INUSULATION METHODS - Research Prospectover steam tracing the foil shall not be less than 0.06mm...

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PROPOSAL (R&D)

INUSULATION METHODS DESIGN – PROCEDURES - GUIDELINES

02/02/2014

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Contents

1. Introduction ............................................................................................................................. 3

Aims, Objectives and Research Questions ...................................................................................... 4

2. Literature Review .................................................................................................................... 4

3. Methodology ........................................................................................................................... 7

4. Considerations and Intended Outcomes ................................................................................. 8

5. References ............................................................................................................................. 10

Appendices .................................................................................................................................... 12

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1. Introduction

Insulation systems are considered to be complex systems with respect to the operational

adaptability and expected outcomes. The diverse circumstances encountered on various

processes can cause serious accidents. In case of doubt on the selection of insulation

system, guidance must be obtained from a local material specialist, engineering

companies and/or from research publications published in the recent past.

The appropriate functional sections of engineering departments and of construction

groups are usually in touch with such situation. This research report has been proposed

to be prepared to provide support in such instance, therefore extensive research which

includes primary as well as secondary data collection will be completed.

Understanding the reason for insulations and the factors that can affect the insulation

under different circumstances is an essential for the selection of insulation. The relevant

design conditions, operating temperature and any other constraints that may exist must

be taken into account, if a successful insulation system is to be achieved (Hall, 2010).

Aspects of design

Insurance of adequate communication between the designer, operating staff, contractor

and/or construction and maintenance organisation holds primary importance in any

process. Any proposed design should be as such to facilitate insulation system.

The Insulation can have an Impact on design of equipment in many ways and so it is

important to make sure that the selected insulation system is compatible with the duty.

Insulation can Impact on:

Atmospheric contamination, mechanical damage, severity of fire hazard

Thermal expansion

Life expected and/or minimum life



Aims, Objectives and Research Questions

Following are the Aims of this research paper;

Develop Understanding of the importance of insulations

Outline the key methods of insulations currently in practice in the UK

Find out methods of improvements through detailed literature review

Complete methodological designs on Insulations

Conduct experimentations to analyze insulation techniques

Propose recommendations for future works

Following are the Objectives of this Research Paper;

Discuss and present the theoretical and practical framework of insulation methods

Discuss the adaptability of insulation

Present data of the previous completed research papers on the subject and critically

analyze the contents through practical experimentations

Complete the design guidelines on the insulation methods

Below are the Research Questions that drives the research to be completed;

What are the aspects of design in Insulation? What are the types? Methods?

Applications? Utilizations? Costs? Impacts? Research and developments?

What are possible factors that can affect the insulation?

How does the water proofing and sealing of protective finishes work?

What are the associated hazards? How can these be eliminated?

2. Literature Review

Much research has been completed in the last few decades in the field of insulation and

associated engineering (AIRAH, 2007). Abdou and Budaiui (2005) compared thermal

conductivity measurements of building insulation materials under various operating

temperatures, which highlighted the fact the insulation material selection is the primary



step in insulation techniques. The research work completed by Anderlind and Johansson

in 1983 presented a theoretical analysis of thermal insulation through which a gas or fluid

flows. However, in this research paper, research will be conducted on the impacts of

insulation on design equipment.

The essential criterion in this research is the external temperature of the insulation system

for personal protection. The primary material types used to achieve this objective is

Calcium silicate, details of which are given as follows in the Table-1;

Pipe Nominal Size (in)

Operating Temperature range C

0 to 250 251 to 350

351to 400 401 to 450 451 to 500 501 to 550 551 to 600

0.5 ---1.0 1.0 ---1.5 2 3 4 6 to 8

25 25 25 25 25 25

25 38 38 38 38 38

25 25 38 38 38 38

25 38 38 38 38 50

25 38 38 38 50 50

25 38 50 50 50 50

25 38 50 50 50 63

Table 1: Calcium silicate insulation thickness for personal protection (source: Hall, 2010)

Temperature range: Recommended for high temperature range i.e. 200 to 600 C.

Comments: The operating upper limit should be 100 C below the BS limit, for longer exposure.

Supports: Stainless steel bands, support rings on vertical surfaces

Protective finish: Metal cladding, asbestos free cement, fire resistant mastic.

When using asbestos-free magnesia, it must be noted that it has a much lower

temperature range (320 C max.) and it tends to be more affected by spillage (ASTM,

2010; ASHRAE, 2009; ISO 6946, 2005)

Mineral wood is another popular material used for the subject purpose;

Pipe Nominal size (in)

Operating Temperature range C

0 to 250 251 to 350

0.5 to 1.5 25 25

1.5 to 8.0 25 38

Table 2: Mineral Wool insulation thickness for personal protection (source: Hall, 2010)



Temperature range: The recommended temperature range for the use of mineral wool (glass, slab, rock)

is 0 to 350 C.

Comments: Mineral wool mattresses must not be applied to horizontal surfaces

Supports: stainless steel bands, support rings, cleats.

Protective finish: Metal cladding. (Fire resistant mastic on canvas covered slabs for resin-bonded

mineral wool)

The following aspects of design will be investigated in this research paper;

Figure 1; Aspects of Design (source: self created using MS word)



3. Methodology

The possible factors that can affect the insulation are to be analyzed through primary as

well as secondary research. Various factors are considered in addition to the reason for

insulation. Experiments will be conducted to obtain the results through the methodology

defined in the following diagram;

Figure 2; Defining the Methodology (source: self created using MS word)



4. Considerations and Intended Outcomes

Requirements of design and experimentations:

1. Selecting appropriate insulation types

2. Preventing warm/hot insulation from becoming wet and hence ineffective and

damaged.

3. Protection against spillage.

4. Water vapor barrier technique utilization for sub ambient system

These requirements will be applied for instances where waterproofing is the primary

precaution against stress corrosion of austenitic steel. Good practice is to leave some

gaps in sheltered regions to allow any water that enters the insulation to escape. Expert’s

advice will be sought before insulation is applied to flanged joints where the process

temperature is above 350C (Yarbrough and Graves, 1997).

The condition of the equipment will be checked if there is a reason to suspect that

insulation has become saturated, or if the standard of waterproofing appears inadequate.

This can cause corrosion under insulation.

The protective system will be developed with the ability to withstand rain, sun and

extremes of ambient temperature and care will be taken to seal gaps where the external

cladding overlaps (e.g. hangers, braches on vessels). This aspect is less important as

long as spillage is unlikely.

NOTE: Stainless steel is much more resistant to weakening in a fire situation as

compared to alternatives of carbon steel or galvanized steel.

Precautions will be taken whenever insulated austenitic steel equipment is exposed to

Temperature range of 70C to 500C (can keep the equipment wet in the temperature

range of 70C to 250C)



When using aluminum foil as an interlayer (a preferred precaution), the temperatures of

the equipment will not be allowed to exceed 500C. Above this temperature the aluminum

foil can melt and damage the equipment, a more serious hazard (ASTM, 2010). For use

over steam tracing the foil shall not be less than 0.06mm (46smg) thickness.3.5.1,

(M5017C).

Expected Outcomes

To avoid austenitic steel from corrosion cracking, the aluminum foil shall be held in

place with stainless steel wire with all laps 50mm (2 in) minimum and formed so as to

shed water. Experimentations will be conducted to confirm this expected outcome.

The durability of different materials types to be used in the experimentations will also

be tabulated in the form conclusive results

Galvanized metal such as cladding or mesh will be allowed to come into contact with

austenitic steel surfaces. The experimentation will provide the impacts of this practice

The aluminum foil will be applied such that it completely encases the austenitic steel,

isolating it from the steam tracing.

Where it is impracticable to apply aluminum foil or where there is a possibility of

temperature rise up to 500C, optimized methods of insulations will be used. These

methods will be outlined through the results obtained from practical applications of

insulation.

Finally, design guidelines will be prepared / issued based on practical implementation

to support the activity of insulation; which will provide support to the engineers,

researchers and developers around the globe.



5. References

o Abdou AA, Budaiui IM (2005) Comparison of thermal conductivity measurements

of building insulation materials under various operating temperatures. J Build Phys

29(2):171–184

o AIRAH (2007) Technical handbook, 4th edn. The Australian Institute of

Refrigeration, Air Conditioning and Heating, Melbourne

o American Iron and Steel Institute (1995) Thermal design and guide for exterior

walls, RG-9405

o Anderlind G, Johansson B (1983) Dynamic insulation – a theoretical analysis of

thermal insulation through which a gas or fluid flows. Swedish Council for Building

Research, Document D8

o ASHRAE (2009) Heat, air, and moisture control in building assemblies – material

properties. In: Handbook of fundamental. American Society of Heating, Refrigerating and

Air-Conditioning Engineers, Atlanta (Chap 26)

o ASTM C 1373 (2010) Standard practice for determination of thermal resistance of

attic insulation under simulated winter conditions. In: 2010 Annual book of ASTM

standards, vol 04.06, pp 793–810

o ASTM C 518 (2010) Standard test method for steady-state thermal transmission

properties by means of the heat flow meter apparatus. In: 2010 Annual book of ASTM

standards, vol 04.06, pp 152–166

o ASTM C 1303 (2010) Standard test method for predicting long-term thermal

resistance of closed-cell foam insulation. In: 2010 Annual book of ASTM standards, vol

04.06, pp 680–706



o ASTM C 1363 (2010) Standard test method for thermal performance of building

materials and envelope assemblies by means of a hot box apparatus In: 2010 Annual

book of ASTM standards, vol 04.06, pp 741–784. http://www.ornl.gov, Dynamic thermal

performance and energy benefits of using massive walls in residential buildings

o ASTM C 1497 (2010) Standard specification of cellulose fiber stabilized thermal

insulation In: 2010 Annual book of ASTM standards, vol 04.06, pp 863–866

o Desjarlais AO, Yarbrough DW (1991) Prediction of the thermal performance of

single and multi-airspace reflective insulation materials. ASTM STP 1116:24–43

o Fine HA, Jury SH, Yarbrough DW, McElroy DL (1981) Heat transfer in building

thermal insulation: the thickness effect. ASHRAE Trans 87(Pt 2)

o ISO 6946 (2005) Building components and building elements-thermal calculation

method

o Graves RS, Wilkes K, McElroy DL (1994) Thermal resistance of attic loose-fill

insulations decrease under simulated winter conditions. Therm Conduct 22:215–226

o Hall MR (ed) (2010) Materials for energy efficiency and thermal comfort in

buildings. Woodhead, Oxford

o Siegel R, Howell JR (1971) Thermal radiation heat transfer. McGraw-Hill, New

York

o Robinson HE, Powell FJ (1957) The thermal insulation value of airspaces, Housing

Research Paper 23. U.S. Department of Commerce, National Bureau of Standards



o Yarbrough DW, Graves RS (1997) The effect of air flow on measured heat transfer

through wall cavity insulation. J ASTM Int 4(5):94–100

Appendices

APPENDIX A:

APPENDIX B:

APPENDIX C:


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