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┌───────────────────────────────────────┐
│ │
│ EIS - Economic Insulation Selection │
│ │
│ Version 2.2 │
│ │
│ Designed and Created By: │
│ Michael Richardson, P. E. │
│ │
│ Richardson Engineering │
│ Laurel, Mississippi │
│ │
└───────────────────────────────────────┘
USERS MANUAL
EIS - Economic Insulation Selection
Copyright 1990-1992 by Richardson Engineering, All Rights Reserved.
TABLE OF CONTENTS Page
1. General Information 2
Welcome To EIS 2
EIS Software 2
License Agreement 2
Disclaimer 3
2. Introduction 3
Minimum System Requirements 3
Program Installation 3
Contents of this Manual 4
EIS Software Program Listing 5
On-Disk Manual Copy 5
What EIS Offers You 6
Who Can Benefit From EIS 7
3. EIS Program Descriptions 7
Getting Started 7
Main Menu Interface 7
4. Sizing Optimum Insulation Thicknesses 8
EPI and EEI Main Menu 8
Menu Selection Sequence 8
Menu Option Description 8
Data Entry Description 10
Interpretation of Results 12
Program Methodology 14
Program Assumptions 16
Error Messages 16
5. Checking Piping Thermal Heat Losses 17
Using EPILOSS 17
EPILOSS Description 17
Running in a Memory Resident Mode 17
Data Entry Description 17
Program Methodology 18
Interpretation of Results 19
Program Assumptions 19
6. Cost File Database Programs 20
EPIDB and EEIDB General Description 20
Main Menu 20
Menu Selection Sequence 21
Menu Entry Description 21
Supported Insulation Thicknesses & Layers 24
Error Messages 25
7. User Support 25
Problems 25
Contacting The Author 25
8. Sample Problems 26
EPI Sample Problem
EEI Sample Problem
Page 1
EIS - Economic Insulation Selection
1.0 General Information
Welcome To EIS
EIS, (E)conomic (I)nsulation (S)election is a complete, stand-
alone software package for establishing economic selection of
heat containing thermal insulation systems. The following pages
contain complete step-by-step instructions needed for a
computer analysis of insulation requirements.
Richardson Engineering's EIS will calculate insulation
thickness recommendations to meet most desired applications
and will perform the following:
1. Calculate energy losses for various insulation
thicknesses as well as uninsulated, bare surfaces.
2. Determine surface temperatures and identify those
thicknesses that may be insufficient for personnel
protection.
3. Establish installed and operating costs based on
pertinent financial information.
4. Identify the insulation thickness which provides a
minimum operating cost to the owner.
Software
Five design programs are provided in the EIS software package.
The main sizing programs, EPI (Economic Pipe Insulation) and EEI
(Economic Equipment Insulation) use thermal and financial
information to identify optimum insulation sizing for piping and
equipment systems respectively. EPIDB and EEIDB (EPI and EEI
DataBases) are the cost database programs for each respective sizing
program, and allows the user to customize program cost files for
special circumstances. EPILOSS is a heat loss calculation program
and simplifies the analysis of piping system heat losses.
License Agreement
The EIS program software, including EPI, EEI, EPIDB, EEIDB, and
EPILOSS, are commercial software products of Richardson Engineering
Inc. which retains ownership of these programs. Copies of the EIS
software may be licensed for use under the following conditions: A
licensed user may use this software on any compatible computer,
provided the software is used on only one computer and by only one
user at a time. Licensed users may make a backup copy of the EIS
software, but any other copying of this software or its documentation
is strictly prohibited except when authorized in writing by
Richardson Engineering Inc.
Distributing, renting, sub-licensing, or leasing this
software or documentation without the express written consent
of Richardson Engineering Inc. is strictly prohibited. No one is
permitted to alter, modify or adapt this software or
documentation, including but not limited to, translating,
decompiling, disassembling, or creating derivative works.
The use of this software constitutes acceptance of this
license agreement.
Page 2
Disclaimer
In no event will Richardson Engineering Inc. be liable for any
damages including lost profits, lost savings or other
incidental or consequential damages arising out of the use or
inability to use this product, even if we have been advised
of the possibility of such damages, or for any claim by any
other party. No warranties are made, express or implied, with
regard to the contents of the program and manual, its
merchantability, or fitness for a particular purpose.
2.0 Introduction
Minimum System Requirements
The following are minimum system requirements to run EIS on
your computer.
- IBM PC/XT, AT, PS-2 or 100% compatible computer.
- MS-DOS 2.1, or later.
- Hard disk drive system or floppy disk drive system (*).
- Minimum 256K RAM memory.
- Color monitor (CGA, EGA, or VGA).
- Standard track printer.
(*) Because of higher access speed and superior storage
capacity, we recommend that EIS be run from a hard disk drive
(any size).
Program Installation
Although you can use EIS from a floppy disk drive system, it
works most efficiently from a hard disk. When you receive the
EIS software, follow the following steps to install the system
on your hard drive.
QUICK AUTO INSTALLATION:
1. Insert the EIS Disk 1 diskette in any floppy disk drive.
2. For hard disk installation, type:
INSTALL (and press Enter at the DOS prompt)
Then follow the screen instructions.
3. To run EIS design software:
At C:\EIS directory, type MENU (press ENTER) <-- Hard Disk
The user may then select the desired program from the main
menu interface.
At A:\ or B:\, the user must insert the specific floppy disk as
described below. Based on the desired program, type the
following:
type EPI (press ENTER) <-- Floppy Disk No. 1
type EIS (press ENTER) <-- Floppy Disk No. 1
type EPIDB (press ENTER) <-- Floppy Disk No. 2
type EEIDB (press ENTER) <-- Floppy Disk No. 2
type EPILOSS (press ENTER) <-- Floppy Disk No. 2
Page 3
Program Installation - Cont.
ALTERNATE INSTALLATION:
For hard disk systems:
1. Open a new hard disk directory. (Suggest User Name it
EIS).
2. Copy all EIS files from floppy disk to the new directory.
3. If you are using an existing older version of EIS, erase
these files from the hard disk directory (ignore Item 1)
and complete Item 2.
NOTE: ALL EIS Files Must Be Located in The Same Directory
For Proper Program Operation.
Contents of This Manual
This manual shows you step by step in narrative format how to
use each of EIS's features. The best way to learn EIS would
be to go through the whole text while implementing the same
functions on the computer.
Chapter 1 contains general information as well as various
notices.
Chapter 2 is a brief introduction to the EIS design programs,
what it has to offer to the user, and who can benefit.
Chapter 3 provides a brief explanation of each EIS design programs,
including design purpose, function, and data output. The hard drive
main menu interface is also briefly discussed.
Chapter 4 deals with actual use of the EPI and EEI programs and
interpretation of program results. This section includes main
menu selection, data entry information, interpretation of
output data, and descriptions of program assumptions and
error messages.
Chapter 5 deals with actual use of the EPILOSS program and
program functions. This section includes data entry description,
interpretation of results, program methodology, and program
assumptions.
Chapter 6 deals with actual use of the EPIDB and EEIDB programs
and program features. This section includes main menu selection,
data entry information, data review, and interpretation of
error messages.
Chapter 7 deals with user support information.
Chapter 8 explains EPI and EEI sample problems.
Page 4
EIS Software Program Listing
The following program files should be included with your
EIS software package. These files stored on Disk 1 include:
EPI.EXE - EPI Main Program File.
EPICALS.DAT - EPI Calcium Silicate Cost File.
EPIFIBR.DAT - EPI Fiberglass Cost File.
EPICELG.DAT - EPI Cellular Glass Cost File.
EPIMARK.DAT - EPI Contractor Markup Cost File.
SAMPLE1.EPI - Sample EPI Data File.
EEI.EXE - EEI Main Program File.
EEICALS.DAT - EEI Calcium Silicate Cost File.
EEIFIBR.DAT -EEI Fiberglass Cost File.
EEICELG.DAT - EEI Cellular Glass Cost File.
EEIMARK.DAT - EEI Contractor Markup Cost File.
SAMPLE2.EEI - Sample EEI Data File.
INSTALL.EXE - Hard Drive Installation File.
README.TXT - Updated program information.
MENU.EXE - Main EIS Menu Panel (Hard Drive
Installation Only)
The programs stored on Disk 2 include:
EPIDB.EXE - EPI Cost Database Program File.
EEIDB.EXE - EEI Cost Database Program File.
EPILOSS.EXE - EPILOSS Heat Loss Calculator.
MANUAL.DOC - EPI Documentation File (ASCII Text).
COSTBAK.EXE - Self Extracting Archive File Containing
Backup Copy of Cost Database Files.
On-Disk Manual Copy
An "on-disk" manual is supplied with the EIS software and is
identified by the file name "MANUAL.DOC". This on-disk manual
is in ASCII format. You can print it by using DOS commands
or text processor.
To read the contents of this file copy, insert the EIS Disk 2
diskette in your floppy drive. Close door. At the DOS prompt,
type,
TYPE MANUAL.DOC (press ENTER)
Page 5
On-Disk Manual Copy
The file will scroll down your screen. To stop scrolling,
press CTRL and NUMLOCK keys simultaneously. Then continue
reading.
To print the contents of this manual file, insert EIS Disk 2
diskette in your floppy drive. Close door. Make sure printer
is ready to print approximately 30 pages. At the DOS prompt,
type:
COPY MANUAL.DOC PRN (press ENTER)
What EIS Offers You
EIS is an easy-to-use software package designed to increase
efficiency and productivity in the optimal selection of thermal
insulation.
Energy cost is now a major item in the operation of any new
or existing mechanical process, power generation plant, or
energy system. That is why the selection of the right
thickness, for the application and energy reduction goals
desired, is an important design step that cannot be
overlooked if the system is expected to attain desirable
investment goals.
Additionally, reinsulation after asbestos abatement work will
necessitate a sophisticated approach to insulation selection
in order to maximize long term project effectiveness.
Unfortunately, determining just the "right" thickness is not
an easy task, but anything less than accurate and complete
computer analysis can reduce the best intentions to a
financial burden. Inflation and the rising costs of energy
are known facts and must be accounted for in any insulation
savings projection. Skimping on insulation or "fast payback"
thickness calculations is false economy.
EIS represents a powerful insulation optimization tool in an
easy to use package. Some benefits to be gained are as
follows:
- A complete, stand-alone system. No other software is
necessary.
- Lightning fast program execution.
- Estimated material and labor cost data are built into
the computer. Data input is simplified.
- Built-in comprehensive on-screen reporting for data
evaluation is provided.
- Instant recap for "what-if" type analysis.
- Supports standard printers.
- Displays pertinent installation and operating cost
data necessary for optimal insulation selection.
- Provides the capability to save program data for
recall and evaluation at future dates.
- Graphical review of results.
And many other advanced features ...
Page 6
Who Can Benefit From EIS
EIS is based on established thermal engineering theory and is
suitable for a wide range of industries, trades, and private
and public organizations ranging in size from one-person
individuals to medium and large size contracting companies,
engineers and architects.
3.0 EIS Program Descriptions
As mentioned previously, the EIS insulation sizing package
includes five main sizing programs along with supplemental files
for cost data, contractor markup, and sample application data.
The user should be familiar with the purpose and function of each
program before evaluating any specific design applications.
Additionally, it is recommended that the user "test-drive" each
EIS program before attempting to design an insulation system.
The sample application data are furnished for this purpose.
Finally, it is important that the user understand the general
program methodology and theory for each program.
Getting Started
The EIS program uses two main insulation sizing programs to
identify optimal insulation thicknesses. The EPI (Economic Pipe
Insulation) program is designed for piping applications where the
process temperature exceeds the ambient temperature. The EEI
(Economic Equipment Insulation) program is designed for equipment
(or flat) insulation sizing, and is very similar in function to the
EPI program. Each program uses thermal data to generate system heat
losses, and financial data to identify capital and operating costs
based on a life-cycle costing approach. Optimal selection is
established by identifying the minimum annualized cost-to-own.
The EPILOSS (EPI Heat Loss) software is a supplemental program for
the EPI piping insulation program. This program allows the user to
initially evaluate an insulation design solely on thermal heat losses
and surface temperatures. For instance, if personnel burn protection
is the primary design criteria, then this program can be used to
identify necessary thicknesses without the need to enter
financial data.
Both the EPI and EEI sizing programs are sensitive to labor and
material costs required for system installation. The cost data
files that are included with the EIS package are estimated amounts
based on average installation conditions. Since insulation
designs may have special site specific cost requirements, the EIS
package contains database programs to revise the EPI and EEI cost
data files. The EPIDB (EPI DataBase) program allows to user to modify
the EPI cost files. Additionally, the EEIDB (EEI DataBase) program
provides for the revision of the EEI cost files.
Main Menu Interface
If the EIS software is installed on a hard drive, a main menu
interface is available for easy selection of the above programs.
After hard disk installation, type MENU from the EIS default
directory prompt. This menu also provides user assistance
including program descriptions, on-line help, and customer
support information.
Page 7
4.0 Sizing Optimum Insulation Thicknesses
EPI and EEI Main Menu
EPI and EEI use a menu driven user interface which allows
for simple selection of various program features. This interface
also is provided with context-sensitive help windows for user
reference. EPI and EEI are designed for the occasional user, with
simple input screens and user-friendly program option
selection.
A schematic of the main menu is as follows:
╔═════════════════[ MAIN MENU ]═══════════════╗
║ ║
║ 1) Enter Data ║
║ 2) Look At Results ║
║ 3) Review Assumptions ║
║ 4) Print Results ║
║ 5) Load Data ║
║ 6) Save Data ║
║ 7) Data Units ║
║ 8) Quit ║
║ ║
╚═════════════════════════════════════════════╝
From this menu, you can access all of the operations of the
program. By using the cursor keys, move the highlighted line
to the desired activity and press the <ENTER> key to select
that option. Press [F1] for additional help messages.
Menu Selection Sequence
Both programs initially require that Option 1 be selected and
completed prior to Looking At Results (Option 2), Printing
Results (Option 4), and Saving Program Data (Option 6). The
user may enter data or load an existing data file from the
computer (Option 5), if available.
English or Metric units may be selected with the use Option 7.
The user may review program assumptions (Option 3) at any
time. Frequent and careful review of this listing is strongly
recommended since some restrictions apply. Special insulation
installations could possibly invalidate program results.
Interpretation by a qualified professional engineer is
suggested.
Menu Entry Description
ENTER DATA (Option 1)
This selection allows the user to enter parameters concerning
the insulation system. Two data windows for this option. A data
window is simply a screen where you enter data requested by the
program. The first window (Thermal Data Window) provides for the
input of project identification and thermal data. The second window
(Financial Data Window) provides for the input of operating and
financial information required for the optimal thickness selection.
As an aid for error checking, all data entry prompts have allowable
ranges which the program will accept. The user will be warned of a
data entry beyond the allowable range.
Page 8
Menu Entry Description - Cont.
LOOK AT RESULTS (Option 2)
Provides a recap screen to review results from Option 1.
Press the ALT C key combination for a graphical display (bar chart)
of analysis results (English Units only).
REVIEW ASSUMPTIONS (Option 3)
Lists program assumptions for user review.
PRINT RESULTS (Option 4)
Allows user to print results from Option 1 to a standard
track printer for hardcopy review. Please note that the use
of a non-standard printers may have unusual results.
LOAD DATA (Option 5)
Allows user to enter the name of an existing data file in the
default drive. Existing data can be recalled from the disk,
modified, and the solution of the modified data set
calculated. Please note that only data files with an EPI or EEI
extension (i.e. Datafile.EPI) can be properly retrieved and
interpreted. Other files retrieved without this extension
will result in a program error.
If you cannot remember the data file name, press [F2] to
search your default directory. The program automatically
identifies those files with the *.EPI or a *.EEI extension.
Move the cursor to the proper data file and press <Enter>. The
program will place the file name in the load window. Press [F10]
for program file loading. Load and use the SAMPLE1.EPI or the
SAMPLE2.EEI datafile for practice.
SAVE DATA (Option 6)
Provides user with a means of storing input data to a file on
the default disk. The program prompts you for the file name. The
file must be a valid DOS file name, up to eight alpha-numeric
characters, without an three letter extension (the EPI or EEI
extension is automatically appended to each data file).
DATA UNITS (Option 7)
Allows the user to select English or Metric (SI) units. Additional
program status information is displayed for reference.
QUIT (Option 8)
This option terminates program execution and places the user
at the DOS prompt.
Page 9
Data Entry Description
The following information provides detail descriptions of
those data entry items which the user must complete prior to
obtaining a recommended economic thickness. Each program
utilizes Option 1 (Data Entry) for user required information.
This option consists of two data windows: 1) Thermal Data
Window and 2) Financial Data Entry Window. For a more general
description of these windows, refer to the previous section.
The entry items are described by window type and include:
THERMAL DATA WINDOW
Project Name - Complete this information so that you can
identify the project. Space is limited. If the name will not
fit, use an abbreviation.
Run Number - Enter this data so that you can identify the
data set during "what-if" type evaluations. That is, if you
perform multiple analysis under the same project name, then
this identification number may be helpful.
Bare Pipe OD (EPI Only) - This data entry refers to the outside
pipe diameter on which the insulation will be installed. Piping
diameters should be entered in inches. The program allows diameters
between 0.5 and 24 inches (SI Units: 0.0127 to 0.6096 meters).
Surface Temperature - This entry establishes the bare surface
temperature in degrees Fahrenheit. The bare surface temperature is
dependant on process temperatures, wall conductivity and thickness,
and surface resistance to heat transfer. For piping, the user may,
in most cases, assume that the pipe interior temperature equals the
surface temperature. For practical purposes, resistance offered by
standard wall pipe is very small. Equipment surface temperatures
will vary by application. In all cases, the user should evaluate
heat transfer to the surface regions.
The program allows surface temperatures between 40 and 1000 degrees
Fahrenheit (SI Units: 4.4 to 538 Degrees C). Additionally, the
user should be aware that insulation materials are limited
regarding temperature ratings.
Ambient Temperature - The temperature of the surrounding
ambient air in degrees Fahrenheit is allowed between a range
of -20 to 150 degrees Fahrenheit (SI Units: -29 to 66 Degrees C).
Conductivity - The values of thermal conductivity , K, for
specific insulation is available from manufacturers, and it
is suggested that data entry be based on information which
apply to the material and brand name of the insulation to be
used. Thermal conductivity is the number of BTU's (British
Thermal Units) which will pass through one square foot of
homogeneous material in one hour with a one degree Fahrenheit
temperature difference per inch of insulation (k = Btu In/Hr,
Sf, Deg F). The program allows for the entry of thermal
conductivity in the range of 0.2 to 0.9 Btu In/Hr, Sf, Deg F
(SI Units: 0.0288 to 0.130 Watts/Meter - Kelvin).
Press the ALT C key combination to graphically display nominal
thermal conductivity information (English units only).
Page 10
Data Entry Description - Cont.
Insulation Code Number - the program supports CALCIUM
SILICATE, FIBERGLASS, and CELLULAR GLASS insulation and has built
in approximated cost values for material and labor installation.
Enter a digit of one (1) for calcium silicate , a digit of
two (2) for fiberglass, or three (3) for cellular glass.
Future updates will include other insulation types.
After the above information has been entered within the
appropriate ranges, press [F10] to view heat loss information
per insulation thickness. After review, press any key for the
Financial Data Window.
FINANCIAL DATA WINDOW
Fuel Cost - Complete the purchased price of fuel in dollars
per million Btu's. The user can calculate this information
from the type and cost of boiler fuel used (i.e. oil, natural
gas, coal) and the fuel heating value. Typical heating values
of fuel are:
Oil: No. 6: 140,000 - 155,000 Btu/Gallon
No. 4: 138,000 - 152,000 Btu/Gallon
No. 2: 134,000 - 146,000 Btu/Gallon
Gas: Natural Gas: 960 - 1,100 Btu/Cubic Foot
Butane: 3,200 Btu/Cubic Foot
Producer Gas: 150 - 200 Btu/Cubic Foot
Coal (or other solid fuel)
Lignite : 8,000 Btu/Pound
Sub-Bituminous : 8,300 - 13,000 Btu/Pound
Bituminous : 11,000 - 14,000 Btu/Pound
Anthracite : 12,000 - 15,500 Btu/Pound
Wood : 4,800 - 6,300 Btu/Pound
Peat : 7,600 - 10,026 Btu/Pound
Bagasse : 8,300 Btu/Pound
The computer accepts fuel costs in the range of 0.1 to 10
dollars per million Btu's (SI Units: 0.0001 to 0.01 $/MegaJoules).
Annual Fuel Inflation (%) - This is an expectation of annual
fuel price increases. Depending on fuel market conditions, 10
percent could be a good estimate. The program accepts an
inflation rate of 0 to 100 percent.
Interest Rate (%) - this represents the value of money and is
always greater than the inflation rate. This represents the
"opportunity cost" if the installation funding was placed in
the best alternate investment. The program accepts an
interest rate between 0 to 100 per cent.
Operating Schedule - This represents the annual operating
hours of the insulation system. The maximum available annual
operating hours is 8760.
Economic Life of New Insulation - Enter the expected life, in
years, of the new insulation. Typical values are between 10
to 20 years. the program accepts a life in the range of 10 to
30 years.
Page 11
Data Entry Description - Cont.
Average Capital Investment Cost of Heat ($/1000 BTU/HR-English or
$/Kilowatts-Metric) This quantity represents the cost of heat
attributed to the heating plant investment (EPI and EEI amortizes
this value to an annual amount). This item is calculated as follows:
Book Value of the Heat Producing Facility ($)
= --------------------------------------------- X 1000
The Average Hourly Energy Production (Btu/Hr)
The average hourly energy production rate can be calculated with
various methods, depending on the available data. However, a
common approach is:
Hourly Fuel Use X Conversion Efficiency X Fuel Heating Value
Boiler Efficiency (%) - Input the thermal energy efficiency
of the boiler plant. Efficiencies vary depending on the
boiler and fuel types; however, typical efficiencies range
from 60 to 80 percent. The program can accept 25 to 95
percent efficiencies.
Installation Labor Rate ($) - Enter the hourly labor rate for
local site conditions. Labor rates can vary considerably
due to geographic regions, installation conditions, labor
agreements, and other site specific occurrences. Refer to
current estimating manuals, insulation contractors, vendors,
or other appropriate sources for hourly wage information.
Interpretation of Results
The following information depicts sample data and program
output created after the completion of Data Entry (Option 1).
Please note that data is entered in the top half of the
screen and output is displayed in the lower screen half. The
user should press [F10] to obtain output after data entry.
The following screen is the Thermal Data Window (EPI example).
╔════════════════════════════════════════════════════════════════════╗
║ ............. THERMAL DATA WINDOW ............. ║
║Enter Project Name : sample║
║Enter Run Identification : 1·····║
║Enter OD of Bare Pipe - Inches : 4·····║
║Enter Pipe Temperature - Degrees F : 500···║
║Enter Ambient Temperature - Degrees F : 40····║
║Enter Ave. Insulation Thermal Conductivity - Btu/Sf-Hr-F-In : 0.45··║
║Enter Insulation Code Number : 1║
║ *** PROGRAM OUTPUT *** ║
║No Layers Inches of Insulation BTU Loss/Hr-Lin Ft Surface Temp-F║
║ 1 1.5 170 110 ║
║ 1 2.0 142 95 ║
║ 1 2.5 124 85 ║
║ 1 3.0 112 78 ║
║ 1 3.5 102 73 ║
║ 1 4.0 95 69 ║
║ 1 4.5 89 66 ║
║ 1 5.5 80 62 ║
║ 1 6.0 76 60 ║
║ 2 7.0 71 57 ║
║ The Bare Pipe BTU Loss per Hr-Lineal Ft of Pipe : 1987 ║
╚═════════════════════Press Any Key To Continue══════════════════════╝
Page 12
Interpretation of Results - Cont.
Output data on the above window denotes heat loss and outer
insulation surface temperature based on insulation thicknesses.
The number of layers per insulation thickness is shown for
additional reference. A bare surface (non-insulated) heat loss
figure is shown at the bottom of the screen. EPI or EEI warns
the user if an insulation surface temperature exceeds 120
degrees Fahrenheit. A "TOO HOT" warning is displayed and
identifies those thicknesses which represent a potential
burn hazard.
The Financial Data Window (EPI example) is shown below. This
window is second screen completed by the user during Option 1.
This screen is also the final data entry point for the
program which uses the financial information to determine
costs required for an optimal insulation selection.
╔════════════════════════════════════════════════════════════════════╗
║ ............. FINANCIAL DATA WINDOW ............. ║
║ ** Data Input Needed Here ** ║
║Enter Fuel Cost - $/ Million Btu : 3·····║
║Enter Annual Inflation, Fuel Cost - % : 10····║
║Enter Annual Interest Rate - % : 12····║
║Enter Operating Schedule - Hours Per Year : 8760··║
║Enter Economic Life of New Insulation - Years : 20····║
║Enter Average Capital Investment Cost of Heat - $/MBtu/Hour :2·····║
║Enter Boiler Plant Efficiency - %: 85····║
║Enter Installation Labor Rate - $/Hour : 25····║
║ *** PROGRAM OUTPUT *** ║
║Number Of Thickness Material Labor Total Inst Heat Loss Cost To ║
║Layers Inches $/Ft $/Ft Cost $/Ft-Yr $/Ft-Yr Own $/Ft-Yr║
║ 1 1.5 6 6 1.77 12.05 13.82 ║
║ 1 2.0 9 6 2.21 10.09 12.30 ║
║ 1 2.5 11 7 2.65 8.81 11.46 ║
║ 1 3.0 13 7 2.94 7.91 10.85 ║
║->1 3.5 16 7 3.53 7.23 10.76<- ║
║ 1 4.0 20 8 4.12 6.71 10.83 ║
║ 1 4.5 23 9 4.69 6.29 10.98 ║
║ 1 5.5 29 10 5.89 5.65 11.54 ║
║ 1 6.0 33 11 6.51 5.40 11.91 ║
║ 2 7.0 42 20 9.08 5.00 14.08 ║
╚══════════════════════Press Any Key To Continue═════════════════════╝
Output data on the above window denotes financial parameters
(including material/labor costs, total installed cost, and
annual cost to own) based on the insulation thickness. The
number of layers per insulation thickness is shown for
additional reference.
Page 13
Program Methodology (English Units)
Labor and material costs are based on average subcontractor
installed costs with a 25 percent markup (this can be modified
using the EPIDB or EEIDB database engine).
The annual cost to own and operate is the total cost of the
yearly heat losses plus the annual total installed cost. It
is left to the user to examine the total costs and determine
which is the correct insulation system for his application.
Normally, the lowest total cost system would be the correct
selection and is HIGHLIGHTED IN RED on the monitor screen.
The Total Cost To Own ($/Ft-Yr for EPI or $/SF-Yr for EEI) is:
TOTCOST = LOSSVAL + TIC
The total installed cost is an annualized installed cost
based on the initial investment, project life, and cost of
money. The total installed cost of the insulation is
calculated as follows:
TIC = 1.1 X CRF X (Material Cost + Labor Cost)
The factor 1.1 allows for an annual maintenance of 10 percent
on the insulation. CRF is the capital recovery factor which
converts a single payment to a series of annual streams based
on the number of years specified, N, and the cost of money,
I. CRF is calculated as follows:
CRF = (I X (1+I)^N) / ((1+I)^N - 1)
The annual value of the heat loss (LOSSVAL), in $/Ft-Yr for EPI
or $/SF-Yr for EEI, is calculated as shown:
LOSSVAL = BTUVAL X HEATLOSS X HOURS
where: HOURS is the hours per year of operation.
The EPI program calculates heat lost (HEATLOSS), BTU/Hr-Foot, for
a given piping system as follows:
HEATLOSS = (0.523 X TEMPDIF X R2) / ((R2 X LN(R2/R1)/
COND)+.6)
Where:
COND = thermal conductivity, BTU-In/Hr-Sf-F
TEMPDIF = fluid temp - ambient temp, F
R2, R1 = Outside and inside radius of insulation shell
in inches.
0.6 = the surface resistance (reciprocal of the air film
coefficient), 1/(BTU/Hr-Sf-F)
The EEI program calculates heat lost (HEATLOSS), BTU/Hr-Sq Ft, for
a given equipment system as follows:
HEATLOSS = TEMPDIF / ((W/COND) + 0.6)
Where:
COND = thermal conductivity, BTU-In/Hr-Sf-F
TEMPDIF = fluid temp - ambient temp, F
W = Insulation Thickness, in inches.
0.6 = the surface resistance (reciprocal of the air film
coefficient), 1/(BTU/Hr-Sf-F)
Page 14
Program Methodology - Cont.
The energy value of the insulation heat losses is determined
as follows:
VALUE OF ONE BTU : The value of 1 BTU lost consists of
* A fuel component (heat loss)
* A plant capital cost component
* A plant operating and maintenance cost component.
The value of the fuel component, $/BTU, of lost heat is
calculated as follows:
COSTHEAT = (AVEFAC X COST OF FUEL) / (BOILER EFFICIENCY)
Where: AVGFAC levelizes the escalating fuel cost based on the
inflation rate, L, cost of money, I, and the number of years.
AVEFAC = CRF X (1- (1+L)^N X (1+I)^(-N)) / (I-L)
The plant capital cost component is determined from the
value of the capital investment heat cost, in $ per thousand BTU/Hr,
which is entered by the user.
COSTPLNT = (CRF * CAPITAL INVESTMENT COST OF HEAT)/(1000 * HOURS)
The plant operating and maintenance cost is assumed to be 10
percent of the fuel cost component. Therefore, the value of
one BTU lost is calculated as follows:
BTUVAL = COSTPLNT + 1.1 X COSTHEAT
The user can review a recap screen by selecting Option 2. A
sample output screen (EPI example) is denoted below and based on the
sample output described above.
╔═══════════════════════════════════════════════════════════════════╗
║ ............. ANALYSIS RESULTS ............ ║
║Enter OD of Bare Pipe - Inches : 4.0 ║
║Enter Pipe Temperature - Degrees F : 500 ║
║Enter Ambient Temperature - Degrees F : 40 ║
║Enter Fuel Cost - $/ Million Btu : 3.0 ║
║Enter Annual Inflation, Fuel Cost - % : 10 ║
║Enter Annual Interest Rate - % : 12 ║
║Enter Operating Schedule - Hours Per Year : 8760 ║
║Enter Economic Life of New Insulation - Years : 20 ║
║Enter Installation Labor Rate - $/Hour : 25.00 ║
║ ║
║Number Of Thickness Material Labor Total Inst Heat Loss Cost To ║
║Layers Inches $/Ft $/Ft Cost $/Ft-Yr $/Ft-Yr Own $/Ft-Yr║
║ 1 1.5 6 6 1.77 12.05 13.82 ║
║ 1 2.0 9 6 2.21 10.09 12.30 ║
║ 1 2.5 11 7 2.65 8.81 11.46 ║
║ 1 3.0 13 7 2.94 7.91 10.85 ║
║->1 3.5 16 7 3.53 7.23 10.76<- ║
║ 1 4.0 20 8 4.12 6.71 10.83 ║
║ 1 4.5 23 9 4.69 6.29 10.98 ║
║ 1 5.5 29 10 5.89 5.65 11.54 ║
║ 1 6.0 33 11 6.51 5.40 11.91 ║
║ 2 7.0 42 20 9.08 5.00 14.08 ║
╚═════════════════════Press Any Key To Continue═════════════════════╝
Page 15
Program Methodology - Cont.
REFERENCE : ECONOMIC THICKNESS FOR INDUSTRIAL INSULATION,
FAIRMONT PRESS, ATLANTA, GA, 1983.
EPI and EEI Program Assumptions
1) Results Are Not Valid For Cold System or Building Insulation.
2) An Air Film Coefficient of 1.67 Btu/Sf-Hr-F Is Assumed.
3) A Maximum Allowable Outer Surface Temperature of 120 Deg F Is Used.
4) Program Uses A Maximum Insulation Thickness of 9 Inches.
5) Program Uses A Maximum Nominal Pipe Diameter of 24 Inches (EPI Only).
6) Material Costs include Insulation with Aluminum Jacket Covering.
7) Calculated Labor and Material Costs Are Estimates. Values should
be verified.
8) SubContractor Installation Assumed with Average Installation
Complexity.
9) Labor & Material Costs Are For Fiberglass, Calcium Silicate, and
Cellular Glass Only.
10) Heating Plant and Insulation Depreciation Periods are Equal.
Error Messages
Menu Selection Error - Alerts user to an incorrect menu
selection prior to complete data specification of the
insulation system.
Data Selection Error - Alerts user to potential data input
errors which may possibly produce inaccurate program results.
Selected Data File Is Not EPI or EEI Supported - Alerts user to
a file which was not created by the EPI or EEI program.
Insulation Cost Data File Not Found - Alerts user to the
absence of required insulation cost data files within the
default directory. Copy cost data files (they have the file
extension ".DAT") into the EPI and EEI default directory.
Incomplete Cost Data Files or Unsupported Pipe Size (EPI Only) -
Alerts user that the cost data file is corrupted OR that an
unsupported pipe diameter has been entered. Supported nominal
diameters are:
0.5, 0.75, 1.0, 1.5, 2.0, 3.0, 4.0, 5.0, 6.0, 8.0, 10.0,
12.0, 14.0, 16.0, 18.0, 20.0, and 24.0.
If a supported diameter has been entered, the data file may be
corrupted. Copy backup cost data files into the EIS directory.
Page 16
5.0 Using EPILOSS
EPILOSS Description
EPILOSS is designed to supplement the EPI insulation sizing program.
EPILOSS allows the user to evaluate thermal characteristics of
various piping insulation systems without entering associated
financial data which is required by the more comprehensive EPI
(Economic Pipe Insulation) sizing program. The user can enter pipe
size, insulation conductivity, and system temperatures. The EPILOSS
program will respond with pre-determined insulation thicknesses,
insulated and uninsulated piping heat losses, surface temperatures,
and inappropriate thicknesses which do not provide adequate burn
personnel protection. Since data entry is much more compact,
insulation type and energy characteristics can be quickly evaluated.
Additionally the user may, as an option, configure the program in
metric units, or load EPILOSS as a memory resident program. Loading
in a memory resident mode allows the user to run other design
programs while retaining EPILOSS in memory. The user can "pop-up"
EPILOSS by pressing a defined keyboard hotkey combination.
Running In a Memory Resident Mode
EPILOSS can be run as a memory resident program. The process of
loading EPILOSS as a memory resident program causes your computer
to exit the EPILOSS program and return you to the DOS command
prompt. You are now ready to run any other programs you choose, but
EPILOSS is still in your computer's memory, ready to be activated
at any time by simultaneously pressing the CTRL - E hotkey
combination.
EPILOSS requires approximately 80K of RAM. Therefore the user
must ensure that memory is available prior to loading EPILOSS.
A check can be made by running DOS's CHKDISK program. Other
requirements include an 80 column visual display in TEXT mode.
EPILOSS will NOT "pop-up" in a graphics mode.
Some memory resident programs may conflict with proper program
function. If this occurs, remove these programs from memory before
running EPILOSS.
Data Entry Description
This following information provides detail descriptions of
those data entry items which the user must complete prior to
obtaining a system heat loss analysis.
Bare Pipe OD - This data entry refers to the outside pipe
diameter on which the insulation will be installed. Piping
diameters should be entered in inches. The program allows
diameters between 1 inch and 24 inches (SI Units: 0.0127 to
0.6096 Meters).
Page 17
Data Entry Description - Cont.
Pipe Temperature - This entry establishes the pipe surface
temperature in degrees Fahrenheit. For practical purposes,
resistance offered by standard wall pipe is very small.
In most cases, the user may assume that the pipe interior
temperature equals the pipe surface temperature. The program
allows surface temperatures between 120 and 1000 degrees
Fahrenheit (SI Units: 4.4 to 538 Degrees C). Additionally, the
user should be aware that insulation materials are limited
regarding temperature ratings.
Ambient Temperature - The temperature of the surrounding
ambient air in degrees Fahrenheit is allowed between a range
of 20 to 120 degrees Fahrenheit (SI Units: -29 to 66 Degrees C).
Conductivity - The values of thermal conductivity , K, for
specific insulation is available from manufacturers, and it
is suggested that data entry be based on information which
apply to the material and brand name of the insulation to be
used. Thermal conductivity is the number of BTU's (British
Thermal Units) which will pass through one square foot of
homogeneous material in one hour with a one degree Fahrenheit
temperature difference per inch of insulation (k = Btu In/Hr,
Sf, Deg F). The program allows for the entry of thermal
conductivity in the range of 0.1 to 0.9 Btu-In/Hr, Sf, Deg F
(SI Units: 0.0288 to 0.130 Watts/Meter - Kelvin).
A conductivity chart will display nominal design numbers for
the three major piping insulation groups including: 1) Calcium
Silicate; 2) Fiberglass; and 3) Cellular Glass. This chart will
pop-up as the user enters the conductivity data entry field.
Additionally, EPILOSS automatically checks user data entry.
If entered data is invalid, the program will flag the user
of an error and will request that the user re-enter the data.
The user will need to use the keyboard cursor keys to correct
or revise data which has been entered.
It is recommended that the user try several practice problems,
utilizing the necessary keyboard functions, before attempting
any design problems.
Program Methodology (English Units)
The program calculates the heat lost (HEATLOSS), BTU/Hr-Foot,
for a given piping system as follows:
HEATLOSS = (0.523 X TEMPDIF X R2) / ((R2 X LN(R2/R1)/
COND)+.6)
Where:
COND = thermal conductivity, BTU/Hr-Sf-F-In
TEMPDIF = fluid temp - ambient temp, F
R2, R1 = Outside and inside radius of insulation shell
in inches.
0.6 = the surface resistance (reciprocal of the air film
coefficient), 1/(BTU/Hr-Sf-F)
Unit heat losses per square foot are also calculated and shown.
Page 18
Interpretation of Results
The following information depicts sample data and program
output created after the completion of data entry. The
user should verify data entry before requesting a program
analysis. The following screen depicts sample program output:
╔═════════════════════════════════════════════════════════════════════╗
║ ............. ENTER THERMAL DATA ............. ║
║ ║
║ Enter OD of Bare Pipe - Inches : 4·····║
║ Enter Pipe Temperature - Degrees F : 500···║
║ Enter Ambient Temperature - Degrees F : 20····║
║ Enter Ave. Insulation Thermal Conductivity - Btu/Sf-Hr-F-In : 0.45··║
║ ║
║ *** PROGRAM OUTPUT *** ║
║ Inches of Insulation BTU/Hr-SF BTU/Hr-Lin Ft Surface Temp-F ║
║ 1.0 218 228 122 TOO HOT ║
║ 1.5 170 177 93 ║
║ 2.0 142 149 77 ║
║ 2.5 124 130 67 ║
║ 3.0 111 116 60 ║
║ 3.5 102 107 54 ║
║ 4.0 94 99 50 ║
║ 4.5 88 93 47 ║
║ 5.0 84 87 45 ║
║ 5.5 79 83 42 ║
║ 6.0 76 80 41 ║
║ 6.5 73 76 39 ║
║ 7.0 70 74 38 ║
║ -------------------------------------------------------------- ║
║ The Bare Pipe BTU Loss per Hr-Lineal Ft of Pipe : 2037 ║
╚═══════════Press C To Continue or Any Other Key To Quit══════════════╝
Output data denotes heat loss and outer insulation surface
temperature based on insulation thicknesses. A bare pipe (non-
insulated) heat loss figure is shown at the bottom of the
screen. EPILOSS warns the user if an insulation surface
temperature exceeds 120 degrees Fahrenheit. A "TOO HOT"
warning is displayed and identifies those thicknesses which
represent a potential burn hazard.
EPILOSS Program Assumptions
1) Results Are Not Valid For Cold System, Flat, or Building
Insulation.
2) An Air Film Coefficient of 1.67 Btu/Sf-Hr-F Is Assumed.
3) A Maximum Allowable Outer Surface Temperature of 120 Deg F Is
Used.
4) Program Uses A Maximum Insulation Thickness of 7 Inches.
5) Program Uses A Maximum Nominal Pipe Diameter of 24 Inches.
6) Pipe Wall Temperature Assumed Equal To Process Temperature.
Page 19
6.0 Cost File Database Programs
EPIDB and EEIDB Description
EPIDB and EEIDB are stand-alone software programs for generating
customized cost database files for the EPI and EEI insulation
sizing programs. The following pages contain complete step-by-step
instructions needed to fully utilize program capabilities.
Richardson Engineering's EPIDB and EEIDB will create cost files to
meet most desired applications and will perform the following:
1. Permits the user to create cost database files based
on the three major insulation material groups including:
1) Calcium Silicate; 2) Fiberglass; and 3) Cellular
Glass.
2. Allows the user to generate customized cost data files
based on site specific material and installation
requirements.
3. Simplifies data entry and permits the user to easily
review and modify cost data within existing files.
The few simple rules in using EPIDB and EEIDB are:
--The user must define the unit material prices and
unit labor rates before building a cost database.
--Since these costs may vary greatly by geographical
region, installation complexity, and contractor,
the user must carefully verify ALL database cost
information.
Main Menu
EPIDB and EEIDB include a menu driven user interface which
allows for simple selection of various program features. This
interface also is provided with context-sensitive help windows
for user reference. Both programs are designed for the occasional
user, with simple input screens and user-friendly program option
selection.
A schematic of the main menu is as follows:
╔═════════════════[ MAIN MENU ]═══════════════╗
║ ║
║ ║
║ 1) Select Insulation ║
║ 2) Look At Database ║
║ 3) Enter Cost Data ║
║ 4) Enter MarkUp ║
║ 5) Reset Database ║
║ 6) Quit Program ║
║ ║
║ ║
╚═════════════════════════════════════════════╝
Page 20
Main Menu - Cont.
From this menu, you can access all of the operations of the
program. By using the cursor keys, move the highlighted line
to the desired activity and press the <ENTER> key to select
that option. Press [F4] for additional help messages.
Menu Selection Sequence
When creating a NEW cost database, each program initially requires
that Option 5 be completed. The RESET DATABASE creates the necessary
program files and organizes the data files for new data entry.
Please note that this menu item must be carefully utilized since
existing cost files will be destroyed if the user activates the
file reset feature.
Menu Entry Description
SELECT INSULATION (Option 1)
This selection allows the user to select the insulation database.
Available database material groups are:
1) Calcium Silicate
2) Fiberglass
3) Cellular Glass
This menu item should be selected when you first run either
program. A selection allows the program to access and "open"
the correct cost data files for user input or review. Subsequent
user operations are dependant on the correct database which is
open. The default selection is Calcium Silicate.
LOOK AT DATABASE (Option 2)
Provides a recap screen to review results from Menu Item 3.
For EPI, the user selects the appropriate pipe size from the
corner selection window and presses [F10] to continue. Pipe
selection is not required for the EEIDB program. Both programs
will access the open insulation data file and display the file's
contents which include pipe size, insulation thickness, unit
material costs (EPI displays dollars per lineal foot of pipe
while EEI displays dollars per square feet of insulation), and
unit labor manhour rates (EPI displays manhours per lineal foot
of pipe while EEI displays manhours per square feet on insulation).
Please note that the cost and labor information should be DIRECT
amounts (i.e. no inclusion of indirect job costs). A separate menu
selection item (Item 4) is provided to account for contractor
markup due to overhead and profit requirements. More discussion of
this will be explained in the ENTER COST DATA menu selection
description.
Page 21
Menu Entry Description - Cont.
The following is an example re-cap screen (EEIDB example) of this
menu selection:
╔══════════════════════════════════════════════════════════════════╗
║ .......... DATABASE REVIEW .......... ║
║ ║
║ Database Opened For : Calcium Silicate ║
║ ║
║ Thickness-In PipeDia-In Labor-MH/LF Material $/LF ║
║ ║
║ 1.0 3.0 0.130 3.3 ║
║ 1.5 3.0 0.160 4.0 ║
║ 2.0 3.0 0.160 6.0 ║
║ 2.5 3.0 0.190 7.3 ║
║ 3.0 3.0 0.190 8.6 ║
║ 3.5 3.0 0.200 11.0 ║
║ 4.0 3.0 0.210 13.3 ║
║ 4.5 3.0 0.240 15.3 ║
║ 5.0 3.0 0.260 17.4 ║
║ 5.5 3.0 0.280 19.6 ║
║ 6.0 3.0 0.300 22.0 ║
║ 7.0 3.0 0.530 28.0 ║
║ 8.0 3.0 0.530 33.3 ║
║ 9.0 3.0 0.580 38.7 ║
║ ║
║ ║
║ End Of Data Review ║
╚═════════════════Press Any Key To Continue ═══════════════════════╝
ENTER COST DATA (Option 3)
EPIDB and EEIDB offer an easy and convenient way to enter data. This
menu selection item is utilized to input new or revised cost data
within an opened database. For EPI, the user selects the appropriate
pipe size and presses [F10] to continue. Next, a data entry
"template" is displayed which denotes program supported insulation
thicknesses, layers, and previously entered cost data if the file
already exists. For EEI, the user does not select pipe sizes, but
enters the data directly.
The user defines the necessary cost structure by entering unit
material costs (dollars per lineal foot for EPI or dollars per
square feet of insulation for EEI), and unit labor manhour
rates (manhours per lineal foot for EPI or manhours per square
feet of insulation for EEI) in a columnar fashion, adjacent to the
appropriate thickness and layer. The following is an example of
the data entry template (EPIDB example):
Page 22
Menu Entry Description - Cont.
╔══════════════════════════════════════════════════════════════════╗
║ .......... DATA ENTRY .......... ║
║ ║
║ Database Opened For : Calcium Silicate ║
║ ║
║ Selected Diameter Is : 3.00 ║
║ ║
║ Layer Thickness-In Material $/LF ManHrs/LF ║
║ 1 1.0 3.3· 0.13· ║
║ 1 1.5 4··· 0.16· ║
║ 1 2.0 6··· 0.16· ║
║ 1 2.5 7.3· 0.19· ║
║ 1 3.0 8.6· 0.19· ║
║ 1 3.5 11·· 0.2·· ║
║ 1 4.0 13.3 0.21· ║
║ 1 4.5 15.3 0.24· ║
║ 1 5.0 17.4 0.26· ║
║ 1 5.5 19.6 0.28· ║
║ 1 6.0 22·· 0.3·· ║
║ 2 7.0 28·· 0.53· ║
║ 2 8.0 33.3 0.53· ║
║ 2 9.0 38.7 0.58· ║
║ Begin Fractional Data With Zeros ║
║ Use Cursor Keys and Enter Data in Column Fashion ║
╚══════════════════════Press F10 To End Input══════════════════════╝
The user should note that cost data entered should be based on
DIRECT costs to be absorbed by the contractor. These direct, or
bare, costs do not include the contractor's overhead and profit
requirements. The Item 4 menu selection, ENTER MARKUP, allows the
user to input a markup multiplier to account for contractor
indirect costs.
In addition, the user should verify that the entered material and
labor costs numbers agree with the associated insulation
thicknesses and layer quantity.
Material cost information and unit labor rates may be obtained from
a variety of sources. Cost estimating manuals, contractor
quotations, and historical plant cost data are potential sources of
information.
ENTER MARKUP (Option 4)
Allows user to enter contractor markup multiplier.
RESET DATABASE (Option 5)
Creates NEW database files and organizes files for data entry. This
menu selection should only be used to generate NEW data files when
the EPIDB or EEIDB program are first used.
Page 23
Menu Entry Description - Cont.
The user should note that existing files will be destroyed if this
menu selection is activated. If the user desires to create
alternate data files based on revised cost structures, the existing
files should be copied to an archive directory - external to the
EIS default directory. It is suggested that this archive directory
be named to reflect the cost data file basis. For example, data
files based on complex installation could be copied to the sample
archive directory tree: C:\EIS\COSTDATA\
EPIDB generates the following piping insulation cost data files:
EPIMARK.DAT - Contractor Markup Data File
EPICALS.DAT - Calcium Silicate Cost Database
EPIFIBR.DAT - Fiberglass Cost Database
EPICELG.DAT - Cellular Glass Cost Database
EPIDB generates the following equipment insulation cost data files:
EEIMARK.DAT - Contractor Markup Data File
EEICALS.DAT - Calcium Silicate Cost Database
EEIFIBR.DAT - Fiberglass Cost Database
EEICELG.DAT - Cellular Glass Cost Database
QUIT PROGRAM (Option 6)
This option terminates program execution and places the user
at the DOS prompt.
Supported Insulation Thicknesses and Layers
EPIDB supports the following pipe insulation thicknesses and layer
quantities:
Insulation Thickness (Inches) Associated Layer Quantity
1.0 1
1.5 1
2.0 1
2.5 1
3.0 1
3.5 1
4.0 1
4.5 1
5.0 1
6.0 1
7.0 2
8.0 2
9.0 2
EEIDB supports the following flat thicknesses and layer quantities:
Insulation Thickness (Inches) Associated Layer Quantity
1.0 1
1.5 1
2.0 1
2.5 1
3.0 1
3.5 1
4.0 1
4.5 1
5.0 1
6.0 1
7.0 1
Page 24
Error Messages
Data File Error - Alerts user to the need to create database files.
This condition normally occurs when first running EPIDB or EEIDB.
Select menu item 4, RESET DATABASE, to generate new data files. In
some cases, existing files may need to be copied to the EIS default
directory. This error will alert the user to the absence of data
files.
Selected Pipe Diameter Not Supported (EPIDB Only) - Alerts user to an
incorrect pipe diameter entry when reviewing data files or entering
new cost information. EPIDB supports the following nominal pipe
diameters (in inches):
0.5 4.0 14.0
0.75 5.0 16.0
1.0 6.0 18.0
1.5 8.0 20.0
2.0 10.0 24.0
3.0 12.0
7.0 General Information
Problems
The use of EIS software is fully supported by Richardson
Engineering. The author of the product will address problems
directly. See "Contacting The Author" in this section
for more information.
Although comments and recommendations from anyone are
appreciated, Richardson Engineering can only provide
technical support for licensed users of this product.
If you have problems with the EIS software, please read this
manual first to make sure you have a thorough understanding of
how the program works and should be used. Richardson Engineering
has sought to provide an error-free product, but because of the
complexity and length of these programs, some rarely-occurring
bugs may exist. If you think you have found a problem, please
take the time to write or call me and explain the problem.
All licensed users will be informed of any problems and their
solutions. Bug-fixes will be provided to licensed users free
of charge. Upgrades to EIS may require a upgrade fee.
Contacting The Author
The best way to contact the author, Michael Richardson, P.E.,
is by writing a letter or postcard to:
Richardson Engineering
P. O. Box 824
Laurel, MS 39441
Another way to contact the author is to leave a message on
the CIME-ISE, "Computers in Mechanical Engineering -
Information and Software Exchange" BBS at (608) 233-3378, 24
hours/day, up to 9600 baud. CIME-ISE is sponsored by ASME.
The author can also be contacted via CompuServe. The author's
user number is 70272,1731.
Page 25
8.0 Sample Problems
The following sample problem is provided to assist the user
in understanding the EIS data input as well as output
interpretation. Two "on-disk" sample files, called SAMPLE1.EPI
and SAMPLE2.EEI, are included if the user desires to review problem
input.
EPI Sample Problem - High Temperature Steam Pipe
An industrial plant steam turbine installation will have a
1,000 foot long, 10 inch NPS high pressure steam line leading
from a steam generator to the turbine generator building. The
superheated steam conditions are 900 PSIA and 850 Degrees F.
The line will be outdoors, where the average ambient temperature
is 62 Degrees F.
The turbine generator will have a maximum output capacity
of 20 megawatts. Total electric generation per year is
expected to be 160 million kWh, and the steam supply line is
expected to be in service 8,000 hours per year. Total expected
capital investment for the steam plant (boiler, piping, condenser,
etc.) is $30 million dollars. The first year fuel cost will
be $50 per ton of coal, which has a heating value of 12,500
Btu/lb. The plant and steam supply line will have a
depreciation period of 25 years (useful service life). The
boiler efficiency is 88 percent, and it requires 10,500 Btu's
of fuel to produce each kWh of electricity.
The return on investment requirement for the company is 12
percent. Fuel cost is expected to increase at an annual
average annual rate of 7 percent.
The insulation to be used on the pipe is calcium silicate
with no more than two layers, and an 0.016 inch aluminum
jacket. Complexity of installation is average (15 to 20
fittings per 100 feet of pipe). The average unit manhour
charge rate is $25 per manhour and is based on local manpower
availability and job conditions. The average direct cost
price estimate per unit on a 10-inch pipe at the time of
construction is as follows (a markup factor is not included;
however, the EPI program uses a 25 percent markup - unless
modified by the EPIDB cost database engine):
Number Insulation Direct Direct
of Layers Thickness-In Labor-MH/LF Material $/LF
1.0 10.0 0.250 6.7
1.5 10.0 0.276 9.4
2.0 10.0 0.303 12.2
2.5 10.0 0.329 15.0
3.0 10.0 0.356 17.8
3.5 10.0 0.382 20.5
4.0 10.0 0.409 23.3
4.5 10.0 0.435 26.1
5.0 10.0 0.462 28.9
5.5 10.0 0.488 31.6
6.0 10.0 0.515 34.4
7.0 10.0 0.787 46.9
8.0 10.0 0.867 54.3
9.0 10.0 0.947 61.8
Page 26
EPI Sample Problem - Cont.
Manually calculate the cost of heat ($ per million Btu):
Price of Coal ($/ton)
= ---------------------- X 1 million Btu's
2,000 Lbs/ton X Heating Value (Btu/lb)
= $2.00/million Btu's
Next, manually calculate the average capital investment
cost of heat:
The expected average annual heat production is:
10,500 Btu/kWh X 160 million kWh/year
= 1680 billion Btu's per year
The capital investment of the heating plant (book value) is:
$30 million dollars
The average capital investment cost of heat is calculated
as follows ($/thousand Btu/Hr):
$30 million dollars
= -------------------------------------- X 1000 Btu's
( 1680 billion Btu / 8,000 Hours per )
per Year Year
= $142.9 per thousand Btu/Hr
Please note that EPI will convert this quantity to an annual
amortized amount.
Now, select the menu option 1 (DATA ENTRY) and enter the
following data:
Project Name : Sample Prob
Run Identification : 1
OD of Bare Pipe - Inches : 10
Pipe Temperature - Degrees F : 850
Ambient Temperature - Degrees F : 62
Ave. Insulation Thermal Conductivity - Btu-In/Sf-Hr-F : 0.52
Insulation Code Number : 1
After data entry, press F10 to begin program calculation.
Page 27
EPI Sample Problem - Cont.
The calculated thermal output is:
Layers Inches of Insulation BTU Loss/Hr-Lin Ft Surface Temp-F
1 2.00 562.41 168 TOO HOT
1 3.00 421.03 136 TOO HOT
1 3.50 377.74 126 TOO HOT
1 4.00 344.29 119
1 5.00 295.86 108
1 5.50 277.72 104
1 6.00 262.36 101
2 7.00 237.73 96
2 8.00 218.79 92
2 9.00 203.73 88
--------------------------------------------------------------
The Bare Pipe BTU Loss per Hr-Lineal Ft of Pipe : 14276
The TOO HOT flags denote insulation with surface temperatures
exceeding 120 Degrees F and should be avoided since they represent
a potential personnel burn hazard.
Now, enter the following financial data:
Fuel Cost - $/ Million Btu : 2
Annual Inflation, Fuel Cost - % : 7
Annual Interest Rate - % : 12
Operating Schedule - Hours Per Year : 8000
Economic Life of New Insulation - Years : 25
Average Capital Investment Cost of Heat - $/MBtu/Hour: 142.9
Boiler Plant Efficiency - % : 88
Installation Labor Rate - $/Hour : 25
Press F10 for calculation of financial data. The program output
will display the following information:
Thickness Material Labor Total Inst Heat Loss Cost To
Inches $/Ft $/Ft Cost $/Ft-Yr $/Ft-Yr Own $/Ft-Yr
2.00 15 9 3.47 29.77 33.24
3.00 22 11 4.68 22.29 26.97
3.50 26 12 5.27 20.00 25.27
4.00 29 13 5.88 18.23 24.11
5.00 36 14 7.09 15.66 22.75
5.50 39 15 7.68 14.70 22.38
-->6.00 43 16 8.29 13.89 22.18<--
7.00 59 25 11.67 12.58 24.25
8.00 68 27 13.32 11.58 24.90
9.00 77 30 14.98 10.78 25.76
Based on a minimum total cost to own, the 6 inch insulation thickness
provides the smallest owning cost.
Page 28
EEI Sample Problem
The plant engineer for a wood products factory is considering
insulating a veneer dryer flash tank that is part of a major
energy expansion. The steam/condensate temperature within the
flash tank is 300 Deg F. The ambient temperature averages 60
Deg F. Because of the relatively thin wall thickness and
negligible surface heat resistances, the tank process
temperature shall be used as the surface temperature.
The boiler plant output averages 100,000 pounds of steam per
hour. The steam temperature is 422 Deg F, and pressure is 300
PSIG. The boiler is in operation 8,400 hours per year. The
plant boiler cost is $10 million dollars, with the cost of
money for the facility being 7 percent. The boiler efficiency
is 65 percent, and the depreciation period for the new plant
equipment is 25 years. The fuel to be used is wood residues
(bark, sawdust, etc.), which costs approximately $18 per
short ton and has a fuel heating value is 6000 btu/Lb. Fuel
price is expected to increase at an annual rate of 6 percent.
The insulation to be used on the tank is fiberglass
with no more than one layer, and an 0.016 inch aluminum
jacket. Complexity of installation is average. The average
unit manhour charge rate is $25 per manhour and is based on
local manpower availability and job conditions. The average
direct cost price estimate per unit on a 72 inch diameter
vertical tank at the time of construction is as follows (a
markup factor is not included; however, the EEI program uses
a 25 percent markup -unless modified by the EEIDB cost
database engine):
Number Insulation Direct Direct
of Layers Thickness-In Labor-MH/LF Material $/LF
1 1.0 0.134 1.3
1 1.5 0.142 1.7
1 2.0 0.149 2.1
1 2.5 0.157 2.4
1 3.0 0.164 2.8
1 3.5 0.171 3.2
1 4.0 0.179 3.5
1 4.5 0.187 3.9
1 5.0 0.194 4.3
1 5.5 0.201 4.6
1 6.0 0.209 5.0
1 7.0 0.224 5.7
1 8.0 0.239 6.5
1 9.0 0.254 7.2
Manually calculate the cost of heat ($ per million Btu):
Price of Hog Fuel Oil at $18 per ton
= -------------------------------------------- X 1 million Btu's
2000 Lbs/ton X Heating Value of 6000 Btu/Lb.
= $1.5/million Btu's
Page 29
EEI Sample Problem - Continued
Next, manually calculate the average capital investment
cost of heat:
The expected average annual heat production is:
100,000 Lbs Steam/Hr X 1203 Btu/Lb Steam, where 1203 Btu/Lb
is the steam enthalpy
at 300 PSIG
= 120.3 million Btu's per hour
The capital investment of the heating plant (book value) is:
$10 million dollars
The average capital investment cost of heat is calculated
as follows ($/thousand Btu/Hr):
$10 million dollars
= ---------------------------- X 1000 Btu's
120.3 million Btu's per hour
= $83.1 per thousand Btu/Hr
Please note that EEI will convert this quantity to an annual
amortized amount.
Now, select the menu option 1 (DATA ENTRY) and enter the
following data:
Project Name : Sample Prob
Run Identification : 2
Pipe Temperature - Degrees F : 300
Ambient Temperature - Degrees F : 60
Ave. Insulation Thermal Conductivity - Btu-In/Sf-Hr-F : 0.28
Insulation Code Number : 2
After data entry, press F10 to begin program calculation.
The calculated thermal output is:
*** PROGRAM OUTPUT ***
Layers Inches of Insulation BTU Loss/Hr-Sq Ft Surface Temp-F
1 1.00 57.53 95
1 1.50 40.29 84
1 2.00 31.00 79
1 2.50 25.19 75
1 3.00 21.21 73
1 3.50 18.32 71
1 4.00 16.12 70
1 5.00 13.00 68
1 6.00 10.89 67
1 7.00 9.38 66
--------------------------------------------------------------
The Bare Surface BTU Loss per Hr / Sq Feet : 667
Note that all of the above insulation thicknesses produce surface
temperatures which are below the recommended limit of 120 Deg F.
Page 30
EEI Sample Problem - Continued
Now, enter the following financial data:
Fuel Cost - $/ Million Btu : 1.5
Annual Inflation, Fuel Cost - % : 6
Annual Interest Rate - % : 7
Operating Schedule - Hours Per Year : 8400
Economic Life of New Insulation - Years : 25
Average Capital Investment Cost of Heat - $/MBtu/Hour: 83.1
Boiler Plant Efficiency - % : 65
Installation Labor Rate - $/Hour : 25
Press F10 for calculation of financial data. The program output
will display the following information:
*** PROGRAM OUTPUT ***
Thickness Material Labor Total Inst Heat Loss Cost To
Inches $/SF $/SF Cost $/SF-Yr $/SF-Yr Own $/SF-Yr
1.00 2 4 0.55 2.61 3.16
1.50 2 4 0.62 1.83 2.45
2.00 3 5 0.68 1.41 2.09
2.50 3 5 0.75 1.14 1.89
3.00 4 5 0.82 0.96 1.78
3.50 4 5 0.88 0.83 1.71
4.00 4 6 0.95 0.73 1.68
-->5.00 5 6 1.08 0.59 1.67<--
6.00 6 7 1.21 0.49 1.70
7.00 7 7 1.34 0.43 1.77
Based on a minimum total cost to own, the 5 inch insulation thickness
provides the smallest owning cost.
Page 31
End Of Manual
