Lloyd

A presentation on

Upgraded Insulation Systemsby

ASHU SHARMA, Manager (Technical)

LLOYD INSULATIONS (INDIA) LIMITED

SUGAR SECTOR

2

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)

Rockloyd Resin Bonded Rockwool Mattresses100-120 Kg/M3 conforming to IS :8183 – 1993,BS : 3958 Part-3, ASTM : C 592-80

For operating temp. up to400 ºC

Rockloyd Resin Bonded Rockwool Mattresses 150Kg/M3, conforming to IS :8183 – 1993, BS :3958 Part-3, ASTM : C 592-80

Temperature above 400 ºC

Rockloyd Rockwool Preformed Pipe Sections -144 Kg/M3 conforming to IS:9842, BS : 3958Part-4, ASTM:C 547-95, up to 350 mm NB pipedia

Up to 650 ºC

UPGRADED THERMAL INSULATION SYSTEM

DESIGN CRITERIA (FOR PROPOSED SYSTEM):Ambient temperature : 40 ˚C

Surface Temp : 60 ˚C

Maximum heat loss : 100 kcal / m2hr.

Wind Velocity : 0.0 m/sec.

Finish : Aluminium-22-24 G (0.2 emissivity)

GI-22-24 G (0.35 emissivity)

Colour Coated GI Sheet (0.65 emissivity)

MATERIAL DETAILS :

Energy Conservation

Energy efficiency technologies and practices can therefore

play a significant role in reducing the threat of global

climate change.

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.

“The judicious and effective use of energy to

maximize profits (minimize costs) and enhance

competitive positions”

SUSTAINABILITY

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

EXSISTING

ENERGY

CONSUMPTION

$ $

INVESTMENT

I

N

S

U

L

A

T

I

O

N

CO2

REDUCTION

REDUCED

ENERGY

CONSUMPTION

$$

SAVINGS

ECONOMIC IMPACT

JOB

CREATION

REDUCED

ILLNESS

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!

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

temperature°C

Heat loss kcal

/m2.hr

25

40

100

150

225

340

600

1910

3225

5330

Heat-in-leak into cold surfacesDifference in Temperature between

ambient & Surface °C

Heat in-leak Kcal/m2h

5

10

15

20

38

76

125

165

Ambient considered : 38 C Shape of Surface : Spherical

Properly designed insulation can restrict the above valuesdown to 10 - 15 kcal / M

SUSTAINABILITY

Insulation

Wind Speed =VSurface1 Emissivity = e

Conducted heat through insulation

Surface Heat Transfer or film Coefficient

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

Heat

Ambient Temp (Ta)

Surface Temp. (Ts)

fRad= 4.876 x 10-8 x e x ( Ts4 - Ta

4 )

( Ts - Ta )

ROCKLOYD ROCKWOOL MATTRESSSPECIFICATION CONFORMANCE

IS : 8183 – 1993

BS : 3958 Part-3

ASTM : C 592-80

APPROVED FOR A-60 CLASS INSULATION .*

*The only product in India.


TECHNICAL SPECIFICATIONS

1 Standard Densities 100, 120, 150 Kg/m3

2 Application Temperatures

-1000C to +8000C

3 Standard Thickness* 25, 40, 50, 65, 75mm

4 Standard Size 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 PIPESECTIONSPECIFICATION CONFORMANCE

IS : 9842

BS : 3958 Part-4

ASTM : C 547-95



1 Standard Densities 144, 150 & 160 Kg/m3

2 Application Temperatures -1000C to +8000C

3 Standard Thickness* 25, 40, 50, 65, 75mm

4 Diameter Range** 12.5mm to 350mm

Nominal Bore

5 Standard Length 0.5, 0.75, 1.0 mtrs.

6 Facings (if specified) 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


SPECIFICATION CONFORMANCE

IS : 8183 – 1993

BS : 3958 Part-5

ASTM : C 612

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 Application Temperatures

-1000C to +8000C

3 Standard Thickness* 25, 40, 50, 60, 65, 75mm

4 Standard Size 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.

ROCKLOYD SLAB


23

Rockwool – Water Repellant Grade

Rock Fibres treated with SILANE

THERMAL INSULATION OF STEAM LINES

24

WATER REPELLENT GRADE ROCKWOOL

25


26


SUPERCERA BRAIDED & TWISTED ROPE


SUPERCERA ROPE


TWISTED / BRAIDED ROPE, CLOTH

Insulation material for small dia / embeddedpipes, DG Set exhaust pipeline, Packing materialbetween expansion and contraction joints,Furnace curtains, Replacement of asbestos clothand tape, Pipe hanger insulation, Cable & wireinsulation, Fuel line insulation, Impulse LineInsulation.


SUPERCERA ROPE, CLOTH, TAPE


SUPERCERA ROPE

Supercera Twisted Rope is a 3 ply ropemanufactured from supercera long fibres having15-20% organic binder.

Supercera Braided Rope in addition is braidedwith 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 coatedsupercera 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 andthickness 50 & 75mm encased in SuperceraCloth and stitched with SS Wire to form pads.Special hooks are stitched to the surface andcorners 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 : 450 deg.C

AT : 40 deg.C

ST : 60 deg.C

Cladding : Aluminium ( 0.2 Emissivity)

Wind Velocity : 0, 0.5, 1

Pipe OD : 8”,10”, 12”

Insulation : ROCKWOOL MATTRESSES

150 KG/M3 DENSITY

Calculation : ASTMC-680 & IS-14164

Procedure

As per IS-14164 As per ASTMC-680

Dia (mm)

Thickness(mm)

Heat Loss(Kcal/m2hr.)

Thickness(mm)


8” 175 105 210 85

10” 185 105 220 85

12” 190 105 230 85

WINDAGE = 0

SUSTAINABILITY

COMPARATIVE OF THICKNESS

` As per IS-14164 As per ASTMC-680

Dia (mm)

Thickness(mm)


Thickness(mm)


8” 135 143 165 119

10” 140 143 175 119

12” 145 143 180 119

SUSTAINABILITY

WINDAGE = 0.5


As per IS-14164 As per ASTMC-680

Dia (mm)

Thickness(mm)


Thickness(mm)


8” 115 174 140 143

10” 120 174 150 143

12” 125 174 155 143

SUSTAINABILITY

WINDAGE = 1


SUSTAINABILITY

WindageThickness reduces with wind impact.

EmissivityThickness 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

Calculation of Insulation thickness

Ambient Temp.

Operating Temp.

Surface Temp.

Pipe OD

Wind Velocity

Cladding Emissivity

Insulation material K value

Thermal Insulation of Steam Lines

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 : 450 deg.C

AT : 40 deg.C

ST : 60 deg.C

Cladding : Aluminium

Wind Velocity : 0

Pipe OD : 10, 12, 14

Pipe Length : 5 mtr.

Insulation : RW, Cal. Sil., CF+RW, Perlite

mm Kcal/m2hr. STDeg.C

RW 185 95 60

Cal. Sil. 200 95 60

CF+RW 160 56 53

Perlite 215 96 60

1. 10” Line



RW 190 96 60

Cal. Sil. 205 96 60

CF+RW 165 62 54

Perlite 220 96 60

2. 12” Line



RW 195 97 60

Cal. Sil. 210 97 60

CF+RW 170 65 54

Perlite 225 96 60

3. 14” Line


mm Kcal/m2hr. ST

Deg.C

RW 240 94 55

Cal. Sil. 250 95 55

CF+RW 235 62 49

Perlite 225 96 60

4. 12” Line, OT = 500 deg.C, AT = 35 deg.C


Mm Kcal/m2hr. ST

Deg.C

RW 275 95 55

Cal. Sil. 290 96 55

CF+RW 250 61 49

Perlite 295 96 60

5. 12” Line, OT = 550 deg.C, AT = 35 deg.C


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 PadsSupercera blankets of density 128 kg/m3 andthickness 50 & 75mm encased in Supercera Cloth andstitched with SS Wire to form pads. Special hooks arestitched to the surface and corners for the purpose ofpositioning & 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

APPLICATION SPECIFICATION FOR IMPULSE LINE INSULATIONvery small dia ¾”, ½”, 1”, 1 ½”, 2”

1. Providing and wrapping Supercera ceramic fibre rope in required thickness over the pipeline so as to cover the piping completely without leaving any gap.

2. Providing and applying one coat of insulkote over the rope.

3. Providing and applying glass fibre cloth 10 x 10 sq. inch apperture over the insulkote and tying with synthetic thread.

4. Providing and applying second coat of insulkote over the glass cloth.

5. Providing and applying a coat of bitumenous based aluminium paint over insulkote.

Insulation of Hot Services

MONSOON SPECIFICATION FOR

HOT PIPELINE INSULATION

1. Cleaning the surface thoroughly to ensure that the surface is free ofall dust, rust and grease.

2. Providing and fixing MS flat ring of size 25x3mm over pipes havingdiameter more than 150mm NB at every 1150mm distance having Lshaped lugs with a packing of ceramic paper duly riveted andtightening it over the surface with nut and bolt.

3. Providing and fixing the recommended insulation thickness ofRockloyd Resin Bonded Rockwool mattress of suitable density stitchedwith one side GI wire netting of size 20mm X 24G.


4. Butting the joints and stitching the mattress properly with GI wire of20G to secure it firmly to the surface.

5. Providing and applying 4mm thickness APP modified membranehelically over the insulation with AL. paint coating.

6. Providing and applying Aluminum sheet as cladding over the MS flatring already provided at 1150 distance duly screwed with self tappingscrew at 150mm distance at the sheet joints making an overlap ofminimum 30mm. Sealing all the joints with mastic MAS-94.

7. Providing and applying 22G AL band at every 450mm c/c over thecladding to secure it firmly to its place.




FOOT TRAFFIC SPECIFICATION FOR HOT PIPE LINE INSULATION

1. Cleaning the surface thoroughly to ensure that the surfaceis free of all dust, rust and grease.

2. Providing and fixing MS flat ring of size 25x3mm, over pipehaving diameter more than 100mm, at every 1150 mm distancehaving L shaped lugs with a packing of ceramic paper, dulyriveted and tightening it over the surface with nut and bolt.

3. Providing and fixing the recommended insulation thickness ofRockloyd Resin Bonded Rockwool mattress of suitable densitystitched with one side GI wire netting of size 20mm X 24G .


4. Butting the joints and stitching the mattress properly with GIwire of 20G to secure it firmly to the surface

5. Providing and applying 25mm thick cement sand plaster overthe insulation material .

6. Providing and applying bitumen primer over the cement sandplaster.

7. Providing and applying 4mm thickness APP modifiedmembrane helically over the insulation with AL. paint coating.


8. Providing and fixing 22 gauge AL sheet cladding over the MSflat ring already provided at 1150mm distance duly screwedwith self tapping screw at 150mm distance at the sheetjoints making an overlap of minimum 30mm. Sealing all thejoints with mastic MAS-94.

9. Providing and applying 22G AL band at every 450mm c/c overthe cladding to secure it firmly to its place.




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 INSULATION

Main insulation material used for Chimney Insulation is Rockloyd ResinBonded Rockwool Slab – 100 kg/m3 in thickness of 50mm having K-valueof 0.052 W/mK at 100 deg.C mean temperature conforming to IS : 8183-1993. Following ancilliary materials are also used for Chimney Insulation:-

Pins & Studs of 10G in 75mm length.

Metal Speed washers 63mm dia or square.

GI Wire Netting of 20G x 25mm.

GI 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 ¾” x 22G whereas the subsequent layers shall be

supported with GI wire netting ¾” 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 6-

10mm 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. : 60 0C

10. Material Details

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 ºC

Density : 200 – 250 kg/m3

Thickness : 260-310 mm

K-Value : 0.039 Kcal/m. hr.0C at 50 ºC (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 loss for the

insulated surfaces in operation.

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

MCM

Insulation Thickness

SUSTAINABILITY

SELECTION OF INSULATION MATERIAL:

THE MATERIALS USED FOR INSULATION SHALL CONFORMTO THE RELEVANT INDIAN STANDARDS WHEREEVER THEYEXSIST.

INSULATION MATERIAL USED SHOULD BE SUITABLE FORUSE AT THE OPERATING TEMPERATURE AS STATED BY THEPURCHASER.

HAND MADE MATERIALS FROM LOOSE WOOL ARE NOTPERMITTED DUE TO POOR CONSISTENCY.

ALL INSULATION MATERIAL SHALL HAVE A PROVENSERVICE RECORD OF SATISFACTORY PERFORMANCE

UNDER INDIAN CONDITIONS IN SIMILAR PROCESS PLANT

SUSTAINABILITY

Corrosion resistant

Water repellents

Fire Proof / non combustible

Durability

Green insulation materials

OTHER IMPORTANT ASPECTS

Supercera Pads for Valves & Flanges Insulation

IOCL, PANIPAT REFINERY

We had carried out Thermal Insulation audit of IOCL PanipatRefinery. The data recorded for open valve are as follows:

1. Average Ambient Temp. - 40 C

2. Average Surface Temp. - 450 C

3. Average Operating Temp. - 450 C

4. Total area insulated - 1 m2

5. Heat Loss - 7922.01 Kcal/m2 hr.

6. Total Heat Loss - 7922.01 Kcal/hr.

7. Cost of Heat Loss - Rs. 500 Rs. /million Kcal.

8. Running Hr. - 8040 / Yr.

9. Average cost of Heat Loss - Rs.31454 /year

we recommended to insulate the un-insulate valve with 150 mm cf padinsulation of 128 kg/m3 density. application procedure was alsorecommended to enhance the life of insulation

After re-insulation the following were the findings :-

1. Average Ambient Temp. - 40 C 2. Average Surface Temp. - 60 C

3. Total area insulated - 1 m24. Designed Heat Loss - 98 Kcal/m2 hr.5. Cost of Energy - Rs.500 /million Kcal 6. Total Savings - Rs. 31064 /year7. Insulation Thickness - 150 mm CF Pad 128 kg/m3 density.8. Total cost of insulation - Approx. Rs. 20,000 /-9. Average pay back period - 8 Months

So proper insulation with a little bit investment accrues lot of savings with a defined shorter pay back period.

OPTIMAL INSULATION

Heat loss, 89 mm pipe, 100 C temp.

Uninsulated Pipe 50mm Insulated Pipe

Heat loss = 255 Kcal/hr.m2 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 = 8760 Hr.

Total Heat loss = 8760 x 175 = 1533000 Kcal/hr.

Consider Boiler Efficiency = 80 %

Cost of fuel (Coal) = Rs. 3500 / Ton

Calorific of Coal = 3200 Kcal / Kg

Yearly fuel saving = 1533000 / ( 3200 x 0.80 )

Yearly fuel saving = 598 Kg/ Year

Upgraded Energy Efficient Thermal Insulation

ROCKWOOL INSULATION

HINDALCO INDUSTRIES LTD., RENUSAGAR POWER DIVISION

We had carried out Thermal Insulation audit of HindalcoIndustries Ltd., Renusagar Power Division for the Boilers. Thedata recorded are as follows:

1. Average Ambient Temp. - 31 °C

2. Average Surface Temp. - 80 °C

3. Average Operating Temp. - 525 °C


5. Heat Loss - 530.704 Kcal/m2 hr.

6. Total Heat Loss - 212282 Kcal/hr.

7. Cost of Heat Loss - Rs. 500 /million Kcal.


9. Average cost of Heat Loss - Rs.853373/year


We recommended to re-insulate the complete plant piping &equipments with 255 mm Rockloyd, Resin Bonded RockwoolMattress of 150 kg/m3 density. Application procedure was alsorecommended to enhance the life of insulation.

After re-insulation the following were the findings:




4. Designed Heat Loss - 98 Kcal/m2 hr.

5. Cost of Energy - Rs.500 /million Kcal

6. Total Savings - Rs. 695789 /year

7. Insulation Thickness - 255 mm RW

8. Total cost of insulation - Rs. 786840/-

9. 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.


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. Thedata recorded are as follows:



3. Average Operating Temp. - 507 °C


5. Heat Loss - 388 Kcal/m2 hr.

6. Total Heat Loss - 7080 Kcal/hr.

7. Cost of Heat Loss - Rs. 664 /million Kcal.


9. Average cost of Heat Loss - Rs.41183 / year


We recommended to re-insulate the complete pipingequipments with combination of insulation 25 mm CF OF 128Kg/m3 density + 170 mm Rockloyd Resin Bonded RockwoolMattress of 150 kg/m3 density. Application procedure was alsorecommended to enhance the life of insulation.

After re-insulation the following were the findings:




4. Designed Heat Loss - 70 Kcal/m2 hr.

5. Cost of Energy - Rs.664 /million Kcal

6. Total Savings - Rs. 33622 /year

7. Insulation Thickness - 25 mm CF +170 mm RW

8. Total cost of insulation - Rs. 40282/-

9. 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.


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.

IS : 14164 - 2008

Colour coated GI Sheet for pipeline insulation

cladding.

Cladding Material & Accessories

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 –

LLOYD INSULATIONS (INDIA) LIMITED

SAVE ENERGY…

PROTECT ENVIORNMENT…

THINK INSULATION…

for a better future

THANK YOU !!

Lloyd

Documents

renusagar

ms flat ring

average ambient

hot servicesapplication

average operating

20swg ss wire

gi wire netting

ceramic fibre