ASHU SHARMA'S PRESENTATION ON UPGRADED INSULATION SYSTEMS

A presentation on Upgraded Insulation Systems by ASHU SHARMA, Manager (Technical)
LLOYD INSULATIONS (INDIA) LIMITED
SUGAR SECTOR
Services Rendered

Thermal Insulation for Industrial / Commercial Applications Refractory & Ceramic Fibre Lining Acoustic Insulation / Enclosures Pre-Engineered Buildings / Structures Turnkey Cold Storage Construction with PUF Sandwich Panels Specialised Cold Storages Construction (CA / Ripening)
Metal Roofing (with & without Insulation)

Specialised Aluminium Roofing Systems Over deck Insulation with Spray applied PUF Waterproofing (Elastomeric / APP / TPO membranes) Coal Tar Enamel Coating & Wrapping for Cross-country Pipelines Passive Fire Protection (Cementaceous / Vermicullate / Intumescent Paint) Fire Protection Systems for Electrical Cable Trays / Cable / Duct penetrations Thermal Insulation Audit (Hot & Cold) ESCO Company (Detailed Energy Audit of Buildings)
2
UPGRADED THERMAL INSULATION SYSTEM

DESIGN CRITERIA (FOR PROPOSED SYSTEM):
Ambient temperature Surface Temp Maximum heat loss Wind Velocity Finish : : : : : 40 C 60 C 100 kcal / m2hr. 0.0 m/sec. Aluminium-22-24 G (0.2 emissivity) GI-22-24 G (0.35 emissivity) Colour Coated GI Sheet (0.65 emissivity)
MATERIAL DETAILS : Rockloyd Resin Bonded Rockwool Mattresses For operating temp. up to 100-120 Kg/M3 conforming to IS :8183 1993, 400 C BS : 3958 Part-3, ASTM : C 592-80 Rockloyd Resin Bonded Rockwool Mattresses 150 Temperature above 400 C Kg/M3, conforming to IS :8183 1993, BS : 3958 Part-3, ASTM : C 592-80 Rockloyd Rockwool Preformed Pipe Sections 144 Kg/M3 conforming to IS:9842, BS : 3958 Part-4, ASTM:C 547-95, up to 350 mm NB pipe dia Up to 650 C
SUSTAINABILITY
Energy Conservation Energy conservation is defined largely as cost-effective ways to reduce energy consumption through existing and improved technologies as well as through sound energy use practices. Energy efficiency technologies and practices can therefore play a significant role in reducing the threat of global climate change.
The judicious and effective use of energy to maximize profits (minimize costs) and enhance competitive positions
SUSTAINABILITY
One of the easiest and most effective energy efficient technologies available today is Thermal Insulation. Overall benefits from insulation are numerous, including thermal performance, personal comfort, sound control, condensation control, fire protection, provided to retard flow of heat or cold from environment to inside of building and vice-versa and personnel protection.
COOLING OF INSIDE AIR IN BUILDINGS
Energy Conservation, Sustainability
& Role Of Thermal Insulation
SUSTAINABILITY
SUSTAINABILITY Insulation is a product or service, which stands up very well on its own offering clear and straightforward energy efficiency and economic advantages and can go much further!
EXSISTING ENERGY CONSUMPTION
I N S U L A T I O N
JOB CREATION
REDUCED ILLNESS
$$ INVESTMENT
$$ SAVINGS
CO2 REDUCTION
REDUCED ENERGY CONSUMPTION
ECONOMIC IMPACT
THERMAL INSULATIONS
THERMAL INSULATION DELIVERS THE FOLLOWING BENEFITS Reduce heat loss or heat gain to achieve energy conservation. Offer better process control by maintaining process temperature. Protect the environment through the reduction of Co2, NOx, & Greenhouse gases. Increase operating efficiency of heating / ventilation / cooling, steam, process & Power system. Control system temp. for personnel & equipment protection. Prevent corrosion by keeping the exposed surface of a refrigerated system above dew point. Provides fire protection to equipment. Absorbs vibration.
Potential for energy loss from a hot surface

Difference between ambient and surface temperatureC 25 40 100 150 225 Heat loss kcal /m2.hr
340 600 1910 3225 5330
Heat-in-leak into cold surfaces

Difference in Temperature between Heat in-leak Kcal/m2h ambient & Surface C
5 10 15 20
38 76 125 165
Ambient considered : 38 C Shape of Surface : Spherical Properly designed insulation can restrict the above values down to 10 - 15 kcal / M
SUSTAINABILITY
Surface Heat Transfer or film Coefficient
Ambient Temp (Ta)
Surface1 Emissivity = e
Wind Speed =V
Conducted heat through insulation
Surface Temp. (Ts)

fRad= 4.876 x 10-8 x e x ( Ts4 - Ta4 ) ( Ts - Ta )
Insulation
Heat
fConv.=1.683 x (Ts - Ta )0.25 x (2.857 x V + 1)0.5
ROCKLOYD ROCKWOOL MATTRESS

SPECIFICATION CONFORMANCE
IS BS : ASTM :
8183 1993
3958 Part-3 C 592-80
APPROVED FOR A-60 CLASS INSULATION .*

*The only product in India.
TECHNICAL SPECIFICATIONS
1
2 3 4
Standard Densities
Application Temperatures Standard Thickness* Standard Size
100, 120, 150 Kg/m3

-1000C to +8000C 25, 40, 50, 65, 75mm 1520 x 1220mm
* Other thickness from 20 to 100mm insteps of 5mm can also be made available.

ROCKLOYD PIPE SECTIONS - pre-formed pipe section of pipe dia upto 350mm NB
ROCKLOYD ROCKWOOL PIPESECTION

IS : 9842
BS
3958 Part-4
C 547-95
ASTM :
1 2 3 4 5 6 Standard Densities Application Temperatures Standard Thickness* Diameter Range** Standard Length Facings (if specified) 144, 150 & 160 Kg/m3 -1000C to +8000C 25, 40, 50, 65, 75mm 12.5mm to 350mm Nominal Bore 0.5, 0.75, 1.0 mtrs. Kraft Paper, Scrim Cloth, Canvas or Aluminium Foil
*Other thickness from 20 to 100mm insteps of 5mm can also be made available. ** Outer diameter of pipe to be specified.
ROCKLOYD ROCKWOOL SLAB / ROLL
ROCKLOYD SLAB
IS : 8183 1993
BS
3958 Part-5
C 612
ASTM :
IMO for A-15, A-30 & A-60 Class Fire Barrier Insulation.**
*The only product to carry this certification in India.
ROCKLOYD SLAB
1 Standard Densities 48, 64, 96,144 Kg/m3
2 3
4
Application Temperatures Standard Thickness*

Standard Size
-1000C to +8000C 25, 40, 50, 60, 65, 75mm

1.0 x 0.50, 1.0 x 0.60 or 1.2 x 0.75 mtr.
*Can be made available with increments in thickness of 5mm against special orders.
THERMAL INSULATION OF STEAM LINES

Rockwool Water Repellant Grade Rock Fibres treated with SILANE
23
WATER REPELLENT GRADE ROCKWOOL
24
25
26
SUPERCERA BRAIDED & TWISTED ROPE
SUPERCERA ROPE
TWISTED / BRAIDED ROPE, CLOTH Insulation material for small dia / embedded pipes, DG Set exhaust pipeline, Packing material between expansion and contraction joints, Furnace curtains, Replacement of asbestos cloth and tape, Pipe hanger insulation, Cable & wire insulation, Fuel line insulation, Impulse Line Insulation.
SUPERCERA ROPE, CLOTH, TAPE
SUPERCERA ROPE Supercera Twisted Rope is a 3 ply rope manufactured from supercera long fibres having 15-20% organic binder. Supercera Braided Rope in addition is braided with SS 304/310 wire netting. Size 6 to 40mm dia, 10/25M coils Density 300 kg/m3
SUPERCERA CLOTH / TAPE Supercera made from 15-20% organic coated supercera long fibres :
Cloth size : 3 x 300 / 1000mm x 10M Tape size : 3 x 50 / 25mm x 10M
SUPERCERA PADS Supercera blankets of density 128 kg/m3 and thickness 50 & 75mm encased in Supercera Cloth and stitched with SS Wire to form pads. Special hooks are stitched to the surface and corners for the purpose of positioning & tieing. USES : Steam Turbine Insulation, Fire Walls for Isolation AVAILABILITY : Width : 610mm; Length Max. : 7 mtr.
SUSTAINABILITY
Thickness Calculation based on ASTM C 680
Upgraded & latest method to calculate thickness of insulation Calculates effect of windage & emissivity for each pipeline Slightly more thickness Reduced heat loss
SUSTAINABILITY
ILLUSTRATION OT AT ST Cladding Wind Velocity Pipe OD Insulation Calculation Procedure : : : : : : : : 450 deg.C 40 deg.C 60 deg.C Aluminium ( 0.2 Emissivity) 0, 0.5, 1 8,10, 12 ROCKWOOL MATTRESSES 150 KG/M3 DENSITY ASTMC-680 & IS-14164
SUSTAINABILITY
WINDAGE = 0
COMPARATIVE OF THICKNESS
As per IS-14164 Dia (mm) 8 10 Thickness (mm) 175 185 Heat Loss (Kcal/m2hr.) 105 105 As per ASTMC-680 Thickness (mm) 210 220 Heat Loss (Kcal/m2hr.) 85 85
12
190
105
230
85
SUSTAINABILITY
WINDAGE = 0.5
COMPARATIVE OF THICKNESS `
Dia (mm)
As per IS-14164
Thickness (mm) Heat Loss (Kcal/m2hr.)
As per ASTMC-680
Thickness Heat Loss (mm) (Kcal/m2hr.)
8
10 12
135
140 145
143
143 143
165
175 180
119
119 119
SUSTAINABILITY
WINDAGE = 1
COMPARATIVE OF THICKNESS As per IS-14164 Dia (mm) 8 10 Thickness (mm) 115 120 Heat Loss (Kcal/m2hr.) 174 174 As per ASTMC-680 Thickness Heat Loss (mm) (Kcal/m2hr.) 140 150 143 143
12
125
174
155
143
SUSTAINABILITY
Windage
Thickness reduces with wind impact.
Emissivity
Thickness reduces with dull surface.
Thermal Insulation
From this, we can see that insulation is a major tool in improving energy availability
Economic reasons for Thermal insulation in industry
Reduces fuel consumption, and hence overall cost of operation Reduces capacity requirements for heating/cooling systems (e.g., boilers/ refrigeration units, etc)
Benefits of higher profits to owner
Savings in Project Capital costs
Thermal Insulation of Steam Lines

Calculation of Insulation thickness Ambient Temp. Operating Temp. Surface Temp. Pipe OD Wind Velocity Cladding Emissivity Insulation material K value

Calculation of Insulation thickness Surface Temp. 60 deg.C (max.) Wind Velocity 0, 0.5, 1 m/sec. Emissivity 0.2, 0.3, 0.6 K Value (Mean Temp.) 0.T + S.T 2 OUTPUT : Thickness, Heat Loss, Surface Temp.

LATEST INSULATION DESIGN METHOD Combination Insulation System for Super Heated Steam Lines : OT = 450 deg.C & above K value varies as per mean temperatures eg. OT= 450 C, ST=60 C , MT=255 C = (450+60) 2 Rockwool - 0.068 Kcal/mhr.deg.C Calcium Silicate - 0.0757 Kcal/mhr.deg.C Ceramic Fibre - 0.066 Kcal/mhr.deg.C Perlite - 0.091 Kcal/mhr.deg.C
Ceramic Fibre has a lower K value at elevated temps. as compared to Rockwool, Calcium Silicate & Perlite. Ceramic Fibre will reduce heat losses maximum An initial layer will bring down Interface temp. Subsequent layers with Rockwool Overall reduction in heat loss & ST

ILLUSTRATION OT : AT : ST : Cladding : Wind Velocity : Pipe OD : Pipe Length : Insulation :
450 deg.C 40 deg.C 60 deg.C Aluminium 0 10, 12, 14 5 mtr. RW, Cal. Sil., CF+RW, Perlite

1. 10 Line
mm Kcal/m2hr. ST Deg.C 60
RW
185
95
Cal. Sil.
200
95
60
CF+RW
160
56
53
Perlite
215
96
60

2. 12 Line
mm Kcal/m2hr. ST Deg.C
RW
190
96
60
Cal. Sil.
205
96
60
CF+RW
165
62
54
Perlite
220
96
60

3. 14 Line
mm Kcal/m2hr. ST Deg.C
RW
195
97
60
Cal. Sil.
210
97
60
CF+RW
170
65
54
Perlite
225
96
60

4. 12 Line, OT = 500 deg.C, AT = 35 deg.C
mm Kcal/m2hr. ST Deg.C 55
RW
240
94
Cal. Sil.
250
95
55
CF+RW
235
62
49
Perlite
225
96
60

5. 12 Line, OT = 550 deg.C, AT = 35 deg.C
Mm Kcal/m2hr. ST Deg.C 55
RW
275
95
Cal. Sil.
290
96
55
CF+RW Perlite
250 295
61 96
49 60

Rockwool is Techno-Economic and available as Water Repellent Grade. Calcium Silicate is expensive and hygroscopic. Ceramic Fibre is Soft Refractory Fibre and thermally most stable. Expanded Perlite is Water Repellent, higher K value & costly.

Effect of Wind Velocity Presence of Wind in surrounding takes away heat generated from cladding surface. A strong wind will carry away heat and ensure a lower surface temperature. Windage has effect on insulation thickness reduces with increase in windage. For energy conservation, windage is taken as Zero.

Effect of Emissivity Heat coming on top of insulation is emitted out. Polished surface will emit maximum heat (Aluminium) Aluminium calls for higher thickness & GI, Plaster lower thickness Old aluminium will emit lower heat as compared to new sheet.

Cladding Cladding corrosion due to condensation on inner side Moisture present on inner side condenses & lower corrosion to cladding sheet. Polysurlyn coated aluminium sheet is now available(earlier bitumen coating underneath).
Supercera Ceramic fibre Removable Pads for Turbine Insulation
Supercera Pads
Supercera blankets of density 128 kg/m3 and thickness 50 & 75mm encased in Supercera Cloth and stitched with SS Wire to form pads. Special hooks are stitched to the surface and corners for the purpose of positioning & tieing. USES : Steam Turbine Insulation, Fire Walls for Isolation, Valves & Flange Insulation
AVAILABILITY : Width : 610mm; Length Max. : 7 mtr.
Supercera Pads for Valves & Flanges Insulation
Supercera Pads for Equipment Insulation
Supercera Pads for Equipment Insulation
WITH CERAMIC PADS
Insulation of Hot Services
APPLICATION SPECIFICATION FOR IMPULSE LINE INSULATION very small dia , , 1, 1 , 2

Providing and wrapping Supercera ceramic fibre rope in required thickness over the pipeline so as to cover the piping completely without leaving any gap. Providing and applying one coat of insulkote over the rope. Providing and applying glass fibre cloth 10 x 10 sq. inch apperture over the insulkote and tying with synthetic thread. Providing and applying second coat of insulkote over the glass cloth. Providing and applying a coat of bitumenous based aluminium paint over insulkote.
1.
2.
3. 4. 5.

1.
MONSOON SPECIFICATION FOR HOT PIPELINE INSULATION
Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease.
Providing and fixing MS flat ring of size 25x3mm over pipes having diameter more than 150mm NB at every 1150mm distance having L shaped lugs with a packing of ceramic paper duly riveted and tightening it over the surface with nut and bolt. Providing and fixing the recommended insulation thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G.
2.
3.

4.
5.
6.
7.
Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface. Providing and applying 4mm thickness APP modified membrane helically over the insulation with AL. paint coating. Providing and applying Aluminum sheet as cladding over the MS flat ring already provided at 1150 distance duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94. Providing and applying 22G AL band at every 450mm c/c over the cladding to secure it firmly to its place.
FOOT TRAFFIC SPECIFICATION FOR HOT PIPE LINE INSULATION
1.
Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease. Providing and fixing MS flat ring of size 25x3mm, over pipe having diameter more than 100mm, at every 1150 mm distance having L shaped lugs with a packing of ceramic paper, duly riveted and tightening it over the surface with nut and bolt. Providing and fixing the recommended insulation thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G .
2.
3.

4.
Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface Providing and applying 25mm thick cement sand plaster over the insulation material .
5.
6.
Providing and applying bitumen primer over the cement sand plaster.
Providing and applying 4mm thickness APP modified membrane helically over the insulation with AL. paint coating.
7.

Providing and fixing 22 gauge AL sheet cladding over the MS flat ring already provided at 1150mm distance duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94.
Providing and applying 22G AL band at every 450mm c/c over the cladding to secure it firmly to its place.
8.
9.

APPLICATION SPECIFICATION FOR EQUIPMENTS
1. Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease. 2. Providing and fixing MS flat ring of size 25x3mm at every 1150mm distance c/c having L shaped lugs with a packing of ceramic paper, duly riveted and tightening it over the surface with nut and bolt. 3. Providing and welding GI wire pins of 8 to 10G diameter having length 20mm more than the thickness of insulation at every 300mmc/c(incase of equipments having diameter more than 1000 mm).

4. Providing and fixing the recommended insulation thickness of Rockloyd Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm x 24G and piercing it through the GI wire pins. 5. Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface. 6. Bending the pins over the insulation surface. 7. Providing and fixing aluminium sheet cladding over the insulation surface.
ELECTROSTATIC PRECIPITATOR (ESP)

Following main materials are used for ESP Insulation :Rockloyd LRB Matts. 100-120 kg/m3 in appropriate thickness conforming to IS : 8183-1993. Aluminium sheet of 20G. GI Wire Netting of 50mm x 65mm x 16 SWG.
ESP INSULATION - THE CASINGS ARE INSULATED WITH ROCKWOOL

CHIMNEY
Main
INSULATION
insulation material used for Chimney Insulation is Rockloyd Resin Bonded Rockwool Slab 100 kg/m3 in thickness of 50mm having K-value of 0.052 W/mK at 100 deg.C mean temperature conforming to IS : 81831993. Following ancilliary materials are also used for Chimney Insulation :Pins
& Studs of 10G in 75mm length. Speed washers 63mm dia or square.
Metal GI GI
Wire Netting of 20G x 25mm. Wire of 16 SWG.
INSULATION OF FLANGES

APPLICATION SPECIFICATION OF STEAM TURBINE SPRAY INSULATION 1. Cleaning of the turbine / valve casing surface with wire brush to remove dust, dirt and such residues. Any contamination due to oil / grease shall be removed with suitable solvent. 2. MS Rod of 10mm dia having length equivalent to insulation thickness should be welded on the MS Pad provided by the turbine manufacturer at a pitch of 250mm (Max.). 3. Providing casing flange joint (parting plate) with a separation made out of Aluminium sheet (2mm thick) as distance line between top and bottom half of the insulation. 4. Casing flange joint shall be provided with a box made out of Aluminium Sheet will be filled in with loose Rockwool for the ease of maintenance.

5. Mask all thermo couples with sleeves made out of aluminium sheet for proper access during maintenance and replacement when and where necessary. 6. Rockloyd fibres (HT) shall be sprayed using specially designed spraying equipments and accessories. The fibres shall be processed to a desired pattern and finally taken through a hose to the spray gun center nozzle. Lloyd binder is taken to three nozzles around the main hose. The spray gun sprays Rockwool along with binder which gets mixed in the air and forms a finely distributed concentric spray. The sprayed fibres strike the surface to be insulated forming a continuous monolithic layer.

The required bulk density shall be achieved by controlling the fibre output. It shall be necessary to use wooden logs / probe for compacting the sprayed mass in congested and other locations in order to provide required density and thickness. The first layer of the insulation shall be supported with SS wire netting x 22G whereas the subsequent layers shall be supported with GI wire netting x 22G and MS Retainers. 7. CAT-9 hard setting special finishing cement plaster shall be trowel applied all over the insulated surface to a thickness of 610mm applied in two layers. The final coat of CAT-9 shall be applied after reinforcing Lloyd fabric all around the plastered surface. 8. The surface shall finally be finished with a coat of Lloyd FR Paint 80/100 microns of special duty oil resistant and heat resistant coating.

9. Design Criteria Ambient Temp. : 40 0C Surface Temp. : 10. Material Details 60 0C
Sprayed Lloydwool fibre : Non corrosive, non combustible, non toxic & asbestos free fibres.
Fibre Dia : 4-5 mirocns
Sulphur Content : Less than 0.6% Max. Service Temp. : 750 C Density : 200 250 kg/m3 Thickness : 260-310 mm K-Value : 0.039 Kcal/m. hr.0C at 50 C (Mean Temp.)

STEAM TURBINE INSULATION

APPLICATION SPECIFICATION OF STEAM TURBINE WITH CERAMIC FIBRE PAD INSULATION 1. Cleaning the surface thoroughly with wire brush to ensure that the surface is free of all dust, rust and grease. 2. Any contamination due to oil, grease shall be removed with a suitable solvent. 3. Providing and fixing MS flat ring of size 25x3mm on casing surface which is secured with either nuts and bolts or welded on the pads already provided on the casing plate.

4. Additional frame work of M.S. strip is provided to impart adequate stand to the holding structure. 3&4 are optional if pads are not adequately available. 5. The M.S. studs of thickness 6mm and height equivalent to the thickness of insulation (175mm) is fixed on the MS flat ring holding structure. 6. Providing and fixing the recommended insulation thickness of hot face insulation quilt/pad of min. 75mm thickness and cold face insulation quilt/pad of min. 100mm thickness (double layer of 50mm).

a) The hot face insulation pad is made out of three layer of ceramic fibre blanket of thickness 25mm and density 128kg/m3 having 0.1mm aluminium foil inserted between 2 layers of ceramic blankets, covered with ceramic cloth on all sides and joints stitched with 20SWG SS wire. Ceramic fibre tape 75mm wide is applied on the edges of the pad so as to cover the cloth overlapping/stitching joints on all the sides. SS washer are fixed on the corner and over the insulation pad Surface. b) The cold face insulation pad is made out of double layer of 50mm each . Each 50mm pad is made out of two layers of ceramic fibre blanket of thickness 25mm and density 128kg/m3 having 0.1mm aluminium foil inserted between 2 layer of ceramic blankets, covered with MFMB glass cloth on all sides and joints stitched with 20SWG SS wire. Glass fibre tape 50mm wide is applied on the edges of the pad so as to cover the cloth overlapping/stitching joints on all the sides. SS washer are fixed on the corners and over the insulation pad Surface.

7. The insulation pads are held in position with the help of SS clip washers provided after piercing of these pads to the supporting cage work( already fabricated and fixed). SS wires are used to tie the pads. The pads placing to have staggered joints. 8. Providing and applying 75mm ceramic tape at the pad overlapping joints. 9. The casing flange joints are provided with 18 SWG aluminium sheet fixed with MS cleats and filled with insulation pads of same thickness.

10. DESIGN DATA FOR TURBINE INSULATION Size of the insulation Pad = 1M X 0.61 M Total insulation thickness=175 to 250mm Ambient Temperature = 400C
Operating Temperature = 330 to 5500C

Surface Temperature = 58-600C Wind Velocity = Still condition (0m/sec)

TURBINE INSULATION USING CERAMIC PADS


SUSTAINABILITY
Thermal Insulation Survey
Thermal
insulation survey is a service oriented towards bringing existing shortcomings and unrealised opportunities of saving energy through extensive field data collection and possible up gradation of insulation materials for achieving higher plant efficiency.
SUSTAINABILITY
Thermal Insulation Survey : Concept It is essential to know precisely the heat

insulated surfaces in operation.
loss for the
Annual heat loss in terms of money are then worked out. A new upgraded insulation system is then designed An economic analysis is then carried out to study the viability of the proposed system. The investment on proposed system and simple payback are then worked out.
SUSTAINABILITY
Thermal Insulation Survey : Methodology

Following operational parameters and design data are collected
from the plant authorities :
Cost of Fuel
Calorific value of fuel

Boiler / Equipment design efficiency
No. of plant operating hours

Pipe OD, Length and Dimension of Equipments
Operating Temperature of Process fluids / Steam
SUSTAINABILITY
Thermal Insulation Survey : Methodology

Following field data are collected :
Average Insulation cladding surface temperature
Corresponding ambient temperature Corresponding air velocity

Emissivity of Insulation cladding surface
SUSTAINABILITY
Thermal Insulation Survey : Analysis
The
data collected during plant survey are then analysed systematically and calculations are performed on present value to arrive at the quantity of energy and financial losses.
SUSTAINABILITY
Thermal Insulation Survey : Economics

The
economic benefits of insulation shall vary according to application and method of financial appraisal. One of the simplest methods of financial appraisal is the Pay Back analysis, where costs are compared with savings and the result is expressed in terms of Pay Back Period.
There is a definite limiting thickness of insulation which is known

as Economic Thickness
SUSTAINABILITY
Thermal Insulation Survey
: Economic Thickness
The Economic Thickness of insulation is that thickness at

which the costs of heat loss, plus the installed cost is at minimum.
Where : I = Cost of Insulation H = Cost Of Heat Loss I+H= Total Cost M = Economic Thickness MC= Minimum Cost
H+I I H
MC Insulation Thickness
SUSTAINABILITY
SELECTION OF INSULATION MATERIAL:
THE MATERIALS USED FOR INSULATION SHALL CONFORM TO THE RELEVANT INDIAN STANDARDS WHEREEVER THEY EXSIST. INSULATION MATERIAL USED SHOULD BE SUITABLE FOR USE AT THE OPERATING TEMPERATURE AS STATED BY THE PURCHASER. HAND MADE MATERIALS FROM LOOSE WOOL ARE NOT PERMITTED DUE TO POOR CONSISTENCY. ALL INSULATION MATERIAL SHALL HAVE A PROVEN SERVICE RECORD OF SATISFACTORY PERFORMANCE UNDER INDIAN CONDITIONS IN SIMILAR PROCESS PLANT
SUSTAINABILITY
OTHER IMPORTANT ASPECTS Water repellents Corrosion resistant
Fire Proof / non combustible

Durability Green insulation materials
Supercera Pads for Valves & Flanges Insulation

IOCL, PANIPAT REFINERY We had carried out Thermal Insulation audit of IOCL Panipat Refinery. The data recorded for open valve are as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. Average Ambient Temp. Average Surface Temp. Average Operating Temp. Total area insulated Heat Loss Total Heat Loss Cost of Heat Loss Running Hr. Average cost of Heat Loss 40 C 450 C 450 C 1 m2 7922.01 Kcal/m2 hr. 7922.01 Kcal/hr. Rs. 500 Rs. /million Kcal. 8040 / Yr. Rs.31454 /year
we recommended to insulate the un-insulate valve with 150 mm cf pad insulation of 128 kg/m3 density. application procedure was also recommended to enhance the life of insulation After re-insulation the following were the findings :1. 2. 3. 4. 5. 6. 7. 8. 9. Average Ambient Temp. Average Surface Temp. Total area insulated Designed Heat Loss Cost of Energy Total Savings Insulation Thickness Total cost of insulation Average pay back period 40 C 60 C 1 m2 98 Kcal/m2 hr. Rs.500 /million Kcal Rs. 31064 /year 150 mm CF Pad 128 kg/m3 density. Approx. Rs. 20,000 /8 Months
So proper insulation with a little bit investment accrues lot of savings with a defined shorter pay back period.
Upgraded Energy Efficient Thermal Insulation

OPTIMAL INSULATION Heat loss, 89 mm pipe, 100 C temp.
Uninsulated Pipe Heat loss = 255 Kcal/hr.m2
50mm Insulated Pipe Heat loss = 80 Kcal/hr.m2
50mm insulation compared with an un-insulated pipe = 255 80 (Consider 1 m length ) = 175 Kcal/hr. No of operating hr. in year Total Heat loss Consider Boiler Efficiency Cost of fuel (Coal) Calorific of Coal Yearly fuel saving Yearly fuel saving = 8760 Hr. = 8760 x 175 = 1533000 Kcal/hr. = 80 % = Rs. 3500 / Ton = 3200 Kcal / Kg = 1533000 / ( 3200 x 0.80 ) = 598 Kg/ Year

ROCKWOOL INSULATION HINDALCO INDUSTRIES LTD., RENUSAGAR POWER DIVISION We had carried out Thermal Insulation audit of Hindalco Industries Ltd., Renusagar Power Division for the Boilers. The data recorded are as follows: 1. 2. 3. 4. 5. 6. 7. 8. 9. Average Ambient Temp. Average Surface Temp. Average Operating Temp. Total area insulated Heat Loss Total Heat Loss Cost of Heat Loss Running Hr. Average cost of Heat Loss 31 C 80 C 525 C 400 m2 530.704 Kcal/m2 hr. 212282 Kcal/hr. Rs. 500 /million Kcal. 8040 / Yr. Rs.853373/year

We recommended to re-insulate the complete plant piping & equipments with 255 mm Rockloyd, Resin Bonded Rockwool Mattress of 150 kg/m3 density. Application procedure was also recommended to enhance the life of insulation.
After re-insulation the following were the findings:
1. 2. 3. 4. 5. 6. 7. 8. 9.
Average Ambient Temp. Average Surface Temp. Total area insulated Designed Heat Loss Cost of Energy Total Savings Insulation Thickness Total cost of insulation Average pay back period
40 C 60 C 400 m2 98 Kcal/m2 hr. Rs.500 /million Kcal Rs. 695789 /year 255 mm RW Rs. 786840/14 Months
So proper insulation with a little bit investment accrues lot of savings with a defined shorter pay back period.

Industries benefits from Energy Audit recommendations made by Lloyd Insulations (I) Ltd.
Combination of Ceramic Fibre & Rockwool Insulation

KRIBHCO SHYAM FERTILIZERS LTD., SHAHJAHANPUR (UP)
We had carried out Thermal Insulation audit of pipe lines. The data recorded are as follows:
1. 2. 3. 4. 5. 6. 7. 8. 9. Average Ambient Temp. Average Surface Temp. Average Operating Temp. Total area insulated Heat Loss Total Heat Loss Cost of Heat Loss Running Hr. Average cost of Heat Loss - 37 C - 77 C - 507 C - 10 m2 - 388 Kcal/m2 hr. - 7080 Kcal/hr. - Rs. 664 /million Kcal. - 8760 / Yr. - Rs.41183 / year

We recommended to re-insulate the complete piping equipments with combination of insulation 25 mm CF OF 128 Kg/m3 density + 170 mm Rockloyd Resin Bonded Rockwool Mattress of 150 kg/m3 density. Application procedure was also recommended to enhance the life of insulation.
After re-insulation the following were the findings:

1. 2. 3. 4. 5. 6. 7. 8. 9. Average Ambient Temp. - 40 C Average Surface Temp. - 60 C Total area insulated - 10 m2 Designed Heat Loss - 70 Kcal/m2 hr. Cost of Energy - Rs.664 /million Kcal Total Savings - Rs. 33622 /year Insulation Thickness - 25 mm CF +170 mm RW Total cost of insulation - Rs. 40282/Average pay back period - 14 Months So proper insulation with a little bit investment accrues lot of savings with a defined shorter pay back period.
IS : 14164 - 2008
For pipelines operating above 5000C combination of Ceramic Fibre & Rockwool can be used for reducing heat loss, taking advantage of lower K-value of Ceramic Fibre at higher temperature.
Cladding Material & Accessories
Colour coated GI Sheet for pipeline insulation cladding.
0.5mm TCT & 240 MPa as per IS : 277 & 513

PIPELINE INSULATION WITH FIRST LAYER CERAMIC FIBRE & SUBSEQUENTLY ROCKWOOL MATTRESS & COLOUR COATED GI SHEET CLADDING
Increasing the supply of energy is in one way of dealing with energy shortage in our country. A second way is to improve energy efficiency by using Firesafe Fire Barrier Thermal Insulation Products
THINK INSULATION
SAVE ENERGY
PROTECT ENVIORNMENT
LLOYD INSULATIONS (INDIA) LIMITED
for a better future
THANK YOU !!

ASHU SHARMA'S PRESENTATION ON UPGRADED INSULATION SYSTEMS

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ASHU SHARMA'S PRESENTATION ON UPGRADED INSULATION SYSTEMS

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A presentation on Upgraded Insulation Systems by ASHU SHARMA, Manager (Technical)

LLOYD INSULATIONS (INDIA) LIMITED

Metal Roofing (with & without Insulation)

UPGRADED THERMAL INSULATION SYSTEM

COOLING OF INSIDE AIR IN BUILDINGS

Energy Conservation, Sustainability

& Role Of Thermal Insulation

REDUCED ENERGY CONSUMPTION

Potential for energy loss from a hot surface

340 600 1910 3225 5330

Heat-in-leak into cold surfaces

Conducted heat through insulation

Surface Temp. (Ts)

fConv.=1.683 x (Ts - Ta )0.25 x (2.857 x V + 1)0.5

UPGRADED THERMAL INSULATION SYSTEM

ROCKLOYD ROCKWOOL MATTRESS

3958 Part-3 C 592-80

APPROVED FOR A-60 CLASS INSULATION .*

UPGRADED THERMAL INSULATION SYSTEM

100, 120, 150 Kg/m3

UPGRADED THERMAL INSULATION SYSTEM

UPGRADED THERMAL INSULATION SYSTEM

ROCKLOYD ROCKWOOL PIPESECTION

UPGRADED THERMAL INSULATION SYSTEM

UPGRADED THERMAL INSULATION SYSTEM

ROCKLOYD ROCKWOOL SLAB / ROLL

UPGRADED THERMAL INSULATION SYSTEM

UPGRADED THERMAL INSULATION SYSTEM

Application Temperatures Standard Thickness*

-1000C to +8000C 25, 40, 50, 60, 65, 75mm

THERMAL INSULATION OF STEAM LINES

WATER REPELLENT GRADE ROCKWOOL

WATER REPELLENT GRADE ROCKWOOL

WATER REPELLENT GRADE ROCKWOOL

UPGRADED THERMAL INSULATION SYSTEM

SUPERCERA BRAIDED & TWISTED ROPE

UPGRADED THERMAL INSULATION SYSTEM

UPGRADED THERMAL INSULATION SYSTEM

UPGRADED THERMAL INSULATION SYSTEM

SUPERCERA ROPE, CLOTH, TAPE

UPGRADED THERMAL INSULATION SYSTEM

UPGRADED THERMAL INSULATION SYSTEM

UPGRADED THERMAL INSULATION SYSTEM

Economic reasons for Thermal insulation in industry

Benefits of higher profits to owner

Savings in Project Capital costs

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

ILLUSTRATION OT : AT : ST : Cladding : Wind Velocity : Pipe OD : Pipe Length : Insulation :

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Thermal Insulation of Steam Lines

Supercera Ceramic fibre Removable Pads for Turbine Insulation