Roxul Industrial Insulation Process User Manual

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Industrial Insulation Process Manual

Industrial & Mechanical Installation Guidelines

Overview: ROXUL® Industrial Insulation Solutions

1.2 Insulation of piping 23 1.6 Insulation of boilers 67

1.2.1 Insulation with pipe sections 29 1.6.1 Insulation of fire tube boilers 67

1.2.2 Insulation with pipe wraps (mats) 31

1.2.3 Insulation with wired mats 33

1.2.4 Insulation support 34

1.2.7 Insulation of valves and flanges 40

1.2.8 Insulation of pipe elbows and T pieces 42

1.2.9 Reducers 43

1.2.10 Expansion joints 44

1.2.5 Cladding 36

1.2.6 Pipe hangers and pipe support 39

1.2.11 Tracing 45

1.2.12 Foot traffic 46

1.3 Insulation of vessels 47

1.4 Insulation of columns 53

1.6.2 Supercritical steam generators 69

1.5 Insulation of storage tanks 59

1.7 Insulation of flue gas ducts 75

1.8 Cold boxes 82

Contents

1. System solutions 7

1.1 Planning and preparation 11

1.2 Insulation of piping 23

1.3 Insulation of vessels 47

1.4 Insulation of columns 53

1.5 Insulation of storage tanks 59

1.6 Insulation of boilers 67

1.7 Insulation of flue gas ducts 75

1.8 Cold boxes 82

2. Theory 85

2.1 Norms & Standards 88

2.2 Product properties & test methods 107

2.3 Bases for thermal calculations 120

3. Tables 127

3.1 Units, conversion factors and tables 130

3.2 Product properties insulation and cladding materials 146

3.3 Usage tables 149

4. Products 169

ProRox® PS 960NA 171

ProRox ENERWRAP® MA 960 ProRox® SL 920 ProRox® SL 930 ProRox® SL 940 ProRox® SL 960 ProRox® SL 540 ProRox® SL 560 ProRox® SL 590 ProRox® SL 430 ProRox® SL 450 ProRox® SL 460 ProRox® SL 760 ProRox® FSL 920 ProRox® FSL 930 ProRox® FSL 940 ProRox® FSL 960 ProRox® MA 930 ProRox® MA 940

PS 980

ProRox® GR 903

ProRox ProRox

LF 970

Rocktight

ROXUL® insulation provide superior thermal and acoustical performance and are fire resistant, water repellent, non-corrosive and resistant to mold. Specialists often willingly turn to our products and expertise in industrial and marine & offshore insulation. We have now packaged that expertise into a practical guide: the 'ProRox® insulation Process Manual‘.

This manual offers a transparent overview of our ProRox® product range, including thermal, fire-resistant, compression, comfort/multi-purpose, fabrication and acoustic insulation solutions for technical installations in the process & power generation industries.

The Process Manual is a convenient resource tool with relevant information at your finger-tips. Fold-out sections take you directly to the right page, whether you are looking for straight forward piping insulation or more complex applications for columns, tanks and boilers. In addition to pictures and photographs, a range of tables and diagrams are included.

The ROXUL Process Manual is a helpful tool for the application of our ProRox® industrial insulation solutions in a process environment. Should you need any further information about a specific application, procedure or practical problem, please consult

www.roxul.com or contact your local ROXUL

representative at 1 800 265 6878.

ROXUL

Industrial Insulation

ROXUL  an independent organization with the ROCKWOOL Group - is a leading supplier of high quality stone wool products in the industrial insulation market. With the ProRox® & SeaRox® lines for the industrial market and for the marine & offshore industry, our experts provide a full range of products and systems for the thermal, acoustic and firesafe insulation of industrial installations. ROXUL continuously monitors the market developments. Our 75+ years of global experience is reflected in a complete set of high-grade products and expert advice. Today, we remain fully committed to providing the very best service in the market and a total range of cutting-edge insulation solutions.

The ROXUL® Industrial Insulation Process Manual

Know-how for designers, engineers, site supervisors and managers of industrial plants

Energy keeps the world in motion. Without it, everything would come to a standstill. The global economy is dependent upon a secure & efficient supply of energy. Over eighty percent of the energy currently being consumed is obtained from nonrenewable resources. Those resources are becoming increasingly scarce, while at the same time the demand for energy is exploding. This means that owners, designers and operators of large, industrial plants are challenged with the task of reducing their energy consumption as much as possible in order to ensure the long term sustainability of their operations.

Solar energy is just one of the possible alternatives. Through, for example, solar power plants we already succeed in converting concentrated sunlight very efficiently into electricity. And this is just one of the solutions that can help us drive down fuel consumption and carbon emissions.

On top of that, insulation significantly reduces the energy needed to manufacture a product or provide a service. Also, new technologies for emission controls at existing fossil burning facilities is greatly enhanced by insulation. Nowadays there are a variety of efficient insulation systems that enable scarce

energy reserves to be put to the best possible use. The ROXUL Industrial Insulation Process Manual illustrates these systems both theoretically and practically. This process manual targets designers, engineers, installers and managers of industrial plants and provides an overview of the modern insulation techniques for, by way of example, chemical or petrochemical installations and power generation facilities. Based on current standards and regulations the manual provides accessible, practical guidelines for the implementation of numerous insulation applications.

Restriction of thermal losses to an absolute minimum, including during transfer or storage, can considerably reduce the energy consumption of industrial plants. This also results in a reduction in carbon dioxide (CO²) emissions, which are created each time fossil fuels such as coal or gas are burnt and which, as a greenhouse gas, is responsible for the global increase in temperature.

From an environmental perspective, adequate insulation of industrial plants is a significant means of reducing (CO²) emissions.

In addition, the right insulation keeps temperatures, for example in pipes and storage tanks, within strict tolerances, thereby ensuring reliable process efficiency. At the same time, adequate insulation protects the plant itself. Modern insulating materials can thoroughly protect plant components from moisture and associated corrosion. Installation and process maintenance costs can be reduced considerably and the effective lifetime ofindustrial plants can be successfully maximized.

Furthermore, industrial insulation also provides a significant contribution to personnel protection. Optimum insulation reduces process temperatures and noise in the industrial environment to an acceptable level, to the limits generally regarded in the industry to be those required for a safe and comfortable working environment.

With a complete range of techniques and insulation systems, ROXUL® offers designers, engineers and construction supervisors optimum tailored solutions for the petrochemical, power generation, ship building, offshore and processing industries.

In the 'Flow of Energy' diagram on the following page, you will find an overview of all of the sectors in which ROXUL is active. All of our ProRox® (and SeaRox®) products, such as pipe sections and boards (slabs) are designed to meet the highest quality and safety standards and comply with the strictest, and therefore safest, fire safety classes. Stone wool is non flammable, non combustible and can withstand temperatures up to 2150 °F (1177 °C) and therefore provides a crucial contribution towards passive fire protection.

As a supplement to this process manual, ROXUL also regularly provides infor mation about technical innovations, product solutions and recent and relevant documents available online at our website

www.roxul.com. NOTE: The process manual is a

guideline and can only provide general advice for specific instances in the field of plant and processes. For these instances, the ROXUL Technical Services Team is available to provide advice during the design, engineering and implementation phases. Please find our contact details on the back cover of this manual.

ROXUL® Industrial Insulation, Flow of Energy

Exploration, drilling and production

Sun

Waste

Coal

Gas

Oil

Flow of energy

Business Areas:

ProRox® insulation for industry:

Our ProRox® product line covers all our thermal, fire-resistant, compression, comfort/multi-purpose, fabrication and acoustic insulation solutions for industrial installations in the process industry.

insulation for shipbuilding and offshore:

SeaRox

SeaRox® comprises the full marine and offshore product line. This sharp focus enables us to combine our expertise and extensive experience like never before to develop outstanding insulation solutions for our customers.

ProRox

Petroleum Rening Processing

Gas Processing

Petrochemicals

Solar Power Plant

Power Plant

End Products

Marine

Oshore

Processing industry

Industrial

Residential

Consumption

Non-residential

SeaRox

System solutions

Industrial insulation

System

solutions

1. System solutions

Table of contents

1.1 Planning and preparation 11

1.1.1 Decision criteria for the design of an insulation system 11 A. Functional requirements 12 B. Safety aspects 16 C. Economics 17 D. Environmental 18 E. Corrosion Prevention 18

1.1.2 Design & planning of the insulation work 19

1.1.3 Corrosion prevention 19

1.1.4 Storage of insulation materials 22

1.2 Insulation of piping 23

1.2.1 Insulation with pipe sections 29

1.2.2 Insulation with pipe wraps (mats) 31

1.2.3 Insulation with wired mats 33

1.2.4 Insulation support 34

1.2.5 Cladding 36

1.2.6 Pipe hangers and pipe supports 39

1.2.7 Insulation of valves and flanges 40

1.2.8 Insulation of pipe elbows and Tpieces 42

1.2.9 Reducers 43

1.2.10 Expansion joints 44

1.2.11 Tracing 45

1.2.12 Foot traffic 46

1.3 Insulation of vessels 47

1.4 Insulation of columns 53

1.5 Insulation of storage tanks 59

1.6 Insulation of boilers 67

1.6.1 Insulation of fire tube boilers 67

1.6.2 Supercritical steam generators 69

1.7 Insulation of flue gas ducts 75

1.7.1 Installation of the insulation systems for flue gas ducts 75

1.7.2 Cladding of flue gas ducts 78

1.7.3 Acoustic insulation of flue gas ducts 81

1.8 Cold boxes 82

Notes

1. System solutions

1.1 Planning and preparation

preparation

Planning and

The design of a suitable insulation system for industrial installations is a major factor for its economical operation, functionality, security, durability and environmental impact. Additionally, the installation-specific heat losses are specified for the entire life cycleof the plant. Corrections at a later stage, such as subsequently increasing the thickness of the insulation, for example, may no longer be possible due to lack of space. Corrections at a later stage may also entail a far greater investment compared to the original planning. Continually rising energy costs are also often overlooked factors when dimensioning the insulation. Insulation thicknesses that are designed to last take energy price increases into account. They form an important criterion for the economical operation of the installation after just a few years.

Properly dimensioned insulation systems constitute an important contribution to environmental protection, carbon dioxide (CO²) reduction and to economic success. CO² reduction is also an economical operation, as it lowers the costs for CO² emission certificates. Nowadays, conservational and economical operations are no longer conflicting ideas, but are two inseparable parameters.

1.1.1. Decision criteria for the design of an insulation system

Selecting a suitable insulation system depends on the following five parameters:

1. Functional requirements a. Object dimensions b. Operation of the installation c. Operating temperatures d. Permissible heat losses or temperature

changes ofthe medium e. Frost protection f. Ambient conditions g. Maintenance and inspection

2. Safety aspects a. Personal protection b. Fire protection c. Explosion prevention d. Noise reduction within the plant

3. Economics

a. Economical insulation thickness

b. Pay-back time

4. Environment

5. Corrosion prevention

1.1 Planning and preparation

A. Functional requirements

a) Object dimensions

The space requirements of the insulation must be taken into account when the installation is being designed and planned. Therefore, the insulation thicknesses should be determined in the early planning stages and the distances between the individual objects should be taken into account in the piping isometrics. To guarantee systematic installation of the insulation materials and the cladding without increased expense, observe the minimum distances between the objects asspecified in the following illustrations.

Minimum distances between vessels and columns; dimensions in inches (mm)

31.5” (800)

40” (1000)

4” (100)

Minimum distances between insulated pipes; dimensions in inches (mm)

preparation

Planning and

4” (100) 4” (100) 4” (100)

Minimum distances within range of pipe flanges; dimensions in inches (mm)

4” (100)

a = distance flange to normal insulation a ≥ 2" (50 mm) x = bolt length + 1.2" (30 mm) s = insulation thickness

1.1 Planning and preparation

A. Functional requirements

b) Operation of the installation

To select a suitable insulation system, the operating method of the installation must be considered. A basic distinction is made between continuous and interrupted operation. With continuous operation, the operating temperatures are constantly above or constantly below the ambient temperatures. The interrupted operating method, also referred to as intermittent or batch operation, is characterized by the fact that the installation is switched off between each operating phase and during that time can assume ambient temperatures. For special applications, e.g. dualtemperature systems, the operating temperature alternates above or below the ambient temperature.

c) Operating temperature

The appropriate insulation material should be resistant to the intended operating/peak temperatures. Thisproduct property is assessed by the maximum service temperature (also see Chapter 2.2 “Product properties & test methods”).

d) Permissible heat losses or temperature

changes ofthemedium

With many technical processes, it is essential that media in vessels, columns or tanks do not fall below a specific lower temperature limit, otherwise chemical processes will not proceed as intended or the media will set and can no longer be pumped or extracted. Over-cooling can lead to the precipitation of, for example, sulphuric acid in exhaust and flue gas streams, which promotes corrosion in the pipes or channels. With flowing media, it is essential to ensure that the temperature of the medium is still at the desired level at the end of the pipe. The thermal insulation is designed according to these requirements. Under extreme conditions (e.g. lengthy periods of storage, longtransport routes or extreme temperatures), installing tracing may be necessary, to ensure that the media is kept within the required temperature limits.

Thermo-technical engineering calculation programs like NAIMA's 3E Plus® or ROXUL's "ROCKASSIST" (coming soon) can aid in ensuring the optimum engineering and design of these insulation systems. More information can be found on our website www.roxul.com. For special situations please contact the ROXUL® Technical Services Team for further guidance.

Inside buildings, uninsulated or poorly insulated parts of installations unnecessarily increase room temperatures, which can have a negative effect on the working environment - both for the people who work long hours under these conditions and for the electronic components. In addition to the increased heat loss, the need for climate controlled rooms requires further energy consumption. The design of the insulation and the related reductions in terms of heat loss from parts of installations should be relevant to the entire infrastructure and use of the building.

e) Frost protection

Installations that are situated outside are at risk from frost in the winter. In addition to the malfunctioning of installations, installations also risk damage caused by the expansion of frozen water. Adequate measures against frost protection are critical to protect the installation from freezing. Insulation can reduce heat loss and aid in frost protection. Insulation alone cannot indefinitely prevent the installation from freezing. Installing additional tracing may be necessary between the object and the insulation. To prevent freezing, the insulation must be designed so the heat flow rate of the insulated object is less than the heat provided by the tracing.

f) Ambient conditions

Select an insulation system that offers long-lasting resistance to the surrounding environme nt.

Atmospheric influences: wind, rain Mechanical loads such as vibrations or

foottraffic

Corrosive environment (proximity to sea,

chemicals,…)

an air space of at least 2/3” (15 mm) between the insulation and the cladding, and create 0.4” (10 mm) diameter ventilation and drain holes in the covering at intervals at a maximum of 12" (300 mm). If necessary, the insulation and cladding must resist chemical influences that develop within the environment. Installations operating below ambient temperatures have a high risk of moisture condensing from the ambient air inside the cladding. Use a continuous vapor retarder on piping operating below ambient temperatures and seal all joints, surfaces, seams and fittings to prevent condensation (use of staples is not recommended).

g) Maintenance and inspection

To avoid complicating routine maintenance and inspection work unnecessarily, maintenanceintensive areas must be taken into account, especially when designing the insulation work. Removable insulation systems, such as removable coverings and hoods, could be fitted in such areas, for example. Easily removable covering systems are also recommended for flanges and pipe fittings. These coverings are generally fastened with quick-release clamps, which can be opened without special tools. The insulation of fixtures such as flanges or pipe fittings must be interrupted at a sufficient distance to allow installation or dismounting to be carried out. In this case, take the bolt length at flange connections into consideration. Any fixtures in the range of the insulation, including the interruption in the installation, should be insulated with removable coverings overlapping the insulation and maintaining continuity across the fixture.

preparation

Planning and

Moisture accumulation in insulation increases thermal conductivity and the risk of corrosion of the insulated installation components. Cladding must be installed to prevent the ingress of moisture into the system. If the ingress of moisture into the insulation is unavoidable, retain

1.1 Planning and preparation1.1 Planning and preparation

B. Safety aspects

a) Personal protection

Surface temperatures in excess of 140 °F (60°C) can lead to skin burns, if the surface is touched. Therefore, all accessible installation components should be designed to protect personnel and prevent injuries. The insulation applied to such plant components must ensure that surface temperatures in excess of 140 °F (60°C) do not occur during operation. Consult our Technical Services Team to determine the required insulation thickness to aid in personnel protection. All of the operational parameters must be known to achieve a reliable design, including, for example, the temperature of the object, the ambient temperature, air movement, surface materials, distance from other objects, etc.

NOTE

As the surface temperature depends on a set of physical parameters, which cannot always be calculated or estimated with any degree of certainty, the surface temperature is not a guaranteed measurement. If the required protection (temperature) cannot be achieved by insulation, apply additional protective devices, such as safety guards or enclosement of theobject.

companies and the operator.

As a basic principle, consider the fact that the fire load in a building or industrial installation can be considerably increased by flammable insulation materials. On the other hand, non-flammable insulation materials such as mineral wool (stone wool), which has a melting point of >2150 °F (>1,177 °C), not only have a positive impact on the fire load, but in the event of a fire, also constitute a certain fire protection for the installation component.

b) Fire protection

The general fire protection requirements imposed on structural installations are usually defined within the local Building Codes or the specifications of plant owner. Structural installations must be designed, built, modified and maintained to prevent the outbreak of a fire and the spread of fire and smoke. In the event of a fire, the rescuing of people and animals and effectively extinguishing the fire must be made possible. During the design of the installation, it is vital to determine the nature and scope of the fire prevention measures together with the building supervisory board, the fire department, insurance

Installation components with tracing, in particular, which use thermal oil as a heat transfer medium, have an increased risk of catching fire in the event of a leak. In this case, ensure that the thermal oil cannot penetrate into the insulation material.

c) Explosion prevention

If there is a risk of fire and explosion, the surface temperature of the object and the cladding must be considerably lower than the ignition temperature of the flammable substance and/or gas mixtures. This requirement also applies to thermal bridges, such as pipe mounting supports, supporting structures and spacers etc. With regard to insulation systems, explosion

preparation

Costs

Planning and

protection can only be achieved with a doubleskin covering. A doubleskin covering is a factory made cladding that has been welded or soldered to make it air proof and diffusion-resistant. In addition special (local) explosion regulations must be observed.

In explosive areas electrostatically charged substances like unearthed cladding or nonconductive plastics must be grounded (earthed). For further guidance please consult your local safety guidelines relating to static electricity.

d) Noise protection

The guidelines for noise in the ordinance and workplace are stated in the local regulations and standards. Generally, the level of the guideline values depends on the nature of the activity.

C. Economics

In the industry there are two grades of insulation. The first grade focuses on reducing heat losses and the prevention of injuries to people operating or working nearby the installations. The second grade of insulation, the so called “economical insulation thickness” focuses on significant heat loss reduction and as a result achieving a better return on investment.

a) Economical insulation thickness

Insulation reduces the heat losses from the object. Thethicker the insulation, the greater theheat reduction and consequently, the more energy is saved. However, the investment and expenditure, e.g. for depreciation, interest rates and higher maintenance costs also rise ifthe insulation thickness is increased. At a certain insulation thickness, the sum of the two cost flows reaches a minimum. This value is known as the economical insulation thickness. Aqualitative curve of a similar costs function is shown below.

Economical

insulation

thickness

Total costs

The sound propagation of installation components can be reduced using insulation systems. The nature and effect of the sound insulation depend onthe frequency and the sound pressure level.

Insulation costs

Heat loss costs

Insulation thickness

The energy costs cannot be based solely on the current price. Developments over recent years indicate energy costs will continue to rise.

1.1 Planning and preparation1.1 Planning and preparation

C. Economics

Increasing energy prices are tending to bring about a shift in economic insulation thicknesses towards larger thicknesses.

b) Pay-back time

In addition to the economical insulation thickness, another frequently used economical parameter is the return on investment period (ROI), also referred to as the payback period. This is defined as the period within which the cost of the insulation is recuperated through savings on heat loss costs.

ROI period =

In the case of industrial insulation systems, the return on investment period is generally very short, often being much less than one year. Considering only the return on investment period, however, can be deceptive, as this approach disregards the service life of the installation. With long-life installations, it is advisable to select higher insulation thicknesses, even if this means accepting a longer return on investment period. Throughout the entire service life of the installation however, the increased insulation thickness results in a significantly higher return on the investment in insulation and achieves a much more economic operation of the installation.

Costs of the insulation

annual saving

[a]

D. Environmental

The burning of fossil fuels, such as coal, oil or gas, not only depletes the available primary energy sources, but also, due to the emission of carbon dioxide (CO²) into the atmosphere, places aburden on the environment.

The increasing CO² concentration in the Earth’s atmosphere plays a significant part in the global increase in temperature, also referred to as the “greenhouse effect”. CO² absorbs the thermal radiation emanating from the earth’s surface andin doing so reduces the dissipation of heat into space. This is leading to a change in the world’s climate with as yet inestimable consequences. Reducing CO² emission can only beachieved through more efficient management of fossil fuels. Increasing the insulation thicknesses is essential for the reduction of CO² emissions.

Reducing CO² emissions also has a positive financial benefit for businesses within the context of an emissions trading scheme. The benefits of increased insulation thicknesses in industrial installations are twofold, as the costs for both energy consumption and CO² emissions are decreased.

E. Corrosion Prevention

See Chapter 1.1.3

preparation

Planning and

1.1.2 Design & planning of the insulation work

Requirements for insulation work must be included in the design and construction phase of industrial plants. It is advisable to involve all project managers at an early stage to avoid unnecessary issues or delays.

All preparatory works must be completed according to the relevant insulation standards. The following preconditions must be fulfilled:

If necessary, work has been carried out on the

object to protect against corrosion

Tracing and technical measurement equipment

have been installed

The minimum distance between the objects

hasbeen observed (see illustrations on pages

12and 13) Surfaces have no coarse impurities Mounting supports have been installed on the

object to accommodate the support structure Collars and sealing discs have been fitted to

theobject Taps on the object are long enough to ensure

that flanges lie outside the insulation and can

be screwed on without hindrance Supports are designed so that insulation,

watervapor retarders and cladding can be

professionally installed The insulation can be applied without any

obstacles (e.g. scaffolding) Welding and bonding work has been carried out

on the object The foundations have been completed

1.1.3 Corrosion prevention

Industrial facility disruptions are due to the lack of, or inadequate forms of, protection against corrosion. This considerably reduces the service life of industrial plants, and more frequently, essential shutdown or overhaul work impairs the efficiency of the installation. It is commonly, but wrongly, assumed that the insulation system also protects an installation against corrosion. For each installation it must be determined whether protection against corrosion is required and, if so, which are the appropriate measures.

Generally, the design of the insulation system & corrosion protection will depend on the following parameters.

Operation of the installation

- Continuous operation

- Interrupted/intermittent operation

- Operation involving varying temperatures

- Type of plant (e.g. Petrochemical, pharmaceutical, etc)

Operating and Ambient temperatures of the

installation

Metals and Materials Used

- Non-alloy or low-alloy steel

- Austenitic stainless steel

- Copper External influences upon the installation

- Environment of the installation (chemically

aggressive?)

- Location

The best practices may vary per country and/or standard. The design of corrosion protection is often carried out on the basis of a small selection of standards, such as ASTM C795, that do not adequately take into account all the specific features of protecting against corrosion in insulation systems. For further details on corrosion protection we recommend referring NACE SP0198 and the ROXUL® Corrosion Under

Insulation (CUI) brochure.

1.1 Planning and preparation1.1 Planning and preparation

1.1.3 Corrosion prevention

In the case of cold insulation, if the object is

made of non-alloy or low alloy steel, it must be protected against corrosion.

In the case of objects made, for example, of

austenitic stainless steel or copper, the installation must be tested in each individual case by the planner to determine whether protection against corrosion is necessary.

Objects made from austenitic stainless steel do

not require protection against corrosion if the temperature never – even for a short period – exceeds 120 °F (50 °C)

NOTE

Protection against corrosion should be applied in the case of all installations made from non-alloy or low-alloy steel where the operating temperatures are below 250 °F (120 °C). Protection against corrosion may be omitted in the case of:

Installations operating continuously under

extremely cold conditions [below -50 °F (-50 °C)] such storage tanks.

Insulated surfaces of power plant

components, such as boiler pressure components, flue gas and hot air ducts and steam pipe systems with operating temperatures that are constantly above

250 °F (120 °C).

If austenitic stainless steel is insulated with any type of insulation - For temperatures of up to 930 °F (500 °C), aluminum foil of not less than .06 mm thick to be applied to the steel surface, arranged to shed water with overlaps of not less than 2" (50 mm) at the joints.

CINI Manual “Insulation for industries”

CINI recommends applying corrosion protection prior to the insulation work at any time.

In all phases, pay attention to CUI (corrosion

under insulation) prevention: design, construction, paint & coating work, application of the insulation system, inspection and maintenance. Equipment and piping sections like nozzles, supports etc. should be designed and maintained to prevent ingress of water into the insulation system.

The “paint” specifications are split up into:

Construction material (carbon steel, stainless steel)

- Temperature ranges from -22 °F (-30 °C) to 1000 °F (540 °C) with special attention to the temperature range between 0 °F (-20 °C) and 300 °F (150 °C).

The corrosion protection can be achieved using

aluminum foil wrapping, thermal sprayed aluminum (TSA) or paint.

Protection against corrosion may be omitted in the case of installations operating continuously under extremely cold conditions [< -22 °F (-30 °C)]

Application

Before applying corrosion protection coating, the surface must be free from grease, dust and acid and, for better adhesion, the priming coat should be roughened. Blasting is recommended as a surface preparation method (with austenitic stainless steel, use a ferrite free blasting abrasive). Observe the corresponding processing guidelines of the coating manufacturer. If metals with different electrochemical potentials, such as aluminum and copper, come into contact with one another, there is a risk of electrochemical corrosion. If necessary, this can be avoided using insulating, intermediate layers such as nonmetallic straps. The presence of moisture will increase the development of electrochemical corrosion.

preparation

Planning and

The table further on this page, which has been derived from the standard DIN 4140, indicates the initial risks of electrochemical corrosion in cases where various combinations of metals are used.

Electrochemical Corrosion Potential

Material Combination material

Metal

Zinc

Aluminum

Ferritic steel

Lead

Austenitic stainless steel

Copper

Surface ratio in proportionto

combinationmaterial

Small - M M H H H

Large - L L L L L

Small L - L H H H

Large L - L M L H

Small L L - H H L

Large L L - L L L

Small L L L - H H

Large L L L - M M

Small L L L L - M

Large L L L L - L

Small L L L L L -

Large L L L L L -

Zinc Aluminum

NOTE

The table does not take into account forms ofcorrosion with other root causes, such as stress corrosion. For further information, see Chapter 2.2 “Product properties & test methods” – AS-Quality on page 115.

Ferritic

steel

Lead

Austenitic

stainless

steel

Copper

L - Light or little corrosion to material M - Moderate corrosion to material, for example, in very humid atmospheres H - Heavy electrochemical corrosion to material

Observation: The table shows the corrosion of the “material”, and not that of the “combination material”. “Light” means: “small-scale in proportion to the combination material”, “heavy” means: “large-scale in proportion to the combination material”.

Example 1: Material is a zinc galvanized screw in combination material, a cladding made from austenitic stainless steel: Row “zinc small”: “H” – heavy corrosion of the screw.

Example 2: Material , a cladding made from austenitic stainless steel screwed on with a screw galvanized with combination material zinc: Row “austenitic stainless steel large”. “L” – the corrosive attack upon the austenitic steel is light.

1.1 Planning and preparation

1.1.4 Storage of insulation materials

Incorrect storage of insulation materials outdoors can cause insulation to deteriorate. Insulation should be protected when stored, during installation and when fitted to minimize moisture exposure, physical damage and contamination. If storage indoors is not possible, protect the insulation material from weather influences by covering it with waterproof material. Insulation should also be stored a minimum of four inches above ground and kept on a solid surface away from ponding water and ground moisture.

Moisture causes many types of corrosion that virtually never develop in a dry system. The major types of corrosion in relation to insulation technology are oxygen, electrochemical and stress corrosion. Insulation materials that are manufactured with properties (such as low chloride content or added inhibitors) can irrevocably lose these properties when exposed to contamination or additives are leached out.

The thermal conductivity of water is approximately 25 times greater than that of air. An increase in moisture therefore results in an increase in the thermal conductivity of the insulation and, correspondingly, a decrease in the insulation efficiency. Higher moisture can also mean a significantly higher weight, which, as a rule, is not taken into account in the static design of an insulation system. It is therefore important to protect the insulation from moisture after installation, as well as ensure insulation is thoroughly dry when installed (especially in sealed application at low temperatures or where the temperature cycles).

1. System solutions

1.2 Insulation of piping

Piping plays a central role in many industrial processes in chemical or petrochemical installations such as power plants, as it connects core components such as appliances, columns, vessels, boilers, turbines etc. withone another and facilitates the flow of materials andenergy. Toguarantee a correct process cycle, the condition of the media within the pipes must remain within the set limitations (e.g. temperature, viscosity, pressure, etc.). In addition to the correct isometric construction and fastening of the piping, the piping insulation also has an important function. It must ensure that heat loss are effectively reduced and that the installation continues to operate economically and functionally on a permanent basis. This is the only way to guarantee the maximum efficiency of the process cycle throughout the design service life without losses as a result of faults.

Requirements for industrial piping

The basic efficiency and productivity factors of piping for the processing industry include: energy efficiency, dependability and reliability under different conditions, functionality of the process control, appropriate support structure suitable for the operating environment, as well as mechanical durability. The thermal insulation of piping plays a significant role in fulfilling these requirements.

Thermal insulation

The functions of proper thermal insulation for piping include:

Reduction of heat losses (cost savings) Reduction of CO² emissions Frost protection Process control: ensuring the stability of

theprocess temperature Noise reduction Condensation prevention Personnel protection against high temperatures

ProRox® products for pipe insulation

ROXUL Inc offers a wide range of high-quality stone wool insulation products for the insulation of industrial plants. These products are part of our extensive ProRox® range for industrial insulation. With this specific field of application in mind we developed our pre-formed pipe sections and pipe wrap (mat) products for pipe insulation. All these products are easy to install and contribute to a high level of efficiency, functionality and reduced heat losses. Continuous internal and external inspection and high levels of quality assurance ensure the consistently high quality ofall ROXUL® products.

The examples of use below cannot fully take into account the particular circumstances of the construction-related factors. Determine whether the products are suitable for the corresponding application in each individual case. If in doubt, consult the ROXUL Technical Services Team.

The applicable standards and regulations must also be observed. A few examples follow:

NACE SP0198 (Control of corrosion under thermal insulation and fireproofing materials - a systems approach)

MICA (National Commercial & Industrial Insulation Standards)

DIN 4140 (Insulation works on technical

industrial plants and in technical facility equipment)

AGI Q101 (Insulation works on power plant

components) CINI-Manual “Insulation for industries” BS 5970 (Code of practice for the thermal

insulation of pipework, ductwork, associated equipment and other industrial

installations)

of piping

Insulation

1.2 Insulation of piping

Hot insulation systems

Principally, a thermal insulation structure for piping consists of an appropriate insulating material, usually covered by sheet metal cladding. This protects the object and the insulation from external influences such as the weather and mechanical loads. Spacers are also essential with insulation such as wired mats, which do not offer sufficient resistance to pressure to hold the weight of thecladding and other external loads. These spacers transfer the cladding loads directly onto the object. In thecase of vertical piping, support structures are fitted totake on the loads of the insulation and the cladding. Ingeneral, support structures and spacers form thermal bridges.

Selecting a suitable insulation system depends on numerous parameters. These are described in greater detail in Chapter 1.1. Regarding the different forms of pipe insulation, a fundamental distinction can be drawn between the following insulation systems.

Insulation with pipe sections

Generally, the best insulation is achieved using ProRox® Pipe Sections and can be used up to temperatures of 1400 °F (760 °C) when using ProRox® PS 980NA Type V insulation. They are supplied ready split and hinged for quick and easy snap-on assembly and are suitable for thermal and acoustical insulation of industrial pipe work. Due to their excellent fit and high compression resistance, pipe sections can often be applied in asingle layer without any additional spacers. If multiple layers are required, ROXUL® can also supply double layered - ‘nested’ - pipe sections. This reduces installation costs considerably. Also the number of thermal bridges, which have a negative influence on the insulation, is greatly reduced, while a lower thickness may be applied compared to wired mats.

Using pipe sections for the insulation of pipes results in considerably reduced installation time and costs. The lack of spacers and “unforeseen”

gaps minimizes heat losses and the risk of personal injuries due to hot spots on the cladding. At temperatures above 550 °F (300 °C), the provisional application of spacers must be determined in each individual case.

Pipe sections are always precisely tailored to the corresponding pipe diameter to minimize the risk of convection and processing defects. ROXUL pipe sections are available in diameters of NPS 1/2" (23 mm) to NPS 28" (713 mm).

Insulation with load-bearing pipe wraps (mats)

Load-bearing pipe wraps (mats), such as ENERWRAP® MA 960NA are the latest development in the insulation sector. ENERWRAP® MA 960NA is a stone wool (mineral wool) insulation wrap available with a black mat or reinforced foil facing and is designed for easy installation of large diameter pipes. Typical applications include:

pipe diameters >NPS 12" (326 mm), or; piping with a high number of shaped pieces

such as elbows or T-joints.

ENERWRAP® MA 960NA can be applied up to temperatures of 1200 °F (650 °C). It is highly compression resistant and can be applied without any additional spacers.

Consequently the number of thermal bridges, which have a negative influence on the insulation, is greatly reduced.

Pipe insulation with wired mats has been a time-tested universal solution for many decades now. Due to their flexibility and high temperature resistance, wired mats can be easily cut and mounted onto piping. Wired mats are ideal for application in situations where the use of pipe sections or load bearing wraps (mats) is difficult or impossible. Historically this included large diameter pipes and high temperatures (where the wired mat provided structural integrity to the insulation at high temperatures), but advanced modern ProRox® pipe section and ProRox® pipe wraps (mats) have provided a suitable alternative to wired mats. Wired mat is still used today in piping with a high number of shaped pieces such as elbows or T-joints.

Wired mats have a relatively low resistance to pressure and from a practical point of view should only be mounted in combination with spacers or support structures. Because of the resulting thermal bridges, better insulation performances are often achieved in thelower and middle temperature range [up to 550 °F (300 °C)] with pipe sections or load bearing wraps (mats).

of piping

Insulation

The result is considerably reduced installation time and costs. The lack of spacers and “unforeseen” gaps minimizes heat losses and the risk of personal injuries due to hot spots on the cladding. corresponding length of the pipe circumference on site and are fastened with clamps.

Pipe wraps (mats) are tailored to the

Insulation with wired mats

Wired mats, are lightly bonded stone wool wraps (mats), usually stitched with galvanized wire onto a galvanized wire mesh. For more details on ProRox® wired mat insulation products, contact your ROXUL® representative.

1.2 Insulation of piping

Comparison of the different insulation systems

The particular advantage of pipe sections and pipe wraps (mats) lies in the fact that support structures are not required and therefore thermal bridges caused by the insulation are minimized or removed. On the other hand, wired mat systems have their advantages due to their ability to be structurally sound when insulating around irregularly shaped pipe sections.

The advantages of pipe sections and load-bearing pipe wraps (mats) at a glance are:

It is not necessary to install spacers or support

structures.

Faster application without the interference of

spacers.

Both products offer an even, firm surface for

installing the sheet cladding.

Insulation system with a spacer ring

The lack of spacers gives rise to lower heat

losses.

It yields an even surface temperature across

the sheet cladding.

In comparison to wired mats, a more shallow

insulation thickness can be applied. Theoperating costs of the installation decrease as a result of lower heat loss.

Generally speaking, a spacer or support structure functions as a thermal bridge, as a result of which theheat loss in the total insulation is increased considerably.

1. Pipe - 2. Insulation: ProRox® Wired Mats - 3. Cladding - 4.Spacer ring

Insulation system without a spacer ring

1. Pipe - 2. Insulation: ProRox® Pipe Sections or Pipe Wraps (Mats): ENERWRAP® MA 960NA - 3. Cladding

Required insulation thicknesses

If the three insulation systems are compared, taking into consideration similar heat losses, clear advantages are seen with regard to the insulation thicknesses with systems using pipe sections or pipe wraps (mats). These do not use spacers, in contrast to insulation systems made using wired mats. The table below shows the required insulation thicknesses taking into account the following boundary conditions:

Medium temperature: 480 °F (250 °C) Ambient temperature: 50 °F (10 °C) Wind speed: 1.1 mph (5 m/s) Cladding: Aluminum Heat loss: 150 BTU/ft.hr (150 W/m) Application of spacers in the case of wired mats

of piping

Insulation

Minimum Insulation Thickness

ENERWRAP® MA 960

Wired mats

NPS

(inch)

Pipe Diameter

Nominal diameter

Ø DN

Pipe diameter

(mm)

Pipe sections Pipe wraps (mats)

PS 960

ProRox

inch inch inch

2 50 60 1" n.a. n.a.

3 80 89 1" n.a. n.a.

4 100 108 1.5" n.a. n.a.

6 150 159 2" n.a. n.a.

8 200 219 2.5" n.a. 5"

10 250 273 3" n.a. 6"

12 300 324 4" 4" 7.5"

14 350 356 4.5" 4.5" 8"

Multiple layer insulation n.a. = not applicable

1.2 Insulation of piping

Selection of pipe insulation systems

Generally, the best insulation is achieved using ProRox® Pipe Sections. The preformed sections are quick and easy to install. Their excellent fit and high compression resistance means pipe sections can be applied in a single layer without any additional spacers. They also have a lower insulation thickness. Pipe wraps (mats), are usually applied for the insulation of large pipe diameters and can be applied to shaped pieces like elbows and T-joints.

Comparison

ProRox

pipe sections and pipe wraps (mats) offer theadvantage that spacers are generally not required.

ProRox

pipe sections and pipe wraps

(mats) are applied more quickly without the inter ference of spacers.

Both products offer an even, firm surface

for installing the cladding. The lack of spacers creates lower heat loss. It yields an even surface temperature

across the cladding. In comparison to wired mats, a more

shallow insulation thickness can be used.

With a same insulation thickness, the

operational costs of the installation

decrease as a result of lower heat losses.

Generally speaking, a spacer or support structure functions as a thermal bridge, as a result of which the heat loss in the total insulation is increased considerably.

The design of an insulation system depends upon many factors such as the dimensions, mechanical loads, safety aspects, economics, etc. Consequently this also requires a considered selection of the insulation material.

1.2.1 Insulation with pipe sections

Generally, the best insulation is achieved using ProRox® Pipe Sections. The sections can be used up to temperatures of 1400 °F (760 °C) when using ProRox® PS 980NA Type V insulation. They are supplied ready split and hinged for quick and easy snap-on assembly and are suitable for thermal and acoustic insulation of industrial pipe work. Their excellent fit and high compression resistance means pipe sections can be applied in a single layer without any additional spacers or support structures. Consequently the number of thermal bridges, which have a negative influence on the insulation, is greatly reduced, while a low thickness may be applied compared to wired mats. The result is considerably reduced installation time and costs. The lack of spacers and “unforeseen” gaps minimizes heat loss and the risk of personnel injuries due to hot spots on the cladding.

At temperatures above 550 °F (300 °C), the provisional application of spacers must be determined in each individual case. ProRox® Pipe Sections are available in a wide range of diameters, ranging from NPS 1/2" (23 mm) to 36" (914 mm)

NOTE

ue to their low thermal conductivity, better thermal insulation values can be achieved with pipe sections than with wired mats. With insulation on straight pipe sections, a combination of both products in the same insulation thickness is therefore not advisable. If this combination is essential, for example, in the case of bends or shaped pieces, it is vital to select the correct insulation thickness. This is the only way to guarantee that no unexpected, potentially hazardous surface temperatures occur.

Insulation thicknesses to guarantee protection against contact

The table below is an initial guide to help select suitable insulation thicknesses for the guards. Itisbased on the following boundary conditions:

Ambient temperature: 75 °F (25 °C) Wind speed: 1.1 mph (0.5 m/s) Cladding: Aluminum Maximum surface temperature: 140 °F (60 °C) Insulation: ProRox® PS 960

pipe sections

of piping

Insulation

Pipe Diameter Temperature

Nominal

NPS

(inch)

he thicknesses mentioned above should be seen as an indication. In the event of differing boundary conditions, please

T contact the ROXUL or NAIMA 3E Plus

diameter

Ø DN

1 25 33 0.5" 0.5" 0.5" 0.5" 1" 1" 1" 1"

2 50 60 0.5" 0.5" 0.5" 1" 1" 1" 1.5" 1.5"

3 80 89 0.5" 0.5" 1" 1" 1" 1.5" 1.5" 2"

4 100 114 0.5" 0.5" 1" 1" 1" 1.5" 1.5" 2"

6 150 168 0.5" 1" 1" 1" 1.5" 1.5" 2" 2"

8 200 219 0.5" 1" 1" 1.5" 1.5" 1.5" 2" 2.5"

10 250 273 0.5" 1" 1" 1.5" 1.5" 2" 2" 2.5" 12 300 324 0.5" 1" 1" 1.5" 1.5" 2" 2" 2.5"

Pipe

diameter

(mm)

Technical Services Team. The thermo-technical engineering program "ROCKASSIST" (coming soon)

can be used to design the insulation according to the specific requirements.

<250 °F

(<120 °C)

inch inch inch inch inch inch inch inch

300 °F

(150 °C)

350 °F

(175 °C)

400 °F

(200 °C)

450 °F

(230 °C)

500 °F

(260 °C)

550 °F

(290 °C)

(315 °C)

600 °F

1.2 Insulation of piping

Installation

Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details.

The ProRox® PS 900 Series pipe sections are mounted directly onto the pipe to form a close fit. With horizontal pipes, the lengthwise joint of the pipe section should be turned towards the underside at the 6 o’clock position. With vertical pipes, the lengthwise joints should be staggered at an angle of 30 ° to one another. Secure the pipe sections with galvanized binding wire or with steel bands. With an insulation thickness exceeding 5 inches (120 mm) [or temperatures > 550 °F (300 °C)], install the insulation in at least two layers. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered.

Support structures and spacers

Spacers are not generally essential in insulation systems with pipe sections. With pipes that are exposed to large mechanical loads (e.g. strong vibrations) and/or temperatures above 550 °F (300 °C), determine whether a spacer ring is required in each individual case.

With pipes that have been installed vertically, with a height in excess of 13 feet (4 m), fit support structures to transfer the dead load of the insulation system onto the pipe. Attach the first support ring to the lowest point of the vertical pipe. The distance between the support rings should not exceed approximately 13 feet (4 m).

1. Pipe - 2. Insulation: ProRox® Pipe Sections -

3. Clamp or binding wire - 4. Sheet cladding -

5. Sheet-metal screw or rivet

1.2.2 Insulation with pipe wraps (mats)

Pipe wraps (mats), such as ENERWRAP® MA 960NA are the latest development in the insulation business. ENERWRAP® MA 960NA is a stone wool insulation wrap available with black mat or reinforced foil facing. The flexible application makes the product easy to cut and install. Pipe wraps (mats) are ideal for installations involving large diameter pipes and a high number of shaped pieces such as elbows or T-joints.

ENERWRAP® MA 960NA can be applied up to temperatures of 1200 °F (650 °C). Due to the high compression resistance, pipe wraps (mats) can be applied without additional spacers in many cases. Consequently, the number of thermal bridges which have a negative influence on the insulation, is greatly reduced.

Pipe Diameter Temperature

NPS

(inch)

Nominal

diameter

Ø DN

Pipe

diameter

(mm)

<250 °F

(<120 °C)

inch inch inch inch inch

The result is considerably reduced installation time and costs. The lack of spacers minimizes heat loss and the risk of personal injuries caused by hot spots on the cladding. Pipe wraps (mats) are precisely tailored to the corresponding length of the pipe circumference on site and are fastened with clamps.

Insulation thicknesses to guarantee protection against contact

The table below is an initial guide to help select suitable insulation thicknesses for the guards. It is based on the following boundary conditions:

Ambient Temperature 75 °F (25 °C) Wind speed: 1.1 mph (0.5 m/s) Cladding: Aluminum Maximum surface temperature: 140 °F (60 °C) Insulation: ProRox® PS 960

300 °F

(150 °C)

400 °F

(200 °C)

500 °F

(260 °C)

600 °F

(315 °C)

of piping

Insulation

12 300 324 0.5" 1" 1.5" 2" 2.5"

16 400 406 1" 1" 1.5" 2" 3"

20 500 508 1" 1" 1.5" 2.5" 3"

The thicknesses mentioned above should be seen as an indication. In the event of differing boundary conditions, please contact the ROXUL engineering program "ROCKASSIST" (coming soon) or NAIMA 3E Plus the specific requirements.

Technical Services Team. The thermo technical

can be used to design the insulation according to

1.2 Insulation of piping

Installation

Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details.

Cut the wraps (mats) to the required length, based on the external insulation diameter (pipe diameter + two times the insulation thickness). Fasten the wrap (mat) firmly to the pipe with steel bands. Ensure that the wraps (mats) form a tight joint and that no lengthwise joints or circular joints are visible. The joints of the individual wraps (mats) are securely taped with self-adhesive aluminum tape. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered.

Support structures and spacers

Spacers are not generally essential in insulation systems with load bearing wraps (mats). With pipes that are exposed to large mechanical loads (e.g. strong vibrations), determine whether a spacer ring is required in each individual case.

With pipes that have been installed vertically, with a height in excess of 14 feet (4 m), fit support structures to transfer the dead load of the insulation system onto the pipe. Attach the first support ring to the lowest point of the vertical pipe. The distance between the support rings should not exceed approximately 14 feet (4 m).

1. Pipe - 2. Insulation: ENERWRAP® MA 960NA - 3. Self-adhesive aluminum tape - 4. Steel bands - 5. Sheet cladding -

6.Sheet-metal screw or rivet

1.2.3 Insulation with wired mats

Wired mats have a relatively low resistance to pressure and from a practical point of view should only be mounted in combination with spacers. Because of theresulting thermal bridges, better insulation performances are often achieved in the lower and middle temperature range [up to 550 °F (300 °C)] with pipe sections or load bearing wraps (mats) rather than with wiredmats.

Installation

Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details.

With an insulation thickness of more than 5 inches (120 mm) [or temperatures > 550 °F (300 °C)], apply multiple layer insulation. If the insulation is assembled in multiple layers, the lengthwise and crosswise joints of the individual insulation layers must be staggered. If mechanical loads are anticipated, use steel straps to secure the wired mats.

of piping

Insulation

Cut the wrap (mat) to a length so that it can be fitted to the pipe with slight pre stressing. Wire the closing joints (lengthwise and circular) of the wraps (mats) together using steel wire or secure with wrap (mat) hooks. Stainless steel pipes and pipes with an operating temperature > 750 °F (400 °C) can only be insulated with wired mats with stainless steel stitching wire and wire netting to prevent galvanic corrosion cracking.

1. Pipe - 2. Insulation: ProRox® Wired Mats - 3. Stitching of the joint edge with binding wire - 4. Sheet cladding -

5. Sheet-metal screw or riveted bolt - 6. Spacer ring

1. Pipe - 2. Insulation: ProRox® Wired Mat- 3. Joint edge closed with mat hooks - 4. Sheet-metal cladding -

5.Sheet-metal screw or riveted bolt - 6. Spacer ring

Support structures and spacers

As wired mats do not offer sufficient resistance topressure to bear the weight of the cladding, spacer or support structures should be applied. More information can be found in 1.2.4.

With pipes that have been installed vertically, witha height in excess of 14 feet (4 m), fit support structures to transfer the dead load of the insulation system onto the pipe. Attach the first support ring to the lowest point of the vertical pipe. The distance between the support rings should not exceed approximately 14 feet (4 m).

1.2 Insulation of piping

(

)

1.2.4 Insulation support

A. Spacers

The purpose of spacers is to keep the cladding at a predetermined distance from the pipe. Spacers are essential when the insulation (e.g. wired mats) cannot bear the mechanical load of the cladding. The use of spacers is generally not necessary ifpipe sections or pipe wraps (mats) are used. Consideration should be given to support structure or spacers on pipes where mechanical loading (e.g. strong vibrations) of the insulation is expected and/or the temperature is higher than 550 °F (300 °C).

Spacer rings usually consist of metal rings on which the sheet cladding rests, and metal or ceramic bars used as spacers, which rest on the pipe. Elastic spacers such as Omega clamps are frequently used to reduce the transference of vibrations. With steel spacers, apply at least three bars, whereby the maximum distance – measured as circumference of the external ring – must be a total of maximum 16 inch (400 mm). With ceramic spacers, apply at least four bars at a maximum permissible distance of 16 inch (400 mm).

Dimension spacers of support construction

The number of spacers depends on the insulation, temperature and the mechanical load. Use the following intermediate distances as a guide.

Horizontal

Insulation

system

Pipe sections none 10 to 13 ft none 16 to 20 ft

Load bearing wraps (mats) none 10 to 13 ft none 16 to 20 ft

Wired mats 3.3 ft 3.3 ft 3.3 ft 16 to 20 ft

piping

≤ 550 °F > 550 °F ≤ 550 °F > 550 °F

Vertical

piping

)

(

1. Pipe - 2. ProRox® insulation - 3. Spacer - 4. Thermal dividing layer - 5. Cladding

The spacers on pipes are located under the circular joint of the cladding. On shaped sections such as pipe elbows, spacers are fitted at the start

1. Pipe - 2. ProRox® insulation - 3. Spacer - 4. Thermal dividing layer - 5. Support ring

and at the end. If the external distance between the two spacers exceeds 27 inch (700 mm), place additional spacers between the two.

B. Support construction

The purpose of support structures is to transfer the mechanical load of the insulation system and the forces affecting the insulation system onto the object. Support structures are essential in the case of vertical piping. In addition to the static and dynamic forces, changes in piping length and support structures due to temperature must also be taken into account when dimensioning. Support structures are fastened to mounting supports, which are welded to the pipe beforehand, or are mounted directly onto the pipe via a clamping action with so-called double clamping rings. With temperatures above 650 °F (350 °C), the support structures must be made of high-temperature steels.

The table below is an initial dimensioning guide, and shows the weight of the insulation system against the nominal width of the pipe and the insulation thickness. The table accounts for an insulation with an apparent density of 6 lb/ft3 (100 kg/m³), including the spacer and a 0.20 inch (1.0 mm) strong galvanized sheet.

Weight of the insulation (lb/ft pipe)

1. Support ring - 2. Bar - 3. Rivet or screw connection -

4. Thermal decoupling - 5. Clamping screw - 6. Screw nut - 7. Internal clamping ring

of piping

Insulation

Pipe Diameter

Nominal

NPS

diameter

(inch)

0.5 15 21 lb / ft 0.3 0.5 0.8 1.1 1.5 2.5 3.7 5.2

1.0 25 34 lb / ft 0.5 0.7 1.0 1.4 1.8 2.8 4.1 5.7

2.0 50 60 lb / ft 0.8 1.1 1.5 1.9 2.4 3.6 5.0 6.7

2.5 65 76 lb / ft 1.0 1.3 1.7 2.2 2.7 4.0 5.5 7.2

3.0 80 89 lb / ft 1.2 1.5 2.0 2.5 3.0 4.3 5.9 7.7

4.0 100 114 lb / ft 1.5 2.0 2.5 3.0 3.6 5.1 6.8 8.7

8.0 200 219 lb / ft 2.9 3.6 4.4 5.2 6.1 8.1 10.3 12.8

12.0 300 324 lb / ft 4.4 5.3 6.3 7.4 8.5 11.0 13.8 16.8

20.0 500 508 lb / ft 7.2 8.6 10.2 11.8 13.5 17.0 20.8 24.8

28.0 700 711 lb / ft 10.0 12.0 14.0 16.2 18.4 22.9 27.8 32.9

planar surface lb / ft

Ø DN

Pipe

diameter

(mm)

Units of weight of insulation system

1.00 1.50 2.00 2.50 3.00 4.00 5.00 6.00

1.3 1.6 1.8 2.1 2.3 2.8 3.3 3.8

Insulation Thickness (inch)

1.2 Insulation of piping

1.2.5 Cladding

Suitable cladding should be applied to protect the insulation from weather influences, mechanical loads and (potentially corrosive) pollution. Selecting the appropriate cladding depends on various factors, such as working loads, foot traffic, wind and snow accumulations, ambient temperatures and conditions.

NOTE

An insulation system resistant to foot traffic must not become permanently damaged if a person weighing 220 lbs (100 kg), (weight including any tools being carried) walks across it. It is not designed to bear additional loads, such as the placing of heavy equipment. For the purpose of the safety regulations, a durable insulation is not considered to be a walkable surface.

When selecting the appropriate cladding, take the following points into account:

As a general rule, galvanized steel is used in

buildings due to its mechanical strength, fire resistance and low surface temperature (in comparison to an aluminum cladding).

Aluminum is used outdoors, because it is easy

to fit and more cost-effective than stainless steel and does not tend to corrode under common weather conditions.

In corrosive environments, aluminized steel,

stainless steel or glass reinforced polyester is used as cladding. Stainless steel is recommended for use in environments with a fire risk.

The surface temperature of the cladding is

influenced by the material type. The following applies as a general rule: the shinier the surface, the higher the surface temperature.

To exclude the risk of galvanic corrosion, only

use combinations of metals that do not tend to corrode due to their electrochemical potentials (also see page 21 in Chapter 1.1).

For acoustic insulation, a noise absorbent

material (bitumen, mylar foil) is mounted on the insulation or inside the cladding. To reduce the risk of fire, limit the surface temperatures of the cladding to the maximum operating temperature of the noise absorbent material.

Max. surface temperature

Cladding material Areas at risk

Aluminum sheet - -

Aluminum/zinc coated steel sheet - -

Galvanized steel sheet -

Austenitic stainless steel sheet

Aluminized steel sheet

Plastic-coated steel or aluminum - -

Glass fiber-reinforced polyester

Rocktight)

(e.g. ProRox

Coatings/mastics - - 175 °F (80 °C)

Foils - -

The thickness of the metal sheet depends on the pipe dameter and the type of the metal. With special acoustic requirements, a larger thickness [> 0.04" (1 mm)] is generally used.

of fire

Corrosive

environment

< 120 °F

(50 °C)

< 140 °F

(60 °C)

< 190 °F (90 °C)

> 140 °F

(60 °C)

Recommended sheet thickness and overlaps regarding cladding made from flat sheets (CINI)

Surface (cladding) temperature °F

Aluminum

cladding

100

105

110

115

120

125

130

Galvanized

steel

Stainless

steel

Paint-coated

Plastic

cladding

Minimum thickness (inches) of metal cladding sheet (recomended by CINI)

External diameter of

the insulation (in)

< 5.5" 0.024 0.022 0.020 0.020 0.020

5" to 12" 0.031 0.031 0.031 0.031 0.031

> 12" 0.039 0.031 0.031 0.031 0.031

Aluminum

(CINI 3.1.01)

Aluminized steelsheet

(CINI 3.1.02)

Alu-Zinc coated

steel sheet

(CINI 3.1.03)

Zinc coated steelsheet

(CINI 3.1.04)

Austenitic stainless

steel sheet

(CINI 3.1.05)

of piping

Insulation

The recommended sheet thickness deviates to a certain level per standard/country. The thickness recommended by CINI is shown in the table above (values converted to inches). See page 148 in Chapter 3.2.2 for the thickness according to DIN 4140 and BS 5970.

To reduce the risk of galvanic corrosion, it is important to use the correct screws, straps etc. See the table on page 21 for more information.

The basic guidelines are:

Fasten sheet cladding on lengthwise joints with

at least six sheet metal screws or blind rivets every meter.

Place the screws or blind rivets equidistant.

Ifscrews or rivets are fitted in two rows, do not stagger the screws or rivets.

The cladding can also be held in place with

corrosion-resistant straps instead of screws orrivets.

Do not use aluminum screws.

Influence of the cladding on the surface temperature

In addition to the insulation thickness, the thermal conductivity of the insulation and the ambient conditions (for example temperature and wind), the surface temperature of insulation is also influenced by the emission ratio (emissivity) of the cladding.

The following applies as a general rule for thermal insulation: the shinier a surface is (lower emissivity), the higher the surface temperature. The following example shows the various surface temperatures that depend on the cladding:

Diameter: 4 1/2" (114 mm) Temperature of the medium: 930 °F (500 °C) Place of installation: Interior [Wind speed 1.1

mph (0.5 m/s)]

Insulation: ENERWRAP® MA 960NA

pipe wrap (mat), thickness 4" (100 mm)

Various cladding materials

- Aluminum sheet

- Galvanized steel sheet, bright

- Stainless steel

- Paint-coated plastic cladding

1.2 Insulation of piping

1.2.5 Cladding

Cladding in corrosive environments

To guarantee the functionality of industrial/ mechanical insulation (sometimes referred to as technical insulation), it is important to protect it against atmospheric influences and prevent the ingress of moisture into the insulation. Moisture in the insulation system increases thermal conductivity, thereby reducing the effectiveness of the thermal protection. It also poses a high risk of corrosion to the component. In certain applications, the cladding system is also expected to offer chemical resistance, as well as being resistant to cleaning methods such as steam blasting. Alongside the insulation and construction, selecting a suitable cladding system is very important as it forms the basis for a long service life, low maintenance costs and low heat loss of a

industrial/mechanical insulation. ROXUL® offers ProRox® Rocktight, an innovative fiberglass polyester cladding system.

Thepolyester then hardens when exposed to ultraviolet (UV) light. Once hardened, ProRox® Rocktight is watertight and forms a mechanical protection for the insulation.

The advantages:

Long service life:

ProRox® Rocktight creates a sealed, watertight cladding for ROXUL insulation systems. This minimizes damage caused by atmospheric influences or general wear and tear. ProRox® Rocktight is resistant to many chemical substances and forms a mechanical protection for the insulation.

Easy to clean:

Insulation systems cased in ProRox® Rocktight can be cleaned with steam-jet air ejectors, without the risk of water penetrating the insulation and causing damage.

Low start-up costs:

The cutting and processing take place directly on site. This avoids costs associated with prefabrication of steel cladding.

Flexible applications:

ProRox® Rocktight can be used for cold and thermal insulation of underground and aboveground pipes, for example in offshore plants. Its high flexibility enables application on complex, shaped objects.

ProRox® Rocktight – a durable protection

for insulation

ProRox® Rocktight is a fiberglass reinforced polyester wrap, which hardens when exposed to ultraviolet (UV) light. The material contains resins, glass fibers and a special filling agent and is (unprocessed) protected against UV rays by foils on both sides.

ProRox® Rocktight is soft and flexible when unprocessed. Itcan be cut or trimmed in any shape and easily mounted onto the insulation in this state.

ProRox® Rocktight is characterized by easy processing. It can be cut easily using a knife directly on site and, as an unhardened ProRox® Rocktight wrap (mat) is highly flexible, it can be simply shaped to cover complex geometric shapes such as pipe elbows, T-joints or pipe fittings. ProRox® Rocktight has a protective foil on both sides. It is supplied in rolls in cardboard packaging. The roll is also wrapped in black foil that is resistant to UV light. The underside (the side facing the object) is covered with a dark foil and has a rough, self-adhesive surface. The flat surface of the outside is covered with a white foil. After each use, place the roll in the sealed cardboard packaging to minimize the risk of hardening caused by daylight or UV light.

ProRox® Rocktight requires a dry, clean (ventilated) work environment. For outdoor applications, tents should be erected if necessary, to protect the unhardened ProRox® Rocktight wrap (mat) from UV light.

NOTE

High temperatures: ProRox® Rocktight can

be used in temperatures of up to 190 °F (90 °C).

Chemical resistance: ProRox® Rocktight is

resistant to numerous chemicals.

Expansion joints: fit expansion joints to

accommodate expansion of the ProRox® Rocktight material and the steel pipe.

1.2.6 Pipe hangers and pipe supports

There is a wide range of solutions for pipe hangers and pipe supports. The following illustrations show the possibilities described below for insulation systems:

Pipe hangers in direct contact with the piping Pipe supports in direct contact with the piping Pipe supports not in direct contact with the

piping (commonly used with cold insulation systems)

Pipe support in direct contact with the piping

1. Pipe - 2. Insulation: ProRox® PS 960NA – pipe section

- 3.Sheet cladding - 4. Pipe clamp - 5. Pipe saddle

Pipe support not in direct contact with the piping

1. Pipe - 2. Insulation: ProRox® PS 960NA pipe sections-

3.Sheet cladding - 4. Load-bearing insulation -

5.Seal - 6.Stirrup - 7. Pipe saddle

of piping

Insulation

Pipe hangers in direct contact with the piping

1. Pipe - 2. Insulation: ProRox® Pipe Sections -

3.Collar - 4. Sheet cladding - 5. Pipe hanger

A basic rule applying to all pipe attachments is that the insulation system (e.g. the insulation and cladding) must not be damaged if the piping expands. Damage to the cladding of outdoor installations, in particular, can allow the ingress ofmoisture in the material. The result may be permanent damage of the insulation system andas a consequence high heat losses, dangerously high surface temperatures and corrosion etc.

1.2 Insulation of piping

(50 mm)

0.8"

(20 mm)

1.2.7 Insulation of valves and flanges

Heat loss incurred through non insulated fixtures such as valves and flanges are substantial, even at low temperatures. An uninsulated valve located outside loses as much heat at 250 °F (120 °C) as 100 ft (30.5 m) of uninsulated piping. The temperature of the medium can also decrease to such an extent at non-insulated fittings or flanges, that process critical temperatures are reached, at which point for example, the medium will start to crystallize. Valves and flanges should therefore be insulated as much as possible. To avoid damage during inspection or repairs, the insulation for valves and flanges is designed with removable coverings or hoods, to allow rapid disassembly. Removable coverings or hoods are usually insulated from the inside with wired mats or flexible ProRox® insulation (FSL Series). The coverings are fastened to the object with lever fastenings, which are fixed directly onto the covering or on to straps. Take the following conditions into account when designing insulated coverings for fittings and flanges:

The overlap distance of the insulated covering

over the insulated pipe should be at least 2"

(50 mm).

The pipe insulation should end at the flanges,

leaving a gap equal to the bolt length +1.2" (30 mm) and should be closed off with a lock washer so the flange can be loosened without damaging the insulation.

With valves, an extended spindle should

preferably be fitted horizontally or below the

pipe to prevent leakage along the spindle shaft.

The cladding must be fitted to prevent the

ingress of moisture in the insulation. On

inclined or vertical piping, for example, mount

rain deflectors above the removable coverings.

If the ingress of moisture into the insulation is

unavoidable, make 0.4" (10 mm). diameter drain

holes in the removable covering.

1. Pipe - 2. ProRox® insulation-

3. Cladding- 4. Sheet-metal screw or Rivet -

5.Swage- 6.Drainage opening -

7. Strap - B ≥ 2" (50 mm) - A= bolt length +1.2" (30 mm)

A number of possible design options for insulation systems for pipe fittings and flanges follow:

1. Pipe - 2. ProRox metal screw or rivet - 5. Rain deflector - 6. Lock washer

- 7. Straps - 8. Rain deflector B ≥ 2" (50 mm) - A = bolt length + 1.2" (30 mm)

insulation - 3. Cladding- 4. Sheet-

(50 mm)

0.8"

(20 mm)

1. Pipe - 2. ProRox® insulation - 3. Cladding- 4. Sheetmetal screw or rivet - 5. Swage - 6.Drainage opening

- 7. Straps – B ≥ 2" (50 mm)

1. Pipe - 2. ProRox® insulation - 3.Cladding - 4. Sheetmetal screw or rivet - 5. Swage- 6.Drainage opening

- 7. Straps – B ≥ 2" (50 mm) - A = Bolt length + 1.2" (30 mm)

1. Pipe - 2. ProRox® insulation - 3.Sheet -

4. Sheet-metal screw or rivet - 5. Rain deflector -

6. Lock washer - 7. Straps - 8. Lock washer - B ≥ 2" (50 mm) - A = Screw length +1.2" (30 mm)

Leakages

With pipes where a leaking fluid content could damage the insulation or the coating system in the removable covering, mount flange straps with a leak detection fitting around the flange. Flange bands can also prevent flammable products from penetrating into the insulation material and can help prevent the outbreak of fire.

of piping

Insulation

1. Pipe - 2. Insulation: ProRox

3. Cladding - 4. Sheet-metal screw or rivet -

5. Removable coverings (insulated from the inside) -

6. Swage

Pipe Sections -

1. Pipe - 2. ProRox metal screw or rivet - 5. Swage - 6.Flange band - 7. Leak detection fitting - 8. Clamps

insulation - 3. Cladding- 4. Sheet-

1.2 Insulation of piping

1.2.7 Insulation of valves and flanges

1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheetmetal screw or rivet - 5. Collar - 6. Collar -

7. Clamps - 8.Rain deflector - 9. Leak detection fitting B ≥ 2" (50 mm) - A = bolt length + 1.2" (30 mm)

pipe elbow with clamps or binding wire. Joints between the individual segments are plugged tightly with loose ROXUL insulation.

1. Pipe - 2. Insulation: ProRox® Pipe Sections -

3.Cladding - A and B = Segmented pipe sections

1.2.8 Insulation of pipe elbows and

Tpieces

The cladding of elbows and T-pieces is susceptible to damage, due to expanding or vibrating pipes. There is a particular risk of moisture penetrating damaged swage connections in the cladding, if the object is located outdoors.

For the insulation of shaped pieces, we recommend using the same insulation in the same thickness as used for the pipe.

Insulation of pipe elbows with ROXUL® pipe sections

For the insulation of pipe elbows with pipe sections (e.g. ProRox® PS 960NA), the pipe sections are cut into segments and tightly fitted onto the pipe elbow with the lengthwise joints facing downwards. The angular division of the segments should correspond to the radius of the pipe elbow. The pipe section segments are fastened to the

Insulation of pipe elbows with wired mats or ProRox® pipe wraps (mats)

If the piping is insulated with wired mats or pipe wraps (mats), shaped pieces such as pipe elbows or T-pieces are generally insulated with the same wraps (mats). In this case, the wraps (mats) are cut into so-called fish-shaped elbow segments. These are mounted onto the pipe elbow to seal the elbow. With wired wraps (mats), all the joints (both circular and lengthwise joints) are sewn together with binding wire or wrap (mat) hooks. Spacers are required at least at the start and end of the elbow (for more details, please see page 34).

Pipe wraps (mats) are fixed to the pipe elbow with metal or plastic straps. Any gaps between the individual segments should be plugged with insulation. Secure the joint edges with selfadhesive aluminum tape.

The diagrams below show how the sheet is

0.6" (15 mm)

0.4" (10 mm)

mounted onto shaped pieces.

1. Pipe - 2. ProRox® insulation - 3. Cladding - A to C: Elbow segments of wraps (mats)

1.2.9 Reducers

Pipes that branch out with many outlets reduce the pipe diameter. Examples of how to install reducers follow:

1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheetmetal screw or rivet- 5.Swage - 6. Reducer

of piping

Insulation

1. Pipe - 2. ProRox

insulation - 3. Cladding

1. Pipe - 2. ProRox® insulation - 3. Cladding -

4. Drainage opening - 5.Edging with mastic compound

1. Pipe - 2. ProRox metal screw or rivet- 5.Swage - 6. Reducer

insulation - 3. Cladding - 4. Sheet-

1.2 Insulation of piping

(100 mm)

4" (100 mm)

1.2.10 Expansion joints

In thermal insulation systems, large differences between the piping and the cladding temperature can occur. The materials used for the pipe, insulation, insulation support and cladding also have different thermal expansion coefficients. Thisleads to different thermal elongations of the various components in the insulation system, which must be allowed for using constructive measures. The elongation “Δl” can be determined as follows:

Δl = l ⋅ Δt ⋅ a

In this formula, l corresponds to the length of the pipe, Δt corresponds to the difference in temperature between the cold and warm pipe (or cladding) and a corresponds to the linear thermal expansion coefficient (see tables in Chapter 3).

Example for the thermal elongation of steel

Δl (inch per foot) Δt (°F) Δt (°C)

0.004 50 28

0.008 100 56

0.012 150 83

0.016 200 111

If bellow expansion joints for thermal length compensation have been built into the pipe, the insulation system will also bellow along with the pipe movements, potentially compromising the insulation. The expansion bellows are covered with a sheet that is then insulated (see diagrams on the right). With temperatures above 550 °F (300 °C), do not use galvanized sheets due to the risk of galvanic corrosion (cracking).

1. Pipe - 2. ProRox® insulation - 3. Cladding-

4. Aluminum foil - 5. Cover sheet - 6. Wrap (mat) pin with clip - 7. Spacer

To compensate for thermal expansion of the cladding, install the expansion joints shown below.

1. Pipe - 2. ProRox

4. Sheet-metal screw or rivet - 5. Swage -

6.Metal strap - 7. Circumferential seam

insulation - 3. Cladding -

1.2.11 Tracing

When media are transported over long distances, in particular, the media inside the piping can spoil, set or be at risk from frost in the winter. Insulation can reduce heat losses and postpone the moment at which the installation freezes. Insulation alone, however, cannot indefinitely prevent the installation from freezing. Installing additional tracing may be necessary between the object and the insulation.

of piping

Insulation

A distinction is made between pipe tracing and electrical tracing. In pipe tracing systems, a heating pipe is fitted parallel and close to the media pipe. Steam, warm water or thermal oil flows through the tracing pipes as a heat transfer medium. Electrical tracing consists of cables mounted onto the pipes. These cables heat the pipes

Traced pipes can be insulated with pipe sections or wraps (mats). Ensure that no insulation occupies the space between the tracing and the pipe; otherwise the heat transfer will be hampered. Pipes are therefore often wrapped in aluminum foil. If pipe sections are used, select a correspondingly larger internal diameter of the pipe section. With vertical piping, sealing the end of each pipe section with loose ROXUL® insulation is recommended to prevent convection (chimney effect).

The diagrams on the right show various design options.

1. Pipe - 2. Insulation: ProRox® Pipe Sections -

3.Electrical tracing - 4. Aluminum foil - 5. Cladding

1. Pipe - 2. Insulation: ENERWRAP

- 3. Tracing - 4.

Mats

5.Cladding

Aluminum

MA 960NA or Wired

foil -

1. Pipe - 2. Insulation: ProRox® Pipe Sections -

3. Tracing- 4. Binding tape - 5. Cladding

1.2 Insulation of piping

1.2.12 Foot traffic

Avoid walking on insulated pipes, as this can damage the insulation. Damage caused by foot traffic includes dented sheet cladding and gaps at the sheet seams. Water can penetrate the insulation through these gaps and cause lasting damage to the entire insulation system. The result is often greater heat losses and corrosion.

NOTE

An insulation system resistant to foot traffic

must not become permanently damaged if a

person weighing 220 lbs (100 kg), (weight

including any tools being carried) walks on it.

It is not designed to bear additional loads,

such as the placing of heavy equipment. For

the purpose of the safety regulations, a

durable insulation is not considered to be a

walkable surface.

In special applications, reinforcing the cladding is recommended, e.g. using a reinforcement sheet.

1. Pipe - 2. Insulation: Sections - 3. Reinforcement sheet (may not be required) - 4. Cladding - 5. Sheet-metal screw or rivet -

6. Joggle

ProRox® PS 980

Pipe

Pipe insulation systems resistant to foot traffic require an insulation material with a high mechanical strength (e.g. ProRox® PS 980NA pipe sections). Using other insulation materials such as wired mats, which are not resistant to pressure, is not recommended, as the sheet cladding only rests on the spacers and tends todent when walked upon.

1. System solutions

1.3 Insulation of vessels

Vessels are a major component in installations for various procedures in almost all fields of industry.

Many production processes require different substances that are stored in vessels and used in the individual processes later in the procedure. The vessels primarily store liquid, solid or gaseous substances, which are added to the process when required. Raw materials, fuels or end products are usually stored in large storage tanks.

It is often important to store the substances within certain temperature limits. If the temperature is too high or too low, the substance can spoil or set, or lose its flowing properties and become incapable of being pumped or discharged. Insulation is therefore a major factor in the functionality of procedural processes. Italso has the following purposes:

Reduces heat loss Aids protection against contact by minimizing

the surface temperature

Reduces cooling of the stored substance, so it

remains fluid and does not set

Prevents the vessel from freezing (with

additional tracers)

Prevents heating of the stored substance (for

example, through solar radiation)

The vessels used in the different industrial processes are so varied that the examples of use cannot fully take into account the particular circumstances of each case.

Determine whether the products and construction described are suitable for the corresponding application in each individual case. If in doubt, consult the ROXUL® Technical Services Team.

The applicable standards and regulations must also be observed. A few examples follow:

ASTM C1696 "Standard Guide for Industrial

Insulation Systems"

NACE SP0198 (Control of corrosion under

thermal insulation and fireproofing materials -

a system approach) ASME "Boiler and Pressure Vessel Code" MICA "National Commercial & Industrial

Insulation Standards" DIN 4140 (Insulation works on industrial plants

and building services installations) AGI Q05 (Construction of industrial plants) AGI Q101 (Insulation works on power plant

components) CINI-Manual: “Insulation in industry” BS 5970 (Code of practice for thermal insulation

of pipe work, equipment and other industrial

installations) PIP (Process Industry Practices)

NOTE

Before starting the insulation works,

ensurethat all preparatory work on the

objecthas been completed. Refer to Chapter

1.1 for details.

Insulation systems for vessels

An insulation system for a vessel generally consists ofthefollowing components:

Insulation Support construction and a spacer Water vapor retarder with cold insulation

systems Cladding

The actual operating temperature (above or below ambient) is essential for the design of the insulation work. The following chapters concentrate on hot insulation.

of vessels

Insulation

1.3 Insulation of vessels

Selection and installation of the insulation

Selecting the appropriate insulation depends on the operating method, the installation temperature, the dimensions and the location of the vessel.

Typically recommended insulation materials are ProRox® wraps (mats) and ProRox® flexible and semi rigid boards (slabs) like the SL 920NA, SL 930NA and ENERWRAP® MA 960NA.

Since vessels are often located outdoors, it is important to select insulation with a low thermal conductivity and excellent water repellent properties. The insulation is usually fastened to the cylindrical vessels with steel straps. These should be made from stainless steel and should be closed with butterfly nuts or quick release fasteners. The strap measurements and intervals for cylindrical objects shown in the table on the next page have proved useful in many projects.

1. Vessel inlet - 2. Crane hooks - 3. Vessel head -

4. Expansion joint - 5. Manhole - 6. Tapping point -

7. Identification board - 8. Vessel base- 9.Vessel outlet

- 10. Fitting insulation - 11.Flange - 12.Vessel leg

Minimum radius ProRox® insulation boards (slabs)

Product

SL 920

ProRox

SL 930

ProRox

SL 960

ProRox

MA 960

ENERWRAP

1 1.5 2 2.5 3 3.5 4 5

16 21 30 40 50 60 72 84

16 22 32 42 60 66 76 100

20 30 48 66 92 100 100 120

12 16 20 24 28 32

Insulation thickness (inches)

External insulation

diameter

8" to 72" (200 to 1800 mm) 1/2" x 0.02" (13 x 0.5 mm) 5/8" x 0.02" (16 x 0.5 mm) 10" (250 mm)

> 72" (1800 mm) 5/8" x 0.02" (16 x 0.5 mm) 3/4" x 0.02" (19 x 0.5 mm) 10" (250 mm)

Internal insulation layer strap

measurement

External or single layer insulation

strap measurement

Distance between

straps

These values can only beused as reference values. In each individual case, determine whether different strap measurements and intervals should be used.

If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered (e.g. masonry bond pattern).

For semi-rigid boards (slabs) and wired mats usually used the insulate vessels with flat vertical walls the insulation is attached with welding pins and spring plates. On flat surfaces, attach the wired mats using minimum 5 pins per board (or 6 pins per m2), and a minimum of 8 pins per board (or 10 pins per m2) on the underneath. Observe the following when pinning the insulation:

With insulation thicknesses ≤ 5" (120 mm), use

8GA (6AWG) pins with a minimum diameter of

0.162" (4 mm).

With insulation thicknesses ranging from 5 1/2"

to 10" (130 to 240 mm), use 6GA (4AWG) pins with a minimum diameter of 0.2043" (5 mm).

With insulation thicknesses ≥ 10" (240 mm) use

4GA (3AWG) pins with a minimum diameter of 1/4" (6 mm).

If the cladding rests directly on the insulation

without a gap between the two, the pins must be 3/8" (10 mm) shorter than the insulation thickness.

Fasten each insulation layer with clips.

With wired mats, all the lengthwise and crosswise joints must be sewn or wired together, or joined with 2 mat hooks per foot. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered.

The following illustrations show a number of typical methods of insulating vessels.

Insulation of a crane hook

1. Cladding - 2. ProRox® insulation - 3.Crane hooks -

4. Insulation covering for the crane hook

of vessels

Insulation

1.3 Insulation of vessels

(50 mm)

1.3 Insulation of vessels

Selection and installation of the insulation

Insulation of a vessel base

1. ProRox® insulation - 2. Support construction - 3. Mounting support - 4. Conical column head-

5. Vessel outlet - 6. Vessel leg

1. ProRox

4. Conical head - 5. Vessel drawdown - 6. Conical head with manhole - 7. Vessel leg

load bearing insulation - 2. Flange inlet for safety valve - 3. Vessel filling nozzles -

(200 mm)

Insulation of a conical head

Support constructions and spacers

The application of support constructions and spacers on vessels is essential. The objective of support constructions is to bear the weight of the insulation system and to bear the weight above mounting supports on the object to be insulated. The spacers keep the cladding of the insulation at a predetermined distance. On vertical pipes, the substructures often assume the function of the support construction and spacer. The design specifications are illustrated in Chapter 1.4. Thecorresponding requirements for support constructions and spacers can be found in MICA National Insulation Standards and the AGI guidelines Q153 and 154.

of vessels

Insulation

Insulation of a conical head with a manhole

Insulation of vessel outlet

Before commencing the insulation works, fit mounting supports to the vessels to which the support constructions are fitted. The shape, construction and measurements of mounting supports for support constructions must enable the insulation to be fitted during assembly. If desired use the design loads specified in DIN guidelines 1055-4 and 1055-5 to dimension the mounting supports and the support constructions and spacers.

Cladding

The cladding of vessels protects the insulation against mechanical influences and the weather. There is a wide range of different flat and profiled sheets available. See Chapter 3.2 for an overview. Flat sheets are primarily used to clad smaller vessels. With large-scale insulation systems, flat sheets can only bear small, static loads exerted by the wind. It is therefore essential to reduce the distance between the support structures.

The result will be a higher number of support structures and thermal bridges. On large surfaces, flat sheets are more likely to buckle or dent, leading to optical damages, than profiled sheets. To improve the stability and optical characteristic, the sheets can be canted diagonally (cambered).

1.3 Insulation of vessels

Selection and installation of the insulation

Preferably use profiled sheets for vessels with a large surface area. They offer structural advantages and can accommodate expansions that are perpendicular to the direction of the swage. The disadvantage is that pipe protrusions are more complex from a structural perspective. Using profiled sheets is only recommended with cladding with a low number of protrusions. Design profiled sheet casings so that rainfall is deflectedsafely.

resistant to cleaning methods such as steam blasting. Alongside the insulation and construction, selecting a suitable cladding system is very important as it forms the basis for a long service life, low maintenance costs and low heat loss of a industrial/mechanical insulation.

ROXUL Inc. has developed an innovative cladding system for industrial/mechanical insulation: ProRox® Rocktight.

ProRox® Rocktight – for durable protection

ProRox® Rocktight is soft and flexible when unprocessed. The polyester then hardens when exposed to ultraviolet (UV) light. Once hardened,

ProRox

Rocktight is waterproof and formsa mechanical protection for the insulation. Pleasesee Chapter 1.2. for more details about processing ProRox® Rocktight.

Cladding in moist or corrosive environments

To guarantee the functionality of industrial/ mechanical insulation, it is important to protect it against atmospheric influences and prevent the ingress of moisture into the insulation. Moisture in the insulation system increases thermal conductivity, thereby reducing the effectiveness of the thermal protection. It may also increase the risk of corrosion to the component. In certain applications, the cladding system is also expected to offer chemical resistance, as well as being

1. System solutions

1.4 Insulation of columns

Columns are pillar-shaped vessels, which are mainly used in the (petro) chemical industry for distillation or the extraction of substances. They often form the key elements in chemical or petrochemical plants. The processes in columns often only operate at certain temperatures. The insulation of columns plays an important role in their functionality.

Reduces heat loss Aids protection against contact by minimizing

the surface temperature

Reduces the cooling of the stored substance, so

it remains fluid and does not set

Ensures the column remains at the necessary

process temperatures

Prevents heating of the stored substance (for

example, through solar radiation)

The columns used in the different industrial processes are so varied that the examples of use below cannot fully take into account the particular circumstances of the construction-related factors. Determine whether the products and construction described are suitable for the corresponding application in each individual case. If any doubt, consult the ROXUL® Technical Services Team.

The applicable standards and regulations must be observed. A few examples follow:

ASTM C1696 "Standard Guide for Industrial

Insulation Systems"

NACE SP0198 (Control of corrosion under

thermal insulation and fireproofing materials -

a system approach) ASME "Boiler and Pressure Vessel Code" MICA "National Commercial & Industrial

Insulation Standards" DIN 4140 (Insulation works on industrial plants

and building services installations) AGI Q101 (Insulation works on power plant

components) CINI-Manual: “Insulation in industry” BS 5970 (Code of practice for thermal insulation

of pipe work, equipment and other industrial

installations) PIP (Process Industry Practices)

NOTE

Before starting the insulation works,

ensurethat all preparatory work on the object

hasbeen completed. Refer to Chapter 1.1 for

details.

Insulation

of columns

Insulation systems for columns

An insulation system for vessels and columns generally comprises the following components:

Insulation Support construction and a spacer Water vapor retarder in the case of cold

insulation systems Cladding

The temperature of the columns, in particular, has asignificant impact on the optimal insulation system. Thischapter focuses on the insulation of hot columns.

1.4 Insulation of columns

Insulation systems for columns

Selection and installation of the insulation

Selecting the appropriate insulation depends on the operating method, the installation temperature, the dimensions and the location of the vessel or column.

Insulation materials such as ProRox® are suitable for use of the insulation of columns.

Since columns are often located outdoors, it is important to select insulation with a low thermal conductivity and excellent water repellent properties. The insulation is usually fastened to the columns with steel straps. These should be made from stainless steel and should be closed with butterfly nuts or quick release fasteners. The strap measurements and intervals for cylindrical objects shown in the table on the next page have proved useful in many projects.

1. Column head - 2. Reinforcement ring - 3. Expansion joint - 4. Working platform - 5. Identification board -

6. Column base - 7. Column skirt

External insulation

(50 mm)

diameter

8" to 72" (200 to 1800 mm) 1/2" x 0.02" (13 x 0.5 mm) 5/8" x 0.02" (16 x 0.5 mm) 10" (250 mm)

> 72" (1800 mm) 5/8" x 0.02" (16 x 0.5 mm) 3/4" x 0.02" (19 x 0.5 mm) 10" (250 mm)

Internal insulation layer strap

measurement

External or single layer insulation

strap measurement

Distance between

the straps

In a wide variety of applications, these values can only be used as reference values. In each individual case, determine whether different strap measurements and intervals should be used. If the insulation is assembled in multiple layers, thejoints of the individual insulation layers must bestaggered. The following illustrations show a number of typical methods of insulating columns.

Insulation of conical column head

Insulation of a reinforcement ring

1. Support construction - 2. Mounting support -

3. Reinforcement ring - 4. ProRox

5.Cladding

insulation -

Insulation

of columns

1. Supporting construction - 2. Mounting support

1.4 Insulation of columns

(25 mm)

8”

(200 mm)

Selection and installation of the insulation

Insulation of a column base

1. Skirt: Column support frame - 2. Sliding cover

Insulation of manhole on the column head, vertical connection

Fire protection in column skirts

The fire protection quality of a column primarily depends on the fire resistance of the column support frame. When used in a system, ROXUL® can aid in fire protection solutions for column support skirts. If you have any questions, please consult the ROXUL Technical Services Team.

Insulation of manhole, horizontal connection

1. Manhole - 2. ProRox® insulation -

3. Cladding - 4. Sheet-metal screw

(100 mm)

(25 mm)

1. Manhole - 2. ProRox® insulation - 3. Stiffener -

4. Stiffener screw or rivet - 5. End cap - 6. Mounting rim -

7.Sheet-metal screw or rivet - 8. Rain deflector

(100 mm)

2" (50 mm)

Various methods for pipe penetrations

Insulation

of columns

Support constructions and spacers

The application of support constructions and spacers on columns is essential. The objective of support constructions is to bear the weight of the insulation system and to bear the weight above mounting supports on the object to be insulated. The spacers keep the cladding of the insulation at a predetermined distance. On columns, which are always vertical, the substructures often assume the functions of the support construction and spacer.

AGI guidelines Q153 and Q154 can be referenced for the design of support constructions and spacers.

Before commencing the insulation works, fit mounting supports to the column to which the support constructions are fitted. The shape, construction and measurements of mounting supports for support constructions must enable the insulation to be fitted during assembly. Use the design loads specified in DIN guidelines 1055-4 and 1055-5 can be referenced to specify design loads and to dimension the mounting supports and the support constructions and spacers.

1.4 Insulation of columns

(

1.25" x 0.125"

1.25" (30 mm)

1.25" x 0.04" (30 x 3 mm)

Support constructions and spacers

1.75"

(40 mm)

)

(

)

≤

(

)

≤

)

(

)

(

≤

1.75"

(40 mm)

Cladding

The cladding of columns protects the insulation against mechanical influences and the weather. There is a wide range of different flat and profiled sheets available. See Chapter 3.2.2 ‘Cladding materials’ for an overview. Further details are also provided in Chapter 1.3 “Insulation of vessels”.

(30 x 3 mm)

0.375" x 2" (M 10 x 50)

(30 x 3 mm)

0.08" (2 mm)

1.25" x 0.125" (30 x 3 mm)

0.375" x 2" (M 10 x 50)

1.25" x 0.125" (30 x 3 mm)

1. Object wall - 2. Mounting support - 3. Bolting -

4. Bar - 5. Omega clamp - 6. Thermal separating layer

Ladder support cleats

ProRox® Rocktight – for durable protection

The ProRox® Rocktight cladding system performs well in moist and corrosive environments. SeeChapters 1.2 and 1.3 for more details.

side view front view

1. Cladding - 2. Ladder support cleat - 3. Ladder

1. System solutions

1.5 Insulation of storage tanks

The availability of raw materials, fuels and the storage of end products is critical in almost all fields of industry. Generally, large tanks are used for raw materials, fuels and end products. Small tanks or vessels (see chapter 1.3) are used to temporarily store semi-finished products. Toconserve the substance and ensure the stability and safety of the production process, it is important to keep the temperature inside the tank between certain temperature limits.

Therefore the industries set high standards for theconditioning temperature of storage tanks. Wegive some examples:

In the food industry, a milk cooling tank is a

large storage tank used to cool and hold milk at a cold temperature until it can be packed and transported to the end-users.

Storage facilities for liquefied gasses such as

LNG, operate at very low temperatures down to

-260 °F (-168 °C). Avoid evaporation or expansion of the liquefied gas, as this can result into safety problems.

In the petrochemical industry, many storage

facilities operate at high temperatures of 90 °F to 430 °F (30 °C to 220 °C) to avoid fluids, such as bitumen, from spoiling or setting. This could result in problems with pumping or discharging from thetank.

Process control: Insulation will prevent tanks

from freezing or being heated by solar radiation. It will also reduce the cooling of the stored substance, preventing it from setting and remaining in a solid form. In both cases additional heating or cooling may be applicable.

Safety: Fire resistant insulation reduces the risk

of a fire outside the tank igniting a flammable medium. It is also protection against contact by minimizing the surface (contact) temperature of the tank.

Insulation of

storage tanks

Conclusion: Insulation of storage tanks is a major

factor in the functionality of storage facilities. It also serves the following purposes:

Cost savings: Insulation significantly reduces

the heat and the so-called breathing losses of the substance. The pay-back time for the hot insulation is, even at lower temperatures [90 °F (30 °C)], usually less than 1 year, whereas the lifetime of the insulation may be many years.

Environment: In addition to the cost savings

achieved, reduced heat losses will also lead to lower CO² emission. Reduced breathing losses of hazardous substances prevents damage to our environment.

Properly designed insulation work mainly depends on the isometrics and location of the storage tank, type of fluid and the purpose of the insulation. Even though the following examples of use are restricted to hot thermal insulation for outdoor application, the types of storage tanks used are so varied that the examples cannot fully take into account the particular circumstances of each case. Determine whether the products and construction described are suitable for the corresponding application in each individual case. If in doubt, consult the ROXUL® Technical Services Team.

1.5 Insulation of storage tanks

The applicable standards and regulations must also be observed. A few examples follow:

ASTM C1696 "Standard Guide for Industrial

Insulation Systems"

NACE SP0198 (Control of corrosion under

thermal insulation and fireproofing materials a system approach)

MICA "National Commercial & Industrial

Insulation Standards"

DIN 4140 (Insulation works on industrial plants

and building services installations) AGI Q05 (Construction of industrial plants) AGI Q101 (Insulation works on power plant

components) CINI-Manual: “Insulation in industry” BS 5970 (Code of practice for the thermal

insulation of pipework, ductwork, associated

equipment and other industrial installations) PIP (Process Industry Practices)

Insulation selection

Storage tanks are located outdoors, so it is important to select a material with a low thermal conductivity and excellent water repellent properties. ProRox® semi rigid boards (slabs) can be used to insulate tank walls. Applying a less water repellent, non pressure-resistant insulation like wired mats are not generally recommended. If foot traffic can occur, a pressure-resistant board (slab) such as ProRox® SL 590NA is applied for the insulation of the tank top. If applying a product which is resistant to foot traffic is impossible, apply a support structure, where needed, to protect the insulation boards (slabs). For temperatures above 210 °F (100 °C) applying the insulation in at least 2 layers (e.g. masonry bond pattern) is recommended.

Insulation of tank tops

Insulating a tank is not easy. Corrosion of the tank top can occur if the insulation is not properly installed and maintained. Therefore, some companies tend not to insulate the tank top.

A common assumption is that the still air above the hot fluid acts as insulation of the tank top. This assumption is, however, not entirely correct. Due

1. No insulation: strong convection - 2. Insulation: reduced convection - 3. ProRox

to the difference in temperature between the hot fluid and the non-insulated tank top there is fairly strong convection, resulting in considerable heat loss. Tank top insulation is feasible if the proper insulation material and mounting and fixing methods are applied.

insulation

Construction

Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details. Outdoor storage tanks are continuously exposed to the environment. Wind causes both pressure and delamination, which can easily result in damage to the insulation protection – usually aluminum sheeting. Consequently, the aluminum sheeting is blown away and rain water can leak into the insulation. Water accumulation can cause corrosion resulting in severe corrosion of the tank, leakage of the substance inside etc. Correct precautions are necessary to ensure the quality and life-time of theinsulation.

Many systems can cope with the demands. The appropriate system will greatly depend on the diameter, temperature tank, the surrounding environment and thepossibilities to use scaffolding/rope access when mounting the insulation. In addition, the plant owner may have specific requirements. Determine whether the products and construction described are suitable for the corresponding application in each individual case. If in doubt, consult the ROXUL® Technical Services Team.

ProRox® insulation

5. Protrusion - 6. Cladding - 7.Roof/wall connection

- 2. Stainless steel bands (weather proofing)- 3.Stainless steel bands- 4. Support ring -

Cladding

A metal cladding is generally applied for the tank wall and top. Thanks to its light weight, low costs and ease of installation, aluminum is commonly applied as cladding. In special circumstances (fire rating, corrosive environment etc) other materials such as stainless steel or ProRox® Rocktight may be used. Please note the comments in Chapter

1.2.5 and watertight covering in this section.

Insulation of

storage tanks

1.5 Insulation of storage tanks

(

)

(

)

Support rings

With vertical applications, the weight of the insulation can damage the insulation layer below. To avoid damaging the insulation, fit horizontal support rings if higher than 14 ft (4 m). The

Expansion

Large storage tanks expand due to changes in temperature and if the substance stored is filled or discharged (sometimes referred to as

“bulging”). These factors can increase/decrease distance between the support rings should not exceed 10 ft (3 m). The construction should be built so that leakage water can be expelled from the insulation.

)

(

)

(

the tank diameter. Example: The diameter of a

storage tank - Ø 65 ft (20 m), Avg T 430 °F (220 °C)

- will increase approx. 2 1/2" (60 mm). This

consequently increases the tank circumference by

approx. 7" (180 mm). To avoid stress/tension on

the insulation protection (aluminum sheeting)

selecting flexible ProRox® insulation board (slab)

or wrap (mat) is important. For high

temperatures, anticipate further expansion by

fitting profiled sheeting.

1. Tank wall - 2. Spacer - 3.

ProRox® insulation

Ladders and manholes

The necessary space requirements for the

5 ft (1500 mm)

insulation must be taken into account when

designing and planning the installation. The

distance between the ladder and the tanks should

be large enough to make installing insulation

afterwards possible. Insulate manholes so they

can still be used frequently without damaging the

insulation.

1. Horizontal support ring - 2. Spacer - 3. Fixing

Tank wall and tank base connection

When a tank is filled, stress may occur at the

welded seam between the wall and base of the

tank. For inspection purposes the first 1 1/2 ft

(50 cm) of the tank wall should not be insulated.

The first support ring is usually welded above this

level and constructed so that leakage water can

be expelled from the insulation.

4”

Connection tank wall - tank roof with railing

7/8”

(20 mm)

about 1/8”

(3 mm)

(100 mm)

1. Tank wall - 2.

4. Cladding - 5. Welded seam

ProRox® insulation

- 3. Support ring -

Tank wall and tank top connection

A rainwater shield is fitted at the seam between the tank wall and tank top to prevent leakage into the tank wall insulation. Weld the safety guard / railing on this rainwater shield.

Connection tank wall - tank top

1. Tank wall - 2.

4. Rain deflector - 5.Support strip - 6. Tank top -

7. Insulation: ProRox

8. Railing - 9. Not insulated roof

ProRox® insulation

pressure resistant insulation -

- 3. L-profile -

Insulation of

storage tanks

1. Tank wall - 2.

4. Cladding (aluminum) - 5. Deflector

ProRox® insulation

- 3. Tank roof -

1.5 Insulation of storage tanks

Protrusions within tank walls

Protrusions within the tank wall insulation may lead toleakage of rainwater or pollution with chemical substances. Keep the number of protrusions to a minimum. Insulate any remaining protrusions as indicated below.

Finishing of tank tops

Similar to tank wall insulation, many

constructions are possible for tank top insulation.

Theappropriate system greatly depends on the

tank diameter and the nature of the seam with

thetank wall. In addition, the plant owner may

have specific requirements. The insulation is

generally cladded with aluminum sheeting,

“rivetted” or in radial segments. As tank tops may

bevulnerable to delamination, screws may be

damaged (pulled loose).

If welding the top is not possible, the steel radial

segments in the centre of the top can be hooked

together in a ring around the perimeter of the

roof. Turnbuckles are used to keep the radials

correctly tensioned.

In many cases, the most critical aspect of tank

insulation is preventing the leakage of rainwater

inside the insulation. Water accumulation can

cause corrosion resulting in severe corrosion of

the tank. Correct precautions are necessary to

ensure the quality and life-time of the insulation.

1. Finishing with aluminum cladding - 2. Finishing with

steel radial segments - 3.

ProRox® insulation

A: welded steel bar attached on the roof with a stainless steel strip

B: applying ProRox® insulation

Protrusions within tank tops

Protrusions within the tank top insulation may lead to leakage of rainwater or pollution with chemical substances due to overfilling of the tank. Keep the number of protrusions in the tank top to a minimum. If this is not possible, apply the construction stated below.

C: Finishing with aluminum cladding

1. Tank roof - 2. Cladding - 3. ProRox® pressure resistant insulation - 4. Aluminum finishing strip -

5. Bolts and rivets (stainless steel) - 6. Strip (stainless steel) - 7. Weld - 8.Welded steel bar

1. Sealing tape - 2. ProRox® insulation - 3. Perforated sheet (ventilation)

Insulation of

storage tanks

1.5 Insulation of storage tanks

Foot traffic

Tank tops are subject to foot traffic. To ensure the insulation system is resistant to foot traffic, apply a pressure-resistant board (slab) such as ProRox® SL 590NA. If the radius of the tank top is too large to allow the use of a rigid board (slab), use a more flexible board (slab) in combination with a (local) metal support construction. The walkways need to be clearly marked.

Watertight covering

Conventional systems for tank top insulation are often sensitive to weather damage (water, wind, etc.) and the effect of chemicals. The costs of maintenance, and the consequently lower operational safety, are often higher than the (energy) cost-savings that are realized by the insulation. For this reason, many tank tops, especially in the lower temperature ranges, are not insulated.

ProRox® Rocktight is applied directly on

ROXUL® tank top insulation on site. As direct cladding supports are no longer needed, it fits seamlessly to all parts of the tank and has unequalled rigidity (hardness) and mechanical strength (e.g. can be walked upon).

In situations exposed to high wind stresses, a

special cable construction can be applied. This will hold the insulation in place under the most extreme weather conditions.

Anti-slip coatings are available that can easily be

applied to ProRox® Rocktight.

The absence of cladding supports virtually

eliminates any risk of corrosion under the insulation.

This ensures perfect protection to the insulation

and storage tank, which guarantees the durability of the insulation.

ProRox® Rocktight ROXUL Technical Services Team – for durable protection

ProRox® Rocktight is a fiberglass reinforced

polyester (GRP) wrap positioned between two sheets of foil. The material contains resins, glass fibers and a special filling agent. It is soft and flexible when unprocessed. It can be cut or timed in any shape and easily mounted onto the insulation in this state. The polyester then hardens when exposed to ultraviolet (UV) light. Once hardened, ProRox® Rocktight is watertight and forms a mechanical protection for theinsulation.

For more information please contact our ROXUL Technical ServicesTeam.

1. System solutions

1.6 Insulation of boilers

Hot water boilers and boilers for the production of water vapor under high pressures are considered to be steam boilers. As a generic term, boiler is used to denote steam generators and hot water installations. Insulating boilers has the following purposes:

Reduces heat loss and increases the efficiency

of the boiler

Aids protection against contact by minimizing

the surface temperature

Prevents heating of the compartment air in the

boiler house, which guarantees an acceptable working

The design and functionality of the boilers on the market is so varied that the examples of use cannot fully take into account the particular circumstances ofeach case. Determine whether the products and construction described are suitable for the corresponding application in eachindividual case. In if doubt, consult the ROXUL® Technical Services Team.

The applicable standards and regulations must also be observed. A few examples follow:

ASTM C1696 "Standard Guide for Industrial

Insulation Systems"

NACE SP0198 (Control of corrosion under

thermal insulation and fireproofing materials -

a system approach) ASME "Boiler and Pressure Vessel Code" MICA "National Commercial & Industrial

Insulation Standards" DIN 4140 (Insulation works on industrial plants

and building services installations) AGI Q101 (Insulation works on power plant

components) CINI-Manual: “Insulation in industry” BS 5970 (Code of practice for thermal insulation

of pipe work, equipment and other industrial

installations) PIP (Process Industry Practices)

1.6.1 Insulation of fire tube boilers

Fire tube boilers are often used in small and medium-sized industrial plants, where small and medium-sized mixtures of hot water or water vapor are required at low pressures. These boilers are used in the mechanical building appliances of large complexes, such as hotels, hospitalsetc.

The fire tube boiler consists of a horizontally positioned cylindrical casing body with diameters of up to four meters. The interior generally contains a corrugated flame tube, where a fuel, usually oil or gas, is burnt. At the end of the boiler are so called reversing chambers, where the flue gas is reversed and pumped back through the boiler. Depending on the design, the boiler will have one or more gas flues, connected at the rear or the front base through the reversing chamber. The chamber surrounding the gas flues and the fire-tube is filled with the water to be heated.

of boilers

Insulation

1.6 Insulation of boilers

1.6.1 Insulation of fire tube boilers

Fire tube boiler

1. Boiler casing - 2. ProRox® insulation - 3. Cladding - 4. Flame tube - 5. Fire tube- 6. Reversing chamber

Load bearing ProRox® insulation is a proven solution in the insulation of flame tube-smoke tube boilers. Insulation is easily mounted onto the horizontal, cylindrical boiler surface and are easily fastened to the boilers with metal straps. Metal spacers, which always create thermal bridges, can be omitted. Due to the compression resistance of at least 210 PSF (10 kPa), the cladding can be mounted directly onto the Duraflex insulation. Alternatively, if the sheet cladding is fitted so closely that it can adopt this function, the fastening straps can be omitted. The insulation is characterized by a consistent rigidity and surface. Due to the lack of spacers, itguarantees an even surface temperature without temperature peaks (hot spots), which pose a hazard in the form of skin burns.

The balanced surface temperature profile also accounts for the thermography of a flame fire tubeboiler shown above. Wired mats are generally used toinsulate the area of reversing chambers and are secured with pins and springclips.

The thermography of a flame tube-smoke tube boiler, which is insulated with ProRox® insulation. (Source LOOS INTERNATIONAL, Loos Deutschland GmbH) The areas insulated with ProRox® insulation show an even temperature distribution without visibly, increased hot spots. The right image shows the position of the thermographic camera. Reading point Sp1 has a temperature of 71 °F (21.7 °C); reading point Sp2 is 70 °F (21.2 °C) and reading point Sp3 is 73 °F (22.8 °C).

Insulation works on a fire tube boiler with

ProRox

insulation

1.6.2 Supercritical steam generators

In the modern energy and heat economy, super critical steam generators, which burn fossil fuels such as mineral coal, brown coal, anthracite etc. are used to generate steam to operate steam turbines. In current utility steam boilers, up to 3,600 t steam is generated per hour under pressures of 4350 PSI (300 bar) and steam temperatures of 1150 °F (620 °C). The most common type is the Benson boiler, that is operated by forced circulation (with boiler feed pumps). In contrast to fire tube boilers, the water or vapor is not located in the vessel, but in pipes, which are fitted in gas-tight, welded tube-fin constructions and form the walls of the boiler. Generally constructed as single-pass or two-pass boilers, these boilers reach levels of up to 560 ft (160 m), depending on the fuel used. The bottom contains the furnace, where finely ground fuel is burned. The flue gases flow through the boiler and heat the water in the pipes, thereby causing it to evaporate. The boiler casing is suspended on a frame and can compensate for any thermal

expansions that occur during operation (vertical

and horizontal expansions). These types of expansions must be considered during the design of the insulation system. The following diagrams show the most important technical components in the insulation of a boiler.

Buckstays (Girders)

Buckstays (sometimes referred to as Girders, Stiffeners or Ribs) are fitted horizontally at regular intervals around the boiler. Buckstays are reinforcement elements, which prevent the boiler from bulging. Adistinction is made between hot buckstays, which are located inside the insulation, and cold buckstays, which are located outside the insulation sections.

Dead spaces

Dead spaces are located in front of the boiler wall or boiler roof, where installation components such as collectors, distributors or pipes are fitted. The dead spaces are located inside the insulation.

of boilers

Insulation

1.6 Insulation of boilers

1.6.2 Supercritical steam generators

Handles

Handles are reinforcement elements, which are fitted vertically between the buckstays (girders) and bear the vertical loads exerted on the buckstays on the boiler wall. Handles can be located inside and outside the insulation sections.

1. Boiler roof - 2. Dead space - 3. Cross bar - 4. Collector- 5.Boiler support tube - 6. Boiler wall -

7.Buckstay - 8.Handles - 9. Burner port - 10. Boiler funnel

Installation of the insulation system for utility steam generators

The following product characteristics are important when selecting a suitable insulation system for utility steam generators:

The insulations used must be non combustible. The maximum service temperature of the

insulation must be higher than the operating temperature of the installation component to be insulated.

The thermal conductivity must be specified as a

function of the temperature.

The (longitudinal) air flow resistance must be as

high as possible. High flow resistances reduce convection in the insulation.

In addition to protection against contact and the maximum permissible surface temperatures of 140 °F (60 °C), industrial parameters such as efficiency factors must beconsidered during the design of the insulation thickness. The AGI guideline Q101‚ “Insulation works on power plant components” recommends that the insulation layer thicknesses for power plant components is designed for a maximum heat flow rate density of

47.5 BTU/hr.ft2 (150 W/m2). In view of rising energy prices and CO²-emission reductions, this generally recommended value is, however, subject to critical analysis. From an economic and environmental perspective, a design parameter of well below 47.5 BTU/hr.ft2 (150 W/m2) is often sensible. ProRox® insulation have proven invaluable in the insulation of utility steam generators over the years. They are flexible and can be easily mounted onto the various geometries or surface structures. ProRox® insulation products are non combustible, have high maximum service temperatures and exhibit a low degree of thermal conductivity across the entire temperature range.

The insulation is assembled in multiple layers, comprising two to three layers of insulation. ProRox® insulation with a maximum service temperature of 1200 °F (650 °C) are a tried and tested solution asa first insulating layer in upper

temperature ranges, as are often encountered in dead spaces. Outer layers can be constructed with different types of ProRox® insulation to optimize the overall performance, depending on the temperature of the adjacent layer. AGI guideline Q101 suggests, galvanized wire netting and galvanized stitching wire in wired mats can only be heated up to a temperature of 750 °F (400 °C). With tempera tures above 750 °F (400 °C), austenitic stainless steel wire netting and stitching wire must be used. Toreduce the convection in the insulation of vertical constructions such as boilers, onlyuse insulations that exhibit an air flow resistance of≥ 50 kPa s/m².

Diagram of a boiler insulation system with wiredmats

walls (tube-fin walls), the pins cannot be fixed to the pipes, but must be welded onto the bars between the pipes. Observe the following when pinning the insulation:

With insulation thicknesses ≤ 5" (120 mm), use

8GA (6AWG) pins with a minimum diameter of

0.162" (4 mm).

With insulation thicknesses ranging from 5 1/2"

to 10" (130 to 240 mm), use 6GA (4AWG) pins with a minimum diameter of 0.2043" (5 mm).

With insulation thicknesses ≥ 10" (240 mm) use

4GA (3AWG) pins with a minimum diameter of 1/4" (6 mm).

If the cladding rests directly on the insulation

without a gap between the two, the pins must be 3/8" (10 mm) shorter than the insulation thickness.

Fasten each insulation layer with clips.

With wired mats, all the lengthwise and crosswise joints must be sewn or wired together, or joined with six mat hooks per meter. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered.

The following illustrations show a number of typical methods of insulating vessels.

Diagram of a boiler insulation system with a gap between the insulation and sheet cladding

1. Tubed wall - 2. Insulation: ProRox® Wired Mats -

3. Fastening pins with spring plates - 4. Cladding

Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details.

ProRox® insulation is minimum 5 pins per board (or 6 pins per m2), and a minimum of 8 pins per board (or 10 pins per m2) on the underneath. The pins are either welded directly onto the surface of the object or are screwed into nuts. With finned

1. Finned pipe - 2. with spring plates - 4. Aluminum foil if necessary -

5. Metal cladding (e.g. profiled sheet)

ProRox® insulation

- 3. Fastening pins

of boilers

Insulation

1.6 Insulation of boilers

1.6.2 Supercritical steam generators

Diagram of a boiler insulation system with nogap between the insulation and sheet cladding

Barriers

The following diagrams show two designs for vertical barriers. Depending on the temperature or structural requirements, the barrier can be manufactured from sheet metal [≥ 0.02" (0.5 mm)] or aluminum foil [≥ 0.003" (80 μm)]. Thebarrier must be fastened to the object on the heated side and must reach to the cladding on the cold side. Fill interstices with loose stone wool (mineral wool). Where the insulation is constructed in multiple layers, cascade thebarriers.

1. Tube wall - 2.

4. Aluminum foil if required - 5.Cladding (e.g. profiled sheet)

ProRox® insulation

– 3.spring plates -

Convection in the insulation

With vertical insulation constructions in particular, where cavities can form on the heated side between the object and the insulation, there is an increased risk of heat loss – caused by convection in the insulation. This risk equally applies to finned walls, as an insulation that follows the contours of the object, in which the cavities in the area of the bars are sealed, cannot always be secured. Take the following measures to prevent convection:

Construct vertical barriers at intervals of 16 to 26

feet (5 to 8 m).

Only use insulations with a longitudinal flow

resistance of ≥ 50 kPa s/m².

Fitting an aluminum foil between the individual

insulation layers and/or on the exterior is recommended.

1. Boiler wall - 2. rock wool - 4. Convection barrier sheet- 5. Aluminum foil ifrequired - 6.Metal cladding - 7.MF profile filling -

8. Z-profile separating sheet

ProRox® insulation

- 3. Fill with loose

Insulation of the buckstays

Buckstays (girders) that are exposed to heat are insulated and fitted with a casing. An example follows.

Buckstays that are exposed to cold are generally not insulated and not cladded. An example follows.

Buckstays exposed to heat on a boiler wall

1. Boiler wall - 2. ProRox® insulation- 3.Fill up with loose fill stone wool (mineral wool) - 4. Support construction - 5. Buckstay exposed to heat -

6.Aluminum foil if required - 7. Cladding/Preformed sheet - 8. Internal buckstay cover, made from black sheet - 9. Mat pins with clips - 10. Aluminum foil barrier - 11. Flat sheet cladding

Buckstays exposed to cold on a boiler wall

1. Boiler wall - ProRox® insulation- 3.Mat pins with clips - 4. Buckstay deflectors- 5.Aluminum foil if required- 6. Metal cladding/profiled sheet -

7. Substructure - 8. Cold buckstay - 9.Boiler handle

of boilers

Insulation

1.6 Insulation of boilers

1.6.2 Supercritical steam generators

Insulation of dead spaces

Dead spaces located in front of the boiler wall or roof containing installation components, are enclosed with cladding, to which the insulation is then mounted. Use a non-scaling sheet with a minimum thickness of one mm. Fasten the sheets to appropriate, structurally measured substructures so that the thermal expansions can be accommodated. The insulation is secured to the dead space sheeting with pins as described above. An example of dead space insulation follows.

Dead space for boiler wall collector

Support construction and spacer

There are various options available to attach support constructions and spacers to boilers. They can be mounted directly onto the boiler, to auxiliary constructions, to buckstays (girders), cross bars or handles. When selecting the support construction and spacer and the corresponding attachment option, a design matching must take place between the insulator and the plant manufacturer. With power plant components with temperatures above 660 °F (350 °C), use high temperature orfireproof steel.

Cladding

With power plant components with large surface areas, such as utility steam generators, profiled sheets are used as cladding material for structural, economic anddesign reasons. The open spans, overlaps and connections correspond to the profile. Refer to the instructions of the relevant profiled sheet manufacturer.

When selecting a suitable cladding material, consider the following parameters: corrosion, temperature resistance, type of construction and architectural design. The contractor and customer should consult about this matter.

1. Boiler wall - 2. loose fill stone wool (mineral wool) - 4. Support construction - 5. Dead space sheeting- 6. Aluminum foil if required - 7. Metal cladding/Preformed sheets -

8. Support construction and spacer

ProRox® insulation

- 3. Fill up with

Galvanized steel sheeting is generally used for the insulation of utility steam generators, which are usually located inside buildings.

1. System solutions

1.7 Insulation of flue gas ducts

Burning fossil fuels produces flue gases, which are guided through flue gas ducts through the various cleaning stages, such as denitrification (DENOX) desulfurization (DESOX) and dust removal (EN), discharged into the atmosphere. Large sections of flue gas ducts are often located outdoors. They are subject to an extent to both internal and external extreme conditions. The effects of external atmospheric influences, such as wind and rain, as well as varying ambient temperatures on the flue gas duct, can lead to intense cooling of the flue gases internally, and therefore to the accumulation of sulphuric acids, which facilitate corrosion.

Insulation systems on flue gas ducts have the following purposes:

Reduce heat losses in the flue gas, thereby

preventing sub-dew point (acid or water dew point) conditions in the flue gas on the interior surfaces of the flue gas duct. This also minimizes the corrosion risk. This also applies to areas with structural thermalbridges, such as support constructions, reinforcements etc.

Reduce the heat losses in flue gas channels of

heat recovery systems Personal protection Adherence to technical specifications with

regard to noise

Designs are so varied in terms of their size and geometry, as well as the materials and layers used, that the examples of use below cannot fully take into account the particular circumstances of the construction-related factors.

Determine whether the products and construction described are suitable for the corresponding application in each individual case. If in doubt, consult the ROXUL® Technical Services Team.

Furthermore, the applicable standards and regulations must be observed.

A few examples follow:

ASTM C1696 "Standard Guide for Industrial

Insulation Systems"

ASME "Boiler and Pressure Vessel Code" MICA "National Commercial & Industrial

Insulation Standards"

DIN 4140 (Insulation works on industrial plants

and building services installations)

AGI Q101 (Insulation works on power plant

components) CINI manual: Industrial insulation BS 5970 (Code of practice for thermal insulation

of pipe work, equipment and other industrial

installations) PIP (Process Industry Practices)

1.7.1 Installation of the insulation systems for flue gas ducts

ProRox® insulation have been a proven solution for rectangular flue gas ducts for many years. They are flexible and can fit onto different geometries and surface structures. ProRox® insulation products are non-flammable, have high maximum service temperatures and exhibit a low thermal conductivity across the total temperature range.

Secure the insulation to the rectangular ducts with welding pins and spring clips. Before the welding pins are fitted, a bonding procedure should be determined by the plant manufacturer and insulator, which does not damage any corrosion coating present on the inside and outside of the flue gas duct. For example, it may be advisable to fit the welding pins before installing the corrosion coating.

ProRox® insulation should be secured to flat surfaces with at least minimum 5 pins per board (or 6 pins per m2), and a minimum of 8 pins per board (or 10 pins per m2) on the underneath.

Insulation of

flue gas ducts

1.7 Insulation of flue gas ducts

1.7.1 Installation of the insulation systems for flue gas ducts

Observe the following when pinning the insulation:

With insulation thicknesses ≤ 5" (120 mm), use

8GA (6AWG) pins with a minimum diameter of

0.162" (4 mm).

With insulation thicknesses ranging from 5 1/2"

to 10" (130 to 240 mm), use 6GA (4AWG) pins with a minimum diameter of 0.2043" (5 mm).

With insulation thicknesses ≥ 10" (240 mm) use

4GA (3AWG) pins with a minimum diameter of 1/4" (6 mm).

If the cladding rests directly on the insulation

without a gap between the two, the pins must be 3/8" (10 mm) shorter than the insulation thickness.

Fasten each insulation layer with clips.

To reduce convection in the insulation, fitting barriers is recommended, for example made from steel, at intervals of 16 to 26 feet (5 to 8 m) when working on large vertical surfaces. The barrier must be effective across the entire section of insulation up to the cladding.

ProRox® insulation is recommended insulation for round flue gas ducts, where temperatures are below 570 °F (300 °C). These are mounted directly onto the flue gas duct and are fastened with straps. Afastening with welding pins and spring clips is generally not required in this instance.

Insulation of reinforcement elements

Large flue gas ducts are fitted with reinforcement profiles to stabilize the duct. These can consist of double T-girders, hollow sections or reinforcing ribs and form potential thermal bridges. This may cause the following problems:

The thermal bridges cause an increased heat

flow and lead to a temperature decrease on the inside wall of the ducts.

Temperature variations between the inner and

exterior lead to stress in the profiles. If the tensile forces become too great, this can lead to deformations and breaking of the welding.

Preventing temperature drops on theinside wall

To prevent a drop in temperature on the inside wall in the area of reinforcement profiles, they must always be insulated. The insulation thickness required depends on factors such as the size and geometry of the profiles, the temperature level and rate of flow within the flue gas duct and the operating method. Complex calculations may be required to determine the insulation thickness. These are usually established by the plant manu facturer, who is aware of the installation parameters. When starting up the installation, a brief drop in temperature below the dew point of the flue gas is unavoidable on the inside wall of the duct.

Reduction of stress due to temperature in the reinforcement profiles

The operating method of the installation influences the problem of stress in the reinforcement profiles caused by temperature.

Less critical is the steady operation, where the flue gas temperature does not change with the passage of time. Generally, stresses due to temperature are not critical if the implementation principles outlined in the AGI guideline Q101 are observed:

The insulation thickness across the

reinforcement elements should be of the same thickness as the insulation on the flue gas duct.

In the case of ducts with reinforcing ribs up to a

height of 4" (100 mm), the thickness of the insulation layer across the ribs must measure at least one third of the insulation thickness required for the duct.

max. 4"

(100 mm)

Insulation of reinforcing ribs

1. Duct wall - 2. ProRox® insulation- 3. Reinforcing ribs - 4. Welding pins with clips - 5. Metal cladding

In the case of non-steady operation, for example, when starting up the installation causes fluctuating flue gas temperatures , measures must be taken if necessary to allow even heating of the reinforcement profiles. The temperatures on the duct wall, as well as on the inside of the reinforcement element, increase rapidly when the installation is started up, whilst the outside of the profile remains cold at first and only heats up after a longer delay. This leads to temperature differences, which can cause undue stressing of the component. The extent of the temperature differences depends on numerous parameters. Afew examples follow:

The operating speed influences the speed at

which temperature of the flue gas increases and the temperature difference in the reinforcement element.

High temperature differences occur in the case

of large profiles.

The shape of the reinforcement profiles

influences an even temperature distribution. Thick walled profiles, for example, do not warm up as evenly as thin walls.

The different thermal conductivities of the

materials used and the heat transfer rates lead to an uneven temperature distribution.

means of radiation and convection from the duct wall to the external flange of the reinforcement profiles. The following shows the design details for a profile insulation system.

Insulation of reinforcing ribs

1. Duct wall - 2.

corrugated sheet - 4. Reinforcing element-

5. Supporting construction and spacer - 6. Aluminum

foil (optional) - 7. Welding pins/clips

ProRox® insulation

- 3. Metal cladding:

This type of design is generally recommended for profiles measuring up to ≤ 10" (240 mm) in height.

To reduce the temperature differences, the insulation must be structurally designed to enable as much heat as possible to be transported by

Insulation of

flue gas ducts

1.7 Insulation of flue gas ducts

1.7.1 Installation of the insulation systems for flue gas ducts

Insulation of reinforcing element with cavity and covering sheet

1. Duct wall - 2. element - 4. Covering sheet - 5. Support construction and spacer - 6. Aluminum foil (optional) -

7. Welding pins/clips - 8. Metal cladding: corrugated sheet

In the case of profiles measuring above 10" (240 mm) in height, a covering sheet should also be installed. The heat transfer from the duct wall to the external flange is therefore not impeded and the cavities do not need to be insulated.

The profile insulation described leads to increased heat losses through convection in the case of vertical steel girders. As a result, barriers – for example in the form of sheets welded into the reinforcement elements – must be fitted at intervals of approximately 10 to 16 feet (3 to 5 m) to reduce convection.

ProRox® insulation

- 3. Reinforcing

1.7.2 Cladding of flue gas ducts

Due to their size and the associated high demands placed upon the flexural rigidity of cladding, flue gas ducts are encased with profiled sheets such as trapezoidal sheets. Flat sheets, which are generally cambered, can also be used. The claddings are secured to the flue gas duct using substructures.

With ducts located outdoors with flue gas temperatures of < 250 °F (120 °C), an air space of at least 9/16" (15 mm) should be left between the cladding and insulation. On clear nights, especially, there is a risk that thermal radiation in space (the small surface of the “flue gas duct” radiates on an endlessly large surface “space”), will cause the surface temperature of the cladding to fall below the dew point temperature of the ambient air. The atmospheric humidity from the ambient air can then condense on the inside of the cladding. Therefore, the insulation and cladding must not be allowed to touch. To drain the water, drill drainage or ventilation holes at the lowest point on the underside.

With round flue gas ducts constructed using ProRox® insulation without a spacer then corrugated straps or bubble wrap are inserted between the insulation and sheet cladding as a spacer.

If the duct is located outside, the upper surface ofthe cladding should have a gap of ≥ 3 %. Thefollowing pages show two examples for the cladding of a flue gas duct with a pent or gabled roof.

Duct located outdoors with a cladding constructed as apent (single sloping) roof

1. Duct wall - 2. cladding: corrugated sheet - 6. Extension (trapezoid)- 7. Z-shaped spacer

ProRox® insulation

- 3.Support construction and spacer - 4. Welding pins/clips- 5.Metal

Insulation of

flue gas ducts

1.7 Insulation of flue gas ducts

1.7.2 Cladding of flue gas ducts

Duct located outdoors with a cladding constructed as a saddle (double sloping) roof

1. Duct wall - 2. corrugated sheet - 6. Extension (trapezoid) - 7. Z-shaped spacer - 8. Support construction - 9. Ridge

ProRox® insulation

- 3. Support construction and spacer - 4. Welding pins/clips - 5.Metal cladding:

1.7.3 Acoustic insulation of flue gas ducts

The thermal insulation of flue gas ducts influences the propagation of airborne noise and structure-borne noise. The effects of this depend on many factors, such as the frequency, the noise pressure level and the structure. The following structural measures influence the acoustic properties of an insulation system:

Changing the insulation layer thickness and/or

the apparent density of the insulation

Changing the clear distance between the flue

gas duct and the cladding

Acoustic decoupling of the cladding from the

flue gas duct using elastic elements within the support construction and spacer (e.g. omega clamp, rubber elements, steel wool pads)

Increasing the basic weight of the cladding

through the choice of material or sheet thickness

Internal coating of the cladding with sound-

deadening materials

Construction of the insulation in multiple

layers, with at least two separate insulating layers and cladding

Insulation of

flue gas ducts

1. System solutions

1.8 Cold boxes

Many industrial applications use gases such as oxygen, nitrogen and argon. These gases are obtained using cryogenic gas separation technology, whereby air is condensed and converted into a liquid. Afterwards, thevarious elements can be separated using fractional distillation.

So-called air separation plants are characterized by an extremely low temperature of as low as approximately -328 °F (-200 °C). In addition to the risk of water and ice forming at this cryogenic temperature, there is also the risk of pure oxygen condensing against the cold parts of the system. The presence of oil and grease may be enough tocause the high concentration of oxygen to spontaneously combust. This is obviously an extremely hazardous situation. The presence of oil and grease must therefore be avoided at all times. It is vitally important to well insulate all cold parts of the system, such as vessels and pipes. Strict specifications regarding the insulation are therefore essential. A standard, frequently applied in Europe, for the insulation of air separation plants is the AGI Q 118 standard “insulation work on air separation plants”. Thisstandard describes in detail the various parts of theinstallation and theinsulation to be applied. Theconstruction method naturally depends on the application. Thefollowing instructions are limited tothe insulation of so-called cold boxes.

Cold boxes

An important component in gas separation plants are the so-called “cold boxes”. Cold boxes are (pressure) vessels that hold a gas or liquid at a very low temperature. The distinctive feature of cold boxes is the double-wall construction, which allows the insulation to be fitted between the inner and outer walls. The cold box is sealed after the insulation has been fitted, so the insulation can no longer come into contact with, for example, water, snow, dust and contaminants.

Choice of insulation

The choice of insulation material depends on avariety of parameters, including the user requirement, standards (e.g. AGI Q118), the operating temperature and the accessibility of the installation. In many cases, mineral wool fibers are used (e.g. ProRox® GR 903), which contain a very low proportion of organic substances- the so-called “Linde Quality”. This can be easily injected into the vessel and has a very long lifespan. The material is easily removed for inspection purposes.

Fitting the insulation

In compliance with the AGI Q118 standard, the fibers are fitted manually or using an injection technique. The hollow spaces in the installation must be free of water and other liquids and contaminants. All filling openings (and non-filling openings) must be sealed. An optimum result is achieved by pulling the packaged, loose fibers apart before injecting or shaking them into the vessel. The ProRox® GR 903 must be injected or shaken into the unit in even layers. If necessary, the wool can then be tamped to achieve the required density. To avoid damage to the installation, manually filling certain parts of the installation may be advisable. The ultimate density of the fitted wool depends on how it is

fitted. Densities of at least 9.4 lb/ft3 (150 kg /m3) are feasible. The official requirement according to the AGI Q118 standard is 10 to 12.5 lb/ft3 (160 to 200 kg/m3) . The procedure is outlined step by step as follows:

1. Create a trial set up by filling a 2 x 2 x 2 ft (60 x 60 x 60 cm) crate with an evenly distributed layer of loose wool, with a thickness of 12 to 16" (300 to 400 mm). Then have a man of average weight compact this layer by treading on it. Repeat this process until the box is full. Calculating the quantity of wool used (by mass) afterwards allows the feasible density to be determined. This also gives a good idea of the tamping method required in order to achieve an effective filling density.

2. Before starting to fill the cold box, fill the installation with air to create a slight overpressure. This will make any possible leaks, which can occur during thetamping process, audible.

3. The cold box is filled with an evenly distributed layer of ProRox® GR 903 granulate, with a thickness of 12 to 16" (300 to 400 mm). Tamp down this layer until a density is reached that corresponds to the density in step 1.

4. Repeat step 3 until the cold box is completely filled. Check the filling density by regularly calculating the mass used in relation to the filled volume. The pressure required to achieve a certain density depends on the procedure that has been followed.

NOTE

As ProRox® GR 903 Granulate may settle after a while or the shape of the cold box may alter due to temperature fluctuations, take into account that the unit will need tobe refilled.

Cold boxes

Notes

Theory

Industrial insulation

Theory

2. Theory

Table of contents

2.1 Norms & Standards 88

2.1.1 Overview of different norms & standards 88

2.1.2 Insulation specification 89

a) ASTM standards 89 b) PIP - guidelines 90 c) Canadian Standards 91 d) MICA Standards 91 e) NACE International Standard Practice 91 f) CINI Guideline 91 g) European standardization (CEN) 92 h) CE-mark 93 i) DIN Standards & Guidelines 94 j) AGI 95 k) BFA WKSB 96 l) FESI 96

m) ISO 97 n) VDI 2055 97

o) British standard 98 p) NF (Norme Française) mark 99 q) Unified Technical Document (Document Technique Unifié, DTU) 102

2.1.3 Relevant guidelines & standards for the industrial/mechanical insulation industry in North America 103

2.1.4 Relevant guidelines & standards for the industrial/mechanical insulation industry in Europe 103

2.1.5 Relevant guidelines & standards for the industrial/mechanical insulation industry within the Benelux 105

2.1.6 Relevant guidelines & standards for the industrial/mechanical insulation industry in Germany 105

2.2 Product properties & test methods

2.2.1 Fire behavior 107

2.2.2 Thermal conductivity 109

2.2.3 Maximum service temperature 112

2.2.4 Water leachable chloride content 115

2.2.5 Water repellency 116

2.2.6 Water vapor transmission 118

2.2.7 Air flow resistance 118

2.2.8 Compression resistance 118

2.2.9 Density 119

107

2.3 Bases for thermal calculations 120

2.3.1 Heat Transfer – ASTM C168 and C680 (North American basis and terms) 120

2.3.2 Heat transfer (European basis and terms) 123

2. Theory

2.1 Norms & Standards

2.1.1 Overview of different norms & standards

There are numerous standards, guidelines and specifications for the planning, design and construction of industrial/mechanical insulation systems. These regulations must be observed to guarantee the functionality, economic operation and safety ofa technical installation, as well as a long service life.

Industrial plants are built and maintained according toa range of requirements, detailed in numerous technical standards that cover all design and equipment requirements.

An overview of the commonly used standards, guidelines and specifications is mentioned below.

Society standards

Published standards from an accredited standards developer. Common examples are ASTM, CAN/ULC, European Standard (EN), DIN. These standards often relate to product performance characteristics.

Industrial guidelines for insulation

In many cases, industrial guidelines are established to ease and to reduce the development & maintenance time and effort of specifications sharing best practices. They contain detailed technical requirements for design, material selection/approval. These specifications often refer to society standards and industrial guidelines. Typical examples in industrial insulation are ASTM C1696, DIN 4140, AGI Q101, PIP, CINI.

Internal plant owner or contractor specifications

Detailed technical requirements for design, procurement, construction, and related maintenance based on a company’s experience (so called best practices), e.g.:

Exxon standards : ES Mobil standards : MS British Petroleum : BP Shell : DEP

These specifications often refer to industrial guidelines and society standards.

General-specific or site standards

General project or maintenance standards for common materials and equipment adopted by owners and contractors. Often, national, countryspecific standards & guidelines are observed, e.g.:

• SaudiOperationSpecification:SOS

• PetroleumDevelopmentOman:POD

2.1.2 Insulation specification

The insulation specification is part of the plant owner or contractors specification. It generally contains:

Guidelines for preparation prior to the

insulation work Material specifications Mounting instructions per application

The insulation specification also often includes the guidelines for corrosion protection. Similar to other specifications, the insulation specification often refers tosociety standards and/or industrial guidelines.

The detailed lay-out per specification will depend on the type of application, the plant owner, contractor and country specific requirements.

A more detailed explanation of the most common standards, guidelines and specifications is given in the following documents. a) ASTM standards b) PIP guideline c) Canadian standards d) MICA standards e) NACE f) CINI guideline g) European standardization h) CE-Mark i) DIN standards & guidelines j) AGI guidelines k) BFA WKSB guidelines l) FESI guidelines m) ISO standards n) VDI 2055 guideline o) British Standard (BS) p) Norme Française (NF) q) Document Technique Unifié (DTU)

a) ASTM standards

ASTM International (ASTM), originally known as the American Society for Testing and Materials, is an international organization that develops and publishes voluntary standards for a wide range of materials, products, systems and services. ASTM is older than other organizations for standardization, such as BSI (1901) and DIN (1917), however it differs from these in that it is not a national standard-setting body. This role is performed in the USA by the ANSI Institute. Nevertheless, ASTM plays a predominant role in the specification of standards in North America and for many international projects – particularly in the Middle East, Asia and South-America.

The ASTM standards are grouped into materials standards and validation standards for product properties. International tenders for the insulation of industrial plants often refer to relevant ASTM standards.

The ASTM annual book of standards comprises 77volumes. The corresponding standards for insulation are incorporated into ASTM Volume

04.06 “Thermal insulation; Building and environmental acoustics”.

More information is available via www.astm.org

The wide variety per country, application and plant owner means these documents cannot convey the entire content and so cannot claim to be complete. For specific applications, please contact our ROXUL® Technical Services Team for advice.

1.1 Planning and preparation2.1 Norms & Standards

2.1.2 Insulation specification

ASTCM C553 Standard specification for mineral fiber blanket thermal insulation for commercial and industrial applications

ASTM C592 Standard specification for mineral fiber blanket insulation and blanket-type pipe insulation (metal-mesh covered) (industrial type)

Materials

Product Properties

Thermal Calculations

Covering

Other

ASTM C547 Standard specification for mineral fiber pipe insulation

ASTM C612 Standard specificaton for mineral fiber block and board thermal insulation

ASTM C1393 Standard specification for perpendicularly oriented mineral fiber roll and sheet thermal insulation for pipes and tanks

ASTM C335 Standard test method for steady-state heat transfer properties of pipe insulation

ASTM C177

ASTM C411 Standard test method for hot-surface performance of high-temperature thermal insulation

ASTM E84 Standard test method for surface burning characteristics of building materials

ASTM C795 Thermal insulation for use in contact with austenitic stainless steel

ASTM C692 Evaluating the influence of thermal insulations on external stress corrosion cracking tendency of austenitic stainless steel

ASTM C871 Chemical analysis of thermal insulation materials for leachable chlorirde, flouride, silicate and sodium ions

ASTM C1104/ C1104M

ASTM C680

ASTM C1129 Standard practice for estimation of heat savings by adding thermal insulation to bare valves and flanges

ASTM C1423 Standard guide for selecting jacketing materials for thermal insulation

ASTM C921 Standard practice for determining properties of jacketing materials for thermal insulation

ASTM C585 Standard practice for inner and outer diameters of thermal insulation for nominal sizes of pipe and tubing

ASTM C929

ASTM C1696 Standard Guide for Industrial Thermal Insulation Systems

Standard test method for steady-state heat flux measurements and thermal transmission properties by means of the guardedhot-plate apparatus

Determining the water vapor sorption of unfaced mineral wool fiber insulation

Standard practice for estimate of the heat gain or loss and the surface temperatures of insulated flat, cylindrical, and spherical systems by use of computer programs

Standard practice for handling, transporting, shipping, storage, receiving, and application of thermal insulation materials for use in contact with austenitic stainless steel

b) PIP - guidelines

Process Industry Practices (PIP) is a consortium of mainly US-based process industry owners and engineering construction contractors who serve the industry. PIP was organized in 1993 and is a separately funded initiative of the Construction Industry Initiative (CII) and the University of Texas at Austin. PIP publishes documents called "Practices". These Practices reflect a harmonisation of company engineering standards in many engineering disciplines.

Specific Practices include design, selection and specification, and installation information. Some of the best practices are mentioned below.

INIH1000 - Hot Insulation Installation Details INSH1000 - Hot Service Insulation Materials

and Installation Specification

More information is available via www.pip.org

c) Canadian Standards

The SCC (Standards Council of Canada) mandate is to promote efficient and effective voluntary standardization in Canada, in particular, to promote, oversee and coordinate efforts of people and organizations involved in the National Standards System.

e) NACE International Standard Practice

NACE International - The Corrosion Society serves nearly 33,000+ members in 116 countries and is recognized as the premier authority for corrosion control solutions. The organization offers technical training and certification programs, conferences, industry standards, reports, publications and more.

In Canada (as in the US) accredited bodies such as CSA (Canada Standards Association) and CAN/ULC (Underwriters Laboratory) produce consensus based standards that can be adopted by various regulatory bodies. ASTM standards are widely used in Canada (see Chapter 2.1.2 on ASTM standards).

Most commonly used standard in Industrial/ Mechanical applications is CAN/ULC S114 (Non-combustibility) and S102 (Surface Burning Characteristics).

Provincial building codes based on the model National Building Code of Canada (NBCC) regulate the general construction of buildings, including industrial buildings housing process equipment.

More information is available via www.scc.ca

d) MICA Standards

First published in 1979 by MICA (Midwest Insulation Contractors Association), the Standards Manual has received wide acceptance throughout the United States and other countries. It has established standardized guides never before available to our field for methods of designing, specifying and installing thermal insulation products. The 7th edition of the National Commercial & Industrial Insulation Standards continues to be the national source of technical information for the design specification and installation of commercial and industrial insulation.

More information is available via www.micainsulation.org

NACE standards represent a consensus of those individual members who have reviewed the documents, their scope, and their provisions.

NACE Standard Practice SP0198-2010 "Control of Corrosion Under Thermal Insulation and Fireproofing Materials - A System Approach" provides the current technology and industry practices for mitigating corrosion under thermal insulation and fireproofing materials, a problem termed Corrosion Under Insulation (CUI).

More information is available via www.nace.org

f) CINI Guideline

CINI is a Dutch association, in which various companies active in the industrial/mechanical insulation of industrial plants have united to develop uniform material and design guidelines. When compiling these standards, CINI works closely with many decision makers from within the insulation sector.

The CINI Standards are guidelines, yet they do not constitute national standards. Nevertheless, the CINI standards are often adopted by operators and design engineers in the Benelux countries, as well as by international companies operating in the petrochemical industry, for example, Shell. They are often used by operators and design engineers as guidelines on tendering procedures for insulation works. The CINI standards also are grouped into material standards and design rules. The validation of the material properties isbased on ASTM and AGI guidelines.

More information is available via www.cini.nl

2.1 Norms & Standards

2.1.2 Insulation specification

Insulation materials (Material standards)

Cladding (Material standards)

Processing guidelines

CINI 2.2.01 Stone wool boards (slabs): ProRox

CINI 2.2.02 Wired mats: ProRox

CINI 2.2.03 Pipe sections: ProRox

CINI 2.2.04

CINI 2.2.05 Lamella mats: ProRox

CINI 2.2.06

CINI 3.1.02 Aluminized steel sheeting: Aluminized steel cladding for the finishing of insulation

CINI 3.1.03 Alu-zinc coated steel sheet: Alu-zinc steel cladding for the finishing of insulation

CINI 3.1.04 Galvanized steel sheet: Continuous hot dip (Sendzimir) galvanized steel cladding for the finishing of insulation

CINI 3.1.05 Austenitic stainless steel: Stainless steel cladding for the finishing of insulation

CINI 3.1.11 GRP: Weather resistant UV-curing glass fiber-reinforced polyester (GRP)

CINI 1.3.10

CINI 4.1.00a Pipes: (Overview) piping insulation details

CINI 4.2.00 Columns: (Overview) insulation/finishing details overview columns

CINI 4.3.00 Vessels: (Overview) insulation/finishing detail overview vertical vessels

CINI 4.4.00 Heat exchangers: (Overview) insulation/finishing details overview horizontal heatexchangers

CINI 4.5.00 Vessels: (Overview) insulation/finishing details for tanks (operating temperature from68 °F (20 °C) to 356 °F (180 °C)

CINI 7.2.01 Corrosion protection: Corrosion protection under insulation

Loose wool: Loose stone wool (mineral wool) without binder for the thermal insulation of valve boxes and the specification stuffing of insulation mattresses

Aluminum faced pipe sections: ProRox insulation of pipes

General processing guidelines: Installation instructions for the thermal insulation of hot pipelines and equipment (insulated with mineral wool)

boards (slabs) for the thermal insulation of equipment

wire mesh blankets for the thermal insulation of large diameter pipes, flat walls and equipment

pipe sections and prefabricated elbows for the thermal insulation of pipes

lamella mats for the thermal insulation of air ducts, pipe bundles and equipment

pipe sections with reinforced pure aluminum foil facing for the thermal

g) European standardization (CEN)

In order to remove technical barriers to trade, the European Union decided to develop uniform European product standards. These product standards describe the product properties, as well as the methods of testing for these properties. The minimum requirements for certain product properties still remain a national responsibility and are laid down in each individual country. The EU issues orders in the form of mandates to CEN (the European Committee for Standardization), which they use uses to develop relevant standards.

For ProRox® insulation, this product standard is the EN14303 “Thermal insulation products for building equipment and industrial installations – Factorymade mineral wool (MW) products – specification”. Following ratification, a European standard must be adopted as it stands by the national standardization organizations as a national standard. Deviating national standards must be retracted. Each European standard adopted is published in each EU country with a national prefix, e.g. in Germany: DIN-EN-XXXX; in England (British Standard): BS-EN-XXX

Product properties, test standards

Product property Standard Description

Thermal conductivity (Piping) EN ISO 8497

Thermal conductivity

(Boards/Slabs)

Water vapor diffusion resistance

coefficient

AS quality

Hydrophobic treatment

Maximum service temperature

Compression resistance EN 826

Air flow resistance

EN 12667

EN 12086

EN 13468 Replaces AGIguideline Q135

EN 13472 Replaces AGIguideline Q136

EN 14706 (for flat products) EN 14707 (for piping)

EN 29053 Determination of airflow resistance

h) CE-mark

The CE marking as it is legally called since 1993 (per directive 93/68/EEC) - abbreviation of French: Conformité Européenne, meaning "European Conformity" is a mandatory conformity mark for products placed on the market in the European Economic Area (EEA). With the CE marking on a product the manufacturer ensures that the product conforms with the essential requirements of the applicable EC directives. Legally, the CE marking is no quality mark. But from August 2012 on, only industrial/mechanical insulation products which comply with the European product standards (see Chapter 2.1.2g) and bear the CE mark may be sold in Europe. A mandatory frame-work will then apply for the key product features of industrial/mechanical insulation materials – such as thermal conductivity, resistance to water vapor transmission, fire

Heat insulation – Determination of steady-state thermal transmission properties of thermal insulation for circular pipes

Thermal performance of building materials and products – Determination of thermal resistance by means of guarded hot plate and heat flow meter methods - Products of high or medium thermal resistance

Thermal insulating products for building applications – Determination of water vapor transmission properties

Thermal insulation products for building equipment and industrial installations – Determination of trace quantities of water-soluble chloride, fluoride, silicate, sodium ions and pH

Thermal insulating products for building equipment and industrial installations – Determination of short-term water absorption by partial immersion of preformed pipe insulation

Thermal insulating products for building equipment and industrial installations – Determination of maximum service temperature Thermal insulating products for building equipment and industrial installations – Determination of maximum service temperature for preformed pipe insulation

Thermal insulating products for building applications – Determination of compression behavior

Acoustics; Materials for acoustical applications; Determination of airflow resistance (ISO 9053:1991)

behavior, tolerances etc. The performance of a mineral wool product is summarized in a designation code, which can be found on the labels of the individual products. E.g. for mineral wool: MW EN 14303-T2-ST(+)680-WS1-CL10-pH9

T2 = Thickness tolerance ST = Maximum service temperature CS = Compressive strength WS = Water absorption CL = Trace quantities of water soluble chloride pH = Level of the pH

The main advantage of the CE-mark and related European standards is that a higher level of transparency is achieved. This allows specifiers, distributors and installers to make a quick and direct comparison between the available products in today’s market place.

2.1 Norms & Standards

2.1.2 Insulation specification

i) DIN Standards & Guidelines

Deutsches Institut für Normung e.V. (DIN; in English, the German Institute for Standardization) is the German national organization for standardization and is that country’s ISO member body.

DIN is a registered association (e.V.), founded in 1917, originally as Normenausschuss der deutschen Industrie (NADI, Standardization Committee of German Industry). In 1926, the NADI was renamed Deutscher Normenausschuss (DNA, German Standardization Committee) in order to indicate that standardization covered many fields, not just industrial products. In 1975 the DNA was finally renamed DIN. Since 1975, it has been recognized by the German government as the national standards body and represents German interests at international and European level.

The acronym DIN is often wrongly expanded as Deutsche Industrienorm (German industry standard). This is largely due to the historic origin of the DIN as NADI. The NADI indeed published their standards as DI-Norm (Deutsche Industrienorm, German industry standard).

Designation

The designation of DIN standards shows its origin.

DIN # is used for German standards with

primarily domestic significance or designed as a first step toward international status.

E DIN # is a draft standard and DIN V # is a

preliminary standard.

DIN EN # is used for the German edition of

European standards.

DIN ISO # is used for the German edition of ISO

standards.

DIN EN ISO # is used if the standard has also

been adopted as a European standard.

DIN standards for the validation of insulation materials can be found under European standards. DIN 4140 “Insulation work on industrial installations…” gives guidelines for the validation of insulation material, mounting and fixing. This standard applies to insulation works on industrial plants. These are production and distribution plants for the industry and for technical building appliances, (e.g. appliances, vessels, columns, tanks, steam generators, pipes, heating and ventilation systems, air conditioning units, refrigeration units and hot water installations). With requirements relating to fire protection, the relevant standards or national technical approvals must be observed. This standard does not apply to insulation works performed on building shells, interior walls and inserted ceilings, neither in the shipbuilding and vehicle manufacturing industry, nor within the control area of power plants.

j) AGI

“Arbeitsgemeinshaft Industriebau e.V”. (AGI) isaGerman association of manufacturers, engineering companies and universities. AGI was founded in 1958 to establish a common platform

AGIguidelines (so called “Arbeitsblätter”) are established in cooperation with the German DIN, VDI and CEN members for insulation. The most relevant standard for insulation work is shown on

the next page. to exchange best practices within Industry. These practices, which are summarized in the

Material standards and design guidelines Field of application/scope

More information is available via www.agi-online.de.

AGI Q02: Insulation works on industrial installations – Terms

AGI Q03: Construction of thermal and cold insulation systems – Insulation works of industrial plants

AGI Q05: Construction of industrial plants – Bases, design, requirements with regard to the interfaces of plant components and insulation

AGI Q101: Insulation works on power plant components – Construction

AGI Q103: Insulation works on industrial plants – Electrical tracing

AGI Q104: Insulation works on industrial plants – Tracing systems with heat transfer media

AGI Q132: rock wool as insulation forindustrial plants

AGI Q151: Insulation works – Protecting thermal and cold insulation systems on industrial plants against corrosion

AGI Q152: Insulation works on industrial plants – Protection against moisture penetration

The terms used in the AGI Q working documents are defined in this working document.

This working document applies to insulation works performed on industrial installations. The working document classifies works into thermal insulation works for operating temperatures above the ambient temperature and cold insulation works for operating temperatures below the ambient temperature.

This working document has been compiled for planners and designers who have to design the industrial plants, including the essential thermal or cold insulation. It examines, in particular, the interfaces between plant construction and insulation.

Working document Q 101 applies to insulation works performed on power plant components such as steam generators and flue gas cleaning systems, pipe systems and steel flues

This working document applies to insulation works performed on industrial plants with electrical tracing.

This working document applies to insulation works performed on industrial installations, which are heated and/or cooled by means of heat transfer and/or refrigerant media, for example in tracing pipes or half pipe sections.

This working document applies to rock wool insulation, which is used for thermal, cold and acoustic insulation of technical industrial plants and technical building appliances.

This working document applies to corrosion protection coating systems for the surfaces of industrial plants, such as appliances, columns and pipes, which are insulated against heat and cold loss. Since the DIN EN ISO 12944 standard provides no explanations with regard to protecting insulation systems against corrosion, this working document should be considered as a supplement to standard DIN EN ISO 12944. This working document does not apply in respect of adhesive primers.

This AGI working document applies to objects where the insulation must be protected against moisture and, above all, against the ingress of liquids, (e.g. water, heat transfer oil).

AGI Q153: Insulation works on industrial plants – Mounting supports for support constructions

AGI Q154: Insulation works on industrial plants – support constructions

AGI working document Q 153 applies to the design and construction of mounting supports. They transfer the loads of the insulation onto the support constructions on the object.

AGI working document Q 154 applies to the construction of support constructions.

2.1 Norms & Standards

2.1.2 Insulation specification

k) BFA WKSB

‘Deutsche Bauindustrie’ is a German branch organization within the building & construction industry. Part of this organization is the Bundes Fach Abteilungen {(BFA) - ‘technical departments’} who are specialized in the technological developments and lobby activities within a specific area of technical expertise. One of them, “BFA WKSB” {Bundes Fach Abteilung Wärme-, Kälte-, Schall-und Brand Schutz}, represents the branche members’ interests in industrial insulation, acoustic insulation and fire proofing in buildings. As well as lobbying towards the various organizations and the German government, they recommend best practices and provisions as stated in the technical letters. These practices are established in cooperation with DIN, AGI, CEN, FESI and testing bodies like FIW. The most important technical letters for hot insulation are shown below.

Technical

Letter

Problems of thermal stress in metal reinforcements of large-dimen sional object with elevated service temperatures

Field of application/scope

l) FESI

FESI, Fédération Européenne des Syndicats d’Entreprises d’Isolation is the European Federation ofAssociations of Insulation Companies. FESI was founded in 1970 and is the independent European Federation representing the insulation contracting sector. FESI promotes insulation as one of the best, themost cost effective and sustainable manners to save energy. FESI represents the insulation associations from 16 European countries whose members are active in insulation for industry, commercial building sectors, ship insulation, soundproofing, fire protection and others. The most important FESI documents (guidelines, recommendations) are shown below.

Document Description

Working Manual: System for measure ment and recording for industrial insulation cladding (English translation of BFA WKSB letter no. 4 and 2).

Problems associated with the warranty of specified surface temperature. ( English translation of BFA WKBS, technical letter no. 5)

3 Prevention of metal corrosion

9 Methods of measuring

10 Measuring point for thermal insulation

11 Moisture in insulation systems

System for measurement and recording for industrial insulation cladding.

Problems with the warranty of specified surface temperatures

High profitability through ecologically based insulation thicknesses

More information is available via www.bauindustrie.de

A2 Basics of Acoustics

"High profitability through ecologically based insulation thicknesses". (English translation of BFA WKBS, technical letter no. 6)

"Principles of metal corrosion". (English translation of BFA WKBS, technical letter no. 3 and 2)

A industrial Acoustics – B Building acoustics – Code of Guarantee

"Problems of thermal stress in metal reinforcements of large-dimensional objects with elevated service temperatures". (English translation BFA WKSB technical letter Nr. 1, 2.)

“Product characteristics “ Acoustic insulation, absorption, attenuation

More information is available via www.fesi.eu

m) ISO

Headquartered in Switzerland, the International Organization for Standardization (Organization internationale de normalisation), widely known as ISO, is an international-standard-setting body composed of representatives from various national standards organizations. Founded in1947, the organization promotes and communicates world-wide proprietary industrial and commercial standards. While ISO defines itself as a nongovernmental organization, its ability to set standards that often become law, either through treaties or national standards, makes it more powerful than most non-governmental organizations. In practice, ISO acts as a consortium with strong links to governments. Most of the ISO standards for insulation focus on the testing of material properties and are embedded in, for instance, EN standards.

More information is available via www.iso.org

n) VDI 2055

Verein Deutscher Ingenieure (VDI) (English: Association of German Engineers) is an organization of engineers and natural scientists. Established in 1856, today the VDI is the largest engineering association in Western Europe. The role of the VDI in Germany is comparable to that of the American Society of Civil Engineers (ASCE) in the United States. The VDI is not a union. The association promotes the advancement of technology and represents the interests of engineers and of engineering businesses in Germany.

VDI 2055 is the most important guideline for industrial/mechanical insulation. The scope of the guideline includes heat and cold insulation of technical industrial plants and technical building equipment, such as pipes, ducts, vessels, appliances, machines and cold stores. The minimum insulation thicknesses for heat

distribution and warm water pipes in technical

building equipment with respect to Germany, are

laid down in the regulations concerning energy-

saving heat insulation and energy-savings in

buildings (EnEVEnergy Saving Ordinance). The

considerations expressed in this guideline may

lead to other insulation thicknesses. Withregard

to heat insulation in the construction industry,

both the EnEV and DIN standard 4108.

Legalrequirements must be observed with regard

to thefire performance of insulation and the fire

resistance classes of insulation, such as federal

state building regulations [Landesbauordnungen]

and the piping system guidelines of thefederal

states [Leitungsanlagen-Richtlinien der

Bundesländer].

The VDI guideline 2055 also serves as a

benchmark for thermo technical calculations and

measuring systems in relation to industrial and

building services installations and for guarantees

and conditions of supply with regard to those

installations. The guideline covers in detail the

calculation of heat flow rates, the design of the

insulation thickness according to operational and

economic aspects, the technical warranty

certificate and the technical conditions in respect

of delivery quantities and services. Furthermore,

the guideline examines measuring systems and

testing methods (forquality assurance).

The VDI 2055 consists of:

Part 1: Bases for calculation Part 2: Measuring, testing and certification of

insulation materials

Part 3: Conditions of supply and purchasing of

insulation systems

Roxul Industrial Insulation Process User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual