HVAC comfort cooling systems. Many industrial processes use chilled water as well to cool products or maintain a process temperature.
These same principles for a winning fiberglass insulation installation apply to the industrial chilled water system, as well as the HVAC chilled water system.
In Summary
Fiberglass insulation forms the basis of a highly effective and economical system for insulating all kinds of chilled water cooling systems. Following sound installation practice, especially related to the vapor retarder features, is key to success, correctly specified and installed fiberglass systems have been used for many years for chilled water systems.
Knauf Earthwool 1000°F Pipe Insulation, ASJ+/SSL+ with ECOSE, and Knauf Pipe & Tank Insulation with ECOSE provide reliable performance and a high level of sustainability for chilled water cooling when done completely and thoroughly.
