Environmentally Sustainable ROXUL Inc. is part of ROCKWOOL International, the largest producer of stone wool insulation, which is made from natural basalt rock and recycled material. ROCKWOOL International was founded in 1909 and today operates worldwide with more than 9,800 employees, with over 28 factories across three continents. Our stone wool production process utilizes some of the most advanced technology available.
Overview: ROXUL® Industrial Insulation Solutions 1.2 Insulation of piping Contents 23 1.3 Insulation of vessels 1.2.1 Insulation with pipe sections 29 1.2.7 Insulation of valves and flanges 40 1.2.2 Insulation with pipe wraps (mats) 31 1.2.8 Insulation of pipe elbows and T pieces 42 33 1.2.9 Reducers 1.6 Insulation of boilers 1.6.1 Insulation of fire tube boilers 1.4 Insulation of columns 1.2.3 Insulation with wired mats 47 53 1.6.2 Supercritical steam generators 67 67 69 1.
Overview: ROXUL® Industrial Insulation Solutions 1.2 Insulation of piping Contents 23 1.3 Insulation of vessels 1.2.1 Insulation with pipe sections 29 1.2.7 Insulation of valves and flanges 40 1.2.2 Insulation with pipe wraps (mats) 31 1.2.8 Insulation of pipe elbows and T pieces 42 33 1.2.9 Reducers 1.6 Insulation of boilers 1.6.1 Insulation of fire tube boilers 1.4 Insulation of columns 1.2.3 Insulation with wired mats 47 53 1.6.2 Supercritical steam generators 67 67 69 1.
Contents 1. System solutions 1.1 Planning and preparation 1.2 Insulation of piping 1.3 Insulation of vessels 1.4 Insulation of columns 1.5 Insulation of storage tanks 1.6 Insulation of boilers 1.7 Insulation of flue gas ducts 1.8 Cold boxes 7 11 23 47 53 59 67 75 82 2. Theory 85 2.1 Norms & Standards 2.2 Product properties & test methods 2.3 Bases for thermal calculations 88 107 120 3. Tables 3.1 Units, conversion factors and tables 3.2 Product properties insulation and cladding materials 3.
ROXUL® insulation provide superior thermal and acoustical performance and are fire resistant, water repellent, non-corrosive and resistant to mold. Specialists often willingly turn to our products and expertise in industrial and marine & offshore insulation. We have now packaged that expertise into a practical guide: the 'ProRox® insulation Process Manual‘.
ROXUL® Industrial Insulation ROXUL - an independent organization with the ROCKWOOL Group - is a leading supplier of high quality stone wool products in the industrial insulation market. With the ProRox® & SeaRox® lines for the industrial market and for the marine & offshore industry, our experts provide a full range of products and systems for the thermal, acoustic and firesafe insulation of industrial installations. ROXUL continuously monitors the market developments.
The ROXUL® Industrial Insulation Process Manual Know-how for designers, engineers, site supervisors and managers of industrial plants Energy keeps the world in motion. Without it, everything would come to a standstill. The global economy is dependent upon a secure & efficient supply of energy. Over eighty percent of the energy currently being consumed is obtained from nonrenewable resources. Those resources are becoming increasingly scarce, while at the same time the demand for energy is exploding.
In addition, the right insulation keeps temperatures, for example in pipes and storage tanks, within strict tolerances, thereby ensuring reliable process efficiency. At the same time, adequate insulation protects the plant itself. Modern insulating materials can thoroughly protect plant components from moisture and associated corrosion. Installation and process maintenance costs can be reduced considerably and the effective lifetime of industrial plants can be successfully maximized.
ROXUL® Industrial Insulation, Flow of Energy Exp lora Sun tion , dr illin ga nd pro duc tion Waste Coal Gas Pro Solar Power Plant Oil Flo w of Gas Processing en er ces sin g in dus try Power Plant gy Con Petroleum Refining Processing Business Areas: Industrial ProRox® insulation for industry: Our ProRox® product line covers all our thermal, fire-resistant, compression, comfort/multi-purpose, fabrication and acoustic insulation solutions for industrial installations in the proce
System solutions Industrial insulation 1 System solutions
1. System solutions Table of contents 1.1 Planning and preparation 11 1.2 1.1.1 Decision criteria for the design of an insulation system A. Functional requirements B. Safety aspects C. Economics D. Environmental E. Corrosion Prevention 1.1.2 Design & planning of the insulation work 1.1.3 Corrosion prevention 1.1.4 Storage of insulation materials 11 12 16 17 18 18 19 19 22 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10 1.2.11 1.2.
Notes 10
Planning and preparation 1. System solutions 1.1 Planning and preparation The design of a suitable insulation system for industrial installations is a major factor for its economical operation, functionality, security, durability and environmental impact. Additionally, the installation-specific heat losses are specified for the entire life cycle of the plant.
1.1 Planning and preparation A. Functional requirements a) Object dimensions The space requirements of the insulation must be taken into account when the installation is being designed and planned. Therefore, the insulation thicknesses should be determined in the early planning stages and the distances between the individual objects should be taken into account in the piping isometrics.
Planning and preparation Minimum distances between insulated pipes; dimensions in inches (mm) 4” (100) 4” (100) 4” (100) 4” (100) 4” (100) Minimum distances within range of pipe flanges; dimensions in inches (mm) 4” (100) 4” (100) a = distance flange to normal insulation a ≥ 2" (50 mm) x = bolt length + 1.
1.1 Planning and preparation A. Functional requirements b) Operation of the installation To select a suitable insulation system, the operating method of the installation must be considered. A basic distinction is made between continuous and interrupted operation. With continuous operation, the operating temperatures are constantly above or constantly below the ambient temperatures.
Planning and preparation e) Frost protection Installations that are situated outside are at risk from frost in the winter. In addition to the malfunctioning of installations, installations also risk damage caused by the expansion of frozen water. Adequate measures against frost protection are critical to protect the installation from freezing. Insulation can reduce heat loss and aid in frost protection. Insulation alone cannot indefinitely prevent the installation from freezing.
1.1 Planning and preparation B. Safety aspects a) Personal protection Surface temperatures in excess of 140 °F (60 °C) can lead to skin burns, if the surface is touched. Therefore, all accessible installation components should be designed to protect personnel and prevent injuries. The insulation applied to such plant components must ensure that surface temperatures in excess of 140 °F (60 °C) do not occur during operation.
Planning and preparation C. Economics protection can only be achieved with a doubleskin covering. A doubleskin covering is a factory made cladding that has been welded or soldered to make it air proof and diffusion-resistant. In addition special (local) explosion regulations must be observed. d) Noise protection The guidelines for noise in the ordinance and workplace are stated in the local regulations and standards. Generally, the level of the guideline values depends on the nature of the activity.
1.1 Planning and preparation C. Economics Increasing energy prices are tending to bring about a shift in economic insulation thicknesses towards larger thicknesses. b) Pay-back time In addition to the economical insulation thickness, another frequently used economical parameter is the return on investment period (ROI), also referred to as the payback period. This is defined as the period within which the cost of the insulation is recuperated through savings on heat loss costs.
Planning and preparation 1.1.2 Design & planning of the insulation work Requirements for insulation work must be included in the design and construction phase of industrial plants. It is advisable to involve all project managers at an early stage to avoid unnecessary issues or delays. All preparatory works must be completed according to the relevant insulation standards.
1.1 Planning and preparation 1.1.3 Corrosion prevention I n the case of cold insulation, if the object is made of non-alloy or low alloy steel, it must be protected against corrosion. I n the case of objects made, for example, of austenitic stainless steel or copper, the installation must be tested in each individual case by the planner to determine whether protection against corrosion is necessary.
Planning and preparation Note he table does not take into account forms T of corrosion with other root causes, such as stress corrosion. For further information, see Chapter 2.2 “Product properties & test methods” – AS-Quality on page 115. The table further on this page, which has been derived from the standard DIN 4140, indicates the initial risks of electrochemical corrosion in cases where various combinations of metals are used.
1.1 Planning and preparation 1.1.4 Storage of insulation materials Incorrect storage of insulation materials outdoors can cause insulation to deteriorate. Insulation should be protected when stored, during installation and when fitted to minimize moisture exposure, physical damage and contamination. If storage indoors is not possible, protect the insulation material from weather influences by covering it with waterproof material.
1. System solutions Piping plays a central role in many industrial processes in chemical or petrochemical installations such as power plants, as it connects core components such as appliances, columns, vessels, boilers, turbines etc. with one another and facilitates the flow of materials and energy. To guarantee a correct process cycle, the condition of the media within the pipes must remain within the set limitations (e.g. temperature, viscosity, pressure, etc.).
1.2 Insulation of piping Hot insulation systems Principally, a thermal insulation structure for piping consists of an appropriate insulating material, usually covered by sheet metal cladding. This protects the object and the insulation from external influences such as the weather and mechanical loads. Spacers are also essential with insulation such as wired mats, which do not offer sufficient resistance to pressure to hold the weight of the cladding and other external loads.
Pipe insulation with wired mats has been a time-tested universal solution for many decades now. Due to their flexibility and high temperature resistance, wired mats can be easily cut and mounted onto piping. Wired mats are ideal for application in situations where the use of pipe sections or load bearing wraps (mats) is difficult or impossible.
1.2 Insulation of piping Comparison of the different insulation systems The particular advantage of pipe sections and pipe wraps (mats) lies in the fact that support structures are not required and therefore thermal bridges caused by the insulation are minimized or removed. On the other hand, wired mat systems have their advantages due to their ability to be structurally sound when insulating around irregularly shaped pipe sections.
Required insulation thicknesses Insulation of piping If the three insulation systems are compared, taking into consideration similar heat losses, clear advantages are seen with regard to the insulation thicknesses with systems using pipe sections or pipe wraps (mats). These do not use spacers, in contrast to insulation systems made using wired mats.
1.2 Insulation of piping Selection of pipe insulation systems Generally, the best insulation is achieved using ProRox® Pipe Sections. The preformed sections are quick and easy to install. Their excellent fit and high compression resistance means pipe sections can be applied in a single layer without any additional spacers. They also have a lower insulation thickness.
Note Due to their low thermal conductivity, better thermal insulation values can be achieved with pipe sections than with wired mats. With insulation on straight pipe sections, a combination of both products in the same insulation thickness is therefore not advisable. If this combination is essential, for example, in the case of bends or shaped pieces, it is vital to select the correct insulation thickness.
1.2 Insulation of piping Installation Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details. The ProRox® PS 900 Series pipe sections are mounted directly onto the pipe to form a close fit. With horizontal pipes, the lengthwise joint of the pipe section should be turned towards the underside at the 6 o’clock position. With vertical pipes, the lengthwise joints should be staggered at an angle of 30 ° to one another.
Pipe wraps (mats), such as ENERWRAP® MA 960NA are the latest development in the insulation business. ENERWRAP® MA 960NA is a stone wool insulation wrap available with black mat or reinforced foil facing. The flexible application makes the product easy to cut and install. Pipe wraps (mats) are ideal for installations involving large diameter pipes and a high number of shaped pieces such as elbows or T-joints. ENERWRAP® MA 960NA can be applied up to temperatures of 1200 °F (650 °C).
1.2 Insulation of piping Installation Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details. Cut the wraps (mats) to the required length, based on the external insulation diameter (pipe diameter + two times the insulation thickness). Fasten the wrap (mat) firmly to the pipe with steel bands. Ensure that the wraps (mats) form a tight joint and that no lengthwise joints or circular joints are visible.
Pipe insulation with wired mats has been a time-tested universal solution for many decades now. Due to their flexibility and high temperature resistance, wired mats can be easily cut and mounted onto the piping. These wired mats are ideal for application on large pipe diameters and shaped pieces as elbows or T-joints. With an insulation thickness of more than 5 inches (120 mm) [or temperatures > 550 °F (300 °C)], apply multiple layer insulation.
1.2 Insulation of piping 1. Pipe - 2. ProRox® insulation - 3. Spacer - 4. Thermal dividing layer - 5. Support ring 34 Horizontal piping Vertical piping ≤ 550 °F > 550 °F ≤ 550 °F > 550 °F Pipe sections none 10 to 13 ft none 16 to 20 ft Load bearing wraps (mats) none 10 to 13 ft none 16 to 20 ft Wired mats 3.3 ft 3.3 ft 3.3 ft 16 to 20 ft ) mm max.
The purpose of support structures is to transfer the mechanical load of the insulation system and the forces affecting the insulation system onto the object. Support structures are essential in the case of vertical piping. In addition to the static and dynamic forces, changes in piping length and support structures due to temperature must also be taken into account when dimensioning.
1.2 Insulation of piping 1.2.5 Cladding Suitable cladding should be applied to protect the insulation from weather influences, mechanical loads and (potentially corrosive) pollution. Selecting the appropriate cladding depends on various factors, such as working loads, foot traffic, wind and snow accumulations, ambient temperatures and conditions.
Minimum thickness (inches) of metal cladding sheet (recomended by CINI) External diameter of the insulation (in) Aluminum (CINI 3.1.01) Aluminized steel sheet (CINI 3.1.02) Alu-Zinc coated steel sheet (CINI 3.1.03) Zinc coated steel sheet (CINI 3.1.04) Austenitic stainless steel sheet (CINI 3.1.05) < 5.5" 0.024 0.022 0.020 0.020 0.020 5" to 12" 0.031 0.031 0.031 0.031 0.031 > 12" 0.039 0.031 0.031 0.031 0.
1.2 Insulation of piping 1.2.5 Cladding Cladding in corrosive environments To guarantee the functionality of industrial/ mechanical insulation (sometimes referred to as technical insulation), it is important to protect it against atmospheric influences and prevent the ingress of moisture into the insulation. Moisture in the insulation system increases thermal conductivity, thereby reducing the effectiveness of the thermal protection. It also poses a high risk of corrosion to the component.
Note High temperatures: ProRox® Rocktight can be used in temperatures of up to 190 °F (90 °C). Chemical resistance: ProRox® Rocktight is resistant to numerous chemicals. Expansion joints: fit expansion joints to accommodate expansion of the ProRox® Rocktight material and the steel pipe. Pipe support in direct contact with the piping Insulation of piping ProRox® Rocktight requires a dry, clean (ventilated) work environment.
1.2 Insulation of piping 1.2.7 Insulation of valves and flanges 1. Pipe - 2. ProRox® insulation 3. Cladding - 4. Sheet-metal screw or Rivet 5. Swage - 6. Drainage opening 7. Strap - B ≥ 2" (50 mm) - A = bolt length + 1.2" (30 mm) A number of possible design options for insulation systems for pipe fittings and flanges follow: 0.8" (20 mm) 2" (50 mm) Heat loss incurred through non insulated fixtures such as valves and flanges are substantial, even at low temperatures.
1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheetmetal screw or rivet - 5. Swage - 6. Drainage opening - 7. Straps – B ≥ 2" (50 mm) 1. Pipe - 2. ProRox® insulation - 3. Sheet 4. Sheet-metal screw or rivet - 5. Rain d eflector 6. Lock washer - 7. Straps - 8. Lock washer B ≥ 2" (50 mm) - A = Screw length +1.2" (30 mm) Leakages 1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheetmetal screw or rivet - 5. Swage - 6. Drainage opening - 7. Straps – B ≥ 2" (50 mm) - A = Bolt length + 1.
1.2 Insulation of piping 1.2.7 Insulation of valves and flanges 1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheetmetal screw or rivet - 5. Collar - 6. Collar 7. Clamps - 8. Rain deflector - 9. Leak detection fitting B ≥ 2" (50 mm) - A = bolt length + 1.2" (30 mm) 1.2.8 I nsulation of pipe elbows and T pieces The cladding of elbows and T-pieces is susceptible to damage, due to expanding or vibrating pipes.
1.2.9 Reducers Pipes that branch out with many outlets reduce the pipe diameter. Examples of how to install reducers follow: Insulation of piping The diagrams below show how the sheet is mounted onto shaped pieces. 1. Pipe - 2. ProRox® insulation - 3. Cladding - 4. Sheetmetal screw or rivet - 5. Swage - 6. Reducer 0.4" (10 mm) 0.6 "( 15 mm ) 1. Pipe - 2. ProRox® insulation - 3. Cladding - A to C: Elbow segments of wraps (mats) 1. Pipe - 2. ProRox® insulation - 3. Cladding 1. Pipe - 2.
1.2 Insulation of piping 1.2.10 Expansion joints In thermal insulation systems, large differences between the piping and the cladding temperature can occur. The materials used for the pipe, insulation, insulation support and cladding also have different thermal expansion coefficients. This leads to different thermal elongations of the various components in the insulation system, which must be allowed for using constructive measures.
1.2.11 Tracing A distinction is made between pipe tracing and electrical tracing. In pipe tracing systems, a heating pipe is fitted parallel and close to the media pipe. Steam, warm water or thermal oil flows through the tracing pipes as a heat transfer medium. Electrical tracing consists of cables mounted onto the pipes. These cables heat the pipes Traced pipes can be insulated with pipe sections or wraps (mats).
1.2 Insulation of piping 1.2.12 Foot traffic Avoid walking on insulated pipes, as this can damage the insulation. Damage caused by foot traffic includes dented sheet cladding and gaps at the sheet seams. Water can penetrate the insulation through these gaps and cause lasting damage to the entire insulation system. The result is often greater heat losses and corrosion.
1. System solutions Vessels are a major component in installations for various procedures in almost all fields of industry. Many production processes require different substances that are stored in vessels and used in the individual processes later in the procedure. The vessels primarily store liquid, solid or gaseous substances, which are added to the process when required. Raw materials, fuels or end products are usually stored in large storage tanks.
1.3 Insulation of vessels Selection and installation of the insulation Selecting the appropriate insulation depends on the operating method, the installation temperature, the dimensions and the location of the vessel. Typically recommended insulation materials are ProRox® wraps (mats) and ProRox® flexible and semi rigid boards (slabs) like the SL 920NA, SL 930NA and ENERWRAP® MA 960NA.
Internal insulation layer strap measurement External or single layer insulation strap measurement Distance between straps 8" to 72" (200 to 1800 mm) 1/2" x 0.02" (13 x 0.5 mm) 5/8" x 0.02" (16 x 0.5 mm) 10" (250 mm) > 72" (1800 mm) 5/8" x 0.02" (16 x 0.5 mm) 3/4" x 0.02" (19 x 0.5 mm) 10" (250 mm) These values can only be used as reference values. In each individual case, determine whether different strap measurements and intervals should be used.
1.3 Insulation of vessels Selection and installation of the insulation 2" (50 mm) Insulation of a vessel base 2" (50 mm) 1. ProRox® insulation - 2. Support construction - 3. Mounting support - 4. Conical column head 5. Vessel outlet - 6. Vessel leg 1. ProRox® load bearing insulation - 2. Flange inlet for safety valve - 3. Vessel filling nozzles 4. Conical head - 5. V essel drawdown - 6. Conical head with manhole - 7.
8" (200 mm) Insulation of a conical head with a manhole The application of support constructions and spacers on vessels is essential. The objective of support constructions is to bear the weight of the insulation system and to bear the weight above mounting supports on the object to be insulated. The spacers keep the cladding of the insulation at a predetermined distance. On vertical pipes, the substructures often assume the function of the support construction and spacer.
1.3 Insulation of vessels Selection and installation of the insulation Preferably use profiled sheets for vessels with a large surface area. They offer structural advantages and can accommodate expansions that are perpendicular to the direction of the swage. The disadvantage is that pipe protrusions are more complex from a structural perspective. Using profiled sheets is only recommended with cladding with a low number of protrusions. Design profiled sheet casings so that rainfall is deflected safely.
1. System solutions Columns are pillar-shaped vessels, which are mainly used in the (petro) chemical industry for distillation or the extraction of substances. They often form the key elements in chemical or petrochemical plants. The processes in columns often only operate at certain temperatures. The insulation of columns plays an important role in their functionality.
1.4 Insulation of columns Insulation systems for columns Selection and installation of the insulation Selecting the appropriate insulation depends on the operating method, the installation temperature, the dimensions and the location of the vessel or column. Insulation materials such as ProRox® are suitable for use of the insulation of columns. Since columns are often located outdoors, it is important to select insulation with a low thermal conductivity and excellent water repellent properties.
External insulation diameter Internal insulation layer strap measurement External or single layer insulation strap measurement Distance between the straps 8" to 72" (200 to 1800 mm) 1/2" x 0.02" (13 x 0.5 mm) 5/8" x 0.02" (16 x 0.5 mm) 10" (250 mm) > 72" (1800 mm) 5/8" x 0.02" (16 x 0.5 mm) 3/4" x 0.02" (19 x 0.5 mm) 10" (250 mm) Insulation of a reinforcement ring Insulation of columns In a wide variety of applications, these values can only be used as reference values.
1.4 Insulation of columns Selection and installation of the insulation Insulation of a column base Fire protection in column skirts The fire protection quality of a column primarily depends on the fire resistance of the column support frame. When used in a system, ROXUL® can aid in fire protection solutions for column support skirts. If you have any questions, please consult the ROXUL Technical Services Team. 8” (200 mm) 1. Skirt: Column support frame - 2.
Various methods for pipe penetrations Insulation of columns m) 2" (50 m Support constructions and spacers The application of support constructions and spacers on columns is essential. The objective of support constructions is to bear the weight of the insulation system and to bear the weight above mounting supports on the object to be insulated. The spacers keep the cladding of the insulation at a predetermined distance.
1.4 Insulation of columns Support constructions and spacers 0 mm) ≤ 10 ft (3000 mm) m) 0m (40 16" 1.25" (3 16" (400 mm) 1.25" x 0.125" (30 x 3 mm) 0.375" x 2" (M 10 x 50) ≤ 8" m) 0m (20 8" (20 0m m ) ≤ 1.25" x 0.125" (30 x 3 mm) 0.08" (2 mm) 1.25" x 0.125" (30 x 3 mm) 1.75" (40 mm) 1.25" x 0.04" (30 x 3 mm) 0.375" x 2" (M 10 x 50) 1.25" x 0.125" (30 x 3 mm) 1.75" (40 mm) 1. Object wall - 2. Mounting support - 3. Bolting 4. Bar - 5. Omega clamp - 6.
1. System solutions 1.5 Insulation of storage tanks Therefore the industries set high standards for the conditioning temperature of storage tanks. We give some examples: I n the food industry, a milk cooling tank is a large storage tank used to cool and hold milk at a cold temperature until it can be packed and transported to the end-users. S torage facilities for liquefied gasses such as LNG, operate at very low temperatures down to -260 °F (-168 °C).
1.5 Insulation of storage tanks The applicable standards and regulations must also be observed.
Insulation of storage tanks 1. ProRox® insulation - 2. Stainless steel bands (weather proofing) - 3. Stainless steel bands - 4. Support ring 5. Protrusion - 6. Cladding - 7. Roof/wall connection Cladding A metal cladding is generally applied for the tank wall and top. Thanks to its light weight, low costs and ease of installation, aluminum is commonly applied as cladding.
1.5 Insulation of storage tanks Support rings 5 ft 5 ft (1500 mm) ((1500 mm) ( 150 5 f 150 5 f 0m t 0m t m m With vertical applications, the weight of the insulation can damage the insulation layer below. To avoid damaging the insulation, fit horizontal support rings if higher than 14 ft (4 m). The distance between the support rings should not exceed 10 ft (3 m). The construction should be built so that leakage water can be expelled from the insulation.
4” (100 mm) Connection tank wall - tank roof with railing ” 7/8 m) m (20 about 1/8” (3 mm) 1. Tank wall - 2. ProRox® insulation - 3. Support ring 4. Cladding - 5. Welded seam A rainwater shield is fitted at the seam between the tank wall and tank top to prevent leakage into the tank wall insulation. Weld the safety guard / railing on this rainwater shield. 1. Tank wall - 2. ProRox® insulation - 3. L-profile 4. Rain deflector - 5. Support strip - 6. Tank top 7.
1.5 Insulation of storage tanks Protrusions within tank walls Protrusions within the tank wall insulation may lead to leakage of rainwater or pollution with chemical substances. Keep the number of protrusions to a minimum. Insulate any remaining protrusions as indicated below. Finishing of tank tops Similar to tank wall insulation, many constructions are possible for tank top insulation. The appropriate system greatly depends on the tank diameter and the nature of the seam with the tank wall.
A: welded steel bar attached on the roof with a stainless steel strip Protrusions within tank tops Protrusions within the tank top insulation may lead to leakage of rainwater or pollution with chemical substances due to overfilling of the tank. Keep the number of protrusions in the tank top to a minimum. If this is not possible, apply the construction stated below. Insulation of storage tanks B: applying ProRox® insulation C: Finishing with aluminum cladding 1. Tank roof - 2. Cladding - 3.
1.5 Insulation of storage tanks Foot traffic Tank tops are subject to foot traffic. To ensure the insulation system is resistant to foot traffic, apply a pressure-resistant board (slab) such as ProRox® SL 590NA. If the radius of the tank top is too large to allow the use of a rigid board (slab), use a more flexible board (slab) in combination with a (local) metal support construction. The walkways need to be clearly marked.
1. System solutions 1.6 Insulation of boilers The design and functionality of the boilers on the market is so varied that the examples of use cannot fully take into account the particular circumstances of each case. Determine whether the products and construction described are suitable for the corresponding application in each individual case. In if doubt, consult the ROXUL® Technical Services Team. The applicable standards and regulations must also be observed.
1.6 Insulation of boilers 1.6.1 Insulation of fire tube boilers Fire tube boiler 6 1. Boiler casing - 2. ProRox® insulation - 3. Cladding - 4. Flame tube - 5. Fire tube - 6. Reversing chamber Load bearing ProRox® insulation is a proven solution in the insulation of flame tube-smoke tube boilers. Insulation is easily mounted onto the horizontal, cylindrical boiler surface and are easily fastened to the boilers with metal straps. Metal spacers, which always create thermal bridges, can be omitted.
1.6.2 Supercritical steam generators Buckstays (Girders) Buckstays (sometimes referred to as Girders, Stiffeners or Ribs) are fitted horizontally at regular intervals around the boiler. Buckstays are reinforcement elements, which prevent the boiler from bulging. A distinction is made between hot buckstays, which are located inside the insulation, and cold buckstays, which are located outside the insulation sections.
1.6 Insulation of boilers 1.6.2 Supercritical steam generators Handles Handles are reinforcement elements, which are fitted vertically between the buckstays (girders) and bear the vertical loads exerted on the buckstays on the boiler wall. Handles can be located inside and outside the insulation sections. 1. Boiler roof - 2. Dead space - 3. Cross bar - 4. Collector - 5. Boiler support tube - 6. Boiler wall 7. Buckstay - 8. Handles - 9. Burner port - 10.
temperature ranges, as are often encountered in dead spaces. Outer layers can be constructed with different types of ProRox® insulation to optimize the overall performance, depending on the temperature of the adjacent layer. AGI guideline Q101 suggests, galvanized wire netting and galvanized stitching wire in wired mats can only be heated up to a temperature of 750 °F (400 °C). With temperatures above 750 °F (400 °C), austenitic stainless steel wire netting and stitching wire must be used.
1.6 Insulation of boilers 1.6.2 Supercritical steam generators Diagram of a boiler insulation system with no gap between the insulation and sheet cladding Barriers The following diagrams show two designs for vertical barriers. Depending on the temperature or structural requirements, the barrier can be manufactured from sheet metal [≥ 0.02" (0.5 mm)] or aluminum foil [≥ 0.003" (80 μm)]. The barrier must be fastened to the object on the heated side and must reach to the cladding on the cold side.
Buckstays that are exposed to cold are generally not insulated and not cladded. An example follows. Buckstays exposed to heat on a boiler wall Buckstays exposed to cold on a boiler wall Buckstays (girders) that are exposed to heat are insulated and fitted with a casing. An example follows. 1. Boiler wall - 2. ProRox® insulation - 3. Fill up with loose fill stone wool (mineral wool) - 4. Support construction - 5. Buckstay exposed to heat 6. Aluminum foil if required - 7. Cladding/Preformed sheet - 8.
1.6 Insulation of boilers 1.6.2 Supercritical steam generators Insulation of dead spaces Support construction and spacer Dead space for boiler wall collector Cladding Dead spaces located in front of the boiler wall or roof containing installation components, are enclosed with cladding, to which the insulation is then mounted. Use a non-scaling sheet with a minimum thickness of one mm.
1. System solutions 1.7 Insulation of flue gas ducts Insulation systems on flue gas ducts have the following purposes: Reduce heat losses in the flue gas, thereby preventing sub-dew point (acid or water dew point) conditions in the flue gas on the interior surfaces of the flue gas duct. This also minimizes the corrosion risk. This also applies to areas with structural thermal bridges, such as support constructions, reinforcements etc.
1.7 Insulation of flue gas ducts 1.7.1 I nstallation of the insulation systems for flue gas ducts Observe the following when pinning the insulation: W ith insulation thicknesses ≤ 5" (120 mm), use 8GA (6AWG) pins with a minimum diameter of 0.162" (4 mm). W ith insulation thicknesses ranging from 5 1/2" to 10" (130 to 240 mm), use 6GA (4AWG) pins with a minimum diameter of 0.2043" (5 mm). W ith insulation thicknesses ≥ 10" (240 mm) use 4GA (3AWG) pins with a minimum diameter of 1/4" (6 mm).
max. 4" (100 mm) Insulation of reinforcing ribs 1. Duct wall - 2. ProRox® insulation - 3. Reinforcing ribs - 4. Welding pins with clips - 5. Metal cladding means of radiation and convection from the duct wall to the external flange of the reinforcement profiles. The following shows the design details for a profile insulation system. Insulation of reinforcing ribs 1. Duct wall - 2. ProRox® insulation - 3. M etal cladding: corrugated sheet - 4. Reinforcing element 5.
1.7 Insulation of flue gas ducts 1.7.1 I nstallation of the insulation systems for flue gas ducts Insulation of reinforcing element with cavity and covering sheet 1. Duct wall - 2. ProRox® insulation - 3. Reinforcing element - 4. Covering sheet - 5. Support construction and spacer - 6. Aluminum foil (optional) 7. Welding pins/clips - 8. Metal cladding: corrugated sheet In the case of profiles measuring above 10" (240 mm) in height, a covering sheet should also be installed.
Duct located outdoors with a cladding constructed as a pent (single sloping) roof Insulation of flue gas ducts 1. Duct wall - 2. ProRox® insulation - 3. Support construction and spacer - 4. Welding pins/clips - 5. Metal cladding: corrugated sheet - 6. Extension (trapezoid) - 7.
1.7 Insulation of flue gas ducts 1.7.2 Cladding of flue gas ducts Duct located outdoors with a cladding constructed as a saddle (double sloping) roof 1. Duct wall - 2. ProRox® insulation - 3. Support construction and spacer - 4. Welding pins/clips - 5. Metal cladding: corrugated sheet - 6. Extension (trapezoid) - 7. Z-shaped spacer - 8. Support construction - 9.
1.7.3 Acoustic insulation of flue gas ducts Insulation of flue gas ducts The thermal insulation of flue gas ducts influences the propagation of airborne noise and structure-borne noise. The effects of this depend on many factors, such as the frequency, the noise pressure level and the structure.
1. System solutions 1.8 Cold boxes Many industrial applications use gases such as oxygen, nitrogen and argon. These gases are obtained using cryogenic gas separation technology, whereby air is condensed and converted into a liquid. Afterwards, the various elements can be separated using fractional distillation. So-called air separation plants are characterized by an extremely low temperature of as low as approximately -328 °F (-200 °C).
fitted. Densities of at least 9.4 lb/ft3 (150 kg /m3) are feasible. The official requirement according to the AGI Q118 standard is 10 to 12.5 lb/ft3 (160 to 200 kg/m3) . The procedure is outlined step by step as follows: 1. Create a trial set up by filling a 2 x 2 x 2 ft (60 x 60 x 60 cm) crate with an evenly distributed layer of loose wool, with a thickness of 12 to 16" (300 to 400 mm). Then have a man of average weight compact this layer by treading on it. Repeat this process until the box is full.
Notes 84
Industrial insulation Theory 2 Theory Theory
2. Theory Table of contents 2.1 2.1.1 2.1.2 Norms & Standards Overview of different norms & standards Insulation specification a) ASTM standards b) PIP - guidelines c) Canadian Standards d) MICA Standards e) NACE International Standard Practice f) CINI Guideline g) European standardization (CEN) h) CE-mark i) DIN Standards & Guidelines j) AGI k) BFA WKSB l) FESI m) ISO n) VDI 2055 o) British standard p) NF (Norme Française) mark q) Unified Technical Document (Document Technique Unifié, DTU) 2.1.
2. Theory 2.1 Norms & Standards 2.1.1 O verview of different norms & standards Internal plant owner or contractor specifications Industrial plants are built and maintained according to a range of requirements, detailed in numerous technical standards that cover all design and equipment requirements. These specifications often refer to industrial guidelines and society standards.
2.1.2 Insulation specification The insulation specification is part of the plant owner or contractors specification. It generally contains: Guidelines for preparation prior to the insulation work Material specifications Mounting instructions per application The insulation specification also often includes the guidelines for corrosion protection. Similar to other specifications, the insulation specification often refers to society standards and/or industrial guidelines.
1.1 Norms 2.1 Planning & and Standards preparation 2.1.
c) Canadian Standards e) NACE International Standard Practice In Canada (as in the US) accredited bodies such as CSA (Canada Standards Association) and CAN/ULC (Underwriters Laboratory) produce consensus based standards that can be adopted by various regulatory bodies. ASTM standards are widely used in Canada (see Chapter 2.1.2 on ASTM standards). NACE standards represent a consensus of those individual members who have reviewed the documents, their scope, and their provisions.
2.1 Norms & Standards 2.1.2 Insulation specification Insulation materials (Material standards) Cladding (Material standards) Processing guidelines CINI 2.2.01 Stone wool boards (slabs): ProRox® boards (slabs) for the thermal insulation of equipment CINI 2.2.02 Wired mats: ProRox® wire mesh blankets for the thermal insulation of large diameter pipes, flat walls and equipment CINI 2.2.03 Pipe sections: ProRox® pipe sections and prefabricated elbows for the thermal insulation of pipes CINI 2.2.
Product properties, test standards Product property Standard Description Thermal conductivity (Piping) EN ISO 8497 Heat insulation – Determination of steady-state thermal transmission properties of thermal insulation for circular pipes Thermal conductivity (Boards/Slabs) EN 12667 Thermal performance of building materials and products – Determination of thermal resistance by means of guarded hot plate and heat flow meter methods - Products of high or medium thermal resistance Water vapor diffusion r
2.1 Norms & Standards 2.1.2 Insulation specification i) DIN Standards & Guidelines Deutsches Institut für Normung e.V. (DIN; in English, the German Institute for Standardization) is the German national organization for standardization and is that country’s ISO member body. DIN is a registered association (e.V.), founded in 1917, originally as Normenausschuss der deutschen Industrie (NADI, Standardization Committee of German Industry).
j) AGI “Arbeitsgemeinshaft Industriebau e.V”. (AGI) is a German association of manufacturers, engineering companies and universities. AGI was founded in 1958 to establish a common platform to exchange best practices within Industry. These practices, which are summarized in the Material standards and d esign guidelines AGI guidelines (so called “Arbeitsblätter”) are established in cooperation with the German DIN, VDI and CEN members for insulation.
2.1 Norms & Standards 2.1.2 Insulation specification k) BFA WKSB ‘Deutsche Bauindustrie’ is a German branch organization within the building & construction industry. Part of this organization is the Bundes Fach Abteilungen {(BFA) - ‘technical departments’} who are specialized in the technological developments and lobby activities within a specific area of technical expertise.
m) ISO Headquartered in Switzerland, the International Organization for Standardization (Organization internationale de normalisation), widely known as ISO, is an international-standard-setting body composed of representatives from various national standards organizations. Founded in1947, the organization promotes and communicates world-wide proprietary industrial and commercial standards.
2.1 Norms & Standards 2.1.2 Insulation specification o) British standard British Standards are produced by BSI British Standards, a division of BSI Group that is incorporated under a Royal Charter and is formally designated as the National Standards Body (NSB) for the UK.
Test methods BS 476-4 Fire test on building materials Part 4, Non combustibility test for materials Part 6, Methods of test for fire propagation of products Part 7, Method for classification of the surface spread of flame products BS EN 13467 Thermal insulating products for building e quipment and industrial installations Determination of dimensions, squareness and linearity of preformed pipe insulation BS EN 13468 Thermal insulating products for building equipment and industrial installations Deter
2.1 Norms & Standards 2.1.
Test standard Insulating materials Assembly Covering NF EN 1602 July 1997 Thermal insulating products for building applications – Determination of the apparent density NF EN 826 September 1996 Thermal insulating products for building applications – Determination of the apparent density NF EN 13468 September 2002 Thermal insulation products for building equipment and industrial installations - Determination of trace quantities of water soluble chloride, fluoride, silicate, sodium ions and pH NF EN
2.1 Norms & Standards 2.1.2 Insulation specification q) Unified Technical Document (Document Technique Unifié, DTU) Object and scope of the DTUs A DTU is a French building regulation and comprises a list of contractual technical stipulations applicable to construction work contracts.
2.1.3 Relevant guidelines & standards for the industrial/mechanical insulation industry in North America In North America there are no regulations or codes governing the design and installation of industrial/mechanical insulation. Best practices is generally adopted following a variety of different standards & guidelines published by bodies such as ASTM, NACE, MICA & PIP.
2.1 Norms & Standards 2.1.4 Relevant guidelines & standards for the industrial/mechanical insulation industry in Europe b) Quality Assurance It is essential that, in addition to the design quality, the product properties guaranteed by the insulation manufacturer, for example, the thermal conductivity or temperature resistance are adhered to during processing in order to achieve flawless operation of thermal or cold insulation constructed according to operational and economic criteria.
c) RAL quality mark RTI Import stone wool insulation products bear the RAL quality mark. They are therefore subject, in addition to the stringent criteria of the quality assessment and test specifications of the (German) Mineral Wool Quality Community [Gütegemeinschaft Mineralwolle e. V.], to continuous inspections, which guarantee compliance with the criteria of the German legislation governing hazardous substances and with the EU directive.
2.1 Norms & Standards 2.1.
2. Theory 2.2 Product properties & test methods The requirements for industrial insulation are high and varied. Piping, boilers, storage tanks require insulation materials with particular properties. Although the application and type of products may vary, the basic definition of all product properties is the same. 2.2.1 Fire behavior 2.2.2 Thermal conductivity 2.2.3 Maximum service temperature 2.2.4 Water leachable chloride content 2.2.5 Water repellency 2.2.6 Water vapor transmission 2.2.
2.2 Product properties & test m ethods 2.2.1 Fire behavior Smoke intensity Smoke intensity is only tested in the classes from A2 to D. There are 3 intensity levels; s1, s2 and s3. Smoke intensity is vital for people trapped in a burning building. The major cause of death in these circumstances is smoke inhalation. Burning droplets Burning droplets are also tested on building materials in the classes A2 to E. There are three classes. No droplets (d0).
2.2.2 Thermal conductivity The material property defining heat flow through an insulation material is thermal conductivity, “λ” (or “k“). It indicates the heat flow rate “Q” through unit area of material “A” induced by unit temperature gradient “∆T / L” in a direction perpendicular to that unit area (Heat-Flux per unit temperature difference “∆T” across a unit thickness “L” of material).
2.2 Product properties & test m ethods 2.2.2 Thermal conductivity Thermal conductivity Fundamental dependency of the thermal conductivity upon the apparent density at a certain temperature 1. Conduction through the dormant air - 2. Thermal radiation - 3. Conduction of the pipe - 4. Convection 5. T hermal conductivity of the insulation Apparent density Thermal conductivity Fundamental dependency of the thermal conductivity upon the temperature for a certain apparent density 1.
Thermal conductivities for industrial/mechanical insulation can be measured according to the test methods below. Guarded hot plate apparatus test method The thermal conductivity of flat products, boards (slabs) and wired mats can be measured with the guarded hot plate apparatus according to ASTM C177 or EN12667. The core components of the apparatus usually consist of two cold-surface units and a guarded hot-surface unit. The insulation material to be measured is sandwiched between these units.
2.2 Product properties & test m ethods 2.2.3 Maximum service temperature The temperature at which an insulation material is used should be within the temperature range specified for the material, in order to provide satisfactory long-term service under conditions of use. This temperature is defined as maximum service temperature. The following factors should be considered when selecting insulation materials to be used at elevated operating temperatures.
According to BS 3958 “standard specification for thermal insulation materials”, the insulation material shall maintain its general form and shall not suffer visible deterioration of fibrous structure when heated to the maximum service temperature. EN14706 (replaces AGI Q132) The maximum service temperature replaces the term classification temperature, which was still the customary term in the AGI G 132 of 1996.
2.2 Product properties & test m ethods 2.2.3 Maximum service temperature Application of maximum service temperature service temperature. When selecting a suitable insulation material in terms of the maximum service temperature, the external influences affecting the insulation system must be considered, for example: S tatic loads (e.g. cladding) D ynamic loads (e.g. oscillations) T ype of construction (with or without a spacer).
2.2.4 Water leachable chloride content ASTM C692 These specific attacking agents include, for example, chloride ions. An insulation material with an extremely low quantity of water-leachable chlorides must therefore be used to insulate objects made from austenitic stainless steel. AS-Quality (AGI Q135 – EN 13468) The corrosion resistance of steel is increased by the addition of alloying elements such as chromium, nickel and molybdenum.
2.2 Product properties & test m ethods 2.2.4 Water leachable chloride content ASTM C795 “Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless Steel”. This specification covers non-metallic thermal insulation for use in contact with austenitic stainless steel piping and equipment.
EN 1609 & EN 13472 Partial immersion BS 2972 Section 12 Partial Immersion BS 2972 Section 12 Total Immersion N ote British Petroleum places specific demands on the water repellency of mineral wool products. In accordance with the BP172 standard, the samples are heated for 24 hours at 480 °F (250 °C). The water repellency is tested afterwards in accordance with BS 2972 Section 12 Partial Immersion. Tested in accordance with two mineral wool standards, e.g.
2.2 Product properties & test m ethods 2.2.5 Water repellency ASTM C1104 / 1104M “Standard Test Method for Determining the Water Vapor Sorption of Unfaced Mineral Fiber Insulation”. This standard covers the determination of the amount of water vapor sorbed by mineral fiber insulation exposed to a high-humidity atmosphere. The test samples are first dried in an oven and then transferred to an environmental chamber maintained at 120 °F (49 °C) and 95 % relative humidity for 96 hours.
2.2.9 Density The density of mineral wool products is the amount of fibers per cubic foot. Special care should be taken when comparing only the densities of insulation products. Density influences several product performance properties. It is however not a product performance property itself. A common assumption is that the higher the density, the more the compression resistance, maximum service temperature, fire performance and thermal conductivity will improve. This is only correct to a certain extent.
2. Theory 2.3 Bases for thermal calculations The following sections outline a number of definitions and approaches to heat transfer calculations. Detailed calculation processes are outlined in the ASTM C680 and VDI 2055, and the EN 12241 standards, as well as in various standards, such as ASTM C680 and BS 5970. The calculation bases are similar in all the standards. In Europe, the VDI 2055 is the most widely used and accepted definitions and calculation basis.
across a unit thickness of material). The unit of thermal conductivity is BTU.in/hr∙ft2∙°F (W/m∙K). λ= (Q ⁄ t) A·(∆T ⁄ L) Apparent Thermal Conductivity A thermal conductivity assigned to a material that exhibits thermal transmission by several modes of heat transfer resulting in property variation with specimen thickness, or surface emittance. Thermal conductivity and resistivity are normally considered intrinsic or specific properties of materials and, as such, should be independent of thickness.
2.3 Bases for thermal calculations 2.3.
2.3.2 Heat transfer (European basis and terms) Terms Heat quantity Q The heat quantity is the thermal energy that is supplied to or dissipates from a body. The unit used to designate the heat quantity is J. Heat flow Q` The heat flow Q` is the heat quantity flowing in a body or being transferred between two bodies per time unit. The unit used to designate the heat flow is W (1W = 1J/s).
2.3 Bases for thermal calculations 2.3.2 Heat transfer (European basis and terms) Heat transfer resistance 1/α The heat transfer resistance “1/α” is the reciprocal of the surface coefficients of heat transfer. The unit used to express the heat transfer resistance is (m²K)/W.
The following symbols are used in this calculation: qR Heat flow density per m pipe W/m ϑM Temperature of the medium in °C ϑL Ambient temperature in °C d1 External diameter of pipe m External diameter of insulated pipe m da αi Surface coefficient of heat transfer inside W/(m² K) αa Surface coefficient of heat transfer outside W/(m² K) λ1…λn Thermal conductivity of the individual insulation layers W/(m K) k Coefficient of thermal transmittance W/(m² K) d1…dn Diameter of individual layers of insulation m The
1.2 B 2.3 Insulation ases for thermal of pipingcalculations 2.3.2 Heat transfer (European basis and terms) The rate of radiation depends on factors such as the material of the cladding (emission ratio ε), the surface temperature and the orientation of the object in relation to other components. The calculation procedures are explained in the VDI 2055 and DIN EN 12241 standards. A detailed description will not be given at this point.
3 Tables Tables Industrial insulation
3. Tables Table of contents 3.1 3.1.1a 3.1.1b 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10 3.1.11 3.1.12 3.1.13 3.1.14 3.1.
3. Tables 3.1 Units, conversion factors and tables 3.1.1a S ymbols, definitions and units (US Convention) Symbol Definition US Unit A Area ft2 L Length ft, in σ Stefan-Boltzman Constant 0.1714 x 10-8 BTU/hr.ft2.°R4 ε Emittance - - Specific heat capacity BTU/lb.°F cp Specific heat capacity at constant pressure BTU/lb.°F cv specific heat capacity at constant volume BTU/lb.
R Definition Thermal resistance r Thermal resistivity ra Apparent thermal resistivity US Unit Notes hr.ft2.°F/BTU linear orientation hr.ft.°F/BTU cylindrical orientation hr.°F/BTU spherical orientation hr.ft2.°F/BTU-in (conventional unit) hr.ft.°F/BTU (alternative) hr.ft2.°F/BTU-in - Heat Energy BTU Q Heat Flow Rate BTU/hr q Heat Flux BTU/hr.
3.1 Units, conversion factors and tables 3.1.
Definition Unit α Linear expansion coefficient K-1 Λ Thermal conductance W/(m2 ⋅ K) λ Thermal conductivity W/(m ⋅ K) ε Emissivity - η Yield, efficiency - ϑ (also t) Temperature °C μ Water vapor resistance factor - μ Water vapor resistance - ρ Density kg/m3 ϕ Relative humidity - Ξ Air flow resistance Pa ⋅ s/m2 Units, conversion factors and tables Symbol 3.1.
3.1 Units, conversion factors and tables 3.1.3 SI pre-fixes Decimal parts and multiples of units are conveyed by means of prefixes and corresponding symbols. Several prefixes cannot be compounded. Name Symbol Conversion factor Atto A 10-18 Femto F 10-15 Piko P 10-12 Nano n 10-9 Mikro μ 10-6 Milli m 10-3 Centi c 10-2 Deci d 10-1 Deca da 101 Hecto h 102 Kilo k 103 Mega M 106 Giga G 109 Tera T 1012 Peta P 1015 Exa E 1018 3.1.
SI Base units The International System of Units, also referred to as SI (Abbreviation for French: Système International d’unités), embodies the modern metric system and is the most widely used units system for physical units. The system was originally established in response to demands from the field of science and research, however it is now the prevalent units system for the economic, technological and trade industries.
3.1 Units, conversion factors and tables 3.1.6a S I derived units with special names (European units) Name Expression in terms of original SI Units Symbol Quantity Unit Plain angle a, b, ...
Units, conversion factors and tables 3.1.6b SI derived units with special names (US units) Name Symbol Quantity (US) Unit Expression in terms of original Units Force, weight F Pound-Force lbf lb ⋅in s2 Pressure, stress p Pound-Force per square inch PSI lb in⋅s2 Energy, work, heat E, W British-Thermal-Unit BTU lb ⋅in2 s2 Celsius-temperature z degrees Fahrenheit °F 0 °F = 459.67 °R 32 °F = 491.
3.1 Units, conversion factors and tables 3.1.7 Compound units derived from SI-units Name Quantity Symbol Definition (Units) Volume Litre l, L 1 l = 1 dm3 = 1L Time Minute Hour Day Year min h d yr 1 min = 60 s 1 h = 60 min = 3600 s 1 d = 24 h = 1440 min 1 yr = 365 d = 8760 h Mass Tonnes Grams t g 1 t = 1.000 kg 1 g = 0.
Temperature scale Conversion formulas Unit Kelvin Kelvin ( TK ) K Celsius ( TC ) °C TC ≈ TK - 273 Fahrenheit ( TF ) °F TF ≈ 9/5 TK - 459 3.1.9 Conversion degrees Celcius and Fahrenheit The white columns show the temperature in degrees Celsius and the grey columns show the temperature values in degrees Fahrenheit.
3.1 Units, conversion factors and tables 3.1.10 Imperial (Anglo-Saxon) units The Anglo-Saxon units (also referred to as Anglo-American meausrement systems) are derived from old English systems and were also used in other Commonwealth states prior to the implementation of the metric system. Nowadays, they are only still used in the USA and to some extent in Great Britain and in some of the Commonwealth states.
Units, conversion factors and tables Overview Imperial units and conversion to SI-Units: Standard measures of volume Imperial Units Symbol SI-Units 1 cubic inch (cu.in.) 16.39 cm3 1 cubic foot (cu.ft.) 28.32 dm3 1 cubic yard (cu.yd.) 0.7646 m3 Specific measures of volume Imperial Units Symbol SI-Units 1 gallon (gal.) 4.546 dm3 (UK) 3.787 dm3 (USA) 1 barrel (bbl.) 163.7 dm3 (UK) 119.2 dm3 (USA) 158.
3.1 Units, conversion factors and tables 3.1.10 Imperial (Anglo-Saxon) units Overview Imperial units and conversion to SI-Units: Force, weight Speed Imperial Units SI-Units 1 lbf (lb. Force) 4.448 N Energy, work, heat Imperial Units SI-Units 1 BTU 1055.06 J Power, capacity Imperial Units SI-Units 1 BTU/sec 1055.06 W 1 BTU/h 0.293 W 1 hp 745.7 W Pressure, stress 142 Imperial Units SI-Units 1 lbg/sq in. 6894.7 N/m2 1 lbg/sq ft 47.88 N/m2 Imperial Units SI-Units 1 Knot intern. (kn.
Unit Joule (J) Joule (J) Kilojoule (kJ) Megajoule (MJ) Kilowatt hours (kWh) Kilocalorie (Kcal) British Thermal Unit (BTU) 0.001 10-6 2.78 * 10-7 2.39 * 10-4 9.479 * 10-4 0.001 2.7810 * 10-4 0.239 0.948 0.278 238.8 948 859.8 3412.3 Kilojoule (kJ) 1000 Megajoule (MJ) 106 1000 Kilowatt hours (kWh) 3.6 * 106 3600 3.6 Kilocalorie (Kcal) 4187 4.187 4.19 * 10-3 1.2 * 10-3 British Thermal Unit (BTU) 1055 1.055 1.055 * 10-3 2.933 * 10-4 0.
3.1 Units, conversion factors and tables 3.1.13 Conversion of pressure scales Pascal (Pa) Unit Pascal (Pa) Bar atm lb/sq ft lb/sq in. 10-5 9.869 * 10-6 0.201 1.450 * 10-4 0.987 2088.5 13.50 Bar 10 atm 101325 1.013 lb/sq ft. 47.88 4.788 * 10-4 4.723 * 10-4 lb/sq in. 6894.8 0.0689 0.0680 5 2116.2 14.70 6.944 * 10-3 144.00 3.1.14 Conversion of SI-units into Imperial units, pre-SI units and technical scales Symbol Quantity SI-Unit Q Heat. energy J Q λ Energy.
Units, conversion factors and tables 3.1.15 Density Conversion table Density Imperial conversion to SI: SI conversion to Imperial: lb / ft3 kg / m3 lb / ft3 kg / m3 kg / m3 lb / ft3 kg / m3 lb / ft3 1 16 8.75 140 20 1.25 125 7.80 1.25 20 9 144 25 1.56 130 8.12 1.5 24 9.25 148 30 1.87 135 8.43 1.75 28 9.5 152 35 2.18 140 8.74 2 32 9.75 156 40 2.50 145 9.05 2.25 36 10 160 45 2.81 150 9.36 9.68 2.5 40 10.25 164 50 3.12 155 2.75 44 10.
3. Tables 3.2 Product properties insulation and cladding materials 3.2.1 Insulation materials In any case, it is important that the product properties and processing instructions are taken into consideration during the application of these products. Further product information can be found in the various standards and regulations, such as DIN 4140, CINI, VDI 2055 and various other ASTM standards for example. The characteristic properties of the individual ProRox® products are described in Chapter 4.
Cladding material Density (lb/ft3) Linear expansion coefficient 10-6 R-1 Emissivity Aluminum, bright 168.56 13.328 0.05 Aluminum, oxydized 168.56 13.328 0.13 Galvanized steel, bright 490 6.16 0.26 6.16 0.44 8.96 0.15 Galvanized steel, oxidized Stainless steel 490 Alu-zinc steel, bright - 0.16 Alu-zinc steel, oxidized - 0.18 Aluminized steel 490 Product properties insulation and cladding materials 3.2.2.2 Product properties and standards 6.16 Painted steel - 0.
3.2 Product properties insulation and cladding materials 3.2.2 Cladding materials 3.2.2.4 Thickness metal cladding in accordance with DIN 4140 Minimum sheet thickness External diameter insulation (mm) Galvanized. Aluminized. Alu-zinc and painted steel Stainless steel E DIN EN 10028-7 and DIN EN 10088-3 Overlap Aluminum Longitudinal joint up to 400 0.5 0.5 0.6 30 400 to 800 0.6 0.5 0.8 40 800 to 1200 0.7 0.6 0.8 1200 to 2000 0.8 0.6 1.0 2000 to 6000 1.0 0.8 1.0 > 6000 1.0 0.
3. Tables 3.3 Usage tables 3.3.1 Construction materials Density lb / ft3 Thermal conductivity BTU.in / (ft2.hr.°F) at 75 °F Specific heat capacity BTU / (lb °F) Linear expansion coefficient 10-6 R-1 Aluminum 169 1532 0.220 13.33 Concrete 150 14.6 0.22 - 0.26 6.16 - 6.72 Bitumen (Solid) 66 1.18 0.41 - 0.46 112 Material Bronze, red brass 512 423 0.088 9.8 Cast iron 490 - 443 291 - 437 0.129 5.82 Wrought (cast) iron 487 465 0.110 6.55 Copper 559 2725 0.096 9.
3.3 Usage tables 3.3.2 F luids which are commonly used in process industry Group Oils Acids Bases Various Material Density lb/ft3 Silicone oil 59 Machine oil 57 Hydrochloric acid (10%) 67 Hydrochloric acid (30%) 72 Nitric acid (10 %) 65.5 Nitric acid (<90%) 93.5 Sulfuric acid (10%) 67 Specific heat capacity BTU/(lb F) at 70 °F 0.399 0.869 0.411 Sulfuric acid (50%) 87.5 Sulfuric acid (100%) 115 0.253 Ammonia (30%) 38 1.132 Sodium hydroxide (50%) 95 Benzol 55 0.
3.3.4 Conversion factors in relation to the heat of combustion Heat of combustion MBTU/1000lb Conversion Factor lb CO2 /MBTU Conversion factor lb CO2/lb fuel Oil 18.2 170 3.1 Liquified gas 19.0 149 28.3 Petrol 19.0 161 3.1 Kerosene 18.8 167 3.1 Diesel 18.5 172 3.2 Ethane 19.9 143 2.9 Petroleum cokes 14.0 227 3.2 Black coal 12.1 220 2.7 Brown coal 5.1 235 1.2 Gas cokes 12.1 249 3 Gas 20.6 130 2.
3.3 Usage tables 3.3.5 Specific enthalpy super heated steam in kJ/kg Steam temperature in °C Pressure in bar 1 150 200 250 300 350 2776.1 400 450 500 600 700 800 2874.8 2973.9 3073.9 3175.3 3278 3382.3 3488.2 3705 3928.8 4159.7 5 2854.9 2960.1 3063.7 3167.4 3271.7 3377.2 3483.9 3701.9 3926.5 4157.8 10 2827.4 2941.9 3050.6 3157.3 3263.8 3370.7 3478.6 3698.1 3923.6 4155.5 20 2901.6 3022.7 3136.6 3247.5 3357.5 3467.7 3690.2 3917.6 4150.9 30 2854.8 2922.
3.3.6 Density super heated steam kg/m3 Steam temperature in °C Pressure in bar 1 150 200 250 300 350 400 450 500 600 700 800 0.52 0.46 0.42 0.38 0.35 0.32 0.30 0.28 0.25 0.22 0.20 5 2.35 2.11 1.91 1.75 1.62 1.51 1.41 1.24 1.11 1.01 10 4.86 4.30 3.88 3.54 3.26 3.03 1.82 2.49 2.23 2.02 20 8.98 7.97 7.22 6.61 6.12 5.69 5.01 4.48 4.05 30 14.17 12.33 11.05 10.07 9.27 8.61 7.55 6.74 6.09 40 17.00 15.05 13.62 12.50 11.57 10.12 9.01 8.
3.3 Usage tables 3.3.7 Dew point table Air temperature -22 154 Maximum water content grain/ft3 0.15 Maximum cooling (°F) of air temperature (to avoid condensation) at a humidity of 30 % 35 % 40 % 45 % 50 % 55 % 60 % 65 % 70 % 75 % 80 % 85 % 90 % 95 % 20.0 17.6 15.5 13.5 11.9 10.3 8.8 7.6 6.3 5.0 4.0 2.9 2.0 1.1 -13 0.24 20.7 18.2 16.0 14.0 12.2 10.6 9.2 7.7 6.5 5.2 4.1 3.1 2.0 1.1 -4 0.39 21.6 18.7 16.4 14.4 12.6 10.8 9.4 8.1 6.7 5.2 4.1 3.
3.3.8 Climate data 3.3.8.1 Average climate data Max. Temperature (1% Frequency) Winter Wind (1% Frequency) Condensation Dew Point Temp (1% Frequency) Mean Coincident Temperature °F °C °F °C MPH m/s °F °C °F °C Acapulco, Guerrero, MX 69 21 92 33 18.6 8.3 79 26 87 31 Bakersfield, CA 35 2 100 38 18.3 8.2 63 17 85 30 Bangor, ME -2 -19 84 29 23.5 10.5 68 20 75 24 Boston, MA 13 -11 88 31 26.8 12 71 22 79 26 Casper, WY -1 -18 91 33 32.2 14.
3.3 Usage tables 3.3.8.1 Average climate data Europe Temperature (°C) Humidity (%) Athens 17.6 66 Berne 8.6 - Geneva 9.2 - Amsterdam 9.8 83 Innsbruck 8.4 - London 9.9 79 Madrid 13.4 67 Moscow 3.6 79 Paris 10.3 77 72 Rome 15.4 Salzburg 8.2 - Warsaw 7.3 82 Vienna 9.8 77 Zurich 8.2 - Africa Min. Temperature (°C) Max.
Min. Temperature (°C) Max. Temperature (°C) Afghanistan, Kabul 12 2 25 Azerbijan, baku 13 6 25 Bangladesh 25 18 29 Brunei 27 23 31 China, Beijing 12 -3 26 China, Shanghai 16 4 28 India, Mumbai 27 23 30 India, Dehli 25 14 32 India, 28 24 32 Indonesia, Jakarta 27 23 31 Japan, Tokio 15 8 27 Malaysia, Kuala Lumpur 27 22 32 South Korea, Seoul 12 -2 25 Taiwan, Taipei 22 16 29 Thailand, Bangkok 28 21 30 Annual Temperature (°C) Min.
3.3 Usage tables 3.3.8.1 Average climate data Annual Temperature (°C) Min. Temperature (°C) Max. Temperature (°C) Australia, Melbourne 14 5 26 Australia, Adelaide 16 7 27 New Zealand, Nelson 12 5 23 Annual Temperature (°C) Min. Temperature (°C) Max.
Temperature (°C) Humidity (%) - Antwerpen 9,6 Beauvechain 9,2 - Botrange 5,7 81 Brussel 9,7 Chièvres 9,0 - Dourbes 8,6 - Elsenborn 5,7 - Florennes 8,2 - Gent 9,5 - Kleine Brogel 9,0 - Koksijde 9,4 - Libramont 7,5 - Spa 7,4 - St-Hubert 6,8 - Virton 8,7 - France Min. Temperature (°C) Max.
3.3 Usage tables 3.3.8.1 Average climate data Temperature (°C) Humidity (%) Berlin 9.1 77 Braunschweig 8.6 - Germany 160 Bremerhaven 8.8 - Dresden 9.3 74 Essen 9.5 82 Erfurt 8.0 - Frankfurt/M. 10.1 76 Frankfurt a.O. 8.2 - Giessen 9.0 - Görlitz 8.3 - Halle 9.1 76 Hamburg 8.4 80 Magdeburg 9.1 - Mannheim 10.2 - Munich 8.1 - Nuremberg 8.5 - Plauen 7.2 - Regensburg 8.1 - Rostock 7.8 - Stuttgart 8.6 - Trier 9.
3.3.8.2 Wind speed Wind speed (m/s) Wind speed mph Definition 0 0 - 0.2 0-1 Calm 1 0.3 - 1.5 1-3 Light air 2 1.6 - 3.3 4-7 Light breeze 3 3.4 - 5.4 8 - 12 Gentle breeze 4 5.5 - 7.9 13 - 17 Moderate breeze 5 8.0 - 10.7 18 - 24 Fresh breeze 6 10.8 - 13.8 25 - 30 Strong breeze 7 13.9 - 17.1 31 - 38 Moderate gale (strong wind) 8 17.2 - 20.7 39 - 46 Fresh gale (strong wind) 9 20.8 - 24.4 47 - 54 Strong gale (strong wind) 10 24.5 - 28.
3.3 Usage tables 3.3.9 Guidelines average velocities in pipe work Type of fluid / piping Steam piping Saturated steam 20 to 35 650 to 1150 30 1000 MP(medium-pressure) steam 40 1300 HP(high-pressure) steam 60 2000 Feed 2 to 3 65 to 100 Return 1 33 Low viscosity 1.5 50 High viscosity 0.5 16 District heating Average 2 65 Central heating (non residential buildings) Main feed stock 0.5 16 3.3.
Nominal diameter (DN/Metric) Outer diameter (inch) Outer diameter (mm) 1/8 DN 6 0.406 10.3 1/4 DN 8 0.539 13.7 3/8 DN 10 0.673 17.1 1/2 DN 15 0.840 21.3 3/4 DN 20 1.050 26.7 1 DN 25 1.315 33.4 1¼ DN 32 1.660 42.2 1½ DN 40 1.900 48.3 2 DN 50 2.375 60.3 2½ DN 65 2.875 73 3 DN 80 3.5 88.9 3½ DN 90 4 101.6 4 DN 100 4.5 114.3 4½ DN 115 5 127 5 DN 125 5.563 141.3 6 DN 150 6.625 168.3 8 DN 200 8.625 219.1 10 DN 250 10.75 273.
3.3 Usage tables 3.3.11 Equivalent pipe length for flanges & valves Reference values for plant related thermal bridges (table A14 - VDI 2055) Temperature range in °F 120 to 210 Item no. 300 to 575 750 to 930 Equivalent length in (ft) 1 Flanges for pressure stages PN 25 to PN 100 1.1 Uninsulated for pipes 1.1.1 In buildings 70 °F 1.1.2 1.
Temperature range in °F 120 to 210 Item no. 300 to 575 750 to 930 Equivalent length in (ft) 2.1.
3.3 Usage tables 3.3.13 Fire curve: ISO and hydrocarbon ISO fire curve 1400 Temperature (°C) 1200 1000 800 600 400 200 0 0 50 100 150 200 250 300 350 200 250 300 350 Time (min.) Hydrocarbon fire curve 1400 Temperature (°C) 1200 1000 800 600 400 200 0 0 50 100 150 Time (min.
Usage tables Notes 167
Notes 168
ENERWRAP MA 960 ® ® Formerly RHT BOARD ® ® Formerly RHT BOARD ® ProRox SL 900 Series ® ® ProRox SL 900 Series ® 900 Series = Thermal Insulation MA = Wrap/Mat ProRox SL 500 Series 500 Series = Compression Insulation 700 Series = Comfort/Multi-Purpose Insulation = Boards/Slabs Local market specifications Application code FSL = Flexible Boards/Slabs PS = Pipe Insulation SL Product identifier 400 Series = Industrial Fabricated Insulation ProRox SL 960 NA Product range e.g.
Industrial insulation 4 Products Products NEW High Temperature Industrial Solutions NAME New product names, logical structure ENERWRAP MA 960 ® NA ® Formerly ENERWRAP ProRox PS 900 Series ® ® Each product name is structured in the same clear way: ® Formerly TECHTON • STURDIROCK e.g.
C547 - Pipe COMPLIANCE New Name Old Name ® NA Nominal Density ® 3 ProRox PS 960 TECHTON 1200 8 lbs./ft. ProRox® PS 980NA STURDIROCK® 11.25 lbs./ft.3 C547 Mineral Fibre Preformed Pipe Insulation I II IV V • • • • • • • E136 Behaviour at 750°C S114 NonCombustibility S102 / E84 Surface Burning Characteristics C411 Hot Burning Characteristics C447 Maximum Surface Performance C356 Linear Shrinkage C1104 Moisture Sorption • • • • • • • • • • <1.3% <0.1% <0.6% <0.
4. Products Through the ProRox® range, ROXUL® Industrial Insulation offers a wide assortment of high quality stone wool (mineral wool) insulation products for sustainable insulation of industrial and power generation plants. Each product is developed with a specific field of application (e.g. pipework, boilers, vessels, columns and storage tanks) in mind.
4. Products The main characteristic of ProRox® products is their excellent thermal insulation capacity. Next to this, they of course also comply with the most stringent requirements on fire resistance and acoustic insulation. Below is a summary of ProRox® items and the recommended applications. More information can be found on our website www.roxul.
ProRox® PS 960NA Applications ProRox® PS 960NA is a pre-formed mandrel wound stone wool (mineral wool) pipe section. The highly durable sections are supplied split and hinged for easy snap-on assembly, and are especially suitable for thermal and acoustic insulation of high temperature industrial pipe work subject to mechanical loads. ProRox® PS 980NA Applications ProRox® PS 980NA is a heavy duty, pressure resistant pre-formed mandrel wound stone wool pipe section.
4. Products ENERWRAP® MA 960NA Thermal Applications ENERWRAP® MA 960NA is a rolled and faced stone wool insulation wrap (mat) designed for high temperature industrial applications where flexibility is required. Product is ideal for large diameter piping, vessels, ducts and equipment subject to light mechanical loads.
ProRox® SL 920NA Thermal Applications ProRox® SL 920NA is a semi-rigid stone wool thermal insulation board (slab) for intermediate temperature industrial applications.
4. Products ProRox® SL 940NA Thermal Applications ProRox® SL 940NA is a rigid stone wool insulation board (slab) for high temperature industrial applications.
ProRox® SL 540NA Pressure Resistance Applications ProRox® SL 540NA is a pressure resistant rigid stone wool insulation board (slab) designed for high temperature applications subjected to light mechanical loads.
4. Products ProRox® SL 590NA Pressure Resistance Applications ProRox® SL 590NA is a pressure resistant rigid stone wool insulation board (slab) designed for thermal insulation of tank tops (vessel heads) exposed to foot traffic or constructions subjected to heavy mechanical loads.
ProRox® SL 430NA Industrial Fabrication Applications ProRox® SL 430NA is a semi rigid stone wool insulation board (slab) that can be fabricated into high temperature industrial pipe and tank wrap.
4. Products ProRox® SL 460NA Industrial Fabrication Applications ProRox® SL 460NA is a rigid stone wool insulation board (slab) that can be fabricated into high temperature industrial pipe sections.
ProRox® FSL 920NA Thermal Applications ProRox® FSL 920NA is a flexible stone wool thermal insulation board (slab) for intermediate temperature industrial applications.
4. Products ProRox® FSL 940NA Thermal Applications ProRox® FSL 940NA is a flexible stone wool thermal insulation board (slab) for high temperature industrial applications.
ProRox® MA 930NA Thermal Applications ProRox® MA 930NA is a rolled stone wool thermal insulation wrap (mat) for intermediate to high temperature industrial applications.
4. Products ProRox® GR 903 Granulated loose fill Applications ProRox® GR 903 is a stone wool granulate with no additives. The granulate is especially suitable for the thermal insulation of cold boxes and air separation plants. Benefits: Complies with the most stringent requirements for the insulation of cold boxes Chemically inert to steel Easy to remove for inspection purposes ProRox® FL 970 Applications ProRox® FL 970 is lightly bonded, impregnated stone wool.
ProRox® Rocktight Watertight insulation cladding ProRox® Rocktight, the watertight cladding Achieving the best insulation system for your application is not easy. Besides the right choice and implementation of the insulation, the insulation protection system also plays an important role. Specific uses call for specific solutions. Certain processes require a fully watertight and closed finish. Strong and easy to clean, with great durability and chemical resistance.
4. Products ProRox® Rocktight: strong and easy to install. Reinforced polyester wrap (mat) positioned between two sheets of film. ProRox® Rocktight can be cut or trimmed into any shape. The polyester cures ultraviolet (UV) light. Optimal mechanical protection and watertight. 186 For more details contact your ROXUL® representative.
Environmentally Sustainable ROXUL Inc. is part of ROCKWOOL International, the largest producer of stone wool insulation, which is made from natural basalt rock and recycled material. ROCKWOOL International was founded in 1909 and today operates worldwide with more than 9,800 employees, with over 28 factories across three continents. Our stone wool production process utilizes some of the most advanced technology available.
