Insulation
Insulation
INSULATION
STRATEGY
ENERGY
EFFICIENCY
EARNINGS
3E STRATEGY
TSI
MI
Y
RG
N
RA
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Neither the European Commission, nor any person acting on behalf of the
commission, nor NOVEM, AEAT, ERI, nor any of the information sources is
responsible for the use of the information contained in this publication
ACKNOWLEDGEMENTS
The Energy Research Institute would like to acknowledge the following for
their contribution in the production of this guide:
. Energy Technology Support Unit (ETSU), UK, for permission to use information
from the ªEnergy Efficiency Best Practiceº series of handbooks.
. Energy Conservation Branch, Department of Energy, Mines and Resources,
Canada, for permission to use information from the ªEnergy Managementº
series of manuals.
. TLV co, Ltd, for permission to use figures from their set of handbooks on steam.
. Wilma Walden of Studio.com for graphic design work (Walden@grm.co.za).
. Doug Geddes of South African Breweries for the cover colour photography.
Guide Book Essentials:
QUICK `CHECK-LIST' FOR SAVING
ENERGY AND MONEY IN INSULATION SYSTEMS
This list is a selected summary of energy and cost savings opportunities outline in the text. Many more are
detailed in the body of the booklet. These points are intended to be a quick `checklist'.
2. FUNDAMENTALS..................................................................................................................................................................................... 2
2.1 Terms and definitions...................................................................................................................................................................... 2
2.2 Selection of Insulation Material ................................................................................................................................................. 2
2.2.1 A Note on Asbestos ............................................................................................................................................................ 3
2.3 Heat Transfer ....................................................................................................................................................................................... 4
2.4 Heat Flow ............................................................................................................................................................................................... 4
FIGURE 1: TYPICAL INSULATED PIPE................................................................................................................................. 5
2.5 Protecting and Sealing the Insulation ..................................................................................................................................... 6
2.5.1 Protective Coverings and Finishes.................................................................................................................................. 6
2.5.2 Vapour Barriers ........................................................................................................................................................................ 6
2.6 Temperature Ranges........................................................................................................................................................................ 6
2.6.1 Low Temperature Thermal Insulation ......................................................................................................................... 6
2.6.2 Intermediate Temperature Thermal Insulation........................................................................................................ 7
2.6.3 High Temperature Thermal Insulation......................................................................................................................... 7
2.7 Insulation Thickness.......................................................................................................................................................................... 7
2.7.1 Selection Procedures............................................................................................................................................................. 7
2.7.2 Recommended Insulation Thickness............................................................................................................................. 7
2.7.3 Limited Budget Insulation Thickness ............................................................................................................................. 8
2.7.4 Economic Insulation Thickness......................................................................................................................................... 8
FIGURE 2: DETERMINATION OF ECONOMIC THICKNESS OF INSULATION...................................... 9
FIGURE 3: HEAT LOSS FROM FLAT SURFACE ............................................................................................................ 10
FIGURE 4: COST OF ENERGY LOSS AT VARIOUS INSULATION THICKNESSES................................ 11
FIGURE 5: INSULATION COST AT VARIOUS THICKNESSES ............................................................................ 11
2.8 Energy Management.......................................................................................................................................................................... 12
2.8.1 Energy Audits ............................................................................................................................................................................ 12
2.8.2 Energy Management Opportunities .............................................................................................................................. 12
3 MATERIALS SYSTEMS............................................................................................................................................................................. 13
3.1 Insulation Forms and Materials.................................................................................................................................................. 13
3.1.1 Types and Forms of Insulation ..................................................................................................................................... 13
3.1.2 Major Insulation Materials................................................................................................................................................ 13
3.2 Insulation Systems ............................................................................................................................................................................. 14
3.2.1 Protective Coverings and Finishes.............................................................................................................................. 15
3.2.2 Properties of Protective Coverings............................................................................................................................ 16
3.2.3 Accessories ............................................................................................................................................................................. 16
3.2.4 Securements .......................................................................................................................................................................... 16
3.2.5 Insulation Reinforcement for Cement and Mastics........................................................................................... 17
3.2.6 Water Flashing...................................................................................................................................................................... 17
3.2.7 Stiffening................................................................................................................................................................................... 17
3.2.8 Supports................................................................................................................................................................................... 17
3.2.9 Sealing and Caulking .......................................................................................................................................................... 17
3.2.10 Expansion and Contraction Compensation.......................................................................................................... 17
3.3 Common Applications.................................................................................................................................................................... 17
3.3.1 Multiple Layer Construction.......................................................................................................................................... 18
3.3.2 Pipe Insulation for Interior Applications.................................................................................................................. 18
FIGURE 6: FIELD AND FACTORY-APPLIED NON-METAL JACKETING ...................................................... 18
3.3.3 Metal Jacketing ...................................................................................................................................................................... 19
3.3.4 Flexible Elastomeric Pipe Covering............................................................................................................................ 19
3.3.5 Fittings Insulation.................................................................................................................................................................. 19
3.3.6 PVC or Glass Fibre Fitting Insulation........................................................................................................................ 19
FIGURE 7: FIELD APPLIED METAL JACKETING ............................................................................................................ 19
FIGURE 8: FLEXIBLE ELASTOMERIC PIPE COVERING............................................................................................. 19
FIGURE 9: MITRED INSULATION ELBOW OVERSIZED APPLICATION ..................................................... 20
FIGURE 10: PVC/GLASS FIBRE ELBOW INSULATION SYSTEM ........................................................................ 20
3.3.7 Insulation of In-line Flanges or Couplings............................................................................................................... 21
3.3.8 Removable and Reusable Insulation.......................................................................................................................... 21
3.3.9 Duct Insulation ..................................................................................................................................................................... 21
FIGURE 11: PVC/GLASS FIBRE COUPLING OR IN-LINE FLANGE INSULATION SYSTEM.............. 21
FIGURE 12: REMOVABLE AND REUSABLE INSULATION.................................................................................... 21
FIGURE 13: FLEXIBLE FIBROUS BLANKET DUCT INSULATION RECTANGULAR/INDOORS .... 22
3.3.10 Field Applied Lining............................................................................................................................................................ 22
3.3.11 Insulation of Tanks and Vessels ................................................................................................................................... 22
FIGURE 14: FIELD APPLIED LINING DUCTS, PLENUMS AND HOUSINGS.............................................. 22
FIGURE 15: CURVED SURFACES RIGID BOARD INSULATION........................................................................ 22
3.3.12 Vessel and Tank Head Insulation ................................................................................................................................ 23
FIGURE 16: METAL HEAD INSULATION, SECUREMENT AND COVER FABRICATION ................. 23
APPENDICES...................................................................................................................................................................................................... 30
Worksheets ......................................................................................................................................................................................................... 30
Glossary .......................................................................................................................................................................................................... 40
Heat loss tables ................................................................................................................................................................................................. 47
Basic types of insulation ± selected properties.............................................................................................................................. 64
Protective coverings and finishes............................................................................................................................................................ 65
Vapour retarders.............................................................................................................................................................................................. 66
Energy Content of Some Fuels................................................................................................................................................................ 67
1. INTRODUCTION
Thermal insulation is the use of special materials to Refractory materials often need high resistance to
retard the flow of heat energy. It prevents the loss abrasion as elevated temperatures. This guide is
of heat, so saving on fuel and money, and only about thermal insulation.
contributing to safety and comfort. Insulating
unlagged hot surfaces is one of the simplest and Insulation materials may come in boards, blocks,
most cost-effective ways of increasing energy bricks, sheets, pre-formed shapes, blankets or as
efficiency. Depending on the pipe's surface tem- castable cements. The choice of materials depends
perature, the payback time for insulating a section on cost, temperature, application, environment and
of pipework is typically less than one year. safety. The thickness of insulation should be
calculated so as to optimise the cost of the
By improving energy efficiency, it is possible to insulation against the savings in energy. This guide
reduce the size of heating, cooling and ventilation covers these topics and gives worked examples of
equipment and so reduce capital costs. Process costs saved by insulation.
temperature control is made easier.
This guide uses metric units throughout but has
Insulation may be divided roughly into three included some Imperial units, which are still used in
temperature ranges. Cryogenic temperatures are some South African plants.
below 73oC. Thermal insulation is for tempera-
tures from 730oC to 982oC. Refractory insula-
tion is for temperatures above 982oC, as would be
found in cement kilns, steelworks and incinerators.
1
2. FUNDAMENTALS
. Conduction is the process, by which heat Where, t material thickness (metres or inches)
flows from a hot body to a cooler body or
fluid, which is in stationary contact with it. . Mean Temperature is the arithmetic
. Convection is the process, by which heat average of the hot and cold insulation
flows from a hot body to a gas or liquid, surface temperatures through which heat is
which is in moving contact with it. transmitted.
. Radiation is the flow of heat from a hot . Emissivity is the ratio of heat energy
body without it being in contact with a fluid radiated from a surface compared to the
or solid. heat energy radiated from an ideal black
. Thermal Conductivity (k) is a measure of body at the same temperature.
heat energy transmitted through a homo- . Black Body is defined either as a body,
geneous material per unit thickness. A which absorbs all radiation falling upon it
material with a low thermal conductivity is and reflects or transmits none, or as a
a good insulator. Expressed as W/(m oC) radiator, which emits at any specific
or (Btu/h ft2 oF). temperature, the maximum possible
. Thermal Conductance (C) is a measure of amount of thermal radiation.
the heat energy transmitted through a
homogeneous material of other than unit
thickness or through an assembly. Ex-
pressed as W/m2.oC) or [Btu/(ft2.hr.oF)].
2.2 SELECTION OF
. Thermal Transmittance (U) is a measure INSULATION MATERIAL
of the heat energy transmitted by a
material or assembly including the bound- The following is a list of important properties,
ary air films. Expressed as W/(m2.K) or which must be considered in the selection of an
[Btu/(h.ft2 oF)]. insulating material.
. Thermal Resistance (RSI or R) indicates
the relative insulating value or resistance to . Thermal Resistance. The higher the value
heat flow of material. Thermal Resistance is of thermal resistance, the better the
the primary consideration in the choice of insulating capability of the material.
2
. Combustibility. This becomes significant as applied over irregular or non-uniform
it provides an indication of the insulating surfaces where the insulation must
material's contribution to a fire hazard. ªbridgeº over a support discontinuity.
. Toxicity. Certain insulating materials are . Capillarity. Where insulation material is in
combustible and release toxic fumes when contact with dangerous or flammable
they burn. These must be avoided where liquids, or in areas where wash down
there is a danger of fire in a confined space. occurs, the resisting capability of the
See also the note on asbestos. material to ªwick-upº (absorb) liquids by
. Shrinkage. Shrinkage or drying is significant capillary action becomes significant.
in high temperature applications. Shrinkage . Appearance. Appearance is significant in
can leave non-insulated gaps. exposed areas and for purposes of identi-
. Resistance to Ultra Violet Radiation. fication.
Where the insulating material is exposed . Density. The density of an insulating
to sunlight in outdoor applications, its material affects many of its other proper-
ability to withstand ultraviolet radiation ties, especially its thermal properties.
without degradation is important. This
can be overcome by covering the insulating Some of these factors may not apply in all
material so that sunlight does not contact insulation applications, however, each should be
the material. considered, and ruled out if not applicable. Work-
. Resistance to Fungal or Bacterial Growth. sheet 1-1 has been developed as a checklist to
This property is significant in food or assist in establishing which properties are important
cosmetic processing areas. in a specific application.
. Chemical Neutrality. The insulation
should be chemically neutral (pH 7) to Properly installed, mechanical insulation will have a
avoid any deterioration of metal contacting life equal to the life of the equipment or piping on
it. This is particularly important in applica- which it is installed. Mechanical insulation should
tions where the insulation could be subject always be installed according to the manufacturer's
to intermittent wetting. installation recommendations.
. Coefficient of Expansion and Contrac-
tion. This property becomes important in
the design and location (spacing) of 2.2.1 A NOTE ON ASBESTOS
expansion and contraction joints and in
multiple layer insulation applications. Asbestos was much used in the past for thermal
. Compressive Strength. Compressive insulation. However, because asbestos fibres when
strength is significant where the insulating inhaled can cause lung cancer, it is no longer used
material must support a load or withstand for this purpose. Asbestos comes in many kinds, of
mechanical abuse without crushing. When which the one most commonly used today is
cushioning or filling in space is needed, such chrysotile, one of the least dangerous types. It is
as in expansion/contraction joints, low believed that there is a threshold below which
compressive strength materials would nor- inhaled chrysotile fibres do no damage to human
mally be specified. health. Chrysotile is now used in cement building
. Breaking Load. Breaking load is significant materials, brake linings and certain other products
in installations where the insulation is but not in thermal insulation.
3
Asbestos was used as an insulation material not so insulation material is to retard heat flow. The
much because its thermal conductivity is low (in term thermal conductivity (k) is used to express the
fact, at about 0.06 W/moC, it is higher than many quantity of heat, which will flow across a unit area
other materials) but because of its non-flamm- when a temperature difference of one degree
ability. Old plants may still have asbestos insulation. exists.
It is often safer to seal and leave it than to remove
it because the removal can release fibres into the Thermal conductivity (k), is expressed as Watts per
air. This is a matter that requires expert advice from metre per degree Celsius [W/(moC)] or [(Btu)/
health and safety authorities. (h.ft2 oF)]. Thermal Resistance can now be defined
as the opposition of the passage of heat through
the insulation and is expressed by the following
2.3 HEAT TRANSFER equation.
4
Now the heat flow in one hour through the For example, consider the heat loss from a 1 metre
insulation can be determined. length of 0.219 metre diameter pipe operating at
DT A 95oC. The 51 mm thick insulation has a thermal
Heat flow in one hour
R conductivity of 0.037 W/(m.oC) and an outside
140 10 10 surface temperature of 25oC. This example is
1:133 shown in Figure 1. The heat flow through the
1147.4 Wh insulation can be determined as follows.
0:219
Heat flow through pipe insulation is somewhat r2 0:051
0
different since the inner and outer surfaces of the
0.1605m
insulation have different areas. This difference in
area must be taken into account in heat flow 0:219
r1
calculations. As the heat from the pipe flows 2
outward through the insulation, the area of the 0.1095m
heat flow path becomes greater. This phenomenon r2 ln r2
r1
has the effect of increasing the value of the thermal R
k
resistance. 0:1605 In 0:1605
0:1095
0:037
To compensate for this effect an ªequivalent 0:1605
1:466
thicknessº of insulation must be used. The
0:037
expression for the thermal resistance for piping
insulation can now be rewritten as follows. 1.66 (m2 oC)/W
Where, D 3.14159
Figure 1: Typical Insulated Pipe l unit length (in this case 1 metre)
(Source: Canadian Govn Pub)
5
Therefore A
0:219 2 0:051 1 Additional details on protective coverings and
finishes may be found in the Material/Systems
(
0:321 : 1
section of this module.
3.14159 0.321
1.008 m2
2.5.2 VAPOUR BARRIERS
A vapour retarder or vapour barrier is a material,
2.5 PROTECTING AND which retards the transmission of water vapour.
This is required for piping and equipment operating
SEALING THE at below ambient temperatures. Water vapour
INSULATION from the air tends to diffuse into the insulation
where, because of the lower temperatures it
condenses and significantly reduces the effective-
2.5.1 PROTECTIVE COVERINGS AND ness of the insulation. Moisture penetration may
FINISHES also cause corrosion of metal surfaces.
The efficiency and service life of insulation is
directly dependent upon its protection from Vapour barriers are applied on site and may consist
moisture entry and mechanical and/or chemical of semi-liquid mastic compositions and coating.
damage. Choices of jacketing and finish materials They may be sprayed, brushed or trowelled. The
are based upon the mechanical, chemical, thermal manufacturer's specified thickness must be applied
and moisture conditions of the installation, as well in one or more continuous coatings. Suitable
as cost and appearance. reinforcement may be required as the vapour
barrier system must be adequate to resist cracking.
Protective coverings are divided into six functional
types.
7
bare steel flat surfaces over the range of cost of the insulation. This is necessary to establish
temperatures normally encountered in most the economic thickness of the insulation.
facilities, and are based on an ambient air
temperature of 21.1oC. One way of improving cost savings through
insulation is to upgrade to the insulation levels
For process applications, tables based on econom- shown in the recommended thickness tables
ics have been developed which provide a recom- (Table 3). These should be used as guidelines.
mended insulation thickness for various insulating
materials and temperatures. Table 3 is a typical In some cases these tables will not apply as plant or
table covering mineral fibre, calcium silicate, and building conditions may not be the same as those
cellular glass insulation for pipes varying from NPS used to determine the thickness charts. In these
1/2 to NPS 36 in diameter and process tempera- cases, individual determinations of insulation thick-
tures between 65oC and 566oC. These tables also ness should be considered to insure a facility is
include flat surfaces. (NPS is Nominal Pipe Size making its optimum investment in insulation.
measured in inches).
It must be noted for a round tank or vessel with 2.7.3 LIMITED BUDGET INSULATION
diameter greater than 914 mm, the surface is THICKNESS
considered flat for purposes of heat loss calculations.
Generally for hot mechanical systems, piping will be
the source of greatest heat loss. On a limited
As an example of the use of these tables, consider
budget, determine where the area of greatest
an NPS 6 steel pipe without insulation operating at
heat loss is and insulate it first. The first 25mm of
121oC in ambient conditions of 21.loC. Table 1
insulation will provide the greatest savings in energy
indicates this pipe will lose 700 Wh/linear metre of
on a system but may not be the optimum
heat every hour it is in operation. If the recom-
insulation level for maximising investment benefits.
mended thickness of 76 mm of mineral fibre
This can also be an excellent approach to cost
insulation as indicated in Table 3 were installed on
reductions if insulation is to be paid out of an
this pipe, the heat loss would be reduced to 37
annual maintenance or operating budget. Bear in
Wh/lineal metre and the outer surface temperature
mind though, if only the minimum 25mm is applied,
of the insulation would be 23oC.
the labour component may be the same as if a
greater thickness of insulation were used.
Insulation manufacturers have prepared tables for
other materials since the thermal resistance varies
both with the material being used and the process
2.7.4 ECONOMIC INSULATION
temperature. In the event that tables cannot be
THICKNESS
obtained, heat loss from piping and flat surfaces
may be calculated using the equation in the Insulation can be considered a long-term invest-
previous section of this module entitled Heat Flow, ment with associated financial benefit, following a
and R values as selected from Table 4 in the relatively short initial payback. There are a number
appendix. of computer programs available to aid in selecting
the most economic insulation thickness. This is the
A series of calculations will have to be performed thickness, which provides the highest insulation
and the energy savings compared to the installed value for the lowest cost.
8
Economics is the primary concern in evaluating not manufactured in single layers of sufficient
investment alternatives. When applied to an thickness and/or to alleviate expansion and con-
insulation system, economics can be used to traction movements. This results in higher total
establish the following items. labour costs than to install one layer equal to the
cumulative thickness. Figure 2 is a typical repre-
. Evaluation of two or more insulation sentation of installed costs for a multi-layer
materials for lowest cost for a given application. The average slope of the curves
thermal performance. increases with the number of layers because labour
. Selection of the optimum insulation thick- and material costs increase at a more rapid rate as
ness for a given insulation type. insulation thickness increases.
In either case economics is used to determine the The cost of lost energy is directly related to the
most cost effective solution for insulating. Beyond rate of heat transfer through the insulation and the
the optimum economic thickness, additional in- Rand value of the energy. As also shown in Figure
sulation does not yield the maximum rate of return 2, the cost of lost energy decreases as insulation
on investment. thickness increases.
Material and often labour costs increase with Consider a process application with a flat surface
insulation thickness. Insulation must often be holding a process fluid at 150oC. The ambient
applied in multiple layers because materials are temperature is 20oC.
9
Calculation of heat loss for 50, 75 and 100 mm of The surface area will remain constant for the
glass mineral fibre insulation with a density of insulation since this is a flat surface.
24 kg/m3 can be performed to establish the heat
losses at the various insulation thicknesses. Heat loss can now be evaluated for a typical 1 m2
area for each insulation thickness.
Process temperature: 150oC
DT A
Ambient Temperature: 20oC Heat loss in one hour
R
DT: 150 20 130oC
Heat loss
130 1
(50 mm insulation) in one hour
From Table 5 thermal conductivity (k) at a mean 0:943
temperature of 93.3oC (closest value not exceed-
137.86 Wh
ing 1300C) is 0.053 W/(m oC).
Heat loss (75 mm insulation)/m
130 1
The thermal resistance (R) can be calculated for in one hour
1:415
the various insulation thicknesses using the equa- 91.873 Wh
tion
Heat loss (100 mm
130 1
t insulation)/m in one hour Wh
R 68:89
K
Using Table 2 it is established that the heat loss
0:050
R50 0.943 from one square metre of the same surface with no
0:053
insulation would be approximately 2100 Wh/m2.
0:075
R75 1.415
0:053
These figures can be plotted on a graph (Figure 3)
0:100 showing insulation thickness versus heat loss to
R100 1.887
0:053 generate a heat loss curve.
Figure 3: Heat Loss from Flat Surface (Source: Canadian Govn Pub)
10
Figure 4: Cost of Energy Loss at Various Insulation Thicknesses (Source: Canadian Govn Pub)
Knowing the value of the heat energy, the cost of The installed cost of the insulation for the various
lost heat at the various insulation thicknesses can thicknesses can now be established and a second
be established by the following equation. curve (Figure 5) can be produced.
Rand loss per unit area Figures 4 and 5 may be superimposed and will
Heat loss per unit area R per unit of heat produce a curve generally of the shape of Figure 2.
energy If the dollar loss and insulation cost curves are
combined, and a new curve plotted, the insulation
Total Rand loss (Figure 4) thickness equivalent to the low point on the new
Total area R Loss/unit area hours/year curve will be the economical insulation thickness.
11
installed cost of the added material. The reduction
2.8 ENERGY MANAGEMENT
in energy consumption establishes the Rand
savings.
12
3 MATERIALS SYSTEMS
Vapour retarders are designed to retard the Resistance to corrosion varies among the plastic
passage of moisture vapour from the atmosphere and metal jacketing materials. Of the metal jackets,
to the surface of the insulation (Table 1). Joints and stainless steel is the most successful in resisting
overlaps must be sealed with a vapour tight corrosive atmospheres, spills or leaks. Mastics are
adhesive or sealer. Refer to Table 8 for detailed also generally resistant to corrosive atmospheres.
information on types of vapour retarders plus
15
3.2.1.5 APPEARANCE COVERINGS insulation), or if a significant amount of vibration
AND FINISHES must be considered.
Various coatings, finishing cements, fitting covers
and jackets are chosen primarily for their appear- 3.2.2.3 TEMPERATURE RANGE
ance value in exposed areas. Typically for piping,
jacketed insulation is covered with a reinforcing The covering must be suitable for the operating
canvas and coated with mastic to give a smooth temperature of the insulation surface.
even finish. When dry it can be painted or left as is
to give a white colour.
3.2.2.4 VAPOUR PERMEABILITY
17
ment methods because of weight. Also, system method of application may be used where available
temperature plays a big part in deciding which insulation thickness is less than that required, or for
application method is most suitable. Insulation retrofitting applications. Care should be taken with
contractors or manufacturers are usually willing to pipe insulation to ensure that dimensional mea-
recommend the most appropriate application sures coincide with standard industry practice to
method. provide a proper fit for multiple layer construction.
1. Pipe.
2. Insulation.
3. Longitudinal lap on factory-applied jacket (self-
adhesive or secured with adhesive).
4. Longitudinal lap on factory-applied jacket secured
with staples (staples are coated with super-barrier
mastic on cold applications).
5. Circumferential butt strip. Self adhering or field
adhering.
6. Longitudinal lap on field-applied jacketing is
adhered with appropriate adhesive or sealer.
7. Butt joint overlap sealed (tape at overlap joints is
optional on cold applications).
8. Wire, tapes or hands securing insulation in place
before the jacket is applied.
18
3.3.3 METAL JACKETING
Metal jacketing is generally used to protect
insulation from physical damage (Figure 7). It is
particularly useful for outdoor applications. The
jacketing material may also be chosen to resist
chemical attack. For example, a highly corrosive
atmosphere may require the application of a
stainless steel jacketing system instead of the
standard aluminium material.
19
1. Pipe.
2. Pipe insulation (shown in A) with factory applied non-metal jacketing
(metal jacketing shown in B). Jacketing extends under the fitting
insulation and finish.
3. Mitered segments of pipe covering, cut to form a tight fit (adhesive
between miters on pre-fabricated applications or when required.)
4. Glass fiber fill insulation (optional ± used as a means of support when
the mitered elbow has not been prefabricated into two self supporting
halves.)
5. Wire or banding (unnecessary when prefabricated.)
6. Pre-formed metal elbow cover secured with sheet metal screws.
7. Finishing cement applied to smooth surface.
8. Fabric applied with adhesive on the surface of finishing or insulating
cement.
Figure 9: Mitred Insulation Elbow Oversized Application (Source: Canadian Govn Pub)
sufficient and a final finishing method (i.e. canvas) is the most common) with either a dull or shiny
not required (Figure 10). These fittings are easy to appearance. PVC jacketing may also be used to
install and come in different colours (white being protect piping insulation.
1. Pipe.
2. Pipe insulation (shown with factory-applied jacket).
3. Collar of oversized pipe insulation.
4. Glass fiber insert wrapped around the elbow.
5. PVC fitting cover.
6. Reducing end cap.
7. Vapor retarder adhesive on all joints and overlaps (cold applications
only.)
8. Vapor retarder tape.
Figure 10: PVC/Glass Fibre Elbow Insulation System (Source: Canadian Govn Pub)
20
3.3.7 INSULATION OF IN-LINE
FLANGES OR COUPLINGS
21
1. Rectangular duct.
2. Blanket insulation (shown with factory-applied vapor retarder jacket).
3. Factory lap (sealed with adhesive and/or staples or vapor retarder tape).
4. Vapor retarder tape over tears and penetrations of the vapor retarder 1. Housing or shaft.
jacket (optional in hot applications.) 2. Liner or fibrous board insulation.
5. Mechanical fasteners supporting insulation n the underside of ducts ovedr 3. Adhesive.
24" wide (spaced 3" from the butt joint.) 4. Mechanical fasteners.
5. Joint sealer.
Figure 13: Flexible Fibrous Blanket Duct Figure 14: Field Applied Lining Ducts,
Insulation Rectangular/Indoors Plenums and Housings
(Source: Canadian Govn Pub)
22
1. Head insulation (rigid block is shown).
2. Floating ring of cable.
3. Head bands on 12" centers.
4. Shell insulation.
5. Head insulation supporting ring (not required for horizontal vessels).
6. 1" joint between support ring and shell insulation packed with mineral
or glass fibre insulation.
7. Segments of flat sheet metal cut in wedge shapes, to overlap and
conform to the surface of the head insulation.
8. Band at base of head insulation cover.
9. Sheet metal screws on 3" centres along horizontal and vertical seams.
10. High density insulation for walkway.
11. Roofing materials or reinforced mastic.
12. Caulking and flashing as required.
13. Banding to secure rim angle.
14. Metal I-beams used to stiffen head structure.
Figure 16: Metal Head Insulation, Securement and Cover Fabrication (Source: Canadian Govn Pub)
manufacturer may recommend choice of type of 3.3.12 VESSEL AND TANK HEAD
product. Rigid insulation such as calcium silicate will INSULATION
have to be scored to conform to the curvature of
the tank. Mineral fibre insulation may be bent to Vessel tops are a major source of heat loss. Thus,
conform to the vessel shape. the insulation of the tops of tanks and vessels
(Figure 16) is important to maintain temperature
Where the tank or vessel comes in contact with within the process. Proper protection of the
the ground, an insulation material that does not insulation on the top of the tank or vessel is critical
wick or absorb moisture should be used around to prevent heat loss in the system.
the base of the tank. Cellular glass is typically used.
In addition to the insulation method shown, roofing
Weather protection of insulated outdoor tanks and contractors normally insulate flat tank surfaces. The
vessels is a key requirement. Sheet steel or nature of the insulation system is critical and should
aluminium panels are fastened together with be performed by qualified insulation contractors
vertical and horizontal laps sufficient to shed rain only.
water to protect the insulation.
23
4 ENERGY MANAGEMENT
OPPORTUNITIES
From Table 3 the heat loss for the same piping with
4.1 HOUSEKEEPING
76 mm of mineral fibre insulation is 28 Wh/m.
OPPORTUNITIES
For a ten-metre length, the reduction in heat loss is
Implemented housekeeping opportunities are en- now calculated.
ergy management actions that are done on a
Heat loss reduction per hour 10 (530 ± 28)
regular basis and never less than once a year. The
10 502
following are typical Energy Management Oppor-
5020 Wh/h
tunities in this category include:
1. Repair damaged insulation. If the pipe in question is in operation 8760 hours
2. Repair damaged coverings and finishes. per year the annual heat loss reduction can be
3. Maintain safety requirements. calculated.
24
Annual heat loss reduction 4.1.1.2 REPAIR DAMAGED
Hourly heat loss reduction operating hours INSULATION COVERS AND
per year FINISHES
Estimated cost to supply and install the insulation is Estimated cost to supply and install 100 mm of
R3000. mineral fibre insulation on the top, side and bottom
R3 000:00 of the tank is R30 000.
Simple payback
R3 736:62 R30 000
Simple payback
0.80 years (10 months) R110 376
0.27 years (3 months)
Worksheet 1-3 is used twice. The first time to 1. Upgrade existing insulation levels.
calculate the reduction in heat loss from a bare 2. Review economic thickness requirement.
vessel to 25 mm of insulation and the second time 3. Limited budget upgrade.
to calculate the reduction in heat loss between the
bare vessel and 51 mm of insulation.
4.3.1 RETROFIT WORKED EXAMPLES
The energy savings in adding 26 mm of insulation
and increasing the overall thickness to 51 mm can
be calculated. 4.3.1.1 UPGRADE EXISTING
INSULATION LEVELS
Energy Savings
During a walk through audit it was noted that an
Savings with 51 mm ± Savings with 25 mm
NPS 6, steam header operating at 288oC for 8760
81 900 000 ± 61 950 000 hours per year was insulated with cellular glass
insulation. The steam header was 100 metres long.
19 950 000 Wh/yr
or 19 950 kWh/yr A review of Table 3 indicated that the heat loss for
this main based on the cellular glass insulation was
Rand savings 19 950 R0.20 145 Wh/m. It was further noted that if the
insulation was changed to mineral fibre, the heat
R3 990
loss would be reduced to 99 Wh/m. It should be
noted that the insulation thickness remained the
Estimated cost to supply and install the additional
same.
insulation is R30 000.
27
(147 ± 100) 100 8760 numerous steam branch mains were not insulated.
41 172 000 Wh/yr These steam mains varied in size from NPS 1 to
or 41 172 000 3.6 NPS 6. It was estimated that the equivalent length
148 219 200 kJ/yr would be equal to 350 m of NPS 4. The
or 148 219.2 MJ/yr temperature of the steam was 121oC and the
mains were in operation for an estimated 4400
The steam was produced in a boiler operating at hours per year. The steam was produced in a low-
76 per cent efficiency using synthetic at a cost of pressure boiler, which used synthetic gas as the fuel
R58.00/GJ. and operated at 77 per cent efficiency. The cost of
148 219:2 R58:00 gas at the facility was R58.00/GJ.
Rand savings
1000 0:76
A review of Table 3 indicated that the recom-
R11 311.50/yr
mended mineral fibre insulation thickness for NPS
4 pipe at 121oC would be 76 mm. and that the
The estimated cost to replace the cellular glass
heat loss would be 28 Wh/m. Table 1 indicates
insulation with glass fibre insulation was R100 000.
that the heat loss for bare steel pipe at 121oC is
R100 000 530Wh/m.
Simple payback
R11 311:50
8.8 years Using Worksheet 1-2 it was established that the
reduction in heat loss if the bare pipe were
In this case the replacement is not justified based insulated to the recommended thickness with glass
on the payback. However, if the original insulation fibre insulation would be or 2 783 088 MJ/yr.
had been less than the recommended thickness, 2 783 088 R58:00
the heat loss and therefore the savings would have Dollar savings
1000 0:77
been much greater. This would have to be
R209 635/yr
calculated using insulation manufacturers published
data.
The cost to supply and install the 76mm insulation
on the uninsulated piping was R80 000
28
Using Worksheet 1-2 again the reduction in heat Even though the simple payback was not as good
loss if 25 mm of mineral fibre insulation is used is 1 as with the 25 mm as with the 76 mm of insulation,
829 520 MJ/yr management was prepared to invest R70 000 for
1 829 520 R58:00 this limited budget upgrade.
Rand savings
1 000 0:77
R137 808/yr
29
APPENDICES
WORKSHEETS
WORKSHEET 1-1
Company: _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Date: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Location: ________________________________________________________________________________________________________________________________________________ By: ___________________________________________________________________________________________________________________________________________________________________
Insulation for: ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Not
Property Important
Important
APPEARANCE (is insulation exposed?)
DENSITY
30
WORKSHEET 1-2
_________________________________________________________________________________________________________________________________________________Wh/h _________________________________________________________________________________________________________________________________________________Wh/h
Annual heat loss Heat loss h/yr Heat loss/h h/yr
___________________________________________________________________________ _____________________________________________________ _____________________________________________________________________________ __________________________________________________________________________
_____________________________________________________________________________________________________________________________________Wh/yr
or ______________________________________________________________________________________Wh/yr 3.6 kJ/Wh
_____________________________________________________________________________________________________________________________________________kJ/yr
Annual Rand savings may now be calculated using cost per unit of heating medium. Ensure that units are
compatible.
31
WORKSHEET 1-2
Company: _____________________________________________ABC
_________________Co.
________________________________________________________________ Date: ___________________________________________________________________________________________________________________________________________________
Location: ________________________________________ANYTOWN
__________________________________________________________________________________________ By: ______________________________________________________________MBE
_________________________________________________________________________________________
Low cost worked example No. 1
Pipe diameter (NPS) ________________________________________________2_________________________________________ Pipe Length _________________________________________________________20
_______________________________________________________ m
Pipe temperature _________________________________________121
________________________________________________ oC Operating
Hours per year _________________________________________2_______880
______________________________________________________ h
Proposed Proposed
insulation type ___________________________________cellular
__________________________glass
__________________________________________________ Insulation thickness _________________________________34
________________________________________________ mm
Uninsulated Insulated
Heat loss
_________________________________Wh/m.h (Table 1)
Per metre ________________________________290 _____________________________________________________Wh/m.h (Table 3)
_________________________________________________35
Heat loss/h Heat loss/m.h length Heat loss/m.h length
___________________________________290
________________________________________ __________________________20
___________________________ ___________________________________35
__________________________________________ _________________________20
______________________________
______________________________________________________________________5_______800
____________________________________________________________________Wh/h ___________________________________________________________________________700
______________________________________________________________________Wh/h
Annual heat loss Heat loss h/yr Heat loss/h h/yr
__________________________________5________800
_________________________________ ________________________2________880
_____________________ _______________________________700
______________________________________________ ________________2_______880
___________________________________________________
___________________________________________16
____________704
________________000
___________________________________________________________Wh/yr (1) _________________________________________________________2_______016
_________________000
_________________________________________________Wh/yr (2)
Reduction in heat loss due
to addition of insulation
(1) ± (2)
______________________________16
____________704
________________000
______________________________________ ± _____2_______016
________________000
________________
_______________________________________________14
____________688
________________000
__________________________________________________________Wh/yr
or _______________________14
____________688
________________000
___________________________________Wh/yr 3.6 kJ/Wh
__________________________________52
____________876
________________800
_______________________________________________________________________________kJ/yr
Annual Rand savings may now be calculated using cost per unit of heating medium. Ensure that units are
compatible.
32
WORKSHEET 1-2
Company: _____________________________________________XYZ
__________________Co.
_______________________________________________________________ Date: ___________________________________________________________________________________________________________________________________________________
Location: ________________________________________ANYTOWN
__________________________________________________________________________________________ By: ______________________________________________________________MBE
_________________________________________________________________________________________
Housekeeping worked example No. 1
Pipe diameter (NPS) ________________________________________________4_________________________________________ Pipe Length _________________________________________________________10
_______________________________________________________ m
Pipe temperature __________________________________________________________121
_______________________________ oC Operating
Hours per year _________________________________________8_______760
______________________________________________________ h
Proposed Proposed
insulation type ___________________________________mineral
____________________________fibre
________________________________________________ Insulation thickness _________________________________76
________________________________________________ mm
Uninsulated Insulated
Heat loss
_________________________________Wh/m.h (Table 1)
Per metre ________________________________530 _____________________________________________________Wh/m.h (Table 3)
_________________________________________________28
Heat loss/h Heat loss/m.h length Heat loss/m.h length
___________________________________530
________________________________________ __________________________10
___________________________ ____________________________________28
_________________________________________ _________________________10
______________________________
______________________________________________________________________5_______300
____________________________________________________________________Wh/h ___________________________________________________________________________280
______________________________________________________________________Wh/h
Annual heat loss Heat loss h/yr Heat loss/h h/yr
__________________________________5________300
_________________________________ ________________________8________760
_____________________ _______________________________2800
______________________________________________ ____________________8_______760
_______________________________________________
___________________________________________46
____________428
________________000
_____________________________________________________________Wh/h (1) _________________________________________________________2________452
________________800
_________________________________________________Wh/yr (2)
Reduction in heat loss due
to addition of insulation
(1) ± (2)
______________________________46
____________428
________________000
______________________________________ ± _____2_______452
________________800
________________
_______________________________________________43
____________975
________________200
__________________________________________________________Wh/yr
or ______________________________________________________________________________________Wh/yr 3.6 kJ/Wh
_____________________________________________________________________________________________________________________________________________kJ/yr
Annual Rand savings may now be calculated using cost per unit of heating medium. Ensure that units are
compatible.
33
WORKSHEET 1-3
_________________________________________________________________________________________________________________________________________________Wh/h _________________________________________________________________________________________________________________________________________________Wh/h
Annual heat loss Heat loss h/yr Heat loss/h h/yr
___________________________________________________________________________ _____________________________________________________ _____________________________________________________________________________ __________________________________________________________________________
_____________________________________________________________________________________________________________________________________Wh/yr
or ______________________________________________________________________________________Wh/yr 3.6 kJ/Wh
_____________________________________________________________________________________________________________________________________________kJ/yr
Annual Rand savings may now be calculated using cost per unit of heating medium. Ensure that units are
compatible.
34
WORKSHEET 1-3
Company: _____________________________________________ABC
_________________Co.
________________________________________________________________ Date: ___________________________________________________________________________________________________________________________________________________
Location: ________________________________________ANYTOWN
__________________________________________________________________________________________ By: ______________________________________________________________MBE
_________________________________________________________________________________________
Operating
Equipment ______________________________Heating
_____________________________tank
_________________No.
________________1________________________________ Hours per year _________________________________________8_______760
______________________________________________________ h
Proposed Insulation
Surface area _________________________________________________10
_________________________________________________________ m2 type __________________________________________________________________mineral
____________________________fibre
____________________________________________________
Proposed
Product temperature __________________________________177
__________________________________________ oC Insulation thickness _________________________________102
________________________________________________ mm
Uninsulated Insulated
Heat loss_______________________________________2_______800
___________________________Wh/m2 (Table 5) _________________________________________________63
________________________________________________________Wh/m2 (Table 3)
Total heat loss/h Surface area Heat loss Surface area Heat loss
___________________________________10
________________________________________ ______________________2_______800
________________________ ____________________________________10
_________________________________________ _________________________63
______________________________
____________________________________________________________________28
____________000
_________________________________________________________________Wh/h ___________________________________________________________________________630
______________________________________________________________________Wh/h
Annual heat loss Heat loss h/yr Heat loss/h h/yr
__________________________28
___________000
______________________________________ ___________________8_______760
___________________________ _______________________________630
______________________________________________ ________________8_______760
___________________________________________________
____________________________________________________245
________________280
________________000
________________________________________________Wh/h (1) _________________________________________________________5________518
________________800
_________________________________________________Wh/yr (2)
Reduction in heat loss due
to addition of insulation
(1) ± (2)
_____________________________245
________________280
________________000
___________________________________ ± ________5_______518
________________800
_____________
_______________________________________________239
_________________761
________________200
_____________________________________________________Wh/yr
or _______________________239
________________761
________________200
___________________________________Wh/yr 3.6 kJ/W
__________________________________863
________________140
________________320
___________________________________________________________________________kJ/yr
Annual Rand savings may now be calculated using cost per unit of heating medium. Ensure that units are
compatible.
35
WORKSHEET 1-3
Company: _____________________________________________XYZ
__________________Co.
_______________________________________________________________ Date: ___________________________________________________________________________________________________________________________________________________
Location: ________________________________________ANYTOWN
__________________________________________________________________________________________ By: ______________________________________________________________MBE
_________________________________________________________________________________________
Low cost worked example No.3
Operating
Equipment ______________________________Heating
_____________________________tank
_________________No.
________________2________________________________ hours per year ___________________________________________8_______400
______________________________________________________ h
Proposed Insulation
Surface area __________________________________________________25
________________________________________________________ m2 type __________________________________________________________________mineral
___________________________fibre
_____________________________________________________
Proposed
Product temperature __________________________________65
__________________________________________ oC Insulation thickness _________________________________51
________________________________________________ mm
Uninsulated Insulated
Heat loss_______________________________________504.7
__________________________________Wh/m2 (Table 5) _________________________________________________32
________________________________________________________Wh/m2 (Table 3)
Total heat loss/h Surface area Heat loss Surface area Heat loss
___________________________________25
________________________________________ ______________________504.7
_______________________________ ____________________________________25
_________________________________________ _________________________32
______________________________
____________________________________________________________________12
____________617.5
_________________________________________________________________Wh/h ___________________________________________________________________________800
______________________________________________________________________Wh/h
Annual heat loss Heat loss h/yr Heat loss/h h/yr
__________________________12
___________617.5
______________________________________ ________________________8________400
_____________________ _______________________________800
______________________________________________ ________________8_______400
___________________________________________________
____________________________________________________105
________________987
________________000
________________________________________________Wh/h (1) _________________________________________________________6________720
________________000
_________________________________________________Wh/yr (2)
Reduction in heat loss due
to addition of insulation
(1) ± (2)
____________________________105
_________________987
________________000
___________________________________ ± ________6_______720
________________000
_____________
_______________________________________________99
____________300
________________000
__________________________________________________________Wh/yr
or _______________________99
____________300
________________000
___________________________________Wh/yr 3.6 kJ/Wh
__________________________________357
________________480
________________000
___________________________________________________________________________kJ/yr
Annual Rand savings may now be calculated using cost per unit of heating medium. Ensure that units are
compatible.
36
WORKSHEET 1-3
Company: _____________________________________________ABC
_________________Co.
________________________________________________________________ Date: ___________________________________________________________________________________________________________________________________________________
Location: ________________________________________ANYTOWN
__________________________________________________________________________________________ By: ______________________________________________________________MBE
_________________________________________________________________________________________
Low cost worked example No. 3
Operating
Equipment ______________________________Holding
______________________________tank
_________________No.
________________2_______________________________ Hours per year _________________________________________8_______400
______________________________________________________ h
Proposed Insulation
Surface area _________________________________________________25
_________________________________________________________ m2 type __________________________________________________________________mineral
____________________________fibre
____________________________________________________
Proposed
Product temperature __________________________________65
__________________________________________ oC Insulation thickness _________________________________25
________________________________________________ mm
Uninsulated Insulated
Heat loss_______________________________________504.7
__________________________________Wh/m2 (Table 5) _________________________________________________115
_________________________________________________Wh/mm2 (Table 3)
Total heat loss/h Surface area Heat loss Surface area Heat loss
___________________________________25
________________________________________ ______________________504.7
_______________________________ ____________________________________25
_________________________________________ _________________________115
______________________________
____________________________________________________________________12
____________617.5
_________________________________________________________________Wh/h ___________________________________________________________________________2_______875
_______________________________________________________________Wh/h
Annual heat loss Heat loss h/yr Heat loss/h h/yr
__________________________12
___________617.5
______________________________________ ________________________8________400
_____________________ _______________________________2_______875
_______________________________________ _______________________8________400
___________________________________________
____________________________________________________105
________________987
________________000
______________________________________________Wh/yr (1) _________________________________________________________21
____________150
________________000
_____________________________________________Wh/yr (2)
Reduction in heat loss due
to addition of insulation
(1) ± (2)
_____________________________105
________________987
________________000
___________________________________ ± _____21
____________150
________________000
___________
_______________________________________________81
____________837
________________000
__________________________________________________________Wh/yr
or _______________________81
____________837
________________000
___________________________________Wh/yr 3.6 kJ/Wh
__________________________________294
________________613
________________200
___________________________________________________________________________kJ/yr
Annual Rand savings may now be calculated using cost per unit of heating medium. Ensure that units are
compatible.
37
WORKSHEET 1-2 (Page 1 of 2)
Company: _____________________________________________ABC
_________________Co.
________________________________________________________________ Date: ___________________________________________________________________________________________________________________________________________________
Location: ________________________________________ANYTOWN
__________________________________________________________________________________________ By: ______________________________________________________________MBE
_________________________________________________________________________________________
Retrofit worked example No. 3
Pipe diameter (NPS) _______________________________________4__________________________________________________ Pipe Length _____________________________________________________350
___________________________________________________________ m
Pipe temperature _________________________________________121
________________________________________________ oC Operating
Hours per year ____________________________________4________400
__________________________________________________________ h
Proposed Proposed
insulation type ___________________________________mineral
____________________________fibre
________________________________________________ Insulation thickness _________________________________76
________________________________________________ mm
Uninsulated Insulated
________________________________Wh/m.h (Table 1)
Heat loss_______________________________________530 _____________________________________________________Wh/m.h (Table 3)
_________________________________________________28
Heat loss/h Heat loss/m.h length Heat loss/m.h length
___________________________________530
________________________________________ __________________________350
___________________________ ___________________________________28
__________________________________________ _________________________350
______________________________
___________________________________________________________185
________________500
______________________________________________________________________Wh/h ___________________________________________________________________________9_______800
_______________________________________________________________Wh/h
Annual heat loss Heat loss h/yr Heat loss/h h/yr
__________________________185
________________500
_________________________________ _______________________4_______400
_______________________ _______________________________9_______800
_______________________________________ _______________________4_______400
____________________________________________
____________________________________________________816
________________200
________________000
________________________________________________Wh/h (1) _________________________________________________________43
____________120
________________000
_____________________________________________Wh/yr (2)
Reduction in heat loss due
to addition of insulation
(1) ± (2)
____________________________816
_________________200
________________000
___________________________________ ± _____43
____________120
________________000
___________
_______________________________________________773
________________080
_________________000
_____________________________________________________Wh/yr
or _______________________773
________________080
________________000
_______________________________Wh/yr 3.6 kJ/Wh
__________________________________2_______783
________________088
________________000
____________________________________________________________________kJ/yr
Annual Rand savings may now be calculated using cost per unit of heating medium. Ensure that units are
compatible.
38
WORKSHEET 1-2 (Page 2 of 2)
Company: _____________________________________________ABC
_________________Co.
________________________________________________________________ Date: ___________________________________________________________________________________________________________________________________________________
Location: ________________________________________ANYTOWN
__________________________________________________________________________________________ By: ______________________________________________________________MBE
_________________________________________________________________________________________
Retrofit worked example No. 3
Pipe diameter (NPS) ________________________________________________4_________________________________________ Pipe Length _________________________________________________________350
_______________________________________________________ m
Pipe temperature __________________________________________________________121
_______________________________ oC Operating
Hours per year _________________________________________4_______400
______________________________________________________ h
Proposed Proposed
insulation type ___________________________________mineral
____________________________fibre
________________________________________________ Insulation thickness _________________________________25
________________________________________________ mm
Uninsulated Insulated
Heat loss
_________________________________Wh/m.h (Table 1)
Per metre ________________________________530 _____________________________________________________Wh/m.h (Table 3)
_________________________________________________200
Heat loss/h Heat loss/m.h length Heat loss/m.h length
___________________________________530
________________________________________ __________________________350
___________________________ ____________________________________200
_________________________________________ _____________________________350
__________________________
______________________________________________________________________185
________________500
___________________________________________________________Wh/h __________________________________________________________________70
____________000
___________________________________________________________________Wh/h
Annual heat loss Heat loss h/yr Heat loss/h h/yr
__________________________185
________________500
_________________________________ ____________________4_______400
__________________________ _______________________________70
____________000
__________________________________ ___________________________4________400
_______________________________________
___________________________________________816
________________200
________________000
_______________________________________________________Wh/yr (1) _________________________________________________________308
________________000
________________000
_________________________________________Wh/yr (2)
Reduction in heat loss due
to addition of insulation
(1) ± (2)
__________________________816
_______________200
________________000
_______________________________________ ± _308
________________000
________________000
___________
_______________________________________________508
_________________200
________________000
_____________________________________________________Wh/yr
or _______________________508
________________200
________________000
_______________________________Wh/yr 3.6 kJ/Wh
__________________________________1_______829
________________520
_________________000
___________________________________________________________________kJ/yr
Annual Rand savings may now be calculated using cost per unit of heating medium. Ensure that units are
compatible.
39
GLOSSARY
Ambient Temperature ± The temperature of the the liquid being the surface tension.
medium, usually air, surrounding the
object under consideration. Caulking Compound ± A soft, plastic material,
consisting of pigment and carrier, used
Batt ± A piece of insulation, of the flexible type, for sealing joints in buildings, and other
cut into easily handled sizes, square or structures, where normal structural
rectangular in shape, usually 609.6 mm movement may occur.
(24º) or 1219 mm (48º) long with a
vapour retarder on one side, and with, or Cellular Elastomeric Flexible Thermal Insulation
without, a container sheet on the other ± Insulation composed principally of
side. natural or synthetic elastomers in ex-
panded cellular form.
Blanket ± Insulation, of the flexible type, formed
into sheets or rolls, usually with a vapour Cellular Glass Thermal Insulation ± Insulation
retarder on one side, and with, or with- composed of glass processed by fusion
out, a container sheet on the other side. to form a homogeneous rigid mass of
closed cells.
Block ± Rigid or semi-rigid insulation formed into
sections, rectangular both in plan and Celsius ± The temperature measuring scale
cross-section, usually 36º (914.4 mm) to (formerly Centigrade) in which the
1219 mm (48º) long, 152.4 mm (6º) to freezing point of water is taken at 0o
609.6 mm (24º) wide, and 25.4 mm (1º) and the vaporisation point at 100o.
to 152.4 mm (6º) thick. Absolute zero on this scale is -273.15oC.
Calcium Silicate Insulation ± Insulation composed Chemically Foamed Plastic ± A cellular plastic
principally of hydrous calcium silicate, produced by gasses generated from
which usually incorporates fibres of chemical interaction of constituents.
varying types to act as a binder.
Chlorinated Solvent ± An organic chemical liquid
Canvas ± A light, plain weave, coarse, cotton cloth characterised by a high chlorine content
with hard twisted yarns, usually not more and used in coating products to impart
than 271 grams per square metre. non-flammability.
Capillarity ± That property of a material which Closed-Cell Foamed Plastic ± A cellular plastic in
enables it to suck a liquid up into or which there is a predominance of non-
through itself, with the driving force of interconnecting cells.
40
Coating ± A liquid, or semi-liquid, protective finish contact: also called contact bond or dry
suitable for thermal insulation or other bond adhesive.
surfaces, usually applied by brush or
spray, in moderate thickness, less than Corrosion Effect ± The wearing away' or destruc-
0.80 mm approx. [30 mils (0.030º)]. tion of a substrate caused by acid or
alkaline reactions between materials
Coefficient of Expansion (Contraction) ± The contained in the insulation and substrate.
increase (decrease) in length of a
material one unit long, due to the Coverage-Wet ± The property of a material which
increase (decrease) of temperature by measures the thickness of wet material
one degree. that must be applied to a given area to
obtain a specific thickness after it has
Combustible ± Capable of uniting with air or cured and dried.
oxygen in a reaction initiated by heating
accompanied by the subsequent evolu- Cryogenic ± Pertaining to the extremely low
tion of heat and light i.e. capable of temperatures, such as the liquefaction
burning. points of gaseous elements, usually
approaching absolute zero (-273.15oC).
Combustibility ± That property of a material which
measures its tendency to burn. It is Curing Agent ± An additive incorporated in a
normally expressed in the arbitrary terms coating or adhesive resulting in increased
of ªFlame Spread Indexº and ªSmoke chemical activity between the compo-
Density Indexº nents, with an increase or decrease in the
rate of cure.
Compressive Strength ± Resistance to change in
dimension when acted on by a compact- Curved Segmental Block ± A piece of rigid pipe
ing force. insulation, moulded or cut from a block
to fit the exact dimensions of a given size
Condensation ± The act of water vapour turning of pipe.
into water upon contact with a surface at
a lower temperature than the dew point Density ± The mass per unit volume of a
of the vapour. substance.
Conduction ± The transfer of energy within a Dewpoint ± The temperature at which the
body, or between two bodies in physical quantity of water vapour in a material
contact, from a higher temperature would cause saturation, with resultant
region to a lower temperature region. condensation of the vapour into liquid
water by any further reduction of
Conductivity ± See Thermal Conductance. temperature.
41
binders and which usually incorporates of 212o with 180 even divisions between
mineral fibres. and corresponding divisions above and
below. Absolute zero on this scale is -
Dimensional Stability ± That property of insulation, 459.67o.
which enables it to hold its original size,
shape and dimensions. Felt ± An insulation material composed of fibres,
which are interlocked and compacted
Drying Time (Adhesives) ± Time elapsed since under pressure.
bonding and the time when no further
increase in bond strength is realised. Fibreglass ± A composite material consisting of
glass fibres and a resin binder.
Drying Time (Finishes) ± Time elapsed after which
no further significant changes take place Filler ± A relatively inert material added to a mastic
in appearance or performance proper- or coating to modify its strength, per-
ties, due to drying. meance, working properties, or other
qualities.
Ductility ± That property of a material which
enables it to undergo large deformations Finishing Cement ± A mixture of fibres, bonding
without rupture. clays, and water mixed to a plastic mass
on the job, and used on the surface of
Elastomer ± Material, which at room temperature insulation to provide a medium-hard to
can be stretched repeatedly to at least hard, even finish.
twice its original length and immediately
upon release of the stress, will return Fire Resistance ± That property of a material that
with force to the approximate original enables it to resist decomposition or
length. deterioration when exposed to a fire.
Emittance ± The ratio of the total heat lost per unit Fire Retardance ± That property of a material,
of time through the same unit area of a which delays the spread of fire, either
perfect blackbody. through or over itself.
Exposed ± Any surface, which will be visible in the Flame Spread ± The rate, expressed in distance and
finished structure. time, at which a material will propagate
flame on its surface. As this is a difficult
Facing ± A thin layer on the surface of an insulating property to measure in time and dis-
product, acting as either a vapour tance, the measure is now by flame
retarder, weather barrier, protector from spread index to enable the comparison
damage or a decorative coating. of materials by one of the following test
methods: CAN2- S102-M83 or ASTM
Fahrenheit ± The temperature scale of The British E84.
System of units in which the freezing
point of water is assigned the value of Flammable ± That property of a material which
32o and the vaporisation point the value permits it to oxidise rapidly and release
42
heat of combustion when exposed to Insulation ± A material of low thermal conductivity
flame or fire, and allows continuous used to reduce the passage of heat.
burning after the external ignition source
is removed. Insulation Coating ± A material, or materials, used
over insulation or over the weather
Flashing ± A thin strip of metal inserted at the coating to provide the desired colour
junction of 2 materials to divert water in or texture for decorative purposes.
a specific direction.
Insulation Cover ± The cover for a flange,
Flash Point ± The lowest temperature of a material pipefitting, or valve, composed of the
(at a fixed pressure) at which it gives off specified thickness of insulating material,
vapour, which, when combined with air and pre-formed into the proper shape
near the surface, forms an ignitable before application.
mixture.
Insulation System ± An application of insulation to
Flexibility ± That property of a material, which piping, ductwork or equipment that may
allows it to be bent (flexed) without loss include the use of adhesives, mechanical
of strength. fastenings, coatings, reinforcing fabrics,
sealant and metal covering.
Flexural Strength ± That property of a material
which measures its resistance to bending Jacket ± A covering placed around an insulation to
(flexing) usually expressed in kg/m (lbs/ protect it from mechanical damage, and,
in). insofar as it is intrinsically able, from
weather, water, ultraviolet light, etc.
Freeze-Thaw Resistance ± The property of a
material which permits it to be alter- Lag ± A long, narrow piece of rigid insulation,
nately frozen and thawed through many rectangular in plan, trapezoidal in cross-
cycles without damage from rupture or section, moulded, or cut from a block of
cracking. the proper thickness.
43
sions when exposed to high tempera- Pipe Insulation ± Thermal insulation suited for
tures. application to cylindrical surfaces of pipe
and tubing.
Loose Fill Insulation ± Particulate material in
granular, nodular, fibrous, powdery, or Pre-formed Pipe Insulation ± Thermal insulation in
similar form designed to be installed dry cylindrical, semi-cylindrical, or segmental
by pouring, blowing, or hand placement sections to fit pipes and tubing.
between retaining surfaces or as a
covering layer. Pre-formed Thermal Insulation Block ± A rigid or
semi-rigid thermal insulating material,
Mastic ± A relatively thick consistency protective either flat or segmental, for application
finish capable of application to thermal as received.
insulation or other surfaces, usually by
spray or trowel, in thick coats greater Primer ± The first application of a coating system
than 30 mils (0.80 mm approximately). used to seal or condition the surface for
the proper bonding of subsequent layers
Metal Lath ± A lattice type of material of various or coats.
gauges and sizes used to provide re-
inforcement for insulation. PVC-Polyvinyl Chloride ± Plastic material moulded
into finished shapes such as fitting covers.
Mineral Fibre (Wool) ± A generic term for all non-
metallic inorganic fibres, which may be Reflective Insulation ± Thermal insulation depend-
natural, or may be manufactured from ing for its efficiency in large part on the
such sources as rock, slag, or glass. reduction of radiant heat transfer across
spaces by use of one or more surfaces of
Mineral Fibre Blanket Insulation ± A blanket high reflectance and low emittance.
thermal insulation composed of inorgan-
ic fibres, with, or without, added binders. Reinforcing Membrane ± A loosely woven cloth
or fabric of glass or resilient fibres, placed
Mitred Insulation ± Insulation that has been cut in approximately in the centre of the
bevelled sections so that when it is fitted vapour retarder or weather barrier to
together, it follows the contour or curve act as reinforcing to the mastic of the
of the object being insulated. barrier.
Non-combustible ± A material that will not Scrim ± Woven screening type fabric used to
contribute fuel or heat to a fire to which reinforce an insulation covering.
it is exposed.
Tack ± The property of an adhesive that enables it
Non-flammable ± That property of a material that to form a bond of measurable strength
prevents it from oxidising rapidly and immediately after adhesive and adherent
releasing heat or combustion when are brought into contact under low
exposed to fire or flame. pressure.
44
Temperature Limits ± The upper and lower formed by the mating surfaces of jackets
temperatures at which a material will and vapour retarders over insulation. A
experience no essential change in its good sealer will not shrink much. There
properties. are several types of sealers, such as non-
setting, and heat resisting.
Thermal Insulation ± Material having air-filled or
gas-filled pockets, void spaces, or heat- Service Temperature Limits ± The temperature
reflective surfaces, which, when properly range within which the applied coating
applied will retard the transfer of heat will provide satisfactory service.
with reasonable effectiveness under or-
dinary conditions. Smoke Density (Smoke Developed) ± The Smoke
Density Factor is the amount of smoke
Reinforcing Mesh ± Generic term for poultry given off by the burning material com-
netting, chicken wire, etc., usually made pared to the amount of smoke given off
from pre-galvanised wire woven in 25.4 by the burning of a standard material.
mm (1 inch) mesh size. Also available in
post-galvanised and rustless metal alloys. Softening Point ± That temperature at which a
material will change its property from
Relative Humidity ± The ratio of the actual firm or rigid to soft or malleable.
pressure of existing water vapour to
the maximum possible (saturation) pres- Solvent ± Any substance, usually a liquid, which
sure of water vapour in the atmosphere dissolves another substance. Normally a
at the same temperature, expressed as a liquid organic compound used to make a
percentage. (See Dewpoint.) coating work more freely.
Resilient ± Capable of recoiling from pressure or Substrate ± A material upon the surface of which
shock unchanged or undamaged. an adhesive or coating is spread.
Sag ± Excessive flow in material after application to a Thermal Shock Resistance ± That property of a
surface, resulting in ªcurtainingº or running. material which enables it to maintain
shape and not distort, crack or shatter,
Self-Ignition Temperature (Autogeneous Ignition) from a sudden temperature change.
± The lowest temperature of a material
which will cause it to ignite without Thermoplastic ± Capable of being repeatedly
another ignition source. softened by an increase of temperature.
Note: Thermoplastic applies to those
Self-Extinguishing ± That property of a material materials whose change upon heating is
which enables it to stop ignition after substantially physical.
external ignition sources are removed.
Thermoset ± A plastic or other coating which,
Sealer ± A substance, composed of various when cured by the application of heat or
materials, used as a barrier to the passage chemical means, changes to a substan-
of water vapour or water into the joint tially infusible and insoluble product.
45
Toxicity ± The degree of hazard to health. Viscosity ± The property of resistance to flow
exhibited within the body of a material.
Urethane Resins ± Resins made by the condensa-
tion of organic isocyanates with com- Water Absorption ± The increase in weight of a
pounds or resins that contain hydroxol material, expressed as a percentage of its
groups. Note: Urethanes are a type of dry weight, after immersion in water for a
isocyanates resins. specified time.
Vapour Retarder ± A material, or materials, which Weather Barrier ± A material, which, when
when installed on the high vapour installed on the outside of the insulation,
pressure side, retards the passage of the protects the insulation from weather
moisture vapour to the lower vapour damage due to rain, snow, wind, atmo-
pressure side. spheric contamination, etc.
Vapour Migration (Permeability) ± That property Weather Coating ± A material, or materials, which,
of a material, which measures the rate at when installed on the outer surface of
which water vapour will penetrate it, due thermal insulation, protects the insulation
to vapour pressure differences between from weather, such as rain, snow, sleet,
its surfaces. wind, solar radiation, and atmospheric
contamination.
Vapour Pressure ± The gas pressure exerted by
the water vapour present in the air. Wire Netting ± Interwoven wires of metal used as
reinforcement for insulation.
Vermiculite ± Lightweight insulation material made
from the expansion of granules at high Wicking ± The ability of a material to draw up
temperatures. liquids by capillary action.
46
HEAT LOSS TABLES
47
48
49
50
51
HEAT LOSS TABLES
TABLE 3
CELLULAR GLASS
NPS PROCESS TEMPERATURE (oC)
52
TABLE 3 (CELLULAR GLASS ± Continued)
NPS PROCESS TEMPERATURE (oC)
53
HEAT LOSS THROUGH PIPES WITH VARIOUS THICKNESSES OF INSULATION
TABLE 3
CALCIUM SILICATE
NPS PROCESS TEMPERATURE (oC)
54
TABLE 3 (CALCIUM SILICATE ± Continued)
NPS PROCESS TEMPERATURE (oC)
12 Thickness 64 102 102 102 127 140 178 203 216 241
heat loss 45 72 116 163 184 256 227 252 288 317
surf. temp 23 24 27 30 30 32 31 31 32 33
14 Thickness 64 102 102 102 127 140 178 203 229 241
heat loss 49 78 125 176 197 233 242 252 296 338
surf. temp 23 24 27 30 31 32 31 31 32 33
16 Thickness 76 102 102 102 140 191 203 229 254 254
heat loss 48 87 138 196 203 228 255 295 325 358
surf. temp 22 24 28 31 29 30 31 32 32 33
18 Thickness 76 102 102 102 140 165 191 216 229 254
heat loss 53 95 153 216 223 249 278 308 353 387
surf. temp 23 24 28 31 30 31 31 31 32 33
20 Thickness 76 102 102 102 140 165 191 216 241 254
heat loss 58 104 167 236 242 270 300 333 366 418
surf. temp 23 25 28 31 30 31 31 32 32 33
24 Thickness 76 102 102 102 140 165 191 216 241 254
heat loss 68 122 195 276 282 312 346 382 420 478
surf. temp 23 25 28 31 31 31 31 32 32 34
30 Thickness 76 102 102 102 140 178 203 229 254 254
heat loss 83 148 237 336 339 354 393 435 479 566
surf. temp 23 25 28 31 31 31 31 32 32 34
36 Thickness 64 102 102 102 165 191 203 229 254 254
heat loss 114 174 280 394 345 390 457 504 554 655
surf. temp 23 25 28 32 29 30 31 32 33 34
FLAT Thickness 64 89 102 140 165 191 216 241 254 254
heat loss 38 63 88 91 104 114 123 136 155 183
surf. temp 23 25 27 27 28 29 29 31 32 34
55
HEAT LOSS THROUGH PIPES WITH VARIOUS THICKNESSES OF INSULATION
TABLE 3
MINERAL FIBRE
NPS PROCESS TEMPERATURE (oC)
56
TABLE 3 (MINERAL FIBRE ± Continued)
NPS PROCESS TEMPERATURE (oC)
24 Thickness 64 102 102 102 140 152 191 203 229 254
heat loss 51 83 141 212 228 284 308 371 422 479
surf. temp 22 23 26 28 28 30 30 32 33 34
30 Thickness 64 102 102 102 140 165 191 216 254 254
heat loss 62 101 172 258 275 319 368 422 462 568
surf. temp 22 23 26 29 29 29 31 32 32 34
36 Thickness 64 102 102 102 140 178 203 229 254 254
heat loss 74 118 203 304 322 350 406 467 535 657
surf. temp 22 23 26 29 29 29 30 31 32 34
FLAT Thickness 51 89 102 114 140 216 241 254 254 254
heat loss 32 44 63 85 98 85 98 120 148 183
surf. temp 22 23 25 27 28 27 28 29 32 34
57
Thermal properties of typical building and insulation materials ± DESIGN VALUES
TABLE 4
MINERAL FIBRE
Description Density Conductivity Conductance Resistance (R) Specific
kg/m3 k (C) Heat
Per inch thickness For thick-
W/m.oC W/m2.oC kJ/(kg .oC)
(1/k) m.oC ness listed
(1/C)
m2.oC
INSULATING MATERIALS
58
TABLE 4 (MINERAL FIBRE ± Continued)
Description Density Conductivity Conductance Resistance (R) Specific
kg/m3 k (C) Heat
Per inch For thick-
W/m.oC W/m2.oC kJ/(kg.oC)
thickness (1/k) ness listed
m.oC (1/C)
m2.oC
Cellular polyurethane (R-11 exp.)
(unfaced) 24.0 0.023 43.38 Ð 1.59
Foil-faced, glass fibre-reinforced cellular
Polyisocyanurate (R-11 exp.) 32.0 0.020 Ð 49.97 Ð 0.92
Nominal 12.70 mm Ð 1.58 Ð 0.63
Nominal 25.40 mm Ð 0.79 Ð 1.27
Nominal 50.80 mm Ð 0.39 Ð 2.53
Mineral fibre with resin binder 240 0.042 Ð 23.94 Ð 0.71
Mineral fibreboard, wet felted
Core or roof insulation 256-272 0.049 Ð 20.40 Ð
Acoustical tile 288 0.050 Ð 19.85 Ð 0.80
Acoustical tile 336 0.0563 Ð 18.74 Ð
Mineral fibreboard,
wet moulded Acoustical tile 368 0.060 Ð 16.52 Ð 0.59
Wood or cane fibreboard
Acoustical tile 12.70 mm Ð Ð 4.54 Ð 0.22 1.30
Acoustical tile 19.05 mm Ð Ð 3.01 Ð 0.33 Ð
Interior finish (plank, tile) 240 0.050 Ð 19.85 Ð 1.34
Cement fibre slabs (shredded wood with
Portland cement binder) 400-432 0.072-0.070 Ð 13.88-13.12 Ð Ð
Cement fibre slabs (shredded wood with
magnesia oxysulfide binder) 352 0.082 Ð 12.15 Ð 1.30
FIELD APPLIED
Polyurethane foam 24.0-40.0 0.023-0.026 Ð 43.38-36.50 Ð
Spray cellulosic fibre base 32.0-96.0 0.035-0.043 Ð 23.11-28.94 Ð
59
Thermal conductivity (k) of industrial insulation ± DESIGN VALUES
W/m.oC
TABLE 5
Form Accepted Typical Typical Conductivity k at Mean Temp oC
Material Composition Max Density
Temp for (kg/m3)
Use, oC 73.3 59.4 45.6 31.7 17.8 3.9 10.0 23.9 37.8 93.3 148.9 260.0 371.1 482.2
BLANKETS & FELTS
MINERAL FIBRE
(Rock, slag or glass)
Blanket, metal reinforced 650 96-192 0.037 0.046 0.056 0.078
540 40.0-96.0 0.035 0.045 0.058 0.088
(
Mineral fibre, glass 180 less
Blanket, flexible, fine-fibre than 0.036 0.037 0.040 0.043 0.048 0.052 0.076
organic bonded 12.0 0.035 0.036 0.039 0.042 0.046 0.049 0.069
16.0 0.033 0.035 0.036 0.039 0.042 0.046 0.062
24.0 0.030 0.032 0.033 0.036 0.039 0.040 0.053
32.0 0.029 0.030 0.032 0.033 0.036 0.037 0.048
48.0 0.027 0.029 0.030 0.032 0.033 0.035 0.045
Blanket, flexible, textile-fibre 180 10.4 0.039 0.040 0.042 0.043 0.045 0.046 0.072 0.098
organic bonded 12.0 0.037 0.039 0.040 0.042 0.045 0.046 0.069 0.095
16.0 0.035 0.036 0.037 0.039 0.042 0.045 0.065 0.086
24.0 0.032 0.033 0.035 0.036 0.039 0.042 0.056 0.073
48.0 0.029 0.030 0.032 0.033 0.035 0.036 0.046 0.059
60
TABLE 5 (Thermal conductivity (k) of industrial insulation ± Continued)
Form Accepted Typical Typical Conductivity k at Mean Temp oC
Material Composition Max Density
Temp for (kg/m3)
Use, oC 73.3 59.4 45.6 31.7 17.8 3.9 10.0 23.9 37.8 93.3 148.9 260.0 371.1 482.2
BLOCKS, BOARDS & PIPE
INSULATION
ASBESTOS
Laminated asbestos paper 370 480 0.058 0.065 0.072 0.086
Corrugated & laminated
asbestos Paper
4-ply 150 176-208 0.078 0.082 0.098
6-ply 150 240-272 0.071 0.073 0.085
8-ply 150 288-320 0.068 0.071 0.082
MOULDED AMOSITE &
BINDER 820 240-288 0.046 0.053 0.060 0.075 0.089 0.104
85% MAGNESIA 320 176-192 192 0.050 0.055 0.060
CALCIUM SILICATE 650 176-240 0.055 0.059 0.063 0.075 0.089 0.104
980 192-240 0.091 0.107 0.137
CELLULAR GLASS 480 136 0.039 0.040 0.042 0.043 0.045 0.046 0.048 0.050 0.052 0.060 0.071 0.101 0.148
DIATOMACEOUS SILICA 870 336-352 0.092 0.098 0.104
1040 368-400 0.101 0.108 0.105
MINERAL FIBRE
Glass,
Organic bonded, block and
boards 200 48-160 0.023 0.024 0.026 0.027 0.029 0.032 0.035 0.036 0.037 0.048 0.058
Non-punking binder 540 48-160 0.037 0.045 0.055 0.075
Pipe insulation, slag or glass 180 48.0-64.0
0.029 0.032 0.033 0.035 0.042
260 48-160 0.029 0.035 0.036 0.037 0.048 0.058
Inorganic bonded-block 540 160-240 0.048 0.055 0.065 0.079
980 240-384 0.046 0.053 0.060 0.075 0.089 0.107
Pipe insulation slag or glass 540 160-240 0.048 0.055 0.065 0.079
61
TABLE 5E (Thermal conductivity (k) of industrial insulation ± Continued)
Form Accepted Typical Typical Conductivity k at Mean Temp oC
Material Composition Max Density
Temp for (kg/m3)
Use, oC 73.3 59.4 45.6 31.7 17.8 3.9 10.0 23.9 37.8 93.3 148.9 260.0 371.1 482.2
MINERAL FIBRE
Resin binder 240 0.033 0.035 0.036 0.037 0.040 0.042
RIGID POLYSTYRENE
Extruded, Refrigerant 12
exp. smooth skin surface 80 35.2 0.023 0.023 0.024 0.023 0.024 0.026 0.027 0.029
Extruded cut cell surface 80 28.8 0.024 0.026 0.027 0.029 0.030 0.033 0.035 0.036 0.039
Moulded beads 80 16.0 0.024 0.027 0.029 0.030 0.032 0.035 0.036 0.037 0.040
24.0 0.023 0.024 0.027 0.029 0.030 0.032 0.033 0.035 0.037
20.0 0.024 0.026 0.027 0.029 0.032 0.033 0.035 0.036 0.039
28.0 0.023 0.024 0.026 0.027 0.029 0.032 0.033 0.035 0.036
32.0 0.022 0.023 0.026 0.027 0.029 0.030 0.032 0.033 0.035
RIGID
POLYISOCYANDRATE
Cellular, foil-faced glass
fibre reinforced, Refrigerant
11 exp 120 32.0 0.017 0.019 0.020 0.022
POLYURETHANE
Refrigerant 11 exp
(unfaced) 100 24.0-40.0 0.023 0.024 0.026 0.026 0.026 0.024 0.023 0.023 0.024
RUBBER, Rigid Foamed 70 72 0.029 0.030 0.032 0.033
VEGETABLE & ANIMAL
FIBRE
Wool felt (pipe insulation) 80 320 0.040 0.043 0.045 0.048
INSULATING CEMENTS
MINERAL FIBRE
(Rock, slag or glass)
With colloidal clay binder 980 384-480 0.071 0.079 0.088 0.105 0.122
With hydraulic setting
binder 650 480-460 0.108 0.115 0.122 0.137
62
TABLE 5 (Thermal conductivity (k) of industrial insulation ± Continued)
Form Accepted Typical Typical Conductivity k at Mean Temp oC
Material Composition Max Density
Temp for (kg/m3)
Use, oC 73.3 59.4 45.6 31.7 17.8 3.9 10.0 23.9 37.8 93.3 148.9 260.0 371.1 482.2
LOOSE FILL
Cellulose insulation (milled
pulverised paper of wood 40.0-48.0
pulp) 0.037 0.039 0.042
Mineral fibre, slag, rock or 32.0-80.0
glass 48.0-80.0 0.027 0.030 0.033 0.036 0.037 0.040 0.045
Perlite (expanded) 122 0.032 0.035 0.036 0.039 0.040 0.043 0.045 0.048 0.050
Silica aerogel 112-131 0.019 0.020 0.022 0.022 0.023 0.024 0.026
Vermiculite (expanded) 64-96 0.056 0.058 0.060 0.063 0.065 0.068 0.071
0.049 0.050 0.056 0.058 0.060 0.063 0.066
63
Basic types of insulation ± selected properties
TABLE 6
TYPE FORM TEMPERATURE k-FACTOR * NOTES
RANGE
Calcium Silicate Pipe Covering Up to 982oC .066 at 150oC Good mechanical abuse
Block Segments (1800oF) .45 at 300oF characteristics, non-com-
bustible. Some are water
absorbent.
Cellular Glass Pipe Covering 267oC to 482oC .077 to 150oC Good strength, water and
Block Segments ( 450oF to 900oF) .53 at 300oF vapour resistant, non-com-
bustible. Poor abrasion re-
sistance.
Glass Fibre Pipe Covering to 455oC (850oF) .035 at 24oC Properties variable. Good
Board .24 at 75oF handling and workability.
0.050 at 150oC May be water absorbent.
Blanket to 510oC (950oF) .35 at 300oF Some are non-combustible.
varies see man-
uf. data
Mineral Fibre Pipe Covering to 870oC (1600oF) .035 at 24oC Non-combustible, good
.24 at 75oF workability water absor-
.061 at 150oC bent.
Board .42 at 300oF
conductivity
varies with
density
Ceramic Fibre Blanket or Board to 1760oC .30 at 93oC Temperature ranges varies
(3200oF) (200oF) with manufacturer, style
and type.
64
Protective coverings and finishes
TABLE 7
WEATHER BARRIERS
TYPE COMPOSITION FASTENERS NOTES
JACKETS: 1. Films laminated to felts or Contact adhesives and/or Corrosion resistant bacteria
foil tape and mildew resistant
2. Stainless steel (various Corrosion resistant bands, Excellent mechanical
alloys ± available with screws or rivets strength, corrosion, mildew
factory-applied moisture and bacteria resistant
barrier)
3. Galvanised Steel (coated Corrosion resistant bands, Good mechanical strength
and with factory-applied screws or rivets
moisture barrier)
4. Aluminium alloys (usually Corrosion resistant bands, Good mechanical strength,
with factory-applied screws or rivets good workability
moisture barrier)
5. Polyvinyl Chloride (PVC) Mechanical fasteners, May require protection from
adhesive or matching tape ultra-violet radiation.
6. High Impact Plastic (ABS) ABS welding adhesive or Resists chemicals and
matching tape bacteria
7. Roofing felt Bands or wire Water base, a breather
mastic
MASTICS: 1. Asphalt emulsion Apply with reinforcing mesh Solvent base, also a vapour
barrier
2. Asphalt cut-back Apply with reinforcing mesh Tough, resilient film
3. Resin emulsion Apply with reinforcing mesh Tough, resilient film
4. Polyvinyl acetate Apply with reinforcing mesh Tough, resilient film
5. Acrylic Apply with reinforcing mesh Tough, resilient film
Covering shall not be termed a weather barrier unless its joints and overlap are adequate to prevent the entry
of rainwater.
65
Vapour retarders
TABLE 8
TYPE COMPOSITION NOTES
JACKETS: 1. Foil Scrim Laminate Seal joints. Mechanical strength is less than metal or plastic.
Generally for indoor applications.
2. Metal Jacketing Seal joints. Mechanical strength is good.
3. Polyvinyl Chloride (PVC) Seal with compatible adhesive and/or tape.
4. High Impact Plastic (ABS) Seal with welding adhesive.
5. Film Laminate Seal with contact adhesive and/or tape
MASTICS: 1. Asphalt cut-back Apply with reinforcing mesh. Combustible.
2. Resins ± advent type Brush or spray application.
3. Elastomeric Polymer Apply with reinforcing mesh. Combustible.
66
Energy Content of Some Fuels
TABLE 9
Fuel Energy content
blast furnace gas 3.1 MJ / cubic metre
coal: bituminous 25 MJ / kilogram
coke oven gas 17.3 MJ/cubic metre
gasworks gas 18 MJ / cubic metre
LPG (liquid) 27 MJ / litre
natural gas 33-42 MJ / cubic metre
oil 42 MJ / kilogram
paraffin 35 MJ / litre
SASOL gas: hydrogen rich 18 MJ / cubic metre
SASOL gas: methane rich 33-36 MJ / cubic metre
wood, air dried 17 MJ / kilogram
67
SOURCES OF
FURTHER
INFORMATION
ªEnergy Management Newsº is a free newsletter issued by the ERI, which contains information on the
latest developments in energy efficiency in Southern Africa and details of forthcoming energy
efficiency events.
68