INDEX

Sr. No Particulars Page No.

1 Project Overview 2
2 Pulp & Paper Industry Pilot Plant 3
3 Heat Treatment Furnace Pilot Plant 6
4 Basic of Insulation & Material Selection 10
5
Method of Calculation of Heat Loss/Gain for
Insulation (IS 14164)
28
6 IS Specification for Bonded Mineralwool (IS 8183) 32
7 Insulation Application Procedure 35
7.1 Veneering in Furnace 36
7.2 Insulation of Dryers 39
7.3 Insulation of Piping and Equipments 46














MovIEE
(Moving Industries towards Energy Efficient future)

PROJECT
OVERVIEW
Page 1 of 68
1 | 3
Background of the project
In India, SMEs contribute to 95 % of all industry establishments, 40 % of domestic exports and industry output and 45 % of the manufacturing sector. The
SME sector is estimated to consist of around 28.5 million entities. Furthermore, this sector has consistently registered a higher growth rate than the rest
of the industrial sector. There are over 6,000 products ranging from traditional to high-tech items, which are being manufactured by the MSMEs
2
in India.
India is 5
th
energy intensive country in the world and there is substantial scope of energy saving
3
.
However, most of the SMEs consider EE measures to be cost and time intensive and diffcult to apply. At the same time, it is sometimes diffcult to gain
access to credit facilities and bankers may have insuffcient information to advise on appropriate measures. Thus, SMEs often lack EE related technical
know-how and resources and are often not aware of the benefts in terms of cost reductions. Consequently they do not make use of the potential of
investment in this area.
MovIEE (Moving Indias SMEs
1
towards a sustainable
future) is a Public Private Partnership (PPP) project
between KAEFER Isoliertechnik GmbH & Co. KG and
GIZ (Gesellschaft fr Internationale Zusammenarbeit
GmbH).
The objective of the project is t0 provide Industrial SMEs
in selected regions of India with access to advisory services,
training and fnancial products that enable them to implement
energy effcient (EE) insulation measures. At the same time, the
project aims to use the success on EE interventions to raise the
awareness of the SMEs on competitive advantages of integrating
sustainability measures into their operations.
1
SMEs - Small and Medium Enterprises
2
Micro, Small and Medium Enterprises
3
Source: BEE Energy Auditors/Energy Managers Guide Book
MovIEE: Public Private Partnership Project between KAEFER and GIZ
> KAEFER: KAEFER is the worlds largest provider of complete insulation solutions. KAEFERs core business is carried
out in its Industry, Marine & Offshore and Construction divisions. Headquartered in Bremen, Germany, KAEFER has
operations in over 50 countries with a current workforce of more than 18,000. The MovIEE project is part of KAEFERs
Corporate Responsibility & Sustainability (CRS) activities in India. The project is being implemented through KAEFER
Punj Lloyd Ltd (KPLL) based in Gurgaon. KPLL has a turnover of around 15 mill. EUR and has approximately 1,500
employees.
> Deutsche Gesellschaft fr Internationale Zusammenarbeit (GIZ) GmbH: Working effciently, effectively and in a spirit
of partnership, GIZ supports people and societies in developing, transition and industrialised countries in shaping their
own futures and improving living conditions.
As a federally owned enterprise, GIZ supports the German Government in achieving its objectives in the feld of
international cooperation for sustainable development. GIZ is also engaged in international education work around the
globe.
> Rockwool: As a third partner, the Rockwool Group provides mineral wool to the project. Rockwool is the worlds leading
producer of stone wool - a material that provides energy-saving and environmentally friendly thermal insulation.
Rockwool products are also used for fre protection and noise reduction. At present, the Group employs more than
8,000 persons, and has a world-wide network of sales offces, distributors and partners.
> Bureau of Energy Effciency (BEE): BEE is an agency under the Ministry of Power, Government of India that develops
programs for increasing energy effciency in India.
Project partners:
Page 2 of 68













PULP & PAPER
INDUSTRY PILOT
CASE

Page 3 of 68
2 | 3
Insulation technology overview
In recent years, the importance of insulation has increased as a method
for improving energy related effciency in times of scarce or expensive
resources. In todays industrialised world, the correct application of
insulation materials can increase overall effciency without major capital
investments. Insulation is a reliable alternative to reduce the waste of
energy used in processes and to decrease greenhouse gas emissions.
Further benefts of insulation include:
> A reduction in overall energy consumption
> Better process control by maintaining process temperature
> Prevention of corrosion by keeping exposed surface of a refrigerated
system above dew point
> Fire protection of the equipment
> Absorbing vibrations
> Personal protection
In the pulp and paper industry, dryers are used for dehydrating the paper
and the plan of the MovIEE project is to insulate them.
Since these dryers are continuously in rotary motion, centrifugal forces try
to push out the insulation material from the surface. Insulation material
should therefore not only have low thermal conductivity, but also be rigid
and dynamically strong.
Based on this, resin bounded mineral wool slabs of 100 kg/m
3
density was
selected as ideal insulation material. An application of material with less
density would have increased the possibility of material bonding getting
loose, whereas an application of higher density material would have
increased the average loading of dryers and consequently also the starting
load.
MovIEE: Moving Indias SMEs towards Energy Effciency
Project goals
To achieve the objective mentioned in the introduction, two pilot plants
in the pulp and paper sector have been selected and improved insulation
systems have been installed. Abefore/after thermal insulation analysis
has been used to assess the impact of the changes.
The project also aims to train representatives from local fnancial
institutions to develop their understanding of EE through insulation and
consequently their ability to promote the corresponding fnancial products
for SMEs.
As a showcase, these experiences have been documented and are
presented to further SMEs during awareness raising campaigns. These
include information about EE and potential benefts of insulation. These
campaigns are being implemented in cooperation with the Bureau of
Energy Effciency (BEE) and its local subsidiaries at universities and
industrial clusters. The BEE is currently also offering energy auditor and
energy manager trainings which will be enhanced and complemented via
the inclusion of the industrial insulation related EE measures.
Among other activities, an Energy Bus has been launched to spread the
message of EE. The bus is used for awareness campaigns and performing
in-situ trainings and is equipped with energy effciency information,
insulation materials, thermographic measurements and analysis tools.
Pilot Plant in the pulp and paper sector
In the beginning, a preliminary survey and walk-through audit was
performed in different industrial clusters to identify industries with
interesting potential for EE through thermal insulation. The Indian pulp
and paper sector was selected as a suitable industry for performing
pilot projects as it has a relatively high energy cost as percentage of the
production costs (see Table 1) and the highest energy saving potential of
all industries (see Table 2).
Sector Overview
The pulp and paper industry in India provides employment to nearly 1.5
million people and contributes Rs.25 billion to the governments kitty.
Today there are about 515 units engaged in the manufacturing of paper,
paperboards and newsprint in India. The pulp and paper industry converts
fbrous raw materials into pulp, paper and paperboard. During the frst
stage of production, raw materials are processed into pulp and during the
second stage paper and paper products are produced out of this pulp.
Those companies which have capacity below 24,000 tonnes per annum
are designated as SMEs. The pulp and paper sector represents one of the
most energy intensive industries and is therefore of particular interest of
environmental discussions. Increases in productivity through the adoption
of more effcient and cleaner technologies will be most effective in
merging economic, environmental and social development objectives.
The pulp and paper cluster
The city of Muzaffarnagar is a major industrial area in the state of Uttar
Pradesh. 29 paper mills operate in this region, all of them using discarded
paper and agricultural waste as raw materials for their paper production.
These mills use conventional technologies that are highly energy intensive.
Iron and Steel 10%
Refneries 10%
Aluminum 10%
Sugar 20%
Fertilizer 15%
Cement 15%
Petrochemicals 15%
Textile 25%
Pulp & Paper 25%
Table 2: Sector wise energy saving potential
Pulp & Paper
Chlor-alkalis 50%
Textile 15%
35%
30%
40%
Cement
Iron & Steel
Aluminium
30%
Table 1: Energy cost as percentage of
production cost
Page 4 of 68
3 | 3
Pilot Plant 1: Tehri Pulp & Paper Ltd, Muzaffarnagar
Tehri Pulp & Paper Ltd, Muzaffarnagar has 39 cylindrical dryers including
one MG dryer
4
. Steam is used to heat the surface of the dryers and
the dryer side-walls were not insulated, as moisture was likely to have
damaged the insulation.
The drums have curved (convex) surfaces on the side and rotate at
approximately 40-60 rpm. Previously installed insulation did not last more
than 3-4 months as it was prone to sagging down and getting damaged
due to centrifugal forces during rotation and the moisture in the machine.
For the heat loss evaluation, the MovIEE project team conducted a
thermographic study of the dryers, which identifed that the average
surface temperature was 120C. The high side wall temperature of the
dryer led to the formation of condensation which limited the speed and
MovIEE: Moving Indias SMEs towards Energy Effciency
4
MG Dryer: is a rotary type dryer with productivity of 50-300tpd.
Conclusion
The aim of the project is to enable industrial SMEs in India to implement
professional energy effcient insulation solutions.
By helping Indian SMEs to upgrade their insulation systems, the project
allows them to improve the sustainability of their business and make
them aware of the benefts which arise from adopting energy effciency
measures. SMEs that install modern insulation systems on their premises
improve their effciency and therefore reduce their energy needs, which
in turn results in a more economical use of energy resources. As a
result of the lower energy consumption, the project also contributes
to environmental sustainability by reducing greenhouse gas emissions.
Decreased fuel consumption and heat loss have a huge impact on our
environment, as energy can be saved and greenhouse gas emissions
reduced. As the availability of fossil fuels is limited and as there is currently
not enough renewable energy available to meet the rising demand,
insulation is the solution that provides energy effciency and environmental
friendly production.
Due to the high saving potential and the possibility to increase
productivity, implementing insulation becomes advantageous in a complex
and highly competitive business environment. The short payback periods
enable them to be fnancially capable to implement these measures.
The insulation of production facilities also improves the working conditions
in terms of health and safety. Due to the reduced surface temperature
of the machines, the risk of burns and related health problems can be
dramatically decreased. Moreover, the insulation will help to lower the
overall temperature within the production facilities creating a more
pleasant working atmosphere.
The results of the MovIEE project highlight the necessity of professional
insulation in industries like the pulp and paper sector that are
characterised by high energy consumption. Although it is a challenge to
raise the awareness for energy effciency, KAEFER and the GIZ are sure
this huge step can be achieved. The measurements undertaken so far
illustrate the success of the project.
forced the plant to shut-down in order to remove the condensation.
Consequently the plant was not able to obtain optimum productivity
despite having the capacity to do so.
The paper is dried by steam. 38 dryers are coupled with one shaft and
rotate at the same time and with the same speed. In the dryers, the side
walls were directly exposed to atmosphere which led to a huge heat loss.
The application of thermal insulation has provided the cheapest solution
to this problem, as well as being the most readily available technology.
With a crew of 15 people it took 12 days to apply the insulation. After the
insulation, the dryers surface temperature fell from 120C to 56C. The
reduction in surface temperature led to a decrease in fuel consumption
with projected cost savings of approximately Rs. 21.41 Lacs in 3 years with
an investment of Rs. 4 lacs and a payback period of only 6 months.
Pilot Plant 2: Meenu Paper Mills Pvt Ltd,
Muzaffarnagar
Meenu Paper Mills Pvt. Ltd, is comparatively smaller in size having 18
cylindrical dryers including one MG dryer. Steam is used to heat the surface
of the dryers and the dryer side-walls were not insulated. The drums have
curved (convex) side surfaces and rotate also at approximately 40-60 rpm.
The thermographic study identifed that the average surface temperature
of the dryer side-wall was around 100C. All dimensions of the dryers
(length, width, etc.) were found to be the same as in the previous case.
Once the professional insulation was installed by the KAEFER team, the
surface temperature decreased from 100C to 47C, thereby reducing fuel
consumption and leading to cost savings of Rs. 12.9 Lacs in 3 years with a
payback period of 7 months and an investment of Rs. 3 Lacs.
MS nut ftted on MS stud welded
on existing MS bolt head to head
Rockwool slab (insulation material)
Dryer body and shaft
MS fat support ring
Speed washer
MS fat
Aluminum cladding
MS nut ftted on MS stud welded on
existing MS bolt head to head
Aluminum cladding
Insulation pin
Table 3: Insulation cross sectional view (Excluding manhole area)
M/S Tehri Pulp M/S Meenu Paper
Project parameter & Paper Ltd. Mill Pvt. Ltd.
Surface temperature pre insulation 120C 100C
Surface temperature post insulation 56C 47C
Investment Rs. 4 Lacs Rs. 3 Lacs
Number of dryers insulated 38 + MG dryer 17 + 1 MG dryer
Annual cost savings Rs. 10 Lacs Rs. 6 Lacs
Proft projection in 3 years Rs. 26 Lacs Rs. 15 Lacs
Payback period 5 Months 6 Months
Table 4: Results of insulation
Page 5 of 68













FORGING
INDUSTRY PILOT
CASE

Page 6 of 68

Pilot Plant

In the begin
clusters to id
Indian forgin
energy-inten

Sector Ove

Forging is th
the exposur
the Oil & Ga
India has be
automobile

There are a
that SMEs a
of productio
come from t
professiona

The forging

Around 50 s
treatment un
24,250 tonn
making thei
demanding

Insulation t

In recent ye
related effic
correct appl
investments
and to decre

Further ben
>A reductio
>Better pro
>Prevention
>Fire prote
>Absorbing
>Personal p

In the forgin
project is to
940C), insu

75mm thick
veneer mod
in compariso
mean tempe
veneer mod
resources a
in the forgi
ning, a preli
dentify indus
ng sector wa
nsive proces
erview
he process w
re to high lev
as industry a
een growing
industry.
round 400 fo
are a very im
on of a forgin
the forging a
l insulation,
g cluster in
small and me
nits. The tota
nes of oil equ
r processes
technology.
technology
ears, the imp
iency in time
ication of ins
s. Insulation
ease greenh
efits of insul
on in overall
ocess contro
n of corrosio
ction of the e
g vibrations
protection
ng industry, h
insulate the
ulation is nee
veneer mod
dules, which
on to the ref
erature of th
dules also pr
are needed fo
ng sector
minary surv
stries with in
as selected a
sses and its
whereby me
vels of heat.
and the aero
at a rate of
orging units
mportant fact
ng plant goes
and heat trea
in order to r
Pune
edium forgin
al annual en
uivalent. Rec
more efficie
overview
portance of in
es of scarce
sulation mat
is a reliable
house gas em
lation include
energy cons
l by maintain
on by keepin
equipment
heat furnace
ese furnaces
eded to ens
dules were s
are applied
fractory. Du
e refractory
revent heat l
or the next s
ey and walk
nteresting po
as a suitable
high energy
tal is manufa
These parts
ospace indus
over 20% a
in India, with
tor in the Ind
s towards en
atment furna
reduce this c
ng units oper
nergy consum
cently, sever
ent, however
nsulation ha
or expensiv
terials can in
alternative t
missions.
e:
sumption
ning process
ng exposed s
es are used t
s. Since thes
ure a decrea
selected as t
to the existi
e to the low
is reduced a
oss during f
startup.
k-through au
otential for E
e industry fo
y costs.
actured into
s are then us
stry. Over the
s a result of
h only a sma
dian forging
nergy costs
aces. This cl
consumption
rate in the P
mption in thi
ral forging u
r the majority
s increased
ve resources
ncrease ove
to reduce th
s temperatur
surface of a
to heat the m
se heaters re
ase of heat l
the best insu
ng refractory
er temperatu
and, conseq
furnace shut
dit were per
E through th
r a pilot proj
the desired
sed in a vari
e last few ye
considerabl
all minority b
industry. Aro
and 60-70%
early empha
n and, as a re
Pune cluster,
s cluster eq
nits have up
y of these un
as a metho
s. In todays
rall efficienc
e waste of e
re
refrigerated
metal and th
each such hi
losses.
ulation mate
y lining, hav
ure of the ve
quently, so is
down, which
rformed in di
hermal insula
ect due to its
shapes and
iety of indus
ears, the forg
le growth in
being large u
ound 10% of
% of these en
asises the ne
esult, also th
along with a
uates to app
pgraded thei
nits still rely
d for improv
industrialise
cy without ma
energy used
system abo
e plan of the
igh tempera
rial for this in
ve lower ther
eneer modul
s the level of
h means tha
fferent indus
ation. The
s reliance on
d parts throu
tries, such a
ging industry
the national
units, meanin
f the total co
nergy costs
eed for a
he costs.
a further 20
proximately
r technology
on old, ener
ving energy
ed world, the
ajor capital
in processe
ove dew poin
e MovIEE
tures (up to
ndustry. The
rmal conduct
es, the expo
f heat loss. T
at fewer
strial
n
ugh
as
y in
l
ng
osts
heat
y,
rgy
e
es
nt
e
tivity
osed
The
Page 7 of 68


Pilot Plant

SB Enginee
and its prod
The furnace
to 940C are

A study was
operation an
storage by t
losses. Ven
KAEFER tea
then monito

For cold sta
to just 4 hou
cold start.

There were
decreased b
leading to re

Table 1 sho
working con
production c



Table 1: Re
Project par

Cold Start
desired tem
Cold Start
Cold Start -
reduction
Heat treatm
consumptio
Payback pe

results
ers is a smal
uction proce
e processes
e required.
s conducted
nd maintena
the refractory
eering was t
am installed
ored for a mo
art, the time r
urs. The new
also benefit
by 8-10% an
educed radia
ows a summa
nditions, redu
capacity.
sults of insu
rameter
time to reac
perature
surface tem
fuel consum
ent process
n reduction
eriod
l scale unit i
ess. The furn
include Nor
to assess th
ance practice
y material a
the insulatio
d the 75mm t
onth, in orde
required to r
w insulation a
ts for the hea
nd the surfac
ation losses.
ary of these
uced greenh
ulation
ch
mperature
mption
fuel
n Pune and
nace is a bo
malizing, An
he energy sa
es. The surv
nd a high fu
on method pr
thick veneer
er to see the
reach the de
also led to a
at treatment
ce temperatu
.
results, how
house gas em
Pre insulat
9 hours
120C



was chosen
ox type furna
nnealing and
aving potent
vey found tha
rnace surfac
roposed to r
r modules ov
positive effe
esired tempe
a 50% reduct
t process. Fu
ure of the fu
wever other
missions, en
tion
n for the stud
ace with a ca
d Tampering
tial based on
at there was
ce temperatu
reduce these
ver a 3 day p
ects of the in
erature of 94
tion in the am
uel consump
rnace decre
positive effe
nhanced refr
4
dy based on
apacity of 0.7
, where tem
n furnace de
s a high amo
ure, which m
e losses. The
period and th
nsulation.
0C reduced
mount of fue
ption during
ased from 1
ects include i
ractory life a
Post insula
4 hours
55C
8-10%
50%
5-6 months
its furnace
7 Ton per ba
peratures of
esign and
ount of heat
meant radiati
e GIZ and th
he furnace w
d from 9 hou
el required fo
this process
20C to 55
improved
and enhance
ation
type
atch.
f up
ion
he
was
urs
or
s has
C,
ed
Page 8 of 68

Conclusion

The aim of t
efficient insu

By helping I
the sustaina
energy effic
improve the
economical
contributes
consumptio
greenhouse
currently no
solution that

Due to the h
insulation be
short payba
measures.

The insulatio
safety. More
more pleasa

The results
the forging s
raise the aw
achieved. T

n
the project is
ulation solut
ndian SMEs
ability of thei
iency measu
eir efficiency
use of ener
to environm
n and heat l
e gas emissio
ot enough ren
t provides en
high saving p
ecomes adv
ack periods e
on of produc
eover, the in
ant working
of the MovIE
sector that a
wareness for
he measure
s to enable i
ions.
s to upgrade
r business a
ures. SMEs
and therefo
gy resource
ental sustain
oss have a h
ons reduced
newable ene
nergy efficie
potential and
vantageous i
enable the b
ction facilitie
nsulation will
atmosphere
EE project h
are characte
r energy effic
ements unde
ndustrial SM
e their insula
and make th
that install m
re reduce th
s. As a resu
nability by re
huge impact
d. As the ava
ergy availab
ency and env
d the possib
n a complex
usinesses to
es also impro
help to lowe
e, enhanced
ighlight the
rised by high
ciency, KAE
ertaken so fa
MEs in India
tion systems
em aware o
modern insu
heir energy n
ult of the lowe
educing gree
t on our env
ailability of fo
ble to meet th
vironmentall
ility to increa
x and highly
o be financia
oves the wor
er the overa
employee s
necessity of
h energy con
FER and the
ar illustrate th
to implemen
s, the projec
f the benefit
lation system
needs, which
er energy co
enhouse gas
ironment, as
ossil fuels is
he rising dem
y friendly pro
ase producti
competitive
ally capable
rking conditio
ll temperatu
atisfaction a
f professiona
nsumption. A
e GIZ are su
he success o
nt profession
ct allows the
ts which aris
ms on their p
h in turn resu
onsumption,
s emissions.
s energy can
limited and
mand, insula
oduction.
ivity, implem
business en
to implemen
ons in terms
re in the fac
and increase
al insulation
Although it is
ure this step
of the projec
nal energy
m to improve
se from adop
premises
ults in a mor
the project
. Decreased
n be saved a
as there is
ation is the
menting
nvironment.
nt these
s of health a
cilities, creati
ed productivi
in industries
s a challeng
can be
ct.
e
pting
re
also
fuel
and
The
nd
ing a
ty.
s like
e to
Page 9 of 68













BASICS OF INSULATION
AND
INSULATION MATERIAL
SELECTION

Page 10 of 68
Today, insulation is well recognised for its multiple applications
in a wide range of industries. Insulation
can be usually found in production
processes and facilities with transport,
storage, handling of materials at
specifc temperatures, whether high or
low, as well as in environments where
temperatures are controlled in order to
make them habitable.
The term thermal insulation, in a practical sense, refers to both
hot and cold insulation. All materials, whether hot or cold, have
a thermal conductivity value (k). This value indicates its ability
to conduct heat. For KAEFER, thermal insulation applies to the
principles of both hot and cold applications.
1. Insulation
1.1 Historical Facts about Insulation
1.2 Practical Advantages of Modern Insulation
Compendium | 11
Basic defnition of insulation: not insulated freezing sheep (left), warm
and covered insulated sheep (right)
Cork, an ancient
insulation material
used by mankind
The importance of insulation has been recognised by humans since
the beginning of civilisation. Man clothed himself with wool and
skins from animals. He built homes out of wood, stone, earth and
other materials for protection from the cold winter and the heat
of summer. The harshness of the climate and the environment
created the need for protection through insulation materials.
One of the frst materials discovered in the ancient times for this
purpose was cork, which was used by the Greeks and Romans
for protection. As industrialisation took place, cork was used
as insulation for icehouses. When mechanical refrigeration was
developed, cork was used to insulate pipes and equipment as
well.
Another important insulation material discovered by the
Hawaiian natives were mineral fbres which were used to blanket
their huts. These fbres came from volcanic deposits where
escaping steam had broken the molten lava into fuffy fbres.
In the early industrialisation period many mineral fbres were
developed and were used for building and industrial insulation.
Throughout the years these fbres evolved and more uses were
found for them. For instance, the fbres were modifed and
moulded into different shapes such as pipe coverings.
Today, materials manufactured from fbreglass, ceramics,
mineral wool, calcium silicate, foamed plastic, glass and other
substances are used in many shapes and forms as insulation
materials in different sectors. The importance of insulation has
increased in recent years as a method for improving energy
effciency in times of scarce or expensive resources, especially
non-renewable sources such as oil and gas. Technological
developments in insulation have brought more applications
and generated more accessibility for different types of users.
The following sections describe how these advances have been
gaining more relevance in our daily lives.
In todays industrialised world, the correct application of
insulation materials can increase overall effciency of processes
without major capital investments, resulting in several
advantages.
a. Energy savings
Energy conservation is the practice of using energy resources in
a suitable way by considering which processes are wasteful and
addressing those ineffciencies. According to research, 200
billion are wasted due to building ineffciencies in the European
Union each year. If such a study had been conducted in large
developing countries, in which the culture of using insulation
is usually also less developed, then numbers would certainly be
overwhelming.
Page 11 of 68
Compendium | 12
Industrial users can achieve energy conservation by applying
thermal insulation to its processes involving either hot or
cold temperatures, above and below ambient temperatures
respectively. Although plants are designed to include insulation
when constructed, is equally important to preserve installed
insulation throughout the whole operational life of the plant.
If this is done effciently, production processes optimise their
energy needs. The picture below illustrates conventional
insulation solutions applied to typical industrial equipments.
The same tank using insulation
installed as mattresses with fabric
exterior
Insulation work on pipes
Industrial insulation installed on a
tank covered with metal jackets
Commonly used insulation material
b. Reduction of operational costs
Industrial plants can consume large amounts of energy and
therefore face substantial energy costs. For example, a large
aluminium smelter can consume as much electricity as a small
city, and the energy costs can amount to approximately 120
million per year.
Energy costs of industrial plants can be reduced signifcantly
by applying the right insulation throughout the processes
and installations. The total amount of savings achievable is
exponentially affected by how effciently plants are insulated.
c. Protection of personnel from hot surfaces
High temperature insulation materials protect humans from
potentially dangerous equipment such as high temperature hoses,
pipes, and machines. Thermal burn injuries caused by accidental
contact with high temperature surfaces are among the industries
leading causes of workplace accidents and injury time loss.
For example, processes in the oil refning industry usually imply
high temperatures of 250C or even more. That is why workers
who operate in this environment are constantly exposed to the
risk of injuries caused by accidental contact during their daily
activities. The best way to prevent individual burns among the
workers is through protective clothing and of course through the
insulation of production equipment.
d. Optimisation of machinery performance
Based on the combination of the right materials such as thickness
and jacketing, it is possible to maintain the optimum temperatures
throughout the process to guarantee a better performance of
the machinery according to manufacture specifcations. This also
extends the operational life of the machinery.
e. Reduction of polluting emissions
The burning of fossil fuels, such as oil and gas, is a signifcant
contributor to the release of greenhouse gases. Industrial
plants with energy intensive processes can produce directly
and indirectly
1
signifcant amounts of these gases. For example,
aluminium smelters produce about two tons of carbon dioxide
(the main greenhouse gas) for every ton of metal, while the huge
quantities of electricity used add another 14 tons. Insulation has
the very desirable effect of reducing the release of these gases
into our atmosphere by increasing energy effciency in industrial
plants and other types of constructions.
1
Indirectly, by consuming electricity or other resources whose production itself required
emissions of greenhouse gases.
Page 12 of 68
Compendium | 13
1.3 Insulation and the Environment
In recent years the increasing environmental effects of global
warming, caused by excessive amounts of non-renewable
2

energy consumption, have caught the worlds attention. Based
on the advantages previously reviewed, insulation is a reliable
alternative to reduce the waste of energy used in processes
and to reduce greenhouse gas emissions.
a. Carbon Dioxide (CO2) & greenhouse gas emissions - global
warming
The greenhouse gases: carbon dioxide (CO2), methane (CH4), sulphur
hexafuoride (SF6), hydro fuorocarbons (HFC), per fuorocarbons (PFC)
and nitrous oxide (N2O)
The emission of greenhouse gases is caused to a large extent
by human activities. The most abundant greenhouse gas in the
atmosphere is CO2 and its presence has increased signifcantly
over the past decades. The overall emissions of CO2 and other
greenhouse gases can be measured for example in a carbon
footprint analysis. The carbon footprint is a measure of the
exclusive total amount of greenhouse gases that are directly
and indirectly caused by an activity. Every greenhouse gas can
be converted into units of CO2 in order to receive measurable
data. In 2009, more than 31 billion metric tons of CO2 were
emitted. This number is supposed to rise to more than 41 billion
metric tons by 2030
3
. Although the other fve greenhouse
gases are not released in the same volumes, their impact can
even be worse than the effects of CO2. For example, the effect
of methane on the atmosphere is 25 times greater than the
impact of CO2.
The breakdown of greenhouse gas emissions by sector is shown
in the following graph:
2
Fossil fuels (Oil, Coal & Natural Gas) are considered non-renewable sources because they can
not be replenished (made again) in a short period of time.
3
Source: KAEFER World Energy Outlook 2009
Page 13 of 68
Compendium | 14
The greenhouse effect refers to the rise of temperature that
the Earth experiences because certain gases in the atmosphere
trap energy from the sun. Without the greenhouse effect, the
Earth would not be warm enough for humans to live in. On the
other hand, if the emission of these gases is too high, it will
cause the Earth to warm. This phenomenon is called global
warming.
An excessively warm Earth can lead to changes in rainfall
patterns, a rise in sea level and have a wide range of implications
for plants, wildlife and humans. Based on research studies
during the last century the average temperature has risen up
about 0.6 C (about 1 F) around the world.
The negative effects of global warming can range from the
melting of the ice cap on Mount Kilimanjaro, Africas tallest
peak, to the loss of coral reefs as oceans become warmer. One
of the biggest dangers, as many experts warn, is that global
warming will cause sea levels to rise dramatically and potentially
food coastal cities. A good example of this would be the case
of Venice, a historical city in northern Italy, which is seriously
threatened by the increasing sea level. Another terrible effect
of global warming on human beings would be the large increase
in malaria cases in Africa due to slightly warmer temperatures.
Temperature increases of as little as 0.5C in some regions of
Africa can make mosquito populations rise by as much as 30-
100% and mosquitoes are the main vehicle for the spread of
malaria. Additionally, the malaria virus is temperature sensitive
and warmer temperatures could lead to easier propagation.
Page 14 of 68
Compendium | 15
1.4 Insulation and Basic Physics
The term thermal insulation can refer to materials used to
reduce the rate of heat transfer or the methods and processes
used to reduce heat transfer.
Heat energy can be transferred by conduction, convection,
radiation or when undergoing a phase change. All these
mechanisms are described in the following passages:
Thermal convection is the mechanism which usually refers to
the movement of molecules within fuids (liquids or gases),
and can be defned as vertical circulation that results from
differences in density. This is ultimately brought about by
differences in temperature and it involves the transfer of heat
through the motion of hot fuid from one place to another.
Convection mechanisms occur in two different forms: natural
and forced. Hot air rising is an example of natural convection.
Hot air has a lower density than that of the cooler air in the
atmosphere, which makes it buoyant. As it rises, however, it
loses energy and cools. This cooled air, now denser than the air
around it, sinks again, creating a repeating cycle that generates
wind.
Forced convection occurs when a pump or other mechanism
moves the heated fuid. Examples of forced-convection
appliances include some types of ovens and even refrigerators
or air conditioners. The picture shows this mechanism through
a home heater.
Air heated by the
heater rises and
is replaced by
cool air, creating a
convection current
that circulates hot
air throughout a
closed space like a
room.
Thermal radiation is the mechanism by which heat is
transmitted from a hot surface to a cooler one in the form of
invisible electromagnetic waves, which upon absorption by the
cold surfaces, raises the temperature of the surface without
warming the space in-between. During this process, the energy
usually travels at the speed of light and does not require a
medium to carry it. The intensity and frequency distribution of
the emitted rays are determined by the nature and temperature
Forced convection process through a
home heater
Thermal radiation through solar waves to the Earth
of the emitting surface. Generally speaking, the hotter the
object, the shorter the wavelength. A hotter object is a better
emitter than a cooler one, and black surfaces absorb better
than silver ones. An example of thermal radiation is the heating
of the Earth by the Sun.
Heat conduction or thermal conduction is the transfer of
energy through matter from atom to atom within a substance;
usually it is also described as heat energy transferred from one
material to another by direct contact. For example, a spoon
in a cup of hot soup becomes warmer because the heat from
the soup is conducted along the spoon. Conduction is most
effective in solids-but it can also happen in fuids.
The fow of heat by conduction occurs as a result of collisions
between atoms and molecules in the substance and the
subsequent transfer of kinetic energy
4
.
4
The kinetic energy of an object is the energy it possesses because of its motion..
Page 15 of 68
from the surface of the material being imaged is measured. The
detector of the thermal imaging camera turns the heat radia-
tion intensity of the object into temperature data from which
a thermographic image is digitally generated in real time. The
thermal imaging camera is primarily used for visualising surface
temperature distribution. Thermal imaging cameras can be
used in industrial preventive maintenance, studying heat proc-
esses and correcting heat correlated failures after insulation.
Thermographic surveys can be used for cold insulation as well.
Cold insulation. Cold insulation should be considered where
operating temperatures are below ambient temperature and
where protection is required against heat gain, condensation
or freezing. In this case the object to be insulated is colder than
the surroundings and the heat fow is directed towards the ob-
ject. The following chart describes typical types of processes
which can be insulated at different temperature ranges:
Compendium | 16
Thermographic survey of the thermal insulation
of a pipe in an industrial facility
a. Thermal insulation is mainly focused on slowing the transfer
of heat through conduction. Materials applied for insulation
purposes are usually poor thermal conductors which mean
a low capacity for heat transfer. On the other side, dense
materials with closer atoms mean high rates of energy transfer.
Thus, gases insulate better than liquids, which in turn insulate
better than solids.
In cold insulation systems it is relatively easy to identify failures
on the insulation because condensation or even solidifcation
of water vapour occurs. For hot insulation this is not the case.
This is why some special techniques like thermographic sur-
veys can be used
in order to identify
such failures.
These surveys help
to measure tem-
peratures without
direct contact to
the object. With
a thermographic
camera the nor-
mal heat emission
5
A temperature gradient is a physical quantity that describes in which direction and at what
rate the temperature changes the most rapidly around a particular location.
But, regardless of the purpose of the cold insulation, the
system is only as good as its vapour barrier and the care with
which it is installed. A vapour barrier is a membrane of very low
water vapour permeance placed on the warm side of insulation
to limit the fow of water vapour into the insulation. When
there is a difference in temperature, or humidity between the
cold surface of the equipment and the ambient temperature
a differential water vapour pressure occurs. Water vapour is a
transparent, tasteless and odourless gas capable of permeating
through most materials depending on the pressure differential
on either side of the insulation.
Many moisture-resistant materials are not necessarily vapour-
resistant. If water vapour penetration is not prevented, it will
condense into liquid or solidify into ice. This consequently will
decrease the effectiveness of the insulation system.
As previously explained, the correct design of the cold insulation
system is to guarantee a good performance after application.
Processes
Hot water and steam condensate lines
Steam, high temperature hot water lines
Turbines, breechings, refning towers,
boilers, etc.
Range of Temperature
16C to 100C
100C to 300C
300C to 800c
Processes
Cold or chilled water lines
Refrigeration devices
Refrigeration and brine facilities
Facilities operating under cryogenic
temperatures

Range of Temperature
5C to 0C
5C to 0C
-40C to -100C
-100C to -273C
1.5 Introduction to Insulation
Hot insulation. Typical materials applied for thermal insulation
on hot applications are, mineral wool , calcium silicate and rigid
expanded perlite. When applying insulation to hot objects,
heat fows away from the object to be insulated into the
surroundings because of the temperature gradient
5
.
The following chart describes typical types of processes which
can be insulated at different temperature ranges.
Page 16 of 68
Compendium | 17
However, in the case of low temperatures, an assumption
should be made that, at some point in time, a breakdown of
the vapour barrier might occur. Condensation is a process
that occurs when water vapour in the atmosphere comes in
contact with a surface at a temperature of less or equal to its
dew point. The presence of condensation on the warm side of
the vapour barrier has no detrimental effect on the insulation
but, nevertheless, it is a condition which has to be avoided in
the designing process. To prevent condensation, the insulation
thickness should be designed so that the temperature on the
warm side of the vapour barrier is above the dew point of
water vapour. For this reason, the jacketing is made of metal
sheets composed of aluminium or galvanised steel as in hot
insulation.
Cryogenic insulation. A special kind of cold insulation is
cryogenic insulation which addresses the insulation of plants
operating at a temperature below -100C. For example,
Liquefed Natural Gas (LNG) which can have a boiling point
as low as -164 C has created a demand for storage facilities
capable of economically reducing evaporation losses.
The following pictures show the decoupled insulation system
using ethylene pipes and the multilayer insulation system for
LNG as typical examples.
Multilayer insulation system
Decoupled insulation system
b. Acoustic Insulation Apart from the industrial requirements
for thermal insulation, the continuous generation of noise and
vibrations has created the need for noise protection. Constant
noise affects those who are subject to it and can detract
considerably from their well-being, especially for employees
and people living in surrounding areas.
The elimination of noise is dependent on the source and requires
a high degree of technological know-how. Noise analysis and
testing are required to detect the main causes and also to
provide reliable solutions through acoustic insulation systems.
The above mentioned analysis must be supported by acoustic
techniques. Acoustics is defned as the science of sound and its
infuence on human beings. Based on that, sound is understood
as vibrations transmitted through an elastic solid, liquid or gas,
with frequencies in the approximate range of 18 to 20,000
hertz
6
, capable of being detected by humans.
There are three basic kinds of sounds: air borne sound, structure
borne sound and sound transmitted in liquids (and gases).
> Air-borne sound is understood as the propagation of
sound through the air such as the sound of traffc on a
nearby roadway.
> Structure-borne sound is the sound for which a signifcant
portion of the transmission path from source to receiver
takes places in a solid structure, such as a metal, rather
than through a liquid or gas.
> The third type is sound transmission through liquids. An
example of sound transmission through water is sonar,
a technique that uses sound propagation to navigate,
communicate or detect other vessels.
For sound to propagate from a source to the human ear, it must
frst travel through air or another medium. In the absence of
any medium (i.e. a vacuum) sound propagation is impossible,
therefore no sound is heard.
As is shown in the pictures below, in air, sound can only travel
in the form of longitudinal waves, and in the case of liquids
the sound is transmitted in the form of transverse waves. The
direction of vibration is parallel to the direction of propagation.
The individual air particles execute vibrations around their static
position in the direction of the sound spread. Neighbouring
6
The hertz (symbol: Hz) is the unit of frequency defned as the number of cycles per second
of a periodic phenomenon. One of its most common uses is the description of sine wave,
particularly those used in radio and audio applications.
Page 17 of 68
Compendium | 18
Transverse wave Longitudinal wave
Sound is a sequence of waves of pressure which propagate
through compressible media such as air or water (or in the
case of structure-borne sound, in solids as well). Waves can be
refected, refracted, or attenuated by the medium. All media
have three properties which affect the behaviour of sound
propagation:
> A relationship between density and pressure. This
relationship is affected by temperature and determines
the speed of sound within the medium.
> The motions of the medium itself, e.g. wind. This is
independent of the motion of sound through the medium,
and if the medium is moving, the sound is transported
further.
> The viscosity of the medium. This determines the rate at
which sound is attenuated. For many media, such as air or
water, attenuation due to viscosity is negligible.
Acoustic insulation can be defned as any means of reducing
the intensity of sound with respect to a specifed source
and receptor. There are several basic approaches to reducing
sound: increasing the distance between source and receiver,
using noise barriers to block or absorb the energy of the sound
waves, using damping structures such as sound baffes, or
using active anti-noise sound generators.
Acoustic insulation affects sound in two different ways: sound
reduction and sound absorption.
Sound reduction simply blocks the passage of sound waves by
using distance and intervening objects in the sound path.
Sound absorption operates by transforming the sound
waves. Sound absorption involves suppressing echoes,
reverberation (echoing), resonance and refection. The damping
characteristics of the materials used are important in noise
absorption. The wetness or moisture level in a medium can
also refect sound waves, signifcantly reducing and distorting
the sound travelling through it, making moisture an important
factor in soundproofng.
Sound is energy and it is scientifcally acknowledged that it
is impossible to get rid of energy, since it is only possible to
transform it. Through insulation, energy contained in sound
waves is changed into heat. The more effectively this is done,
the greater the sound reduction. The molecules within the
insulation material start vibrating as a result of the exposure to
noise. Energy is required to make the molecules vibrate, which
comes directly from the sound waves. This process is illustrated
below using as example mineral wool insulation:
Sound waves passing through mineral wool are
continually being defected and broken up by
the individual fbres. The fbres vibrate with the
sound energy, which is converted into heat
It is also important to mention that when analysing noise
levels, not only the overall sound-pressure level is important,
but also the different frequency shares present in the noise,
since different materials attenuate only certain frequencies and
the aim is to dampen all frequencies present.
Insulation systems which have to address both cold and
acoustic issues are very interesting cases because materials
for cold insulation are closed cell materials, while for acoustic
insulation open cell materials are required. To optimise the
acoustic insulation, KAEFER experts then put a second cover
sheet of steel on the existing cold insulation. In this case an air
gap is left between the cold insulation and the second cover
sheet. Many other forms of solutions have been developed by
KAEFER for acoustic and cold insulation needs.
particles are hit in the process so that an impact occurs, the
speed of which is dependent on the medium.
c. Insulation Systems The necessity to insulate is present in
many types of industries which makes the scope of applications
very broad. Additionally, the insulation systems can vary
signifcantly within the same industry. This is why it is crucial
to design specifc solutions for specifc needs.
Giving a typical example on how an insulation system is designed
will help us understand what variables these systems have to
address, and more specifcally what an insulation system really
is.
Page 18 of 68
Compendium | 19
Standard Insulation System
The sketch shows an insulation system applied to perhaps the most common
equipment, a pipeline. It highlights the two most important elements within
an insulation system, the insulation material and the jacketing protection.
The frst step is to design the insulation system in accordance
with the process requirements. This step identifes the type
and properties of materials to be employed. This process can
easily be explained through the following questions.
1. What needs to be insulated?
Is it a vessel, a piping system or a machine? The nature and
geometry of the element to be insulated will sometimes
dictate what material is best suited for the insulation system.
With this consideration, the operating temperature is of great
importance in choosing the appropriate type of insulation.
2. Which are the environmental conditions?
Environmental conditions play an important role in the design
of an insulation system. It is vital to distinguish between
indoor and outdoor conditions. If the insulation system is
to operate in an outdoor environment, then the selection of
metal jacketing or the insulation material may be different
than if the system is indoors. E.g. Indoor ventilation ducting
may not even use insulation jacketing at all. In outdoor
conditions, it is very important to ensure that no water or
water vapour penetrates into the insulation system, because
water in an insulation system will diminish its insulating
value.
3. What is the nature of the process?
It is signifcant to know what processes are taking place
and if they have any unique properties that might infuence
the design of the insulation system. This often relates to
the properties of the area or element to be insulated. E.g.
radioactivity, fammability, corrosion, noise.
4. How much insulation thickness is needed?
The fnal step in design, after selecting the materials and
determining the extent of insulation, is to calculate the
appropriate thickness. Thickness should be based on the
requirements of the system to be insulated. For example the
thickness required for personnel protection will be different
than the one required for optimum heat conservation. The
important criteria for the insulation thickness are: surface
temperature, heat fow, economical insulation thickness,
cooling time and heating time. KAEFER has developed its
own software to support this calculation.
1.6 Insulation Materials
Insulation materials are a key component to guarantee the
reliability of any insulation system. Based on that, the following
section describes the general characteristics of the most
relevant materials in the insulation business for KAEFER. These
materials can be divided into the following generic types:
a. Fibrous insulation
b. Cellular materials/foams
c. Granular insulation
d. Others
a. Fibrous insulation
Fibrous insulation is composed of small diameter fbres, which
fnely divide air space. The
fbres may be perpendicu-
lar or horizontal to the
surface being insulated,
and they may or may not
be bonded together. Glass
wool, mineral wool, slag
wool and refractory ce-
ramic fbres are used for
this type of insu- Fibres
Page 19 of 68
b. Cellular materials
Cellular materials are made of small in-
dividual cells separated from each other.
The cellular material may be glass or
foamed plastic. Examples are polysty-
rene, polyurethane, and elastomeric. The
most common cellular insulating materi-
als are described below.
Glass fbres are available as fexible blankets, or rigid boards, and
other pre-moulded shapes. The product is non-combustible and
has good sound absorption qualities. The service temperature
range is 40 C to 400C. Manufacturers of this material are:
> Knauf Insulation GmbH (Germany)
www.knaufnsulation.de
> Superglass Insulation (UK)
www.superglass.co.uk
> Isover (France)
www.isover.de
Expanded silica and perlite is made from an inert siliceous
volcanic rock combined with water. The rock is expanded by
heating, causing the water to vapourise and the rock volume
to expand. This creates a cellular structure of minute air cells
surrounded by vitrifed product. Added binders resist moisture
penetration and inorganic fbres reinforce the structure.
The material has low shrinkage, high resistance to substrate
corrosion, is non-combustible and operates in the intermediate
and high temperature ranges. Manufacturers of this material
are:
> Howred (USA)
www.howred.com
> Industrial Insulation Group (USA)
www.intelligentinsulation.com
> World Minerals (USA)
www.worldminerals.com
Mineral fbres are bonded together with a heat resistant binder
to produce loose blankets, boards, pipe insulation, and moulded
shapes. The material is non-combustible, has good sound
control qualities and the upper temperature limit can reach
600C. Mineral fbre insulation prevents convection by holding
air still in the matrix of the insulating material. Still (trapped or
non-dynamic) air is a good insulator and limits the conduction
of heat through the body of insulation. Manufacturers of this
material are:
> Manson Insulation (Canada)
www.imanson.com
> Fibrex Insulation (USA)
www.fbrex.org
> Rockwool International (Denmark)
www.rockwool.com
Cellular glass insulation materials are available in board and
block form and capable of being fabricated into various shapes.
The temperature range at which this insulation material is
applicable is 40C to 400C. This insulation material has
good structural strength, but a poor impact resistance. It
is non-combustible, non-absorptive and resistant to many
chemicals. Manufacturers of this material are:
> Pittsburgh Corning (USA)
www.pittsburghcorning.com
> All Thermal Insulation (USA)
www.allthermalinsulation.com
> ZES Cold Insulation Technology (China)
www.zesfoamglass.com
Refractory insulations are mineral or ceramic fbres including
alumina and silica, bound at extremely high temperatures.
The material is manufactured in blanket or rigid form and
its temperature limits reach 1,200C. The material is non
combustible. Manufacturers for this material are:
> Jayne Industries (Canada)
www.jayneindustries.com
> Alfso (Austria / India)
www.alfso.com
> Unifrax (USA)
www.unifrax.com
Compendium | 20
Glass Fibres
Cellular/Foam
materials
Mineral fbres
Cellular glass block
Refractory fbre
lation material. The following is a detailed description of the
most common fbrous insulating materials.
Perlite materials
Page 20 of 68
hot piping and surfaces. It is water absorbent but can be dried
out without deterioration. Decades ago it was commonly used
for thermal insulation, nowadays because of its relatively high
weight compared to substitute materials, its usage is more
seldom and in regions like Europe it is more commonly applied
as a passive fre protection material. Jacketing for calcium
silicate depends on the feld in which this insulation material is
applied. Manufacturers of this material are:
> Manson Insulation (Canada)
www.imanson.com
> General Insulation (USA)
www.generalinsulation.com
> Calorisol (Brazil)
www.calorisol.com
Compendium | 21
Elastomeric materials are composed of foamed resins combined
with elastomers, which produce a fexible cellular material.
Available in pre-formed shapes and sheets, elastomeric
insulations possess good cutting characteristics and low
water and water vapour permeability. The upper temperature
limit is 80C. Elastomeric insulation is cost effcient for low
temperature applications since no jacketing is necessary.
Manufacturers of this material are:
> Armstrong World Industries (USA)
www.armstrong.com
> Karman (USA)
www.karman.com
> Armacell (USA)
www.aerofexusa.com
Calcium silicate is a granular insulator made of lime and silica,
reinforced with organic and inorganic fbres and moulded into
rigid forms. The service temperature range covered is 38C to
650C. Calcium silicate is non-combustible can be applied to
d. Other types of insulation materials
There are also some insulation materials that do not ft into
these categories:
Microspheres insulation typically consists of hollow glass
bubbles. It has high resistance to crushing, low density, is non-
combustible, and performs well in a soft vacuum. Microspheres
provide robust, low maintenance insulation systems for
cryogenic transfer lines. They also do not suffer from problems
regarding compaction. Manufacturers of this material are:
> Technology Applications (USA)
www.techapps.com
> Epitaxy (Russia)
www.microspheres.ru
Foamed plastic insulations are produced from foaming plastic
resins creating predominantly closed-cellular rigid materials.
Foamed plastics are lightweight with excellent moisture
resistance and cutting characteristics. Available in pre-formed
shapes and boards, foamed plastics are generally used in the
temperature range, -120C to 100C, in the case of foamed
plastic insulation, the introduction of inert gases in the
voids can also contribute to the effciency of the insulation.
Manufacturers of this material are:
> Bayer AG (Germany)
www.bayer.de
> BASF GmbH (Germany)
www.basf.de
> Duna-Corradini (Italy)
www.dunagroup.com
Elastomeric insulation
Calcium silicate
insulation
Microspheres insulation
panel
Foamed plastic
c . Granular insulation
Granular insulation is composed of small nodules, which con-
tain voids or hollow spaces. It is not considered a true cellular
material since gas can be transferred between the individual
spaces. This type may be produced as a loose or porable ma-
terial, or combined with a binder and
fbres to ensure a rigid insulation. Insu-
lation materials used for this insulation
type include calcium silicate, and cel-
lulose. The following picture illustrates
granular insulation materials. Granules
Refractory bricks are heat-resistant bricks made out of clay.
Their melting point is well above the operating temperatures
of the process and refractory bricks line most steel making
vessels that come in contact with molten metal, like the walls
of the blast furnace. Refractory lining using bricks or refractory
fbre is employed in boilers and kilns as well. Manufacturers for
this material are:
> RHI
www.rhi-ag.com
> Mayerton
www.mayerton.com
Refractory Brick
Page 21 of 68
Insulating and fnishing cements are a mixture of various
insulating fbres and binders with water and cement that are
used to form a soft, plastic mass for application on irregular
surfaces. Cements may be applied to high
temperature surfaces. Manufacturers of
this material are:
> Ramco
www.ramcoinsulationproducts.com
Vacuum insulation is an advanced thermal insulation technology
that signifcantly outperforms closed-cell foams, foams beads
or fbre blankets. Whilst these traditional systems attempt to
trap gases to reduce the transfer of heat, vacuum insulation
removes the gases within the insulating space. As the
space is evacuated or placed under vacuum, the molecular
presence and movement needed to transfer heat is greatly
reduced. KAEFERs own innovations in this feld allow 72% less
insulation thickness and 83% less volume
after application. Manufacturers of this
material are:
> Va-Q-Tec
www.va-q-tec.com
Aerogels are often known as frozen smoke because they
weigh twice as much as air and comprise of a tangle of silica
containing as much as 99.5% air. In the manufacturing process,
tiny pockets of between 5 to 150 nanometres in diameter
are formed. Aerogels represents what technology experts
consider the best insulation material ever invented. It weighs
virtually nothing. Its fexible. Its translucent. And it can survive
temperatures of 1,600C. Aerogels have unsurpassed thermal
insulation values, as well as sound and shock absorption
characteristics. Specifcally, an aerogel is the lightest weight
solid on earth, and has the worlds best insulating value. As this
is quite a modern product, manufacturers
of these materials are still limited, but
include:
> Aspen Aerogels
www.aerogel.com
Compendium | 22
Aerogel
Insulating cement
Vacuum Insulation
Finally the following chart shows the most common applications
of insulation materials based on the surface temperature of the
objects that will be insulated.
Service temperature of insulation materials

Material Service Temperature
Cellular glass -202C 430C
Perlite -200C 750C
Mineral Wool -180C 600C
Polyurethane rigid foam -175C 140C
Expanded polystyrene foam -173C 90C
Phenolic foam -170C 120C
Polyethylene foam -60C 110C
Flexible foam -30C 110C
Glass fbres -40C 538C
Glass wool 15C 420C
Calcium silicate 15C 880C
Microporous insulation 15C 1020C
Calcium-Magnesium-Silicate-fbre (CMS) 15C 1050C
Ceramic wool 15C 1210C
Aerogel -40C 1600C
Elastomeric foams Up to 104.04C
Refractory fbre Up to 1648.9C
Cement Depending on the
material used, e.g.
portland cement up
to 1450C
Page 22 of 68
> Fire retardancy
Flame spread and smoke developed ratings are of vital
importance in case of a fre emergency.
Insulation is not installed on standard shaped equipment. The
rule is that these objects can vary greatly in size and shape.
In order to custom ft the shapes of the
objects to be insulated, a transformation
process has to take place. Initially metal
is available in coils. In order to transform
it into ready to install pieces a designing,
cutting and moulding process has to take
place.
Compendium | 23
1.7 Insulation Jacketing
Besides of the insulation material itself, a second and very
important component in an insulation system is the covering
or casing. This usually refers to a protective metal jacketing
made out of aluminium or galvanized steel. The main difference
between both of these metals is that galvanized steel is more
resistant to corrosion. All metals employed for jacketing have
a refective surface
(this refects ra-
diation and hence
doesnt heat up
excessively) and
physical barrier
properties (in or-
der to protect in-
sulation materials). Metal jacketing on insulation
Sheet metal coil
Metal jacketing,
curved tube section
Off set
Tee piece
Concentric cone
Equal tee Round cap
Cover Tube section Offset tee piece
The jacketing may act as a weather barrier, a vapourbarrier,
a mechanical abuse covering, a corrosion resistant covering,
or as a fre resistant covering. The properties of jacketing and
mastic
7
materials that must be considered are:
> Chemical compatibility
The chemical composition of coverings must be compatible
with the insulation material over which they are applied,
as well as being resistant to elements in the environment
such as industrial chemicals, salt, air and ultraviolet or
infrared light.
> Resistance to internal and external movement
This property is signifcant if the covering must absorb
or compensate for thermal expansion and contraction of
the insulation it covers (i.e. shrinkage of high temperature
insulation) or if the vibration of the equipment to be
insulated must be considered.
> Temperature range of the fnish or covering
The temperature range must be compatible with the
surface temperature of the insulation surface.
> Vapour permeability
Permeability should be considered for below ambient or
dual temperature systems
8
. The covering should prevent
the passage of moisture vapour into the insulation.
The pictures below after that illustrate common jacketing
elements for different type of applications.
a. Center radius
b. Segment
c. Half segment
d. Overlap
7
Mastics are vapour-retardant, highly fre resistant, fexible, tough and durable pasty cement
coatings for thermal and cold insulation. They can substitute metal jacketing.
8
Dual temperatures systems are those in which insulation has to address changing
temperatures, both hot and cold.
Page 23 of 68
> Simple operation
> Punching (continuous stroke) for
standard pipes
> Touch screen / colour monitor
> Bingo 2
Universal cutting to length machines.
> Up to 8 assembly-ready pipes per
minute
> Even faster working speed
> Fully automatic sheet changing
> Fully automatic width with
adjustment
Since this machinery can be quite capital intensive, its
acquisition and usage brings the most advantages when
dealing with high volumes of work. Additionally the usage
of this machinery becomes especially attractive in countries
where labour costs are relatively high.
Among the most important machines for producing insulation
coverings are:
> MABI 16-4 Rohrblitz
Straightening, cutting, punching, beading, rolling and swaging
for sheet metal and ready-to-ft ducts.
> Up to 8 meters/minute or 480 pieces/hour
Compendium | 24
In order to shape the metal sheets into a tube, a roller is
employed and in order to ft two sections together, both ends
of the respective sections are folded and creased as follows.
Trained professionals
operating machinery
Automation is especially useful
for large volumes of production
Creasing machine (produces the swages)
Swages
Sheet metal works are usually a very labour intensive process.
The availability of skilled sheet metal workers is of great
importance for insulation companies. Nevertheless, in some
regions of the world these works are done in automated
processes which demand high investments in machinery.
> Jacketing fabrication automation examples
The metal coverings may be manufactured with the help of
insulation machinery that simplifes and speeds up the process.
Four straight insulation pipes can be produced in one minute in
this manner and a high productivity is ensured.
Page 24 of 68
Compendium | 25
1.8 Insulation Applications
Pipelines
The transfer of fuids through pipelines is an application
found in almost all industries. When fuids being transferred
are meant to remain at certain temperatures which differ to
those of their external environment, then thermal insulation
becomes necessary. Generally, pipelines are insulated with
foam material since fuids are transported internally; therefore
porous insulating material can be inappropriate because they
would absorb the liquids in cases of leakage.
In the majority of cases, pipelines are insulated with thermal
insulation, although sometimes acoustic insulation is also
necessary as pipelines can be important sources of noise in
industries such as oil refneries. In the case of cold insulation,
pipelines are insulated with
closed cellular foam which
stops air and vapour fow
towards the cold pipe, where
otherwise water would
cumulatively condense. For
example, the process that
occurs on the surface of a
cold glass of water when exposed to strong sunlight. This may
cause the insulation system to collapse. Additionally, a cover
sheet for protection against high mechanical impact is usually
included.
On pipelines, acoustic insulation also consists of mineral wool
and a cover sheet. The distances between the pipe and cover
sheet are often bigger than in thermal insulations. To increase
the sound reduction, a deebooming material
9
is glued on the
inside of the cover sheet increase its weight.
Other requirements for pipeline insulation may include surface
protection.
Insulation requires maintenance. It can frequently become
damaged or removed during maintenance and sometimes it
isnt replaced by the plant operator. Another common way
to damage the insulation is through steam leaks on pipes.
Installing and maintaining effcient insulation on piping can save
signifcant amounts of money and prevent employee injuries.
Boilers and furnaces
Furnaces and boilers play important roles in many industries as
well as in the heating of commercial and institutional buildings.
They heat products in petroleum, chemical and pharmaceutical
industries and produce or handle molten products in glass, steel
and other industries. As such these equipments operate at very
high temperatures and throughout long periods of time.
Most steam and hot water boilers are often in use for over
8,000 hours a year, and during this time they release heat into
the surrounding atmosphere. These losses can be in the form
of thermal radiation and conduction. Other factors relating to
the design of the boiler such as number of thermal bridges
10

can also play a role with regards to energy losses.
Boilers are fully insulated, except for the compensator that
takes care of the heat expansion of the boiler during heat
exposure. If the devices to be insulated do not have to be easily
accessible, the insulating material is covered with a custom-
made metal sheet jacketing. The insulation material used on
boilers (as well as in other devices that work with hot steam
or operate at high temperatures) should also have fre proof
properties, such as mineral wool.
Thermal insulation minimises the energy loss signifcantly
and as such reduces the operative costs of the plant operator
and reduces the usage of fossil fuels. Additionally insulation
protects personnel working around the boiler by reducing the
external temperature of the equipment. Boilers and furnaces
may additionally have an internal refractory lining which also
contributes to the advantages previously mentioned.
When valves, fanges and other equipment require frequent
maintenance, easy access is extremely benefcial. To keep
Insulated pipelines in the Kyritz
Biodiesel factory, Germany.
Alcan gove evaporator insulation
9
A deebooming material is bitumen material used to reduce structure borne sound.
10
A thermal bridge is created when materials that are poor insulators come into contact,
allowing heat to fow through the path created. For industrial equipments usually metallic
structural supports act as such
Page 25 of 68
Compendium | 26
the facility operators maintenance costs under control, it is
benefcial to use removable insulation blankets or removable
insulation boxes. These replace conventional insulation on
those fttings and equipment which require frequent removal
of the insulation followed by re-insulation.
In some cases, industrial facility operators choose not to use any
insulation on valves, fanges and other frequently maintained
equipment. While plant maintenance departments may have
seemingly good reasons to do so (makes their daily work faster,
and reduces their budget), the quantity of additional energy
loss and the value of that energy at todays energy costs is
extreme. For example in a study conducted for an oil refnery,
it was demonstrated that a cost payback of about 1.5 months
was achieved when insulating previously bare valves and fanges
with removable blankets. This represents approximately a 700-
percent ROI.
Insulation of turbines
In the case of turbines, insulation mattresses or blankets are
employed, since devices may have very distinct shapes and
mattresses are fexible and can be installed and wrapped
around corners and edges easily. Furthermore, they may be
removed at any time to work on valves or outlets.
On turbines, different support-types are
welded/ screwed in order to physically
attach insulation mattresses onto these.
The mattresses are easily assembled
according to the
Layout-Plan.
For further information about the insulation of turbines and
nuclear plants please see the individual sections.
Nuclear power plant devices
Workers in a nuclear power plant need to reduce their time
exposure in radioactive areas. This is
why cassette insulation is used in nuclear
power plants since it can very easily and
quickly be mounted and demounted.
This insulation system is used for devices
such as tank covers in the vicinity of the
reactor.
If the cassettes are subject to nuclear contamination, they may
be easily and effectively cleaned since the insulation material
itself is composed of vacuum wrapped in metal sheets.
Devices such as turbines, and vapour
pipes that are not in danger of being
contaminated are insulated with
conventional blankets or mattresses.
Acoustic insulations in nuclear power
plants is comparable to the insulation in
conventional power plants and the materials used to insulate
are basically the same as in other industrial facilities.
Application of insulation to cold storage facilities
Cold storage insulation is normally applied in the form of boards.
Two layers are usually applied with joints staggered between
layers and insulation tightly butted. Insulation boards must be
frmly and permanently bonded to the wall, ceiling, roof, or to
the other layer of insulation. Generally, thick coatings of heavy
bodied adhesives are used to provide some straightening or
bridging on an irregular wall surface. Single layer insulation is
used only in dry coolers where the service is not demanding.
Another very common possibility is to use foam-insulating
material. It is spray-applied and adheres tenaciously to almost
any substrate, eliminating the need for seams, fasteners
and adhesives. The foam dries within
seconds after being applied to a surface
and expands to approximately 30 times
its original volume. It has a weather-
tight seal and has excellent anticorrosion
qualities. The foam layer is usually
covered with a protective coating such
as elastomerics.
Assembled nuclear
turbine cassettes
Mattresses in steam
generator
Butane Storage Tank
Page 26 of 68
Page 27 of 68










METHOD
OF
CALCULATION
OF
HEAT LOSS/GAIN
FOR INSULATION
Page 28 of 68
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Page 30 of 68
Page 31 of 68










IS SPECIFICATION
FOR
BONDED
MINERALWOOL
Page 32 of 68
Page 33 of 68
Page 34 of 68













INSULATION
APPLICATION
PROCEDURES

Page 35 of 68













APPLICATION PROCEDURE
FOR
VENEER MODULES
ON
BRICKS AND PREFIRED
CASTABLE REFRACTORY
Page 36 of 68
APPLICATION PROCEDURE FOR VENEER MODULES
ON BRICKS AND PREFIRED CASTABLE REFRACTORY

1. REFRACTORY SURFACE PREPARATION:
a) Refractory should be in level. If extensive unevenness or broken refractory
is present, the same should be replaced before veneering.
b) For minor unevenness or extensive iron oxide accumulation or severe
glazing, preparerefractory surface by chipping, grinding, sand blasting,
mortar spraying etc.
c) Remove loose dust and dirt by wire brushing.

2. Apply 1-2mm thick layer of veneer mortar to one side of the module working it
back and forth. If the module is to be fixed on insulating brick or insulating
castable, then apply 2-3 mm thick layer of veneer mortar.

3. Apply 3-4mm thick layer of veneer mortar on the refractory surface. If the
refractory surface is one insulating bricks or insulating castable, then apply 2-3
mm thick layer of slightly dilute mortar on the refractory surface.

4. Install module on to the refractory by firmly applying equal pressure on full
surface of the module. With pressure on the module, slightly twist it in clockwise
and then anticlockwise direction to remove any air pockets in the mortar. Slight
amount of the mortar should come out from between the module and refractory.

5. Allow modules to set for 24 hrs. before applying FiberfraxCoating. The
minimum time required for modules to set is eight hours but it is strongly
recommended that the 24 hrs guideline is followed whenever possible.

6. Quantities:
a) Approximate mortar requirement is 1.0 kg/ft2
b) Approximate coating requirement is 170 to 200 gms/ft2 for spray coating
and 250 to 300 gms/ft2 for brush coating.

7. ADDITIONAL INFORMATION:
a) In case where modules are being installed over existing IFB lining, dilute
mortar must be applied over existing refractory.
b) After mortar has set, cut out the modules holding strips from hot face. Do
not pull out the strips from the back.
c) Castables must be prefired before veneering.
d) In areas where the existing refractory is badly spalled or cracked, one can
use chopped up veneer module material and veneer mortar for filling and
repairing.
e) In those areas where modules are ended, such as around burner
openings, the ended edge of the modules should be tapered at 45 deg
angle and coated with an extra thick layer of FibefraxCoating. This will
provide increased resistance to air flow and gas velocity.
Page 37 of 68
f) When installing modules in curved areas, such as nosings, it may be
helpful to cut a notch in the back of the modules so that it can easily bend
to confirm to the curvature of the area.
g) While installing modules parquet them. However, all Felt type modules
should not be paraquated and should be installed with strips in the
direction of the flame.
h) If the surface is uneven in a certain portion, cut the modules in similar
sections corresponding to levelled surface and then install.
i) Veneer module installation should be done only when the refractory
surface is below 45
O
C. Otherwise mortar may not properly stick to the
refractory surface.
j) For fibre to fibre veneering, follow same procedure as that for veneer
module over IFB.
k) For veneering of boards procedure is same as that for veneer modules.
However, the board size should be restricted to maximum 1 sq.ft. In case
the board is to be veneered on curved surface cut the board into smaller
width strips depending on the curvature and then install each individual
strip.

Page 38 of 68













APPLICATION PROCEDURE
FOR
INSULATION OF ROTARY
DRYERS
Page 39 of 68
Method of application of insulation and schematic drawings
1. Fabricate cladding sheet as per drawings shown

2. Drill holes on MS bolts heads

3. Do tapping on the drilled holes for the size of bolts to be fitted

4. Clean the surface that will be insulated with the help of a grinding wheel and suitable
solvent so that it is free from rust, dust as well as paints

5. Fix up the insulation pins with suitable thermal resistant adhesive and ensure that
insulation pins are tightly fixed to the dryers body.

6. Apply aluminium foil laminated Mineral Wool slab insulation of 100 kg/m3 density and 50
mm thickness. Secure the insulation with the help of insulation pins and speed washer.

7. Finally provide support frame made of M.S. Flat 25 x 3 mm in order to secure and to
make it more compact. All the joints of insulation should be stitched and tighten by
means of stitching and lacing G.I.wire.

8. Fix up the of 1 mm thick aluminium sheet with M.S.frame by means of pop rivets/ self-
tapping screw and also ensure that the overlapping area of aluminium cladding sheets is
closed with an appropriate vapour/ moisture barrier.

9. Fix nuts to head of the bolt fitted on dryers head.

10. Ensure that cladding sheet peripheral end is properly inserted at the dryers periphery
and manhole opening.


Page 40 of 68
Sincethesizeofdryersmayvaryfromplanttoplant,thedimensionsarenotmentionedintentionallyin
theschematicdiagram.

MSBOLTFITTEDONDRYERBODY
DRYERSHAFT
CROSSSECTIONALVIEW OFDRYER
MANHOLE
Page 41 of 68

DETAILINSULATIONDRAWINGBEFOREAPPLICATIONOFCLADDING
Page 42 of 68

ALUMINUMCLADDING
MSNUTFITTEDONMSSTUDWELDEDON
EXISTINGMSBOLTHEADTOHEAD
MSNUTFITTEDONMSSTUDWELDEDON
EXISTINGMSBOLTHEADTOHEAD
MS FLAT
MSFLATSUPPORTRING
ROCKWOOLSLAB(INSULATIONMATERIAL)
DRYERBODYANDSHAFT
ALUMINUMCLADDING
INSULATIONCROSSSECTIONALVIEW(EXCLUDINGMANHOLEAREA)
SPEEDWASHER
INSULATIONPIN
Page 43 of 68
MSSUPPORTDRAWING
HOLESFORSELFTAPPINGSCREWS
HOLESFORSELFTAPPINGSCREWS
HOLESFORMSBOLT
Page 44 of 68
HOLESFORSELFTAPPINGSCREWS
HOLESFORMSBOLT
EXTRASHEETFOROVERLAP
MANHOLE
FRONTANDSIDEVIEWDRAWINGOFALUMINUMCLADDING
Page 45 of 68













APPLICATION PROCEDURE
FOR
THERMAL INSULATION
FOR
PIPING AND EQUIPMENTS

Page 46 of 68
THERMAL INSULATION FOR PIPING AND EQUIPMENTS
1.0 INTRODUCTION
In a thermal power station or process plant, thermal insulation or heat lagging of
piping and equipments carrying hot fluids is essential for hest economy and
protection of operating personnel. Any pip which is at a temperature higher than
it s surroundings will loose heat and the amount of heat lost will depend upon
the temperature of the fluid and the thermal conductivity of the piping
material/covering.
The heat lost through bare pipe increases with
a) Increase in the temperature of fluid conveyed
b) Decrease in ambient temperature and
c) Increase in wind velocity of the surroundings.
The heat so lost hast potential for work and rapidly increasing cost of fuel in the
recent past has promoted to find all possible means to conserve energy.
Providing proper and adequate insulation on to the piping and equipments
controls heat transfer and maintains the required services temperature.
2.0 METHOD OF APPLICATION
The method of application is highly skilled job. Badly fitted/laid insulation can
lead to greater hear loss, higher cold surface temperature than that estimated
and frequent maintenance. Following are the important points to be considered
in the application of the insulation.
2.1 Before applying insulation, it should be ensured that all instrument tappings,
clamps, lugs and other connections on the surface to be insulate d have been
properly installed as per relevant drawings.
2.2 All surfaces to be insulated shall be cleaned of all foreign materials such as dirt,
grease, loose scale, moisture etc.
2.3 Welding of lugs, attachments, clips etc. on the surface to be insulated for
supporting insulation shall not be carried out without the permission of the
authorized person.
2.4 All flanged joints shall be insulated only after final tightening and testing.
2.5 The insulation shall be applied to all surfaces when they are at ambient
temperature.
2.6 Where more than one layer of insulation is involved, mattresses should have
staggered joints (at 60 deg) and they must be held in close contact with face of
Page 47 of 68
pipes/fittings by means of binding wires / Aluminum bands / seals.
Circumferential joints of multilayer insulation should also be staggered by at
least 150 mm.
(Refer Drg. No. PE-4-999-169-01).
2.7 For the first layer of insulation and in case of multi layer of insulation, mattresses
with hexagonal wire netting will be facing on outer side.
2.8 Insulation mattresses shall be held in place by fastening over with binding wire.
Care should be taken to see that the flexible insulation mattresses are not
unduly compressed. The ends of binding wire shall be lightly twisted together,
bent over and pressed into the insulation. For mattresses, binding wire shall be
used at intervals of 300mm.
In the addition Aluminium bands shall also be provided at 300 mm intervals for
diameters greater than 500mm. (Refer Drg No. PE-4-99-169-01.)
2.9 Where junctions between bodies of different diameters occur and difference in
insulation thickness is specified, the greater thickness is to be continued for a
length equal to one diameter of the smaller body and then smoothly tapered to
the required smaller thickness over a length equal to two diameters of the small
body.
2.10 The indicated thickness of insulation are minimum requirement which should be
maintained. Any change in the thickness of the insulation should be done only
after prior approval of the design engineer.
2.11 The day-to-day insulation work should be covered with suitable protective
materials to prevent the rain water entry, if same is expected.
2.12 The insulation shall be cut to fit the piping O.D / equipment and shall be wrapped
on the piping / equipments and held in position with proper support and wires. All
the joints should be properly staggered and tightly butted and adjacent edges
laced (Refer Drg No. PE-4-999/169/01)
2.13 The insulation of valves and flange joints shall be enclosed in a removable
jacketing so that it may be removed without disturbing the concerned equipment
or piping. The thickness of insulating shall be same as that of the pip line in
which these valves and fittings are located. (Refer Drg No. PE-4-999-169-07.)
2.14 Steam / Air / Gas leakages in and around the pipes to be insulated with be
attended before applying insulation.
2.15 In order to provide support to Aluminium cladding, support rings made out of 20
x 3 mm M.S. flats shall be fixed at equal intervals of approximately 850 mm
spacing and at every circumferential joints. These rings shall be fixed with L
Page 48 of 68
type lugs and shall be fabricated from 20 x 3 mm M.S flats. To reduce that
conductivity through these lugs 20 mm x 3 mm size Ceramic mill board shall be
used between rings and lugs (Refer Drg No. PE-4-999-169-04 and PE-4-999-
169-13).
2.16 Spacing between supporting rings for vertical piping shall be 3 mtrs. Support
rings are to be provided only when the vertical height exceeds 3 mtrs.
(Refer Drg No. PE-4-999-169-03-and PE-4-999-169-05).
2.17 For vertical pipes since support rings is provided ate every 3 mtrs interval, only
two spacer rings shall be provided in between support rings.
2.18 Spacer rings shall be provided at both ends of elbows/bends, valves and flanges
pipe having dia more than 89mm.
2.19 Wherever the end of hanger clamp assembly protrudes out of the insulation at
the bottom suitable box structure are to be provided. Pipe hangers and supports
should be covered in such a way that the moisture cannot penetrate into the
insulation.
2.20 It is very important that sheet metal cladding should be done by a well
experienced and competent fabricator. Person doing the job can alter the
method of fixing of cladding sheet after consulting the concerned design
engineer.
2.21 The longitudinal joint in the outer cladding sheet should always be at the lower
half of the circumference for horizontal piping so that no rain water enters the
insulation through the joints. (Refer Drg No. PE-4-999-169-01).
2.22 The joints of outer cladding should be staggered axially.
2.23 Inside surface of all Aluminium sheet will have two coats of Bituminous paint
applied uniformly.
2.24 Aluminium sheets covering on outdoor horizontal pipes will be provided with 3
mm drain hole at the bottom center line at 6 mtr intervals.
2.25 The cladding sheet shall provides directly over the insulation/finishing cement
(1F APPLICABLE). Suitable flashing and weather proofing shall be provided at
all nozzles, manholes and other projections to prevent the entrance of water.
2.26 Loose wool can be taken from wool mattresses. Wherever gaps and voids have
to be filled.
2.27 Sealing compound to be applied on Aluminum cladding sheet joints.
Page 49 of 68
2.28 Support rings/spacer rings shall be provided if the insulation thickness > 40mm
and pipe diameter > 89mm.
2.29 Equipments name plates shall not be insulated.
2.30 Clips made out of sheet be riveted inside the box for insulation of valves and
flanges to hold the insulation in box. (Refer Drg No. PE-4-999-169-06).
2.31 The insulation local to the inspection points of the critical piping shall be
removable.
3.00 For Thermal Insulation Material Specification related to the project refer
Annexure 1.
IMPORTANT POINTS TO BE TAKEN CARE DURING APPLICATION
I) Binding wires for all layers of insulation will be at distance of 300mm.
ii) In addition Aluminum bands/seals also to be provided at distance of 300 mm for
sizes above 500mm.
iii) Aluminum bands/seals to be provided over aluminum sheets at distance of
500mm.
iv) Ceramic mill boards to be used between all L type lugs and the support rings.
v) Inside surface of Aluminum sheets to have 2 coats of bituminous paint applied
uniformly.
vi) Gaps to be properly filled with loose wool taken from mattresses.
vii) End of hanger clamp assembly protruding out of insulation at the bottom should
be suitably boxed with Aluminum sheets.
viii) Valves to be insulated properly in box structure as given in enclosed drawings.
ix) Multilayer longitudinal and circumferential joints should be staggered.
Page 50 of 68
ANNEXURE 1
1.0 Thermal insulating materials shall be per the details given below:-
1.1 Lightly Bonded Mineral (Rock) wool Mattresses of density 150 Kg / Cub. Mt
with S.S. wire netting will be applied for the first layer of insulation where hot
face temperature greater than 400 degree centigrade. For subsequent layers
matters of density 150 Kg / Cub. Mtr with G.S. wire netting will be applied.
1.2 Lightly Bonded Mineral (Rock) wool Mattresses of density 100 Kg/Cub. Mt
with G.S. wire netting will be applied for all layers of insulation for host face
temperature less than and equal to 400 degree centigrade.
2.0 Binding and lacing wires: For insulation matters shall be of stainless steel for
all insulation interface temperatures.
3.0 Aluminum cladding sheet shall be provided over the Mattresses ad per details
given below.
18 SWG (1.22 mm thk.) For pipes with dia over insulation above 450 MM.
20 SWG (0.91 mm thk.) For pipes with dia over insulation above 150 MM
and less than equal to 450MM.
22 SEG (0.71 mm thk.) For pipes with dia over insulation less than equal
to 150mm.
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