Introduction to Insulation

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NUCLEAR POWR CORPORTION OF INDIA LIMITED

(A Government of India Enterprise)

In-House Training Program

on

INSULATION

FOR NUCLEAR POWER PLANT PIPING AND COMPONENTS

BY

P.C. a!i"arAddl. Chief Engineer (RAS)

Directorate of roc!rement

"RGA#ISED BY $%

no#$e%ge Managemen! Grou&DIRECTORATE OF R'D AND M( NPCIL


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INSULATION

CONTENT

&. I#'R"DC'I"#

. *A'ERIA+S

,. RE-ERE#CE S'A#DARDS -"R I#S+A'I#G*A'EIRA+S

. I#SA+A'I"# '/IC0#ESS

1. A+ICA'I"# R"CEDRES

2. E3A*I#A'I"# A#D 'ES'I#G

4. 5A+I'Y ASSRA#CE +A#S

6. SB*ISSI"# "- 'EC/#ICA+ D"C*E#'S 7 /IS'"RY

D"C0E'S

8. 'E#DER D"C*E#' -"R I#S+A'I"# AC0AGE

(A CASE S'DY "- RA%,7)


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Insu$a!ion

).* In!ro%u+!ion

'hermal ins!lation provides man9 !sef!l p!rposes in :oth

ind!strial and commercial piping applications. In the

simplest of terms; thermal ins!lation serves the p!rpose of

red!cing heat flo< from one s!rface to another. -or hot

(a:ove am:ient) piping applications thermal ins!lation

red!ces heat loss. "n cold (:elo< am:ient) piping

applications the ins!lation generall9 serves the p!rpose of

minimi=ing heat gain.

B9 providing a medi!m for retarding heat transfer; thermal

ins!lation offers man9 !sef!l f!nctions in ind!strial and

commercial piping applications. In specif9ing an ins!lation

s9stem; it is important to consider the parameters of 9o!r

process and application needs. 'he follo


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Con!ro$$ing Hea! Loss on Ho! Pi&ing

'he o:>ective :ehind controlling heat loss on hot piping can :e

ver9 narro< in scope or ver9 :road;


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Re%u+ing Hea! Gain on Co$% Pi&ing

In cold piping applications the main o:>ective of providing

ins!lation is the red!ction of heat gain. 'his process is most oftenevidenced in terms of providing process control and limiting or

retarding s!rface condensation. 'he most important controlling

factor in the effort to minimi=e heat gain on cold piping is the

prevention of moist!re migration; or


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. MATERIALS,

'here are man9 different t9pes of ins!lating materials

availa:le for :oth commercial and ind!strial piping applications.'here are in fact too man9 to disc!ss in detail here. A fe< of the

more common commercial and ind!strial piping ins!lation t9pes;

or classifications; are descri:ed here. 'he follo


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nonmetallic fleFi:le >acet. "n indoor applications the9 re

fre!entl9 covered acet.

Per$i!e Insu$a!ion

erlite ins!lation is generall9 !sed in the same t9pes of

applications as calci!m silicate. It is some


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Po$"ure!ane an% Po$"iso+"anura!e Foam Insu$a!ions

ol9!rethane and pol9isoc9an!rate foams are t


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ASTM S&e+i/i+a!ion Re/eren+e$

Ma!eria$ ASTM s&e+i/i+a!ion

Calci!m silicate C1,,%61

Cell!lar glass C11%8&

Elastomeric foam C1,%66

-i:erglass and mineral aceting C8&%68

ASJ >aceting C8&%68

Asphalt c!t:ac mastic C24%68

-R >aceting C8&%68

/9palon mastic C24%68

Stainless steel :anding materials C8&%68Stainless steel >aceting C8&%68

2F2 pol9ester mesh fa:ric #A

&F& glass scrim C&226%62

A+r"$i+ La!e1 Mas!i+

Acr9lic lateF mastic is a heav9 :odied


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A$uminium 2an%ing Ma!eria$s

Al!mini!m :ands are !sed as a sec!rement for man9 t9pes of

ins!lation materials. 'he most common si=es specified range :etaceting is !s!all9 factor9 applied and

serves the primar9 f!nction of providing moist!re protection. 'hese

are not vapor :arriers; :!t the9 can provide a


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asphalt c!t:ac mastics are !s!all9 covered acet for

aesthetic p!rposes.

FRP 3a+4e!ing

-R stands for -i:er Resin lastic or -i:er Reinforced lastic. B9

either definition it is a hard plastic mem:rane that is reinforced aceting can :e !sed in man9 of the same

applications aceting is often !sed aceting materials come in sheet or rolled from

and the laps are sealed


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515 Po$"es!er Mes Fari+

2F2 mesh refers to the n!m:er of strands of the primaril9 fi:er in & in

of fa:ric. A 2 F 2 mesh


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,. Re/eren+e s!an%ar%s /or insu$a!ing ma!eria$s an% me!o% o/ !es!ing

Fo$$o#ing are !e Re/eren+e /or insu$a!ing ma!eria$s an% !es!ing

me!o%s

IS$44 $ Galvani=ed steel sheets (lain and corr!gated)

specification.

IS$,& *ineral


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-ollo


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Sla:s and pipe sections shall have a normal densit9 of ,2 gm, and


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'ests for thermal material shall :e carried o!t as per IS$6&6, and IS$,&

and test certificate


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'he pipe section (snap%on t9pe) shall :e strong; d!ra:le; non%

corrosive; non h9groscopic;


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. INSULATION THICNESS

'he :asis for selection of ins!lation thicnesses of vario!s operating

temperat!res and piping and e!ipment are given in 'a:les A and B.

'he ins!lation thicness given in 'a:le%A are for hot ins!lation and

'a:le B is for cold ins!lation.

TA2LE-A

Insu$a!ion !i+4ness 8in mm9 /or o! insu$a!ion

Pi&e Si:e

N.2 8mm9

F$ui% Tem&era!ure 8Deg.C9

U&!o

)**

)*) !o

);*

);) !o


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11 1 1 4 8 &

2 1 1 4 8 &

2 7

E!ipment;

flat s!rface

1 1 4 8 &

Ins!lation thicness given in 'a:le MA has :een calc!lated :ased on the

follo


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1 , 1 2 41

11 , 1 2 41

2 , 1 2 41

> 2 7

E!ipment;flat s!rface

, 1 2 6

Ins!lation thicness given in 'a:le MB has :een calc!lated :ased on the

follo


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(Fi) -or vertical piping *.S. Collars ection

from :are s!rface not eFceeding 4O of the thicness of

ins!lation shall :e spaced at not over . * from each other.

(Fii) Jaceting;


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-a:ricate cladding of specified thicness oints.

-iF cladding on the spacers !sing specified overlaps and scre< spacing.

Joints to :e provided ect metered !antit9 of pol9!rethane

chemical miFt!re.

'ape off po!r and riser holes

C!t; trim and appl9 *AS ,1 mastic or e!ivalent on po!r holes

A&&$i+a!ion Pro+e%ure /or Remo?a$e 2o1 T"&e Insu$a!ion /or

Caron S!ee$ 6a$?es( F$anges an% E>ui&men!

(i) 'he ad>acent pipe ins!lation shall :e lap >oint and finished;


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(vi) *astic sealer and vapo!r :arrier are applied as specified earlier.

'he cladding is replaced and fitted; closing all points for

possi:le


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Bonded mineral


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A&&$i+a!ion Pro+e%ure /or &re-/orme% Minera$ Woo$ Pi&e Se+!ions

an% Resin 2on%e% Minera$ Woo$ S$as Insu$a!ion o/ Pi&es an%

E>ui&men!

-or ins!lation of piping and e!ipment; preformed sections tested in

accordance aceting.

Ins!lation sections sla:s shall :e s!ita:l9 c!t to give a proper fit !p on

pipe fittings; valves and flanges. 'he :locs shall :e sec!red firml9 in

place oints shall :e filled :9 step of :onded mineral


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-or all ins!lation cladding s9stems; GI sheets of minim!m .4& mm

thicness shall :e !sed for >aceting


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:!cles shall :e provided to sec!re the halves together tightl9. 'he

metal cladding shall have an eFtended overlap length on each side to

ens!re that the remova:le ins!lation section is seated properl9 and

cladding >oint gets sealed to the cladding on the line ins!lation against

ingress of


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commissioning; operation and maintenance. -or s!ch areas;

arrangement ma9 :e follo


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% R'D ca:les; flo< monitoring t!:es; D# monitoring t!:es are

penetrating from the !pper front face of the ins!lation ca:inet.

% End shield cooling pipe lines are penetrating from the :ottom face of

the ins!lation ca:inet

% /eader o!tlets are penetrating from top face of the ins!lation

ca:inet.

% Ann!l!s gas monitoring :!tes are penetrating from the east and


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In case of


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PREFORMED

FI2REOUS

INSULATION

'hermal cond!ctivit9; chloride

content; moist!re content andmoist!re a:sorption test

I R

IK GI SHEET83ACETING

MATERIAL9

'ensile test; :end test;dimension; coating test

I R;C

K INSULATIONCEMENT

Consistanc9 of ect tosoaing heat; adhesion of dried thermal ins!lation

ca:inet

I R

KII SPRA0MINERAL WOOL

Densit9; dimensions I R;C

Compressive strength; thermalcond!ctivit9; adhesion; heat

resistance; incom:!sti:ilit9

I R

KII CALCIUMSILICATE

Densit9; dimensions I R;C

Compressive strength; heat

resistance; liner shrinage;fleF!ral strength; alalinit9;

moist!re content; chloride;

thermal cond!ctivit9

I R

, INSTALLATION

I GENERAL All ins!lation material is in

close contact oint.

Close to one another over their


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S$.

No

Des+ri&!ion Con!ro$ an% !es!s A+!ion "

su&&$ier

ua$i!"

Sur?ei$$an+e "

Pur+aser or

is au!ori:e%

re&resen!a!i?e

I GENERAL8+on!inue /rom

&re?ious &age9

In m!lti la9er ins!lations; all >oints shall :e staggered.

Each la9er shall :e separatel9

sec!red to the s!rface.

I R;C

-ittings on the e!ipments and

vessels shall :e covered


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Clean s!rface shall :e coated


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S$.No Des+ri&!ion Con!ro$ an% !es!s A+!ion "su&&$ier ua$i!"Sur?ei$$an+e "

Pur+aser or

is au!ori:e%

re&resen!a!i?e

III COLD SURFACE8+on!inue /rom

&re?ious &age9

Kapo!r seal material shall :e

applied all over the eFposed

edge of the ins!lation and :onded to the s!rface of pipe

or vessel. At all s!ch points

mastic fillet shall :e providedto ro!nd off the angle :etointl9 ins!lated pipelines; each pipe lines shall

:e ins!lated separatel9. 'his

is to avoid the effect of

differential eFpansion d!e todifference in temperat!re.

I R;C


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IK HOT SURFACE Stiffener angles;


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• Ins!lation application proced!re in detail indicating step :9 step

complete activities for each >o:.

• 5!alit9 controldetailed 5A and proced!res indicating step :9 step

complete !alit9 controlinspection programme at all stages of each >o:.

• Inspection and test proced!res.

• *aring; identification and pacaging proced!res; if an9.

His!or" Do+4e!

Contractors shall s!:mit 1 copies of :o!nd histor9 docet containing the

follo


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responsi:ilit9 of the contractor to ens!re that the prod!ct s!pplied and

installed is in accordance


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Introduction to Insulation

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