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Thermal Insulation
A provision made to retard heat flow from a hot surface to a cold environment and from cold surface to a warm environment. This simple device in Industry has acquired enormous importance in recent times for what it can do for us if we were to give a very little extra attention
Todays need is for Correctly designed and well installed insulation system. Which is Easy on the purse Speedy to erect Stays maintenance-free & Efficient in service An efficient insulation in place serves our best interests in todays context Economy: safety :smoother process control at Plant level Substantial reduction of fuel costs & enhanced profitability at the corporate level Reduction of Greenhouse gas emissions at the larger Global level
25 40 100 150 200 Insulation can kcals/m2.hr. being down heat losses
SUSTAINABILITY Thermal
transmission, or the transfer of heat from a warmer body to a colder body may in principal take place in the following ways:
2) Convection 3) Radiation
- The moving of heat through moving fluid or gas. - Transfer of heat by means of electromagnetic waves.
SUSTAINABILITY
Heat Conduction
Q = heat transferred in time = K = thermal conductivity of the barrier A = area T = temperature d = thickness of barrier
SUSTAINABILITY
SUSTAINABILITY
Surface Heat Transfer or film Coefficient ( f )
Conv.
Rad.
SUSTAINABILITY
Surface Heat Transfer or film Coefficient
Ambient Temp (Ta)
Surface1 Emissivity = e
Wind Speed =V
Insulation
Heat
SUSTAINABILITY
Surface Heat Transfer or film Coefficient
: :
5.7
7.9 10.2
4.9
6.8 8.7
SUSTAINABILITY
q=
q=
To - Ta
d ln d1 d + 2K d fd1
To = Operating Temperature Ta = Ambient Temperature K = Thermal Conductivity of Insulation L = Thickness of Insulation f = Surface Film Coefficient
SUSTAINABILITY
Thickness Calculation based on ASTM C 680
Upgraded & latest method to calculate thickness of insulation Calculates effect of windage & emissivity for each pipeline Slightly more thickness Reduced heat loss
SUSTAINABILITY
ILLUSTRATION OT AT ST Cladding Wind Velocity Pipe OD Insulation Calculation Procedure : : : : : : : : 250 deg.C 40 deg.C 60 deg.C Aluminium ( 0.2 Emissivity) 0, 0.5, 1 8,10, 12 ROCKWOOL MATTRESSES 100 KG/M3 DENSITY ASTMC-680 & IS-14164
SUSTAINABILITY
WINDAGE = 0
COMPARATIVE OF THICKNESS
As per IS-14164 Dia (mm) 8 10 12 Thickness (mm) 105 110 115 Heat Loss (Kcal/m2hr.) 98 98 98
SUSTAINABILITY
WINDAGE = 0.5
COMPARATIVE OF THICKNESS
As per IS-14164
Dia (mm) 8 10 12 Thickness (mm) 65 65 65 Heat Loss (Kcal/m2hr.) 145 145 145
As per ASTMC-680
Thickness (mm) 70 75 80 Heat Loss (Kcal/m2hr.) 117 117 117
SUSTAINABILITY
WINDAGE = 1
COMPARATIVE OF THICKNESS
As per IS-14164 Dia (mm) 8 10 12 Thickness (mm) 55 55 55 Heat Loss (Kcal/m2hr.) 163 163 163
As per ASTMC-680 Thickness (mm) 60 65 65 Heat Loss (Kcal/m2hr.) 141 141 141
SUSTAINABILITY
Windage
Thickness reduces with wind impact.
Emissivity
Thickness reduces with dull surface.
SUSTAINABILITY
SELECTION OF INSULATION MATERIAL:
THE MATERIALS USED FOR INSULATION SHALL CONFORM TO THE RELEVANT INDIAN STANDARDS WHEREEVER THEY EXSIST. INSULATION MATERIAL USED SHOULD BE SUITABLE FOR USE AT THE OPERATING TEMPERATURE AS STATED BY THE PURCHASER. HAND MADE MATERIALS FROM LOOSE WOOL ARE NOT PERMITTED DUE TO POOR CONSISTENCY. ALL INSULATION MATERIAL SHALL HAVE A PROVEN SERVICE RECORD OF SATISFACTORY PERFORMANCE UNDER INDIAN CONDITIONS IN SIMILAR PROCESS PLANT
SUSTAINABILITY
OTHER IMPORTANT ASPECTS Water repellents Corrosion resistant
IN INDIA
THERMAL INSULATION
a) Design Data Design ambient Temp. Max. Cladding Temp. Wind Speed : : : 40 deg.C 60 deg. C 0 or 0.25 m/sec. for inside 0.5 m/sec. for outside 0 m/sec. for Energy Conservation
THERMAL INSULATION b) Design Data Emissivity of cladding Aluminium GI Colour coated GI Plaster Glass Cloth c) d)
: : : : :
Thickness Calculation Method : ASTM C-680 (Determination of Heat Gain or Loss and the Surface Temperatures of insulated pipe and Equipment system
250000 200000 150000 100000 50000 0 40 50 60 70 80 90 Surface Temp. over insulation in C (specified) 1982 1988 1991 1998 2004 2008
System details: Pipe Dia-(NB): 100mm Surface Film Coeff :12kcalm2hr C Ambient Temp : 29 C Hours of Operation : 8000 Hrs. Conversion Eff.: 100%
Reduces fuel consumption, and hence overall cost of operation Reduces capacity requirements for heating/cooling systems (e.g., boilers/ refrigeration units, etc)
Thermal Insulation
The function of Thermal Insulation is performed not just by a single material, but by an assembly of engineered provisions or components termed as, Thermal Insulation System. As called for in all such works, there is need for careful design of all such elements. From this, we can see that insulation is a major tool in improving energy availability.
The task of the insulation designer is to evolve system which fit the need-like a glove to a hand that would wear it.
Temperature resistance- limiting service temperature Thermal conductivity Coefficient of Expansion / Contraction Thermal diffusivity, and Thermal shock resistance
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A. For single layer insulation up to maximum thickness of 75mm Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease. Providing and fixing MS flat ring of size 25x3mm, over pipe having diameter more than 100mm, at every 1150 mm distance having L shaped lugs with a packing of ceramic paper, duly riveted and tightening it over the surface with nut and bolt. Providing and fixing the recommended insulation thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G . Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface .
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A. For single layer insulation up to maximum thickness of 75mm Providing and fixing Aluminium / Zincalume steel sheet cladding screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94.
Please note that for bare zincalume sheet the MS flat ring should be fixed at 1200mm distance.
Providing and applying 22G Aluminium band at every 450mm c/c over the cladding to secure it firmly to its place
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APPLICATION SPECIFICATIONS FOR HORIZONTAL / VERTICAL HOT PIPELINES B. For multiple layer insulation above 75mm thickness. Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease. Providing and fixing MS flat ring of size 25x3mm, over pipe having diameter more than 100mm, at every 1150 mm distance having L shaped lugs with a packing of ceramic paper, duly riveted and tightening it over the surface with nut and bolt. Providing and fixing the first layer of insulation in recommended thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G. Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface
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B. For multiple layer insulation above 75mm thickness. Providing and fixing the second / subsequent layer of insulation in recommended thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G. Butting the joints and stitching the mattress properly after every layer with GI wire of 20G to secure it firmly to the surface. Providing and applying 22G Aluminium band at every 450mm c/c over the final layer of insulation to secure it firmly to its place. Providing and fixing Aluminium / Zincalume steel sheet cladding screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94. Please note that for bare zincalume sheet the MS flat ring should be fixed at 1200mm distance. Providing and applying 22G AL band at every 450mm c/c over the cladding to secure it firmly to its place
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Supercera needled Blankets and fabrications such as: Folded modules Encased flexible sections Supercera Bulk Fibre Supercera rigid Boards / Vacuum formed blocks & Shapes Moist felt / Paper / Rope Calcium Silicate.
Ceramic Fibre: Supercera range Also used as Fire protection in Structural Steel applications Cable Trays Ship Bulkheads / deckheads Turbine Insulation Removable Type Pads
SUPERCERA PADS
Supercera blankets of density 128 kg/m3 and thickness 50 & 75mm encased in Supercera Cloth and stitched with SS Wire to form pads. Special hooks are stitched to the surface and corners for the purpose of positioning & tieing.
USES : Steam Turbine Insulation, Fire Walls for Isolation, Valves & Flange Insulation
AVAILABILITY : Width : 610mm; Length Max. : 7 mtr.
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SUPERCERA PADS
VESSEL INSULATION
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Polyurethane Foam (PUF) Polyisocynurate Foam (PIR) Foamglass Phenolic Foam Expanded Polystyrene (EPS)
Among the listed materials, Polyurethane and Polyisocyanurate, representing products of lowest Thermal conductivity are materials of choice because of the easy availability in commercial quantities and the versatility they offer. As is well known, these materials offer great flexibility to the specifier and user since they can be applied as Preformed shapes or installed in-situ- by Pouring or by spray.
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PIPELINE IN TRENCHES 30-50mm Polyurethane Foam Cast-in-Situ application 40-45 kg/m3 with 4-5mm HDPE cladding
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PIPELINE IN TRENCHES
AT
Operating Windage RH Materials Method
: 40 deg.C
: 5 deg.C : 0 m/s : 85% : PUF, RW, EPS : IS : 14164 & ASTM C-680
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THICKNESS OF DIFFERENT INSULATION MATERIALS FOR CHILLED WATER PIPELINES DESIGN CRITERIA (CHILLED WATER P/L)
1.Ambient Temperature 2.Max. Allowable surface temp. 3.Windage 4.Emissivity of cladding 5.Relative humidity 6.Calculation Procedure
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Insulation Materials
-15 90
-20 100
-25 100
+5 65
+10 60
+15 50
+20 45
+25 35
80 85 90 100 55
75 75 80 90 50
65 75 75 85 45
55 60 65 70 40
45 50 55 60 35
50 80 100 150
80 80 95 105
85 85 105 115
90 90 110 120
95 95 115 125
70 70 80 90
60 60 70 80
55 55 65 70
45 50 55 60
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40 40 45 50
Insulation Materials
-10 95
-15 100
-20 105
-25 110
+5 75
+10 65
+15 55
+20 45
+25 45
25
85
50 80 100 150
75 85 90 100
65 75 80 85
55 65 65 75
55 60 65 70
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There is a requirement to shift from EPS to PUF for Cold Insulation and Rockwool for specific areas for Energy Saving.
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Insulation Finishes
The outer cover over insulation.. Weather Barriers/ claddings- These all have one basic function - to protect insulation from the known hazards like external media, mechanical abuse etc. External coverings are what we get to seeing in a completed plant or pipeline. Aesthetics becomes a secondary, but significant role assigned to this provision.
Insulation Finishes
As can be easily appreciated, all metal cladding materials need careful selection from external corrosion point of view as a first consideration. However, another important aspect concerns corrosion from within- contributed by condensation of vapours from the insulation system on the inner surface. Since most insulants are faintly alkaline, such condensed water attacks the metal particularly Aluminium and causes it to pit and fail as a barrier. All metal cladding, as a rule need protection on the inner surface- like a factory laminated Poly Surlyn treatment.
Cladding Materials
PolySurlyn
Corrosion Pits
0.5mm TCT & 240 MPa as per IS : 277 & 513 For Mechanical strength & lower thickness
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Installed on the high vapour pressure side-I.e., the warmer side of the insulation systemprior to cladding), Vapour Barrier (or Vapour retarder as it is referred sometimes) is designed to arrest entry of moist vapour into the insulation, causing it to soak and possibly to freezing. Insulating Material, when wet can be 30 times more conductive and would no longer be an insulant! Freezing of water is always accompanied by volumetric expansion resulting in rupture. In cold insulation system, therefore, the soundness of the VB virtually determines how good the insulation system is.
There are a set of materials, which serve both as a weather barrier and vapour retarder at the same time. These are mostly in the form of Mastics- trowelled or brush applied- which set to becoming a tough outer skin. Aluminium foil laminated insulation pipesections.
3.
Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease. Providing and applying a coat of bitumen primer followed with a coat of bitumen (85/25 grade) or cold adhesive compound like CPRX or MAS-83 used as adhesive compound. Providing / Fixing the recommended insulation thickness of Expanded Polystyrene Pipesection of suitable density and sealing up all the joints with hot Bitumen (85/25 grade) or cold adhesive.
5.
Providing and applying two coats of insulkote @2.5 kg/m2 for each coat sandwiched with glass fibre cloth between the coats as vapour barrier. Providing and fixing Aluminium sheet cladding screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94. OR using aluminium foil laminated prefab shiplap joint Polyurethane pipe sections and sealing the joints with 75mm wide aluminium tape.
Todays plants need a wide expanse of extremely low temperature piping. Unless supports are highly insulating, the exposed surfaces would attract condensation and very heavy corrosion at these important bearing points- with corroded load bearing points and avoidable unsafe slippery floors underneath.
These are made from Highest efficiency insulants i.e., Urethanes, made to high density to afford an Engineered load bearing capacity. These are made in all the possible shapes and with specific features- for sliding, guide and anchor duties. Support design and selection are very vital design inputs for the Process Piping Engineeer / designer.
Small diameter pipeline or DG exhaust insulation with Supercera Ceramic Fibre Rope
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DESCRIPTION
ROCKWOOL MATTRESS
5 6 7 8
G.I. WIRE AL. SHEET (22 SWG) S.T. SCREWS AL. BAND
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SUPERCERA B BLOCKS Supercera B Blocks are special shaped blocks of density 110, 220, 250 kg/m3, dimension 450 x 550 mm, thickness 80/58mm, having one side circular corrugation shaped, suitable for direct fixing on to the boiler tubes.
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SUPERCERA B BLOCKS
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BASIC INSULATION FUNCTION AND REQUIREMENTS FOR APPLICATION BETWEEN -800C TO 7500C AS PER IS : 14164 (Code of Practice for Industrial application and finishing of Thermal Insulation Materials)
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METHODS OF APPLICATION All insulation materials applied, shall be in close contact with the surface to which they are applied, with the ends butted to one another. b) Proper density and thickness of material to be applied.
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MULTI LAYER INSULATION All joints to be staggered and each layer shall be separately secured.
All fittings shall be insulated separately and should be taken out easily without disturbing the main insulation.
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For pipelines operating above 5000C combination of Ceramic Fibre & Rockwool can be used for reducing heat loss, taking advantage of lower K-value of Ceramic Fibre at higher temperature.
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APPLICATION SYSTEM All pipes (upto 14) should preferably be insulated with pipe section. The pipe sections shall be held with pins or wires at a spacing of not more than 450mm.
When multiple layer to be used, the 2nd layer should be with mattress and tightly held with wires. For vertical and near vertical piping metal rings to be used over pipes to stop downward displacement of insulation.
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APPLICATION SYSTEM
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Pins should be inserted with mitred segment of mattress. All flanges, valves and other fitting on hot and cold piping shall be insulated separately and preferably should be of removable type.
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All stainless steel surfaces shall be applied with a layer of aluminium foil or sodium silicate before application of insulation to avoid corrosion. INHIBITED ROCKWOOL & CERAMIC WOOL All insulation supports shall be properly insulated.
All joints between aluminium sheet & insulation shall be sealed with a suitable mastic compound. CERAMIC PAPER TO REPLACE ASBESTOS MILL BOARDS FOR CONDUCTION INSULATION
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. Prefab Panels
Lloyd Standing Seam 2000 Panels The panels are fixed by a concealed metal clips fastening system held between flanges of panels which are mechanically seamed together to result in a robust and water-tight seam. A seaming tool forms the adjacent panels into a vertical seam that includes the clip. Clips are fastened to Insulation Support Rings with vertical spacing of 2000 mm and horizontal spacing of 450 mm Clips have provision to accommodate thermal expansion and contraction The clip cross section is chosen as per wind load requirements.
PANEL CONSTRUCTION
Tank Shell Anchor Cable Retaining Clips Rockloyd Insulation of Rockwool Slab Metal sheet machine Formed, Double - Locking Standing Seam in panel
COMPONENTS
Standing Seam
Insulated Panel
Retaining Pin
Rockloyd Mattress
Turnbuckles
Rockloyd Slab
PANEL CONSTRUCTION
PANEL CONSTRUCTION
PANEL CONSTRUCTION
CONSTRUCTION DETAILS
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