Document LgYRQBpKbvoVO57M8N7awd5e5

into COATINGS AND INSULATION MANUAL - THERMAL INSULATION SYSTEM SPECIFICATION 6XX CALCIUM SILICATE SYSTEM WAN. SECT PART "" K11.2 STD 6 issue 3 DATE 1/85 PAGE 1 OF 4 : SCOPE TM* "at*11*1* specification is for inaulating pipe, tubing, fittings, duct * s vessels and equipment. The specification includes insulation materials and Verier materials to for* a complete insulation system. Thy system designation is For complete designation, a barrier system must be selected, see Par. 4. E ^ Temperature 100 to 1200 F (35 to 650 C). f, materials i msulatlon The insulating material is asbestos-free premolded reacted hydrous K.leiwT silicate. Shapes include pipe covering, flat blocks and fittings. Pipe |S*ring i* available with factory applied jackets. TfT^eptable Materials Select materials fro* those listed in the following tables, f^titution oi. materials not listed shall be authorized in writing by the Engineer. MATERIAL Calsilite Insulation Thermo-12 Insulation Kaylo lo AF Insulation Caltemp Insulation VENDOR Harbison-Walker Manville Corporation Owens Corning Flberglas corp. Pabco Insulation fj,3 insulating Cement Used to fill voids and insulate irregular surfaces. MATERIAL Superteap 1900 Cement No. 375 Cement MW-One Cement VENDOR Raaco Products Manville Corporation delotex Corporation AUXILIARY MATERIALS f.l Description The following materials are used with the insulation and barrier iterials to for* a complete insulation systea in accordance with installation details. 6*T.F. STANLEY (4-6942) AODlTirtJJC Fte c 003085 COATINGS AND INSULATION MANUAL THERMAL INSULATION DESIGN INSULATION MATERIAL PROPERTIES Design Dot* MAN. SECT FAST Kll.l STD 3 ISSUE FACE 3 DATE 1 OF 1/85 9 ft SSCtOuPrEt This s---t-a--ndard lists Materials. p ropr. ** for thermal Insulation and barrier * used In the Thermal Insulation Sys- ]** specifications. Additional data for other aat_erjl.all.s lIes npi*rAouv4idHead/l.. rco-o" 2. MATERIALS PROPERTIES OATA 2.1 Insulation Materials Properties Table I provides physical and thermal properties for materials shown In the Insulation System Spec ifications and a few additional materials of frequent use. Es ||y |T Insulation Charactariatica L Material | Description f" Form <rtura Range (F) Ip^nai Conductivity m. Ihk/hr ft3 F) Si Mei Temperature w||far Shrinkage Bfci%atTamp Limit frill*tv ite/'Ft' mile Strength PSI {wpresaive Strength PSI aural Strength PSI BbAdoue of Elasticity PSI Mellon Resistance MR Lose by Tumbl ing Me Spread Index Hna Deneity Index HptAMorption HE'* 24 hr. Immersion Hnarity Hpttpiclty % Vol. HRVapor Tranamission Bbln. tNInlty Ph Marida Content (PPM) Hlaaivitv Bm Diffusivitv (Ft'/Hr.) BBPWc Heat (BTU/lb/* F) KVl TABLE I. MATERIALS PROPERTIES Fibrous Glass K11.2 STD 6 Type of Insulation ASTM Tsat Mathod Calcium Silicata K11.2 STD 8 Glass Fibar With Organic Bindar Reactsd Hydrous Calcium Silicata Shaat and Pips Covaring Block and Pipa Covaring 0 to 450 K Temp .21 50 .24 100 .29 200 .35 300 100 to 1200 K Tamp .38 100 .40 200 .47 400 .56 BOO None 4-9 3 at 10% Deformation 1.6 12 20 100 at 5% Deformation 25 50 90 Non# .2 , * 35 10 Min fen Non-Combustible / 90 Wicks 10% by Weight 9 Loot than 30 .02 .20 10.2 200 .16 .20 Good Strength. Absorbs Water. ASTM Test Mathod T.r. STANLEY (A-S948 OOLOS6 W**- / v< ft I* CCAIII.'/, A,e> A1 It . wamjAL *. L'fAU IN'. JL AT ION MAlt *4 1*1 * 1C AT ION & CALCIUM SILICATE SYSTEM Elrvoted Tcmpciotui* *, ,1 AMI K11.2 STO 100 'Slut 4C C t 0*7* \ or i it 2 ENTER ONE COPY IN EACM M A N U A L. IC C TABLE OP CONTENTS FOB PLACEMENT. A" " IN D IC A T E S A P P B O V A L O B A C C fP T A N C S A T L O C A T IO N . " A " AT "O IV H IN D IC A T C * DIVUION-W IOC A P P R O V A L OB A C C E P TA N C E . / locations STDS A *T Af A SUBS A Acm. OIV A 41 44 CH04ST R. 1. INSULATING MATERIAL 1.1 Description Insulating material is prcmoldcd reacted hydrous calcium silicate and asbestos fiber. The following shapes and sizes normally are used in Monsanto practice: 17 ITEM Flat blocks without bevel. Flat blocks bevelled to suit specified diameter. Sidewall segments curved and bevelled to suit specified diametet. APPLICATION SIZE All flat surfaces; Vessels over 24'0'* in diameter. 24" wide x 36" long, 1" to 3" thick. Vessels 6`0" in diametet to 24*0" in diameter. 12" wide x 36" long, 1" to 3" thick. Vessels 3*0" in diameter to 6'0" in diametet. 12" wide x 18" long, 1" to 3" thick. SPEC GEK1NG HTORO OIV A 04 11 44 iNO*a OIV A > 04 10 M 17 14 24 Z* 40 CS Head segments shaped to suit type and specified diameter. Sectional covers. . Vessel heads. Coppet tubing 3/ft" to 3M diameter. 1" to 3" thick. 10 to suit specified diameter. 1" to 3" thick. ASTM C-344 Sectional covers to 24" diametet, segmental covers 30" and 36" diameter. Pipe and vessels to 36" diameter. 10 to suit specified diameter. 1" to 3" thick. Ptemolded sectional covers to 6" IPS, pretormed sectional covers 3" to 3S" nominal ptpa size. Copper tubing and pipe fittings, valves, and flanges. ID to suit specified diameter. 1" to 3" thick. -1.2 Thickness Thickness stated on Drawings or in the Thermal Insulation Schedule shall be used. Thick nesses given in Table I shall be used only when directed by the Engineer and when operating temper atures are given. 2. AUXILIARY MATERIALS 2.1 Description The following materials are used with the insulating material to fora a complete system. Apply them as directed in the Construction Specifications. ORO OIV A 01 0* 04 Of 14 TO IMS PLASTIC OIV A IS 27 SI 34 34 ITEM WELDING STUDS HIGH TEMPERATURE CEMENT FILLER MATERIAL CAULKING AND FINISHING CEMENT BANDS AND SEALS GENERIC TYPE Carbon steel studs and clips. Expanded vermiculite cement with heat resistant binder. ASTM C-196 Spec. Calcined diatomaceous eaith and long asbestos fibet, with out bindet. Nodular mineral fibers com bined with bonding materials. V x 0.015" flat Stainless Steel bands and staling devices. APPLICATION Used to secure insulation to vessel and piping surfaces. Used to point up broken or rounded coiners and irregular surfaces; fill voids and slots; build-up insulation on small pipe fittings. Used to papk expansion spaces and to build-up insula tion whole preformed fitting covers are not available. Used to smooth depressions and to fill minor voids and irregularities in the finished insulation surface. Used to secute insulation to vessois and piping. c 003908 ruAx TIE WIRE 16 gauge cold-drawn, brightannealed Stainless Steel wire. Used to secure insulation to vessels and piping. -- JtEPERCNCE*. _ ,, _________________ __ __________________________________ _ LATKST AnniTIONt OB REVISIONS ABE SHOWN BV OB OUTLINING.. DELETIONS ABE SHOWN BY Novembt r 1, 19i# P.cviird JdnuAry 31, 1964 Rcvtacd August 18, 1964 MONSANIO ClltMlCAl COMPANY HTDkOC AiHONi UlVISION (NOltlltCl.JO CONSTRUCTION &. MAINTENANCE SPECIHCAT ION - M . .1 srf.UMr. 6o) Pii'E cover.inc 1 OK UNlIKHCKOllMI .iCKVICE APPLICATION* Pipeline* burled In earth, or on contact with earth or concrete at grade. Maximum service temperature 1S0*F. Mill applied coating and w tapping (hall be equivalent to that below, and (hall have an ovor-wrapping of Kraft paper. STEP MATERIAL O* PROCEDURE tOTAl _ METHOD Of T (Not* 1) turn. Jl REMARKS System 603 - Hot Enamel Coating at d ~Wrapp(iig for u idnrgrcutttd lsijKApplied In The } leld 1 Clean outside of pipe with wire brush ,or traveling type motor driven cleaning machine. Remove grease and oil with suitable'solvent*. As an alternate. cleaning may be accomplished by sand* blasting to a commercial finish. Remove .'til dirt, loose rust and mlllscalc, and other foreign materials. Cuilc-ti, kflives. * brushes, etc. , or. machine shall be approved by Monsanto's engineer. 2 1 coat of pipeline primer , . 1 optional ; Apply by spray, brush, mop or rotating carpel (ling with revolving brushes. Finished coat *hall be smooth and even. Allov/ to dry 3 1 coat of hot pipeline enamel /,, Apply with a bucket and canvas sling, or with an approved coating machine. Heat enamel In accordance with manufacturer1 e recommendation*. 4 1 spiral wrap of open mesh glasa mat 5 1 coat of hot pipeline enamel ... - -- - 1/8* Apply over enamel while it is soft and imbed in enamel. Thoroughly saturate and cover glass mat. 6 1 spiral wrap IS lb asphalt saturated asbesto* felt * * Nap proceeding spiral 1* minimum Joints between succeeding strips shall lap at least 4*, at the top of the pipe and be scaled with hot enamel or imbedded by heating the entire finish coat. Couplings, flanges, fittings and field we is in mil wr*pp< d pipe shall be coated and wrapped in a manner equivalent to.that a >ov*. Repairs to defective or damaged coating shaTl be nade by removing felt, daubing with hot enamel, and imbedding new felt, at the ti ns the p >e is lo re red into the ditch. - V C 003909 NOTES: 1. Coatings nay ba brushed, rolled, or sprayed, when the method Is'optional. 2. Total dry film thickness (BFT) In mils (thousandths of an Inch) accumulated at the step Indicated. 3. Pipe shall be left on tkids behind the wrapping machine for electrical inspection and repairs befors lowering into ditch. J 4. Coating shall be checked for holidays with an approved machine at'^ 10,000 volts. ' On hot enamel coating. If the felt lap joint* only are to be sealed, apply the spark test before j Wrapping. If the felt Is to be Imbedded in the hot finish coat, apply lire test after wrapping 5. Coated pipe shall ha handled carefully, ualng belt sllngs-of proper dimensions. Ropes, cables, or chains will not be permitted in contact. 6. No coating operations shall be carried out during weather which 1* unfavorable in the ............................ ..................Pin* shall be clean and dry before application of / CS 11.4.603 Page 2 of Z NOTES: 1. Pipe shall b left on skida behind the wrapping machine for electrical Inapection and repair* before lowering Into ditch. 2. Coating shajl be checked for holiday* with *n approved instrument at 10,000 volt*. On hot enamel coating, 11 the felt lap joint* only are to be sealed, apply the spark test before wrapping. If the (ell is to be imbedded in tha hot finish coat, apply the test after wrapping. 3. Coated pipe shall be handled carefully, using belt slings of proper dimensions. Ropes, cablet, or chains will not be permitted In contact. d. No coating operations shall be carriod out during weather which Is unfavorablt In thf opinion of Monsanto's engineer. Pipe shall be cleftn and dry before application of primer or enamel. it > t C 003910 _'_>u _ *'0 O >01 5 or 1 |.u 1 %**, <ot I v_ t.mu.k ii. i.i.N(i7ii ()i; (i;r ok "sihkk ii oin" i-okm'.mm.i-.ss sii-.kl JACKKTINO OVI-K I*1PI: (.OVI-.KING Pipe Size (In.) V, *4 1 11 /J' 2 3 4 6 8 10 12 14 16 18 20 24 30 Nominal Thickness of Pipe Covering Length of Cut for Stainless Steel, in Inches (Calculated to Nearest *4") l 1`4 2 2*4 3 3V, 4 4*4 5 5 V, 11 r ii 17*4 22*4 11 14V, 17*4 22*'. 25V. 29 26 29 32 35V, 38V, 32V, 35V, 39 6 13 16 19V, 22*4 26 14V, 17V, 22V, 26 29 16 19V, 22V, 26 29 29 32V, 35V, 39 32V, 3SV, 38*4 41*4 32 V, 3SV, -38V, 42 19V, 22'/. 26 29 32*1 35*', 38*4 42 22*4 26 29 32V, 35V, 38*4 42 46 29 32V, 35V, 38*4 . 42 46 48*4 52 46 48*4 52 48V. 52 55V, 55*4 58V, 61V, 29 42 46 48*4 52 55*4 58*4 61*/, 65 68 46 48*4 52 55V. 58V. 61V, 65 68 71 74 52 55`4 58V, 61V, 65 68 71 74 77*4 80*4 55V, 61 *4 68 58V, 65 71 61*1 68 74*4 65 68 71 74 77*4 80*', 71 77*4 83V. 74 80V, 86*4 77*4 83*4 90 80*1 86V. 93 83*4 90 O90fil' 74*4 86*4 ios*; 77*4 90 108*4 80*, 93 112 83*. 96*4 115 86V. 99*4 118*4 90 102V, 121*1 93 105*4 124*, 96*4 108V. 127*4 99*1 112 130*4 102*4 115 134 c 003911 V #- %* '.w* ' INO'. IUC.UL * 1 IUU I'.VJL *TIC#* "UtliCH U ARHICM MM H'tCIflCUlOU STAINLESS steel jacketing EJtfvolcd on<J Low Temperature! ** '* 1,1 *? K 1 1 3 STD 65 'SVUt CAOC 1 DATE 1 or SM 7 STOS A ST AF A w , SUOS A Hz is? AORI. Ol V A 5* A\ 31 42 5r <O UJ k sH sUzl CHFMSTB. 0. H OU oUZ Ul OZ ko or uHzj <w-0 C E RING UJ K HYDRO oi v A 04 44 1. WEATHER BARRIER MATERIALS 1.1 Description Stainless Steel Jacketing is com mercially available in forms of 36" * 96" sheets; rolls 36" 'ide at 300 sq ft per roll; and rolls 48" wide at 400 sq ft per roll. Material in both sheets and rolls in .010" thick) with *y(4" corrugation. Moisture barrier backing on the inner surface is not required. 1.2 Fitting Covers Prefabricated sectional covers for insulated short and long radius elbows, tecs, line flanges, and screwed and butt-welded ASA 150 lb and 300 lb valves shall be used when readily available. T.-3 Hcod Covers Prefabricated gore-type covers for insulated 2 to 1 elliptical heads shall be used through 13' --0" diameter when readily available. 1.4 Material Requirements and Coverage (for Insu lation Piping) See Tables I and 11. 2. AUXILIARY MATERIALS 2.1 Strops ond Seals Straps and seals used to secure Stainless Steel jacketing in place shall be V * .015" stainless steel or monel for vessel and equipment jacketing, x .015" stainless steel or monel for pipe jacketing. 2.2 Screws and Rivets Sheet metal screws used to secure Stainless Steel Jacketing in place (over insulation in elevated temperature service only) shall be Pan Head No. 7 x * stainless steel. Pop _Uvets_. used in similar service shall be stainless -steel. TABLE I. STAINLESS STEEL WITH 2" LAP INORG OIV A 07 OB - U 10 1 -> e 17 K0 18 < J ZB -5 2t U t s* es oH *8 ORO U OIV A Of j L> 03 $5 Oft 00 13 *5 30 _ mH WQ I<u- .Z- ENG 5* PLASTIC 55 OIV A 12 X7 31 34 38 PLA X 1 (In.) 1 2 14 Quantities (Squore Feet) Required for 100 Linear Feet of Pipe Covering1 Nominal Insulation Thickness (Inches) 1 1'r 2 n 3 3V, 4 4 V, 5 5*4 96 130 155 200 226 255 283 312 340 97 128 156 201 226 256 283 313 340 6 1 114 142 172 201 229 256 284 313 341 1`a 127 155 198 227 255 283 312 340 367 2 142 171 201 229 256 284 313 341 369 3 171 201 229 256 284 313 341 369 405' 416 450 4 201 229 256 284 313 341 369 423 429 450 480 6 256 284 313 341 369 403 430 457 486 506 533 3 341 369 405 429 457 488 515 543 562 590 10 403 43! 458 486 514 541 569 597 603 642 12 458 486 516 541 569 598 626 654 675 692 14 488 516 543 571 598 626 654 681 707 727 16 543 571 599 626 654 681 709 737 754 781 IB 598 629 654 682 709 737 764 792 808 . 834 20 654 682 709 737 764 792 820 847 875 889 24 764 729 820 847 875 903 930 958 972 1135 30 930 958 986 1013 1041 1069 1096 1124 1136 1163 ^.Quantities, in square feet, are those required to covet 100 linear feet of Insulated'straight piping. Longitudinal 2" laps are included;iTbutt laps,~5ased orTWMdhg rolls of felt, also are included. c 003912 REFER ENCES Il twtur., DELETIONS ARE SHOWN BY t \ I no to oi ; or ? I. -*aue 1 t A M iuoi U / TAItl.k II. I.KNG'l II ()!' CUT OH "SI KI-. I CH OUT" I-OH ALUMINUM JACK HUNG OVER PIPE COVERING Pipe Sire (In.) 1'1/ *'*/ 1 11 11 Nominol Thickness of Pipe Covering Length of Cut for Aluminum, in Inches (Calculated to Nearest IV, 2 2V, ..3 3 V, 4 4 V, 5 5 V, 11 17V. 22V. 25V, 29 14V; 17V. 22V, 26 29 32 35V, 32'/, 35'4 38'/, 39 6 1 13 16 19'/, 22V, 26 ' ` i 14V, 17'; 22'/, 26 29 2 16 19'/, 22*/, 26 29 29 32V, 35V, 39 32'/, 35'/, 38V. 4IV. 32'/, 35V, 38V, 42 3 19'/, 22'/. 26 29 32'/, 35V, 38V, 42 4 22'/, 26 29 32'/, 3S`i 38V, 42 46 -6 - 29 32'; . 35'; 38V, , 42 46 48V, 52 46 48V, 52 48V, 52 55'/, 55'/, 58'; 61'/, a '0 12_ 29 42 46 48V. 52 55',; 58V, 61V, 65 68 46 43V. 52 55V, 58'/, 6IV, 65 68 71 74 52 55'/. 58'/, 61V, 65 68 71 74 77',; so'/, 14 16 . ia. _ ssv. 58'/, 61V, 65 68 71 74 77',; 80`4 83V, 61 V, 65 68 71 74 77',; 80V, 83*/, 86V, 90 68 71 74'/. 77',; 80'.; 83*,; 86V, 90 93 96',; 20 74',; 77'/, 80'/, 83V, 86V, 90 93 96'/. 99'; 102*4 24 86',; 90 93 96'/. 99'; 102'.; losV; 108'; 112 115 30. 105V; 108V, 112 115 118',; i2iV; 124V, 127V, 130V. 134 2. AUXILIARY MATERIALS 2.1 Strops and Seals Straps and seals used to secure Aluminum Jacketing in place shall be */" * .016" aluminum for vessel and equipment jacketing, 4" x .016^ aluminum for piping jacketing. 2.2 Screws and Rivets Sheet metal screws used to secure Aluminum Jacketing in place (over insulation in elevated temperature service only) shall be Pan Head No. 7 x lj', aluminum. Pop rivets used in similar service shall be aluminum. C 003913 W. | COAli*.'.'. Iti'.UL A 1 WV. MANUAL IN'.Ut A T IC. *L A T ( U f:i:.U|CU f/AICOALO Cl F 1C A7 IONS ALUMINUM JACKETING EIcvoted and Low Temprratutes ww*. y O i *M K 1 1 . 3 STD 60 i'.IUC 1 OAT C **Gt 1 or 5U 1 IN T E R ONE COPT IN EACH M a n u a l . SEC TABLE OP CONTENTS FOR PLACEMENT. A IN D IC A T E S A P P R O V A L OR A C C E P T A N C E AT L O C A T IO N . " A "" AT " O IV " IN D IC A T E * DIVIJION-W IOE APPRO VAL OR ACCEPTANCE. LOCATIONS STOS A ST AF A SUBS A a Gm. OIV A 41 42 CHfMST R. 1. WEATHER BARRIER MATERIALS 1.1 Description Aluminum.jacketing is commercially available in standard forms of 36" y 96" sheets; rolls 36" wide at 300 square feet per roll; and rolls 18" wide at 400 square feet per roll. Material in ,.1'Oth sheets and rolls is .016" thick, with V,," corrugation. A factory-attached moisture barrier ...covers:the inner surface.--- " 1.2 Fitting Cover* Prefabricated sectional covers for insulated short and long-radius elbows, tees, line flanges, and screwed and bun-welded ASA 130 lb and 300 lb valves shall be used when readily available. 1.3 Hcod Covers Prefabricated gore-type covers for insulated 2 to 1 elliptical heads shall be used through 13' -0" diameter when readily available. 1.4 Materia! Requirements and Coverage (for insu lated piping) GCfttNG HYDRO" OIV A 04 If 44 1NORO OIV A 07 Of to 11 17 U 21 2f SS cs ORO DIV A ft OS 00 Of ts m CNO PLASTIC OIV A U 77 SI S4 30 PLA X TABLE I. ALL'MINL'M tt'ITH 2" LAP (In.) 1.. - .'2 ! '4 Quantities (Squore Feet) Required for 100 Linear Feet of Pipe Covering* TM ----------- -- --Nominal Insulation Thickness~(lnches) 1 2 <2`i 3 3V, 4 4% 5 5*; .96 130 97 128 155 2oo.r -226 156 201 226 255 283 312 340 256 283 313 340 6 1 114 142 172 201 229 256 284 313 341 '*, 127 155 198 227 255 283 312 340 367 2 142 171 201 229 256 284 313 341 369 3 171 201 229 2S6 284 313 341 369 405 416 450 4 201 229 256' 284 313 341 369 423 429 450 480 6 256 284 313 341 369 403 430 457 486 506 533 8 341 369 405 429 457 488 515 543 562 590 10 403 431 458 486 514 541 569 597 603 642 12 458 486 516 541 569 598 626 654 675 692 14 488 S16 543 571 598 626 654 681 707 727 16 543 571 599 626 654 681 709 737 754 781 18 598 629 654 682 709 737 764 792 808 834 20 654 682 709 737 764 792 820 847 875 889 24 764 729 820 847 B7S 903 930 958 972 1135 30 930 958 986 1013 1041 1069 1096 1124 1136 1163 'Quantities, in squate feet, are those tequited to covet 100 linear feet of insulated straight piping. Longitudinal 2" laps Me included; T butt laps, based on 4t" long rolls of felt, also are included. C 003914 REFERENCES -- i \ V" m S4 C C * 1 M.o v * * L . -JL a T IL. WfchUAL Itr JL * T (O/rf RL A 7 hL ^ (j AM'IC** MATIMALS S^LOT 1C *7 IONS CUTBACK ASPHALT VAPOR SEAL Low Tempcroluie K 1 1 .3 STO 7 S |'0C O.TC 1 of i <-> I ENTER ONE COPY IN EACH M A N U A L. SEC TA B LE OP CONTENTS POR PLACEM ENT. AM IN 0 IC A T C 1 A P P R O V A L OR A C C E P T A N C E A T LO C A T IO N . 4,A** T O IV ** IN D IC A T E S 01 V IS IO N -W ID E A P P R O V A L OR A C C E P T A N C E . LOCATION! STOS A st af A SUBS A AGRt. OIV A 41 4 It CHEMSTR. GENING HYDRO OIV A 04 19 44 -- - INORG OIV A 0? 0 10 11 17 19 a 29 99 CS ORO OIV A 01 09 09 00 11 90 END RLASTSC OfV A u Z7 91 94 99 1. WEATHER BARRIER MATERIALS VcJthcr barrier maicrials arc vapor-scaling cutback asphalt mastic, /ire-rctardant spray grade for general weather harrier application, trowel grade for providing heavy fillets at' inside corners in the insulation construction. Color of the cured film is black. 1.1 Description and Application Characteristics Material Description Fire-retardant cutback asphalt, spray grade. Film Thickness Wet Dry I , H 1/ M Coverage1 Sq Ft/Gal 13 Fire-retardant cutback Determined by requirements of construction. asphalr, trowel grader: 'Coverage values are 7S'< of theoietical; for estimating purposes only. Limitations Materials may remain soft for 90 days or more, depending on climatic conditions. Materials are not recommended for areas subject to solvent or alkali splash and spillage. Trowel must be kept wet with mineral spirits. 2. MIXING INSTRUCTIONS Mix spray grade materials thoroughly with mechanical agitation. 3. THINNING INSTRUCTIONS No thinning required. . 3.1 Cleon-Up Thinner Mineral Spirits. 4. APPLICATION INSTRUCTIONS Apply spray grade materials by brushing or with spray apparatus described in Paragraph 4.1. Apply trowel grade materials with steel trowel, in heavy fillets at inside corners as specified. 4.1 Spray Equipment material hose. Use DeVilbiss P-MBC gun with MB-4339-V, inch nozzle combination. Use inch 4.2 Pot Life Indefinite 4.3 Recoat Time Two hours at 73 F. 5. AUXILIARY MATERIALS Auxiliary materials are glass fiber mesh, 10 x 10 mesh, asphalt impregnated, in sheets for vessels and equipment, and in rolls for piping. c 003915 FLAX REFERENCES LATEST AOOITIONS OR REVISIONS ARE SHOWN BY OR OUTLINING. DELETIONS ARE SHOWN BY V. U ii.; >o ",.{ I |r*et J o' ] I. MINIMI \M l.OLD-Kl.'KJ-Af K Tl.Ml'I-.H.M I Hl- f 1)1 C.IU.LS 1-1 a - __ IPS and Nominal Pip* Size l'/1H _ V_ 1 1V," 2* 3 4" 6* 8to 12 14 16 " 18 " 20 * 24 * 30 " 36 Flat NOMINAL INSULATION THICKNESS1 Single Loyer Double Loyera I- IV 2" 2V 3- 3VO 4"D 4*i"D 5"D -- -r 25 is -15 -40 -65 3S 15 -15 -35 -50 45 20 -10 -25 -40 4S 30 -10 -25 -40 55 30 -5 -15 -30 55 30 5 . -5 -20 -*-35 -SO -85 -90 : 55 ' 40 IS 0 -20 ~-25 .0"4S -80 -85 55 40- 20 . 5 -20 -25 -4S ... -75 -80 55 45 20 10 -20 -25 -45 -70 -75 - 55 45 25 10 -20 -25 -45 -65 -70 55 . 45 25 , 10 -20 -25 -40 -60 -65 55 45 :* 25 15 -15 -25 -40 -55 -60 55 45 25 15 \ -15 ,, *25 -35 -50 -55 55 45 30 20 --IS -25 -25 -45 -50 55 45 30 20 -10 -25 , -30 -40 -45 55 45 30 20 -10 -20 -30 -35 -40 60 45 30 20 -10 -20 -25 -30 -35 60 45 35 25 -5 -10 -20 -25 -30 65 50 40 30 15 0 -10 -15 -20 5VO 6"D -120 -90 -85 -80 -75 -70 -65 -60 -55 -50 -45 -40 -35 -25 -125 -100 -95 -95 -95 -90 -85 -80 -75 -70 -65 -60 -55 -30 `Table t is based on design conditions to pievent conden* 'insulation in thicknesses 3'4" through 6" shall be applied satiori of moisture on the insulation surface. Design in double layers according to the following schedule: conditions to the left of and below the heavy black line are 90F still.ait at SOti.relative humidity; heat gains' ^ average 7*9 Btu/ht, sq It, based on the exterior insula tion surface. Design conditions to the right of and above the heavy black line are 40 F air at S01 relative humidity and moving air at 2 miles per houi velocity; heat gains average 2-4 Btu/ht sq ft, based on the extetior insula tion surface; these design conditions apply only to in 3V 1* inner layer. 2" outer layer. 4" 2" inner layet, 2" outer layer. 4V 2" inner layer, 2V outer layer. 5" 2*4" inner layer, 2*4a outer layer 5V 2*4" inner layet, 3" outer layer. 6* : 3* inner layer, 3" outer layet. stallations in unprotected areas; consult manufacturers' - literature tor recommended thickness when installations ato indoors or in sheltered areas. When cold-surface temperature falls between two thickness columns, use the greater thickness. c 003916 ------ sac tuOWN ST OR OUTLINING. DELETIONS ARE SHOWN 8Y * 5! > l*C 4'.*0 .1 ; G r 2 j' gt I k4 ' AUXILIARY MATERIALS .l Description The following materials arc used with the insulating material to form a complete system. Apply them as directed in the Construction Specifications. ITEM ADHESIVE CEMENT GENERIC TYPE Low temperature hydraulic cement. APPLICATION Used to secuie insulation suppoit clips to vessel ot piping sutfaces at tempetatuies -20 F and above. ^SUPPORT CLIPS Caibon Steel, galvanized. Used to secuie insulation to vessel and piping suifaces whete additional suppoit is icquned, at tempetatuies -20 F and above. BORE COATTNG--------- Vinyl-base roast it ." Used to piovide an anti-abtasive cushion between the cellular glass insulation and the surface to be insulated. JOINT COMPOUND Low tempcraluie cutback asphalt with wax additive. v Used to butter joints of insulation and as a low temperatuie cement lot filling slots, devices, and voids in .insulation blocks, segments, and sections. CAULKING MASTIC Fiie-ietardant cutback asphalt Used to smooth depiessions and to (ill minot voids and iiiegulaiities in the finished insulation suiface. FILLER MATERIAL Asphalt-impiegnated flexible polyuiethane. Used to pack expansion and contraction spaces, and voids caused by construction methods. SUPPORT AND ... Soft wood inner layer, haid Used to suppoit and isolate pipe when piping is sup 1S0LATIQNCRAQLES- _wpo.dLmner layet._,, ___ ported from below. BANDS AND SEALS '4" x 0.015" Hat-Stainless Steel bands and sealing devices.' - Used to secuie insulation to vessels and piping, and to secuie metal jacketing in place. FLASHING STRIPS Flexible plastic sheet. Used for flashing expansion joints. c 003917 E N T E R ONE C O P T IN EACH M A N U A L . SEE T A B LE OP CONTENTS FOR PLACEM ENT. **4\J*l /V K4 c (j A T |v v * *0 I'.'.Ul Alio*# T (#,' -,/L A ' 10 W MAT l *. * CELLULAR GLASS SYSTEM Low Tcmpcrolure K 1 1 . 2 STO 4 0 0 * IWt I /LA rt S e.4 aJ LOCATIONS ST OS A st *r A sues A AGRI. Ol V A <1 42 6# CHCMSTR. gering H YORO otv A 04 19 44 INORO OIV 07 0| A 10 11 17 IS 24 24 24 es ORO otv A Of 02 04 00 92 20 CNO PLASTIC OIV A 12 27 29 24 24 1. INSULATING MATERIAL 1.1 Description Insulating material is foamed glass with hermetically sealed cells. Tie following sh-ipes . and sizes normally arc used in Monsanto practice: ITEM Flat blocks without bevel. Flat blocks bevelled to suit specified diameter. Sidewall segments curved and bevelled to suit specified diamctei. Segments shaped to suit type and specified diametei. Sectional covets to 12" diamelet, segmental covets 14" to 36" diametei. Pieloimed covets. APPLICATION All Hat suitaces, vessels over 24'0" in diametei. Vessels 4'0" m diametei to 24'0" in diametei. Vessels 3`6" m diameter to 4'0" in diameter. Vessels 3'0" in diameter to 3`6". Vessel heads. SIZE 18" wide i 24" long, 1" to 3" thick. Cut to tit; 1" to 3" thick. 9" wide x 24" long, 1" to 3" thick. 6" wide x 18" long, 1" to 3" thick. 1" to 3" thick. Pipe and vessels to 36" diameter. ID to suit specified diameters. 1" to 3" thick. Pipe fittings, line flanges, sciewed or butt-welding valves to 12" IPS. ID to suit specified diameters. 1" to 3" thick. SPEC. A STM C-343 1.2 Thickness Thicknesses stated on Drawings or che Insulation Schedule shall be used. Thicknesses given in Table 1 shall be used only when directed by the Engineer and when operating temperatures are given. C 003918 ' INDICATES APPR O VAL OR ACCEPTANCE AT LO CATIO N. " A " AT o iv m in d ic a t e s o iv u io n -w id e a p p r o v a l or a c c e p t a n c e . PLA X REFERENCES --- OR REVISIONS ARE SHOWN T | ) OR OUTLINING. OELETIONS ARE SHOWN 8Y ' II.I IIO I'jO . "i o j r>Tvj i K4-, TAHI.k I. `.tAXl'llM UUT-''VH.V.\Cb Tn.Ml'KKATrKh (Ul-r.KJ-ES F) IPS and Nominal Pipa Site r soo v." soo 1 " soo \`c soo 1*4" 400 2 " 400 3 " 400 4 " 300 6 " 300 8 * 300 10 " 12 * 2S0 2S0 14 ** 250 16 * 2S0 18 " 250 20 " 2S0 24 " 30 " 36 " 2S0 2S0 | 250 Flat 2S0 NOMINAL INSULATION THICKNESS* Singio I.Off 1*4" 2" 1 2*4" 3" 3*4" 4" DoubU Loft* 4*4" 5" 600 aoo 1100 1200 600 800 1000 1100 1200 600 800 900 1100 1200 600 800 900 1100 1200 600 800 900 1100 1200 600 700 800 900 1100 1200 SOO 600 800 900 1000 1100 1200 SOO 600 800 900 1000 1000 1100 1200 500 600 400 600 800 900 700 800 900 1000 1100 800 900 1000 1200 1100 3S0 SOO 700 800 350 SOO 600 700 800 900 1000 1100 800 800 900 1000 300 400 SOO 600 700 800 900 1000 300 400 SOO 550 700 800 900 1000 300 400 SOO 550- 700 800 900 1000 300 j 400 SOO 550 700 800 900 1000 300 400 soo 550 700 800 900 1000 300 400 500 550 300 400 500 550 700 800 900 1000 700 800 900 1000 300 400 500 550 700 SOO 900 1000 5*4" 1200 1200 1100 1100 1100 1100 1100 1100 1100 1100 1100 4" 1200 1200 1200 1200 1200 1200 1200 1200 1200 `Table I is based on design conditions to hold the temper ature of the insulation surface to 120 F, maximum, in 80 F still ait. When hot-suefaee tempeiatuie falls between two thickness columns, use the gieatei thickness. 'Insulation in thicknesses 3*4" through 6' shall be applied in double layers according to the following schedule: 3V : IV inner layer, 2" outer layer. 4" : 2" inner layer, 2" outer layer. 4V : 2" inner layer, 2*4" outer layer. 5" : 2`4" inner layer, 2*4" outer layer. S*4" : 2V inner layer, 3" outer layer. 6* : 3* inner layer, 3* outer layer. C 003919 Monsanto STANDARD* .0^ COATINGS ANO INSULATION MANUAL THERMAL INSULATION OESIGN INSULATION MATERIAL PROPERTIES Dtslfn Data MAN. SECT PART Kll.l STD 3 ISSUE 2 OATE 4/73 RAGE 1 OR 9 1. SCOPE This standard lists materials properties data for thermal insulation and barrier materials used in the Thermal Insulation System Specifications. Additional data for other common materials is provided. 2. MATERIALS PROPERTIES DATA 2,1. Insulation Materials Properties Table 1 provides physical and thermal properties for materials shown in the Insulation System Specifications,and a few additional materials of frequent use. . * . __ . r- ^-Insulation Characteristics TABLE I. MATERIALS PROPERTIES "" , i.. i. sulatlon '__---------- "Fibrous, Glaas---------* K11.2 STD 5 ASTM Test Method - Calcium Silicate K11.2 STD 6 Material Description Glass Fiber With Organic ------- Binder Reacted Hydrous Calciuit Silicate Form - temperature Range(F) Sheet and Pipe Covering ' 0 to 450 Block and Pipe Covering - ---------- ' ------------ 100 to 1200 Thermal Conductivity " (BTU ih; thk/hr ft1 *F) At MeanTemparature ~" K: ~ ----Temp - -- .21 "" 50 .24........ "100 -- --.... K--------------Temp .38 100 -------.40 ---------- -200 *- ni ue. 729 200 .35 300 --------.47 .56 - 400 600 LinearShrinkaga Max %' at Temp Omit Density" lbs/Ft*............. Tensile Strength PSI'*' TOUStlOlS "None 49 " - - ----------- ' -------------------- ---------------- ----- 1.6" 12 20 _ ------------ Compressive Strength PSI 3 at 10% Deformation 100 at 6% Deformation Flexural Strength PSI Modulous of Elasticity PSI " ' - " ----- Abrasion Resistance % Wt. Loss by Tumbling Firs Exposure Flame Spread Index ' 25 35 - 10 Min Run * Non-Combustible . - ----- - ------ ' Smoke Density Index 60 Water Abeorption % Vol. - 24 hr. Immersion Capillarity Hygroacopiclty % Vol. 90 None .2---------------------- ---- --- -- - 90 Wicks ------- 10% by Weight Water Vapor Transmission Perm In. Alkalinity Ph Chloride Content (PPM) 9 Less than 30 10.2 200 " -..... -- Emiseivity Thermal Diffusivity (Ft'/Hr.) Specific Heat (BTU/lb/*F) .02 .20 .16 .20 Remarks---------------------- - ----------- ---------------- -- Good Strength. Absorbs Water. i -------- ASTM Teat Method SOURCE____________________________________________________ - --TM . - A..*.*..* A* RnMOiAai AK Cunwhi av I I nt iTi iNINf*. DELETIONS ABE SHOWN 8V C 003072 k ii.i PACE 2 rto 3 OF 9 ISSUE 2 Monsanto ITANOAROS TABLE I. MATERIALS PROPERTIES (Continued) Insulation Characteristics Cellular Plastic K11.2 STD 7 Type of Insulation ASTM Test Method Polyurethane X11.2 STD 8 Material Description Closed Cell Foamed Plastic Expanded Polyurethane Form Temperature Range (F) Thermal Conductivity (BTU in. thk/hr ft* F) At Mean Temperature SHaat and Pipa Covarlng . *T*~T-- 50 to 220 . X Temp .27 70 .28 90 Expansion Coefficient Linear Shrinkage Max % at Temp Limit *7 Density Ibs/Ft' Tensile Strength PSI Compressive Strength PSI Flexural Strength PSI 6 80 ? 40 at 10% Reformation. * : '-rzzc 3" -Modulous of Elasticity PSI Abrasion Resistance % Wt. Loss by Tunbling' ` Fire Exposure Flame Spread Index . ... ... ' " - ` - Self-Extinguishing 60 Smoke Density Index 500 Water Absorption % Vol. - 24 hr. Immersion Capillarity Hygrosccpicity % Vol. " Water Vapor Transmission Perm In. Alkalinity Ph 1 0 .28 ' Chloride Content (PPM) Emissivity Thermal Diffusivity (Ft'/Hr.) . Specific Heat (BTU/lb/*F) .19 to .27 D-1667-64 D-1692-69T D-1056-62 C-356-64 Block, Pipe Covering t Spray -400 to 200 X Temp .16 -100 .18 -50 .18 0 .17 50 .18 100 40X10"*', : -- - 2.0 - 2.5 40-70 30-40 60-70 Self-Extinguishing 25 and Higher Less Than 500' 1.5 to 3.0 1.5 .012 40 026 - .23 " ,f.......... ASTM Teat Method D-1622 D-1623 D-1621 0203 D-1692 0366 ' Remarks Coating Required for Exterior Exposure Foam Should not be E^josed to Sun or Weathering Elements. , .... _ - 0 003073 Monsanto STANDARDS K11.1 STD ISSUE 2 |PAGE 3 3 OF 9 TABLE 1. MATERIALS PROPERTIES (Continued) Insulation Characteristics Mineral Fibers K11.2 STD Material Description Form Temperature Range (F) Thermal .Conductivity (BTU in. thk/hr ft1 *F) At Mean Temperature ^ r t st r 1 ``Mineral Fibers With Inorganic Binders Block and Pipe Covering 100 to 1200 K. Temp .33 100 .36 200 .42 400 .51 600 Expansion Coefficient Linear Shrinkage Max % at Temp Limit Density Ibs/Ft* Tensile Strength PSI 4 ,V 15 ' '*------ Compressive Strength PSI ' ' 10 at 5%'Deformation Flexural Strength PSI 40 Modulous of Elasticity. 'PSI _. Abrasion Resi stance f- % Wt. Loss by Tumbling 'Z ," :;r -- Fire Exposure Non-Combustible Flame Spread Index Smoke Density Index Water Absorption ^- l %Vol. -2a Hr. Immersion 90 Capillarity Wicks Hygroscopicity % Vol. .2 Water Vapor Transmission Perm In." - Alkalinity Ph " ,,. 8 . Chloride Content (PPM) - - 20 Emissivity Thermal Diffusivity (Ft'/Hr.) Specific Heat (BTU/lb/*F) .01 .22 ' Remarks -rtird.' e -c ^v .r -- .... - _ Type of Insulation A8TM Test Method Cellular Glass K11.2 STD 10 Hermetically Sealed Glass Cells ; Block and Pipe Covering -450 to 800 K Temp .32 -50 .35 0 .41 100 .47 200 .55 300 4.6~x 10-* i. 9 50 100 75 180.000 - Non-Combustible .2 0 0 0 7.5 Less Than 5 / .018 .20 . i lGood Comoreesive Strength. ASTM Test Method C 003074 - ' --__ inniTinuc ns ecuicmue t wnwti RY I I OR OUTLINING. DELETIONS ARE SHOWN IV SiSsiSSSS, K11.1 STD 3 PAGE 4 OF 9 ISSUE 2 -' -- .. . Monsanto T ANDAftOS TABLE I. MATERIALS PROPERTIES (Continued) Insulation Charactsristlcs Expanded Silica K 1.2 STD 11 Material Description - Form Perlite With Glass Fiber Binder And Watar Repellent Block and Pipe Covering Temperature Range (F) Theramal Conductivity (BTU in. thk/hr ft* * F) At Mean Temperature Linear Shrinkage Max % at Temp Limit Density Ibs/Ft' ........ . Tensile Strength PSI Compressive Strength PSI Flexural Strength PSI Modulous of Elasticity PSi 4 Abrasion Resistance % Wt. Loss by Tumbl ing Fire Exposure Flame Spread Index Smoke Density Index Water Absorption % Vol. -24 Hr. Immersion Capillarity Hygroscopicity % Vol. Water Vapor Transmission Perm In. Alkalinity Ph Chloride Content (PPM) Emissivity Thermal Diffusivity (Ft'/Hr.) Specific Heat (BTU/lh/ F) 100 to 1600 K Temp .33 - 100 .38 200 .47 400 .57 600 1.2 IQ . . 81 at 5% Deformation 85 Non-Combustible 3.7 18 9 50 .014 .22 / Type of Insulation ASTM Test Method Alumina Silica High Temperature Ceramic Fiber - , Blanket and Bulk , __ 100 to 2300 K"> Temp .40 600 .70 1000 1.10 .1400. *8 lb Density ASTM Test Method 3 to 12 Non-Combustible Less Than SO ... . .26# 1900 F >- ' ' - Remark* - High Temperature And High Cost. May be Used in Combination With Low Cost Materials. ai W C 003075 Monsanto STANOAftOS COATINGS A NO INSULATION MANUAL THERMA'. INSULATION OESIGN - MATERIAL S ifSI EM SELECTION GUIOE MAN.,SECT PART Kll.l STD 1 ISSUE 3 OATE 4/73 CAGE 1 Of 18 1. SCOPE This information stand../;! outlines the selection and design proce- dures for thermal insulation, and discusses some of the considerations governing successful performance of insulation. . . .crystallization or other deposits on the walls. . . .viscosity changes or product degradation. . . .vaporization losses (in cold service). 2. DESIGN PROCEDURE The essential steps in thermal insulation selection and design are: (1) Determine whether insulation is required (Par. 3). - .. (2) Obtain.application data (Par. 4). (3) Select appropriate insulation material (par-.,5)-.i - ^ - - (4) Determine how much insulation is required (Par. 6). (5) Verify material selection, select barrier materials for.a complete system (Par. 7). (6) Properly identify final selection on drawings, in schedules, and in ; summaries. (7) Establish construction details (See K11.4 standards). 3. INSULATION FUNCTION Thermal insula tion simply reduces heat flux out of hot. c surfaces or into cold surfaces. Because it is expensive to install and maintain, insulation must pay for itself in at least one of the following ways: (1) Utility Conservation: Every heat flux represents a loss of energy. Most of these losses represent a cost increment in fuel, electrical power, cooling water, and o'ther utilities. - ... . . (2) Equipment Economy: Unwanted heat losses may require oversizing heat exchangers, distillation columns, pipelines, etc., simply to make up for the loss' - which may in some cases be a significant fraction of* process heat flux. (The alternative to oversizing may be yield loss or product degradation from excessive heating and/or pressure drops in the equipment.)3 (3) Process Protection:- Heat flux requires temperature gradients in equipment walls and -fluid contents. Undersirable effects of these gradients may include: ______ aj.Si; (4) Fire Protection: Insulation may ' serve the primary or secondary purpose of protecting equipment and structures from early loss of strength during a fire - at least long enough to permit fighting the fire to bring it under .control., ,,__ _ . (5) Personnel Protection: Where the fore going considerations call for no insulation, or not enough, insulation must be added only in those areas where operating and maintenance personnel are likely to contact the hot surfaces. (See Par. 5.1.6) . ,(6) Insulation and Plant Protection: In cold service,,insulation must be thick enough, regard less--of the above consi derations, to prevent deterioration - and premature failure due to moisture attack. In "chilled" service insula tion may be required to avert the housekeeping and maintenance expenses ,, resulting from sweating and dripping. This requirement is most likely to apply in controlled environments. 3.1 Noise Control'" "The* use of insulation materials to absorb noise emitted from piping and equipment is a specialized subject not covered in this Selection Guide. Consult an expert in the noise control field. 4. APPLICATION DATA Prior to selection of insulation, the following kinds of data should be compiled to minimize the risk of picking an insulation system in the dark: (1) Surface temperature range (Use tempera ture of contents unless a different temperature can be reliably specified. Note any rapid or extreme temperature ...fluctuations or cycling. For low - - temperature applications, determine whether the aystea will be heated under some, circumstances, and list the maximum as well as minimus temperature! (2) Limits on permissible heat flux.(These are process-imposed requirements which , should be in performance data. In most instances no specific limit will be imposed,) (3) Critical temperature limits. (Same considerations as in. Item (2) above.) C 003076 SOURCE i atcct Af>r*tnrMc no ocwicmuc aoc cuawu iv I 8 no mtTl INlMft DPI PTIOMft ARP SHOWN tY K11.1 STO MGf 2 'Of 18 1 ISSUE 3 Monsanto T AN 0 A* 0t (4) Critical environmental conditions. (These are normal temperature and relative humidity, indoors. Outdoors, the critical conditions for hot and cold services are discussed in Par. 5.1.1 thru 5.1.6 Consider possible wind damage.) (5) Operating department data. (Consider fire hazard, possible leakage of flammable materials info-insulation, washdown practices, possibility of hose stream impact during a fire, etc. Consider also possible abuse: foot, vehicle traffic, vibration, mechan ical shock .) ----- --- (6) Economic data. (See normal values in T4.9 STD 2, List 8. These factors are required to choose economic insulation thickness. Actual eco nomic-values, if available, may be substituted for normal factors.) 5. INSULATION MATERIAL SELECTION Assuming a preliminary determination has been mads that insulation is required, refer to Table I, entering at the appropriate surface temperature range. Observe remarks on Use and Limitations, if a Table II reference is given, review the general considerations "irrPaTT '5.i"before selecting an insulation material. The preferred (bold-face) mate rial will be the most economical selection unless one or more general considerations forces an alternative selection. It is recommended that all insulation selec tions be reviewed at an early project stage with the Thermal Insulation specialist. ,$h process -will be more efficient, and considerations can be evaluated-on a broad basis of experience. 5.1 General Considerations In Table II, each material is characterized with respect to six considerations which may in some cases ' i TABLE I- PRELIMINARY INSULATION SELECTION Surface Temperature P C Remark on Use and Limitations Refer to Table Below -100 Below -73 - No standard insulationsystem can * * <* . :be generally recommended.^consult insulation specialist. . --.-s-! Above -100 - - Above -73 To -50 - To "-46 Design and construction methods are critical. Consult insulation specialist. II A Above -50 . Above -46 To 0 TO i -18 Close adherence to all material and installation- details is essential to avoid rapid deterioratioh. II B Above 0 To 40 Above -18 To +4 Above to Above To 40 Above 4 140; To ,..60 tr.u,Csr:*~ 140 Above 60 450 To 235 Above 450 Above 235 To . 1200 To 650 Same as above. Outdoors, above 32 r (0 C) it may occasionally be -possible to omit .insulation.. ..._______ , ..... Insulate only if required by speci fic process or plant protection function.,u , II C II D Optimum selection and application will result ip. greatest cost reduction. a ' ._ - , i i k/ 1 * t 1 * Double layer .insulation usually specified above 600 t (305 >C); in any case,, specify on drawings and summary. ^ wa II E II r Above 1200 Above 650 No standard insulation system can be generally recommended. Internal insulation or refractory lining should be considered. Consult insu lation specialist. -- C 003077 Monsanto STANOAftOS - Kll.l STO 1 ISSUE 3 PAGE 3 Of 18 have a decisive effect on performance, safety, or economy. The preferred (bold face) insulation material should be selected unless application data developed in Step 2 (par. 4) indicates another choice. 5.1.1 Thermal -Performance ^ The key consideration is thermai-conducfTvity (tabulated here for a single representative temperature). Stability of this value with respect to age, moisture content, etc., is noted. Maximum temperature limits are given, where significant. For infrequent cases where specific heat, diffusivity, or thermal shock limitations may apply, see Kll.l STD 3. 5.1.2 Chemical- interactions Ther-e three types of interactions ;; (1) insulation material affects insulated surface. (2) process contents deteriorate insulation. (3) .flammable xontents'are"degraded , by insulation (Spontaneous combustion risk). ,,_t A number of insulating materials can release halides enough to cause stress corrosion ' cracking of austenitic stainless alloys. These are noted. Any alkaline insulation can attack aluminum, especially when moist. Nearly all insulations are attacked by strong acids and alkalis. No special note is made, since most of surroundings are also attacked. Special note is made where'sol vents deteriorate the insulation. ' ' '" sifters, and h-overs, chutes, or ducts fitted with vibrators :c facilitate bulk material flow. Materials of h;-:'-; compressive strength are first choice w>ore vehicle damage or foot traffic,.must be reckoned with. Top heads Of vessels "With agitators usually require consideration. Insulation used to support flat bottomed vessels must be of high com pressive strength. ._ 5.1.4 Economics Systems offering the lowest installed cost for a given heat flux are listed in bold-face type. Others are selected only where process or performance .considerations are over-riding. 5.1.5 Moisture Problems Most types of insulations, except those with closed-cell construction, have high water absorptivity. For elevated temperature service, the barrier system must be permeable enough to vent moisture vapor, yet resist passage of liquid water. For low-temperature service moisture in,all.forms must be. excluded,by an imperme able barrier, and the barrier must be mechanically durable. Low-temperature lines should always be located above-grade or in service tunnels if feasible. Hightemperature lines may be routed above-grade or well-drained, ventilated trenches or tunnels. High-temperature lines insulated fpr direct burial represent a specialized problem not covered by standards. "5.1:6 Safety Considerations One safety hazard' is'mentioned in'Pair. 5.1.2. This is not a major risk. Others, more often encountered are: Cases have _been reported in which flammable 1 iqu id" leaka"ge*Thas. been- absorbed by insula tion. Later, when hot insulation was breached for repair work, flames were noted. Contributing factors have not all been identified, but it may be prudent to avoid some insulation materials on lines and equipment containing flammable liquids in areas classified as Division 1 with respect to electrical installations'. ~ 5.1.3 Mechanical Durability In some applications the completed insulation system must'Withstand-unusual loadings or possible abuse. If a mechanically durable insulation cannot be used, shielding or guarding may be necessary.____________________________ Wind forces impose special"support and attachment requirements in applications' where uplift or suction can become signifi cant. Loads on barrier membranes may be particularly hard to sustain. Vibration and mechanical shock loadings also impose special support and attachment prob lems, particularly on rotary dryers or blenders, oscillating equipment such as (1) Fire damage protection (2) Safe surface temperature (3) Toxic contamination The first problem is significant if it is determined that equipment or piping requires protection (time delay) from high temperature "Of a .fire, and the thermal insulation is relied'on for part or"a11 of this protection. In such cases, ability of the insulation system to withstand heat effects and mechan ical impact of water hose streams will be major considerations in selection. Aside from designing insulation for fire protection it will be desirable in some cases to avoid insulating"materials which 'have a high flame spread index, or will add fuel to the fire. The second consideration applies mainly where people can contact the insulation inadvert ently (c.g., unprotected skin of back or "upper arms) T'"informal experiments indicate that painted metal surfaces or painted metal insulation jackets should be limited to 140 F max. in areas of personnel exposure. Bare unpainted metal should be held to 130 F. c 003078 K11.1 ITO fAQl 4 or 18 ISSl..'. 1 Monsanto ITANOAMOi Non-metallie pip.r.q and insulation surfaces can b permitted up to 160 P. Metal sur faces in areas ov low hazard and infrequent personnel contact ~(e.g.-, yard, piping near '-- grade and storage tank farms) can be per mitted to reach 150 F. Surfaces above these temperatures should be -controlled by insula- -- tion only in areas where personnel' contact " is reasonably likely. (If portable ladders or scaffolds are needed for access, tempo rary safeguards may be provided at that time). The final hazard - contamination of the insulation by toxic leaks and spills - must be dealt with on a case basis. Does "the need to handle insulation aggravate an exposure problem? What disposal and decontamination problems are involved? Should insulation be omitted - or per haps be provided with a barrier around. the installation? f y" system. ryv 0*. 'i-orn e-OS' a'cirtt" IS St* r* *V t? i -TC S A,-R . i - , 'zr-v&j?: -* * v "16*!.: !C -Crw-- '*+C- V - r. -.jf'.'V tit'i : cf-. ."ITHC. "X" ---- - w.rnpCfAt*cn ccftnc*A*fiii*<* ------ 1.- tc wl" ati H" bJK ' "I. W tar # ~ _v - . . 'A' *4U-;S7ttr.? c* -,4.. m OOSf3t:Wt. c 003079 Monsanto STANDARDS r 1C 11.1 STO 1 ISSUE 3 RAGE 5 01 15 TABLE II A TABLE II B Temperature Rang* -100 to -60 F (-73 to -48 C) * Insulation Standard K11.2 STD S - POLYURETHANE k =0.17 at -75 F Excellent thermal properties. 200 F limit when system is heated (e.g., for process clean out). Temperature Range -60 to OF (-46 to -18C) Ineulation Standard X11.2RTD 8 - POLYURETHANE Insulation Standard R11.2 STD 10 - CELLULAR GLASS k = 0.18 at -25 F k =0.31 at -25 F Excellent thermal properties. ' 200F limit when system is heated (e.g.. for process clean out). Requires 2 to 3 times the insulation thickness compared with system 8. -L-_ THERMAL * CONSIDERATION 3l No reaction between insulation . and substrate. if o* o o No reaction between insulation ' - No reaction between insulation and substrate. and substrate. ' " *` - * z JO < > Medium compressive strength; - 11 il Medium eomprassive strength; - High compressive1Strength. may require metal jacket may require metal jacket application to improve resistance application to improve resistance is SI So __*u,, from external mechanical forces (foot traffic and bumps). from external mechanical forces (foot traffic and bumps). - For equipment support consider -- ` K11.2 STD 10. ,A- ;rt, a- T- can? z Use sectional shapes for pipe; Use sectional shapes for-pipe; " r. Installation cost of cellular glass block construction is applicable block construction is applicable systems are 60 to100 percent i 1 where total insulation equipment requirements are less than 500 square feet and sprayed foam for where total insulation equipment - . greater than polyurethane. ' requirements are less than 500.- . square feet and sprayed foam for 'vs<j f- "I areas greater than 500 square feet areas greater than 500 square feet. Where feasible provide a shelter from rain to extend life and retard heat flux. ,, _ r, , ~ n^rr^r-;.' 'r^ Where feasible provide a shelter from rain to extend life and retard heat flux. n.V ; \ - = rv- Where feasible provide a shelter from rain to extend life and .xatard.heat flux.______ ,, in >: 14 CONSIDERATION CONSIDERATION MOISTURE SAFETY * ' ' Material Is combustible; rated self-extinguishing^' Interior sprsy appncation._requlr*e.v*ntilion___ or respiratory aquipmant. > . 3!)-r* Material combustible; rated self extinguishing. Interior spray application requires ventilatioaor respiratory equipment For fire resistance consider K11.2 STD 10 or add non-combustible insulation - - over polyurethane. . % i Non-combustible. REMARKS 6 Block construction for vessels requires insulation support hardware; reference D3._2 STD.83,_ Support hardware not required for spray application. Block construction for vessels *'*' ,J Do not use on vibrating requires insulation support aquipmant. .hardware; reference D3.2 STD 83. Support hardware not required ... ; fur ' lr~ X ' for spray appl icatiorw , , * . - ^ ruuifr ?'-5. - rf' ` Tftermat conductivity (k) units m Btu in.Ihk/hr ft,0F. ?- sr. '* r" *^1" i't` t ' f* -os.- A o- "r- =._ c 003080 CONSIDERATION CONSIDERATION CONSIDERATION CONSIDERATION CONSIDERATION K11.1 efao* *T0 or 18 1 issue 3 Monsanto STANDARDS TABLE I) C THERMAL CHEMICAL Insulation Standard 811.2 STD 8 - POLYURETHANE k =0.17 at 20 F " Excollont thermal proporties. 200F limit when system is heated (.g.. for process clean out). Temperature Range 0 to 4PF (-IS to +4 C) Insulation Standard Ineulation Standard I01.2 STD 7 - caLLILAR PLASTIC , K1J.2 STD 10 - CELLULAR GLASS k = 0.24 at 20 F k = 0.33 at 20F - Requires 2 to 3 times the insulation thickness as compared to polyurethane or cellular plastic insulation for comparable insulation value. No reaction between insulation and substrate. No reaction between insulation and substrate. Typical interior installations do not include a jacket covering and a solvent or plasticizer environment destroys the insulation. No reaction between insulation and substrate. Medium compressive strength; may require metal ;jacket_appl ica-T' tion toImprove resistance from external mechanical forces (foot traffic and bumfs'). For equipment support consider K11.2 STD 10. Cellular sponge construction with_ . low compressive strength. ... --' High compressive strength. *" ' ..T.C } " Use sectional shapes for pipe; Low cost system for interior pipe block construction is appiicablo"r' ..ana tubing to 2 <nches nominal- where total insulation equipment, diameter; cost greater.than-, requirements are less than 500 polyurethane insulation for * square feet and sprayed foam for exterior application. areas greater than 500 square feet. For small diameter pipe consider K11.2 STD 7. WhereTeasible provide a shelter 1 ~ WhereTfeasTble provide a shelter from rain to extend life and retard from rain to extend life and retard heat flux. heat flux. Installation cost of cellular glass systems are 50 to 100 percent L... greater than polyurethane or cellular plastic insulation. Where feasible provide a shelter from rain to extend life and retard heat flux. MECHANICAL ECONOMIC MOISTURE B jj h o o ! Material is combustible; rated" self-extinguishing. Interior spray application requires ventilation or respiratory equipment. For fire resistance consider K11.2 STD 10 or add non-combustible insulation over polyurethane. Block construction for vessels requires insulation support hardware; reference D3.2 STD 83. Support hardware not required for spray application. Material is combustible; rated self-extinguishing. Sheet material is available for irregular shape equipment application (refrigeration compressors, instruments, etc.). Tfcernal conductivity (k) units are Btu in. thk/hr ft,0F. Non-combustible. . - Do not use on vibrating equipment. C 003081 Monsanto STANDARDS TABLE II D K11.1 STD 1 ISSUE 3 I PAGE 7 Of 18 - - -..................... Insulation Standard Insulation Standard K11.2 STD S --r^r- K11.2STD7 FIBROUS GLASS ,..r. c,CELLULAR PLASTIC k = 0.23 at 70 F k = 0.26 at 70F i t i i l! tree Range (4 to 60C) Inaulation Standard Ml .2 STD 8 POLYURETHANE k = 0.17 at 70F -Excellent thermal properties. Ineulation Standard K11.2STD 10 CELLLTLAJIGLASS k = 0.37 at 70 F THERMAL * CONSIDERATION o' ag< 5 is i g o No reaction between insulation ami substrate. Typical interior installa tions do not include a jacket covering and a solvent or plasticizer environment destroys the insulstion. No reaction between _ No reaction between insulation and substrate. insulation and substrate. MECHANICAL CONSIDERATION 'Cellular sponge con-^-~- = struction with low compressive strength. Medium compressive strength; may require metal jacket application to improve resistance from external mechanical forces (foot traffic and bumps). High compressive strength. it p Ss OUJ MZ. o o Low costsystem*cost svstc Low cost system for , furTT'i^ f'^r-.v^as interior pipe and tubing to 2 inches nominal ~ - diameter: cost greater than polyurethane or fibrous glass for exterior application. Use-sectional shapes for Installation cost of pipe: block construction - cellular glass is 60 to Is applicable where tote/ 100 percent greater than insulation equipment re other ineulation materials quirements are lees than in this temperature range. GOO sq ft and sprayed foam for requirements greater than 600 sq ft. Poly urethane cost usually higher than fibrous glass or cellular plastic. 22. ii nS o o For operating temperatures of 30 to 70 F and a relative humidity range of 70 to 100 percent use KII ^STO S,-- Polyurethane Insulation or K11.2 STD 7. Cellular Plastic Insulation. Good performance in high humidity environments. ... Good performance in high humidity environments. -- S gfSq 9 M 8Z Glass fibers are non* combustible; contains small amount of resin binder which Is-----------------combustible. Material is combustible; rated self-extinguishing. Material is combustible; rated self-extinguishing. Interior spray application. ~tequlrerventilation or reapiratory equipment. Non-combustible. 1 .ri-,u,,:nv r a. Sheet material is avail able for irregular shape equipment application -heMgeratioa-compreaeerSr p instruments, etc.). Block construction for vessels requires insula tion support hardware; roferenceD3.2STD'83.------ Support hardware not required for spray appli cation. Do not exceed 200 F for equipment or pipe dean-out operation. Do not use on vibrating equipment. * Thermal conductivity (k) units are Btu in. ttik/hr ftlsF. 0Q3082. K11.1 STO 1 PAG! 8 ' Of 18 ISSUE 3 TABLE II E Monsanto STANOAROS Insulation Standard K11.2 STD 8 FIBROUS GLASS k = 0.31 at 260 F Tempsrature Rang. 140 to 480F (80 to 238C) Insulation Standard K11.2 STD 8 CALCIUM SILICATE Insulation Standard K11.2 STD 8 MINERAL FIBER Insulation Standard K11.2 STD 10 CELLULAR GLASS k = 0.40 at 260 F k = 0.28 at 260F k = 0.80 at 250 F Hygroscopic, k greatly increased by moisture. For thermal shock application consult insulation specialist. Insulation Standard K11.2 STD 11 EXPANDED SILICA k a 0.40 at 250F THERMAL * CONSIDERATION CHEMICAL CONSIDERATION Adequate com pressive strength. Insulation pH about 10. Wet insulation will corrode alumi num rapidly. Also, wet insulation will initiate stress cor rosion of austenitic stainless steel. See K1.1 STD 2. Good compressive strength. Adequate com pressive strength. High compressive strength. Good compressive strength. MECHANICAL CONSIDERATION MOISTURE CONSIDERATION ECONOMIC CONSIDERATION z 0 1 ?9 1 o 1 Usually lowest cost system in this temperature range. High watsr absorptivity. Glass fibers are non-combuetibla; contains small amount of rssin binder which is combustible. Calcium silicate installation cost usually higher than fibrous glass or mineral fiber; equal in cost as compared to expanded silica; cost less than cellular glass insulation. High watsr absorptivity. / Non-combustible. Mineral fiber installation cost usually higher than fibrous glass; how ever, cost is less than othsr Insulation listed within this temperature range. Installation cost of cellular glees systems are 60 to 100 percent higher than other insula tion systems listed in this temperature range. Installation cost of ejqMnded silica usually compares favorably with cost of calcium silicate systems. Jiigh water absorptivity. Very low watsr absorptivity. Non-combustible. Non-combustibla. Low water absorp tivity to 300 F. Insulation formula tion contains a water repellent which degradatss at temperatures above 300 F. Non-combuetiblo. Watsr that enters the insulation system through the weather barrier tends to remain within the insulation system and will causa severe corrosion. Water that enters the insulation system through the weather barrier tends to remain within the insula tion system and will cause severs corrosion. * 'nwraal conductivity (k) units art Btu In. tbk/hr ft*F. C 003083 CONSIDERATION CONSIDERATION CONSIDERATION CONSIDERATION CONSIDERATION Monsanto $TANOAROI Insulation Standard K11.2 STD 9 - MINERAL FI6ER k = 0.40 at 600 F - TABLE II F Kll.t STD 1 issue 3 I FAGt 9 OF 18 Temperature Range 460 to 1200F (236 to 660C) Insulation Standard K11.2 STD 6 - CALCIUM SILICATE k = 0.50 at 600F Hygroscopic, k greatly increased by moisture. Insulation Standard K11.2 STD 11 - EXPANDS SILICA k = 0.52 at 600 F , THERMAL CONSIDERATION CHEMICAL MECHANICAL ECONOMIC Adequate compressive strength. Good compressive strength. Good compressive strength. Usually lowest cost system in this temperature range. Installation cost of calcium silicate is usually higher than mineral fiber systems. Installation cost of expanded silica compares favorable with calcium silicate systema. High water absorptivity. High water absorptivity. Very low water absorptivity to 300F. Water repellent degrades above 300F. Non-combustible. Non-combustible. Non-combustible. MOISTURE SAFETY REMARKS * Thermal conductivity (k) unit* ace Btu In. thk/hr ft,0F. C ,003084 Monsanto STAHDAROI Plant Requirements Manual Texas City Plant THERMAL INSULATION REQUIREMENTS man. sect fart L52.ll NST 1 ISSUE 2 OATt 3/70 FACE 1 OF 4 {CJ 1. SCOPE This information standard lists exceptions''tO'and modifications of Monsanto?Standards. and other requirements for preferential use in the application of thermal insulation to projects-at the Texas'4:ity_.JPlant-.-i:i.* _ ^ .... 2. GENERAL REQUIREMENTS ---2 a 1 . Insulation for-Personnel^Protection Thermal insulation is - i.applied to -protect personnel -from^injuries due to burns or'shock awhen temperature-of the vessel, equipment, or piping is 140,F. 2.2 Insulation-Economic -Thickness Unit cost of steam at the Texas City Plant is approximately51 cents per 1000 pounds produced; about^38 centa)per-4M Btu> Calculation of economic insulation thickness that-will hold to a minimum the combined costs of installed :insulation -andrlost heat is warranted. 2.3 Insulation Materials As a general safety practice, all thermal insulation materials must be at least fire retardant, preferably non-combustible. 3. THERMAL INSULATION FOR ELEVATED TEMPERATURE SERVICE The following insulation materials are preferred for project applicationi (1} Calcium Silicate Material and available shapes are described in K11.2 STD 100. Temperature range is suitable for all plant requirements. Preferred for general use in all plant areas. 0 3.1 Auxiliary Materials for Elevated Temperature Service 3.1.1 High Temperature Cement EAGLE - PICHER NO. 166 is the preferred material; other vendors are accepted}le for projects. 3.1.2 Filler Material Use fibrous glass blanket material to fill expansion joints in insulation. 3.1.3 Bands and Seals Use 3/4" X .015" stainless steel bands and seals to secure insulation to equipment, vessels, and piping and to secure metal jacketing to insulation. 3.1.4 Tie Wire Use 16 gauge galvanized steel or 16 gauge stainless steel tie wire where required to secure field formed insulation covers, or in areas where banding is impractical. COMPANY CONFIDENTIAL T h li O m iM i C M ta ki Ctwpwy CwN M xt l i l k ta a u d M m i mult t iMuriwd, with- M l n ft* * K tlM M Auplkalian. Amn On laclptant kavaa h it p*M nt u s lfia w it. at M any tlM upM raawaat Th* itc lp k n l ahtll kMp cMlIdantlal, aid taqulia oth la kaap eanMantlal InfcuMtlut centtk a d haiald. T h it tta d a d ahtll ba daiboytd V>t IRPF nmrse* /-nri* n C 1 n m_ i.. r> 1 4- C 003054 MM Cawtr^e L52.-U,,nst1-pagt :^2 o* 4 | mu* 2 Monsanto STANDARD* 3.1.5 Welding Studs Use NELSON welding studs and caps of the same material as the metal to be insulated, and of size and length to suit th6 insulation thickness as supplemental securements to bands . and ,seals,,tjnJLixge or irregular surfaces.' DO NOT FIELD APPLY WELDING STUDS TO STRESS - RELIEVED SURFACES, OR TO ALLOY LESS THAN1 1/4* THICK*L_-ri^vx^-rj--^ 3.1.6 Aluminum Jacketing Use .016" thick aluminum jacketing epoxy coated on both sides, as weather protection on equipment-,'vessel sidewalls, and straight iruns of piping. -Use .016"-thick preformed' aluminum fitting'Covers for insulated piping tees -and*dong'cr short radlbs elbbws. * - r 3 .^1.^- " Weather -Barrier Mastic- Use LION M-10 Polyvinyl acetate mastic reinforced with glass fiber mesh as weather protecticn^tfr'^^u^ation on pipe bends, flange covers, valve covers, special* fittings:,":irregular shapes, and vessel heads where the cost of-"mitering,''''^goring, and fitting metal jacketing in the field would -be-high. '' 4.' THERMAL INSULATION MATERIALS FOR COLD AND CRYOGENIC SERVICES The following insulation materials are preferred for project application. Cl) Rigid Polyurethane Material and available shapes are described in K11.2 STD 430. Temperature range is suitedle for all plant requirements. Preferred for general use except for equipment, vessels, and piping in oxygen service. See Thickness Table in Kll.l NST 5201. (2) Cellular Glass Material and available shapes are described in Kll.2. STD 400. Temperature range is suitable for services to - 100 F. Preferred for equipment, vessels, and piping in oxygen service, and beneath concrete slabs or compacted sand bases that directly support vessels in other cold services. See Thickness Tables in Kll.l NST 5201. Auxiliary Materials for Cold and Cryogenic Services 4.1.1 IniultegC6fl't Mastic Polyurethane insulation is \ \destroyed in the early stages of accidental fire, provides nu v ^protection to the insulated surface from fire distortion. A ) < recommended procedure is to apply intumescent fireproofing J materials described in A4.10 STD 15 to critical vessels and^^ piping prior to application of insulation. 4,1.2 Buttering Compound Use LION BUTTER ASPHALT for buttering joints in Insulation blocks, segments, or sections where required. C 003055 1 ST AMOAR OS L52.ll NST 1 ISSUE 2 PAGE 3 Of 4 4,1.3 Filler M to fill expansion joi Use fibrous glass blanket material insulation. 4.1.4 Bands and ''^HTls ^Use 3/4". X .015" stainless steel bands and seals to secure insulation to equipment, vessels, and ifflng; ' raa" where 4^-^-^ei-gtHq-^-t-iras~r: DQ-NOT "USE "WELDTNGSTUDS OR CLIPS' TO ~SECU RE" LOW'TEHjPERATUBE I^SULfiT'ION'r----------------- -------- -- ' ----------- astlc '`Use LION NOKORODE FIRE- mastic reinforced iroteeglon for all insulation. it. ;0 " Q _1 tX *) ( 0 | 9 - 1-120 -4-riy? - -Aluminum-Jacketing--Use TOl'6 " 'thick aluminum -j ackting^poxy-cearte<f:'cn~^h-o\rtside surface in addition to ^yaa^ier barrier* masrtl'C only'- bn'fportions' of insulation'exposed image,-;by-plant; operations or -fgot-jbxaffic. v DO NOT-tbsE'r. i t6S' HEj^ 'tyE^AL-4SCREWS~JOR" POP~RIVETS_TO SECURE JACKETING. MON'FOR"DUAL---^TEMPERATURE SERVICE "Use insulation -marterxalsTforr-cqld -and-cryogenic temperature service when-process' temperatureg fluctuate -between -100 F and 275 F. When--upper L-emperature in ^he ~cycle-is below -100~For above ; 2 75; F t -ccmsuirt .the-plrantr~fdr features;"-gif|unique -insulation--! - -design;------------------- z~~4,-- -------- ^- "7 7^6 .--"THERMAL'"IN SULAT ION"FORrANT I-CONDENSATION- SERVICE -r~The,;;;, * "^-nEolibwing materials-are"preferred--for "project application to- prevent condensation of moisture on cool or cold surfaces: (1) Cellular Rubber,.Material and available shapes are described :in"'Kll * 2 STD 910. Temperature range is 40 F to 150 F. Use on equipment items, small-diameter (5'-0") vessels# and piping-thru 4". NPS. (2) Cork-Filled Mastic Material and available grades are described in Kll.2 STD 700. Temperature range is 40 F to 275 F. Use on airconditioning supply duct, large diameter vessels, and piping larger than 4" NPS. LION K-KOTE is preferred. 7. THERMAL INSULATION APPLICATION SPECIFICATIONS The following Monsanto Standards are acceptable for projects: (1) K11.4 STD 2, "General Insulation Specification" for all applications. (2) K11.4 STD 10, "Rigid Insulation Systems in Elevated Temperature Service." C 003036" L52.ll NST 1 PAOE 4 <E 4 I ISSUE 2 Monsanto ST ANOAROS 7. THERMAL INSULATION APPLICATION SP (3) K11.4 STD 20, "Rigid Insula Temperatures Service.u AT IONS (continued) 'Systems in Low (4)___K11.4 STD 80nMetal" Jafckfe.tjlngTApplication" for all 8. QUALIFIED CONTRACTORS The following contractors.are_familiar with,plant safety procedures, have experience with Monsanto application ^specifications,, and- are well qualified to apply the typesjof~ thermal insulation preferred-ln plant practice: ..i i i_ _o____ ;____o 3 , -7.- i ! ' :ARMSTRdNS"CONTRACTjING3CO^,-Houston/ Texas - B &l B ENGINEERING CQ^:,0 Houston, Texas - -BALDWIN-EHRET-HILL CO;} Houston,-Texas -: INDUSTRIAL INSULATORS CO., Houston, Texas `'7 JOHNS-MANVILLE .CO., Houston,oTexas ' r-50 i -7u S^REClSlON.INSULATION.CO., Houston, Texas7 i -60 0 ~J i 60 p 5 "t 4G ' i .is -`f 0 :5 ; "_v :r : ,0 ; ~C> =... 1 : 1~ -iij .. - 50 , -S U i zr\ n >-4 0 i 'i " ,, Zi --*- -v- - ..7: -- . f * _J7 * `t - _ ; - 1-0 ^ j0 ` # v; > -J 1 f- j 20 "j lu C tl r ; 40 . -i --^ ", Z- . r ^r .ir,----fir. nT ' .: j. 2, : -. -- ... - - ___ - ___ r 0030^7 Monsanto STANDARDS Painting and Insulation Manual Thermal Insulation Design RECOMMENDED THICKNESS TABLES Texas City Plant MAN. SECT PART Kll.l PST 5201 2issue date 3/70 RAGE 1 OR 2 1. SCOPE This standard presents tables or recommended materials thickness to control temperature of the outside surface of thermal insulation. 2. THICKNESS OF MATERIALS FOR LOW TEMPERATURE SERVICES Tables I and II in this standard show minimum temperatures at which single and double layers of insulation materials preferred for the Texas City Plant can be used to prevent condensation of moisture on the insulation surface under 40 F, 85% R. K. ambient conditions. Thicknesses in these tables do not necessarily coincide with those required when process requirements inpose a minimum permissible rate of heat gain to the process fluid. Calculate thickness requirements when this design criterion prevails. TABLE I MINIMUM TEMPERATURES FOR POLYURETHANE USE. SEE NOTE 2. NFS NOMINAL INSULATION THICKNESS Sinale Laver Double Laver 1" 1 IV 1 2" I' 2*s" J 3" 3*s" i 4" 1 4*5" 15" 1 5*5" 1 6" h 0 -60 -120 -170 -260 -300 3/4 0 -60 -no -150 -250 -280 -320 1 10 -40 -85 -no -210 -260 -300 1*5 10 -30 -80 -no -180 -280 -310 2 10 -30 -80 -no -160 /-250 -280 -310 3 20 -15 -60 -90 -no -220 -280 -310 i o00 4 30 -10 -55 -100 -180 -260 -300 6 30 -10 -45 -75 -100 -120 -240 -300 . S 30 -10 -30 -60 -80 -no -210 -30(7 10 30 -10 -30 -60- -80 -no -200 -280 -330 12 30 -10 -30 -60 -80 -no -200 -26a -320 14 30 -10 -30 -60 -80 -100 -200 -240 -300 16 30 -10 -30 -60 -80 -100 -180 -200 -280 -320 18 30 -10 -30 -55 -80 -100 -160 -180 -260 -310 20 30 -10 -30 -55 -75 -100 -150 -170 -240 -300 24 30 -10 -30 -55 -75 -100 -140 -160 -220 -280 30 30 -10 -25 -55 -75 -100 -130 -150 -200 -250 36 30 -10 -25 -55 , -75 -95 -125 -150 -180 -240 1 FLAT 40 o ________ !______________________________________________________ . -20 -5.0,-] '-75 ...--90-1 -120 -140 1 -160 -220 l -270 1 NOTESS (1) Calculate thickness required to hold heat gain to process fluid within design limits. (2) Ambient conditions are 40 P, 85% R. H. SOURCE HF.n STDS. CEA 0517. - ______ C 003058 *11.1 PST 5201 *AG* 2 or 2 issue 2 Monsanto STANOAROS TABLE II MINIMUM TEMPERATURES FOR CELLULAR USE. SEE NOTE 2. NPS NOMINAL INSULATION THICKNESS Sinale Laver Double Laver 1" IV 1 2" 1 2ku 1 3" 3*5" 1 4" 14V' 15" |5V` 16" % 40 20 0 3/4 40 30 10 1 40 30 10 l*s 50 45 20 2 50 45 20 3 55 45 20 4 55 45 30 6 60 45 30 8 60 45 30 10 60 45 30 12 60 45 40 14 60 45 40 16 60 50 40 18 60 50 40 20 60 50 40 24 60 50 40 30 60 55 40 36 60 55 40 -20 -50 -105 -10 -50 -95 -130 -10 -50 -80 -110 / 0 -40 -60 -75 -110 0 -30 -55 -65 -110 10 -20 -40 -60 -95 -120 20 -10 -30 -50 -85 -100 20 0 -20 -40 -60 -85 -90 -130 20 0 -10 -30 -50 -70 -80 -110 20 0 -10 -30 -40 -65 -75 -100 30 10 0 -20 -35 -40 -70 -90 0 --1 1 30 15 0 -30 -35 -60 -80 30 15 0 -10 -25 -35 -60 -75 30 15 0 -10 -25 -35 -55 -75 30 15 5 -10 -20 -35 -45 -70 35 15 10 -10 -20 -35 -45 -70 35 20 10 -10 -15 -35 -45 -60 35 20 10 0 -10 -35 -45 -60 I FLAT I 60 1 55 45 35 20 I 10 I 0 -10 1-20 I -30 1-50 I NOTESt (1) Calculate thickness required to hold heat gain to process fluid Within design temperature limits. (2) Ambient conditions 4085% R. H. C 003059 Monsanto COATINGS AND INSULATION MANUAL THERMAL INSULATION OESIGN MATERIAL SYSTEM SELECTION GUIDE MAN.SECT PART K11.1 STD 1 ISSUE 4 date 1/85 PAGE 1 OF 18 1. SCOPE This information standard out lines the selection and design procedures for thermal insulation, and discusses some of the considerations governing successful performance of insulation.. 2. DESIGN PROCEDURE The essential steps in thermal insulation selection and design (1) Determine whethef^"Insulation is required (Par. 3). (2) Obtain application data;(P|i|^ 4). (3) Select ' appropriate/insulation mate rial (Par. 5). " , " (4) Determine how much insulation is required (Par. 6). (5) Verify material selection, select barrier materials for a complete system (Par. 7). -~ (6) Properly identify final selection on drawings, in schedules, and in sum maries. (7) Establish construction details (See K11.4 standards). 3. INSULATION FUNCTION Thermal insulation simply reduced heat flux out of - hot sur faces or into cold surfaces. Because it is expensive to install and maintain, insulation must pay for itself in at least one of the following ways: (1) Utility Conservation Every heat flux represents a loss of energy. Most of these losses represent a cost increment in fuel, electrical power, cooling water, and other utilities. (2) Equipment Economy Unwanted heat losses may require oversizing heat exchangers, distillation columns, pipelines, etc., simply to make up for the loss - which may, in some cases, be a significant fraction of process heat flux. (The alternative to oversizing may be yield loss or product degradation from excessive heating and/or pressure drops in the equipment.)3 (3) Process Protection Heat flux requires temperature gradients in equipment walls and fluid contents. Undesirable effects of these gradi ents may include: . . .crystallization or other depos its on the walls. . . .viscosity changes or product degradation. . . .vaporization losses (in cold service). (4) Fire Protection Insulation may ser.ve. tne primary or secondary pur pose - of protecting equipment and structures from early loss of strength during a fire - at least . long enough to permit fighting the fire to bring it under control. (5) Personnel Protection Where the foregoing considerations call for no insulation, or not enough, insula tion must be added only in those areas where operating and mainte nance personnel are likely to con tact the hot surfaces. (See Par. 5.1.6). (6) Insulation and Plant Protection in cold service, insulation must be thick enough, regardless of the above considerations, to prevent deterioration and premature failure due to moisture attack. in chilled" service, insulation may be required to avert the housekeeping and maintenance expenses resulting from sweating and dripping. This requirement is most likely to apply in controlled environments. 3.1 Noise Control The use of insulation materials to absorb noise emitted from piping and equipment is a specialized sub ject not covered in this Selection Guide. Consult an expert in the noise control field. 4. APPLICATION DATA Prior to selection of insulation, the following kinds of data should be compiled to minimize the risk of picking an insulation system in the dark: (1) Surface Temperature Range Use tem perature of contents unless a dif ferent temperature can be reliably specified. Note any rapid or extreme temperature fluctuations or cycling. For low temperature applications, determine whether the system will be heated under some circumstances, and list the maximum as well as minimum temperature. (2) Limits on Permissible Heat Flux These are process-imposed require- , ments which should be in performance data. In most instances, no spe cific limit will be imposed. SOURCE T.F. STANLEY 14-6942) ILATEST ADDItTonToR*REVISIONS AflESHOWN BY I OToutlining. deletions are Shown by C 002238 K 11.1 PAGE 2 STO 1 (issue 4 Monsanto STANOAROS (3) Critical Temperature Limits Same considerations as in Item (2) above. (4) Critical Environmental Conditions These are normal temperature and relative humidity, indoors. Out doors, the critical conditions for hot and cold services are discussed in Par. 5.1.1 through 5.1.6. Con sider possible wind damage. (5) Operating Department Data Consider " lre hazard, possible leakage of ' flammable materials into insulation, washdown practices, possibility of hose stream impact during a fire, etc. Consider also possible Mabuse; foot, vehicle `braffic, vibration, mechanical' shock. -; (6) Economic Data See normal values in Monsanto tI.IQ STD 11, List 8. These factors are required to choose economic insulation thickness. Actual economic values, if availa ble , may be substituted for normal factors. 5. INSULATION MATERIAL SELECTION Assuming a preliminary determination has been made that insulation is required (refer to Table I) entering at the appropriate sur face temperature range. Observe remarks on Use and Limitations. If a Table II reference is given, review the general considerations in Par. 5.1 before select ing an insulation material. The preferred (bold-face) material will be the most eco nomical selection unless one or more gen eral considerations forces an alternative selection. It is recommended that all insulation selections be reviewed at an early project stage with the Thermal insulation Special ist. The process will be more efficient, .and considerations can be evaluated on a broad basis of experience. 5.1 General Considerations In Table II, each material li characterized with respect to six considerations which may, in some cases, have a decisive effect on TABLE I. PRELIMINARY INSULATION SELECTION Surface Temperature F C Below -100 Below -73 Above -100 Above -73 To -50 To -46 Above -50 To 0 Above -46 ' To -18 Above 0 To 40 Above -18 To +4 Above 40 Above 4 To 140 To 60 Above 140 Above 60 To 450 To 235 Above 450 Above 235 To 1200 To 650 Above 1200 Above 650 .t Remark on Use and Limitations Refer to Table No standard insulation system can be generally recommended. Consult insulation specialist. -- Design and construction methods are critical. Consult insulation specialist. II A Close adherence to all material and installation details is essential to avoid rapid deteriora tion. II .B Same as above. Outdoors, above 32 F (0 C) it may occasionally be possible to omit insulation. II C Insulate only if required by speci fic process or plant protection function. II D Optimum selection and application will result in greatest cost ' reduction. II E Double layer insulation usually specified above 600 F (305 C); in any case, specify on drawings and summary. . II F No standard insulation system can be generally recommended. Internalinsulation or refractory lining should be considered. Consult insu lation specialist. -- C 002239 Monsanto STANDARDS Kll.l' STD ISSUE 4 PAGE 1 3 performance, safety, or economy. The pre ferred (bold-face) insulation material should be selected unless application data Materials of high compressive strength are first choice where vehicle damage or foot traffic must be reckoned with. Top heads developed in Step 2 (Par. 4) indicates another choice.. . .. of vessels with agitators usually require consideration. Insulation used to support 5.1.1 -Thermal Performance The key con sideration is thermal conductivity--(tabu flat bottomed vessels must be of high com pressive strength. lated here for a single representative temperature). Stability of this value with respect to 'ige, moisture content, etc., is noted. Maximum temperature limits are given, where significant. For infrequent cases where specific heat, dif- 5.1.4 Economics Systems offering the lowest installed cost for a given heat flux are listed in bold-face type. Others are selected only where process or perfor mance considerations are over-riding. fusivity, or thermal shock limitations may apply, see Monsanto Kll.l STD 3. 5.1.5 Moisture Problems Most types of insulations, except those with closed-cell , r. . construction,: have high tester absorp- 5.1.2 Chemical interactions Tnere are tivity. For elevated temperature service, three types of interaction: the barrier system must be permeable enough to vent moisture vapor, yet resist (1) Insulation materialaffectsinsu- ' passage of liquid water. For low- lated surface. temperature service moisture in all forms must be excluded by an impermeable bar- (2) Process contents deteriorate insula- rier, and the barrier must be mechanically tioh. -or-str. ,'3KabJ.e. Low-temperature lines should ^always be located above-grade or in ser (3) Flammable contents are degraded by vice tunnels if feasible. High- insulation11'' (spontaneous combustion temperature lines may be routed above risk). ^ grade or well-drained, ventilated trenches or tunnels. High-temperature lines insu A number of insulating materials can lated for direct burial represent .a spe release halides enough to cause stress cialized problem not covered by standards. corrosion cracking of austenitic stainless alloys. These are noted. 'Any alkaline 5.1.6 Safety Considerations ~ One safety insulation"Can attack aluminum, especially hazard is mentioned in Par. 5.1.2. This when moist; " - - is not a major risk. Others more often 'encountered are: Nearly " all insulations are attacked by strong acids and alkalis. No special note (1) Fire damage protection is made, since * most'of surroundings are also attacked. Special note is made where (2) Safe surface temperature solvents deteriorate the insulation. Cases have been reported in which flamma (3) Toxic contamination ble liquid leakage has been absorbed by The first problem is significant if it is insulation. Later, when hot insulation determined that equipment or piping was breached for repair work, flames were requires protection (time delay) from high noted. Contributing factors have not all temperature of a fire, and the thermal been identified, but it may be prudent to insulation is relied on for part or all of avoid - some insulation materials on lines this protection. In such cases, ability and equipment containing flammable liquids of the insulation system to withstand heat in areas classified `as Division 1 with effects and mechanical impact of water respect to electrical' installations. hose streams will be major considerations is selection. Aside from designing insu 5.1.3 Mechanical Durability In some lation for fire protection, it will be applications, the completed insulation desirable in some cases to avoid insulat system must withstand unusual loadings or ing materials which have a high flame possible abuse. If-a mechanically durable spread index, or will add fuel to the fire. insulation cannot be used, shielding or guarding may be neessary. The second consideration applies mainly where people can contact the insulation Wind forces impose special support and inadvertently (e.g., unprotected skin of attachment . requirements in applications back or upper arms). Informal experiments where uplift--or suction can become signif icant. Loads on, farrier membranes may be particularly hard to sustain. -indicate that painted-- metal surfaces or painted metal insulation jackets should be limited to 140 F max. in areas of person nel exposure. Bare unpainted metal should Vibration and mechanical shock loadings also impose special support and attachment problems, particularly on rotary dryers or blenders, oscillating equipment such as sifters, and hoppers, chutes, or ducts fitted with vibrators to facilitate bulk material flow. be held to 130 F. Non-metallic piping and insulation surfaces can be permitted up to 160 F. Metal surfaces in areas of low hazard and infrequent personnel contact (e.g., yard, piping near grade and storage tank farms) can be permitted to reach 160 F. Surfaces above these temperatures r 00D24Q K11.1 STD 1 PAGE 4 | ISSUE 4 ~ Monsanto STANOARDS should be controlled by insulation only in increased (25 ft. and higher). A survey areas where personnel contact is reasona of storm damages and recommended design bly likely, (if portable ladders or scaf improvements,concluded the following: folds are needed for access, temporary safeguards may be provided at that time.) (1) Minimum thickness of aluminum insu~ -- elation - jacket (1 1/4" corrugated) The final hazard . - contamination of the insulation... by _ toxic leaks and spills must be dealt with on a case" basis. Does" the need to handle insulation aggravate an exposure problem? what disposal and should be .024". -l K *' ` ! 11 ** '1 (21 "Band-spacing should be 12" with 4* expansion spring at 25 foot inter vals. decontamination problems are involved? Should insulation be omitted - or perhaps be provided with a barrier around the (3) Use weld construction (.063* alumi num) for fabricated components. installation? (4) Use 3/16" diameter structural 6. HURRICANE DESIGN .2n_ia83,--the chemical- __________"cherry T rivet" at 6* spacing for and oil refinery plants in the Houston i-rr,..Z joint closure.. ,,.,,pn , area sustained severe insulation damages, from Hurricane Alicia. Insulation damage increased as vessel diameter increased (25 ft.^and larger) and as height above ground The 'above design criteria should be con sidered ' for coastal locations such as Alvin, Texas City, Luling and Pensacola. ! f nr - -Vt-s 5 r- ' " c 002241 Monsanto STANDARDS K11.1 STD ISSUE 4 PAGE 1 5 TABLE II A Temperature Range -100 to -60 F 1-73 to-46 C) Insulation Standard K11.2 STD 8 - POLYURETHANE k = 0.17 at -76 F Excellent thermal properties. 200 F limit when system is heated (e.g.. for process clean out). TABLE II B Temperature Range -50 to OF (H to -18C) Insulation Standard K11.2 STD 8 - POLYURETHANE Insulation Standard K11.2 STD 10 - CELLULAR GLASS k = 0.18 at-25 F k =0.31 at -25 F Excellent thermal properties. 200F limit when system is heated (e.g., for process clean out). Requires 2 to 3 times the insulation thickness compared with system 8. THERMAL * CONSIDERATION No reaction'between insulation and substrate. No reaction between insulation and substrate. No reaction between insulation and substrate. CHEMICAL CONSIDERATION CONSIDERATION CONSIDERATION CONSIDERATION 'z ^l2 <w 'iS Z ui <Q Im Oz io *jo Medium compressive strength;-- may require metal Jacket application to improve resistance from external mechanical forces (foot traffic and bumps). ECONOMIC Use sectional shapes for pipe; block construction is applicable where total insulation equipment requirements are less than 500 square feet and sprayed foam for ' areas greater than 500 square feet. Where feasible provide a shelter from rain to extend life and retard heat flux. ___ .. Medium compressive strength: . , may require metal jacket '' application to improve resistance from external mechanical forces (foot traffic and bumps). For equipment support consider K11.2 STD 10. Highxompressive strength. Use sectional shapes for pipe; block construction-is applicable where total insulation equipment requirements are less than 500 square feet and sprayed foam for - areas greater than 500 square feet. Where feasible provide a shelter from rain to extend life and retard heat flux. ........... Installation cost of cellular glass systems are 50 to 100 percent greater than polyurethane. Where feasible provide a shelter from rain to extend life and retard heat flux. MOISTURE , SAFETY Material is combustible; rated self-extinguishing. Interior spray application requires ventilation or respiratory equipment. Block construction for vessels requires insulation support hardware; reference D03-2004. Support hardware not required^___ for spray application. Material combustible; rated self extinguishing. Interior spray application requires ventilation or respiratory equipment. For fire resistance consider addition of non-combustible insulation over polyurethane. Non-combustible. Block construction for vessels requires insulation support hardware; reference D03-2004. Support hardware not required for spray application. .----- Do not use on vibrating equipment. REMARKS * Thermal conductivity (k) units are Btu in. thk/hr ftJoF. c 002242 CONSIDERATION CONSIDERATION CONSIDERATION CONSIDERATION CONSIDERATION CONSIDERATION K11.1 STD t PAGE - 6 | ISSUE 4 Monsanto STANDARDS TABLE II C THERMAL * ECONOMIC. < MECHANICAL ' CHEMICAL Insulation Standard K11.2 STD 8 - POLYURETHANE k = 0.17 at20F Excellent thermal properties. 200F limit when system, is treated (e.g., for process clean out). Temperatm Range 0 to 40F {-18 to 440 Insulation Standard .K11.2 STD 7 - CELLULAR PLASTIC k = 0.24 at 20F Insulation Standard K11.2 STD 10 - CELLULAR GLASS k = 0.33 at 20F Requires 2 to 3 times die insulation thickness as compared to polyurethane or cellular plastic insulation for comparable insulation value. No reaction between insulation ` and substrate. " No reaction between insulation anid substrate. Typical interior installations do not include a jacket covering end a solvent or plasticizer environment destroys .theinsulation. No reaction between insulation and substrate. Medium compressive strength; ~ .may require metaLjacket applies;' , tion to improve resistancetrom > sexternal mechanical forceslfoot traffic and bumps). For equipment support consider K11.2 STD to. Cellular sponge construction with .low.compressive strength.,___ ,,_____ ucfo =oct>- ` K'Ch CC High compressive strength. Use sectional shapes for pipe; block .construction is applicable___ where total insulation equipment " requirements are less than 500 square feet and sprayed foam for areas greater than 500 square feet. For small diameter pipe consider K11.2 STD 7. Low cost system for interior pipe and tubing to 2 inches nominal diameter; cost greater than polyurethane insulation for exterior appl ication. Where feasible provide a shelter from rain to extend life and retard heat flux. Where feasible provide a shelter from rain to extend life and retard heat flux. Installation, cost of cellular glass systems are 50 to 100 percent greater than polyurethane or cellular plastic insulation. Where feasible provide a shelter from rain to extend life and retard heat flux. ' MOISTURE SAFETY Material is combustible; rated self-extinguishing. Interior spray application requires ventilation or respiratory equipment. For fire resistance consider addition of non-combustible insulation over polyurethane. Material is combustible; rated self-extinguishing. Avoid application in concealed ceiling space. Block construction for vessels . 2 requires insulation support hardware; reference D03-2004. Support hardware not required for spray.application.- .. Sheet material is available for irregular shape equipment application (refrigeration compressors, instruments, etc.). * Thermal conductivity (k) units are Btu in. thk/hr tt*F. Non-combusti bl e. Do not use on vibrating equipment. C 002243 Monsanto STANDARDS TABLE II D K11.1 STD ISSUE 4 PAGE 1 7 CONSIDERATION CONSIDERATION CONSIDERATION THERMAL * CHEMICAL MECHANICAL Insulation Standard K11.2 STD S FIBROUS GLASS k = 0.23 at 70 F -1 Temperature Range 40 to 140F (4 to 60C) Insulation Standard K11.2 STD 7 CELLULAR PLASTIC Insulation Standard K11.2 STD 8 POLYURETHANE k = 0.26 at 70 F k = 0.17 at 70F Excellent thermal properties. ^arsperanure or -*i Insulation Standard K11.2 STD 10 CELLULAR GLASS k = 0.37 at70F . ,, _ --------------------------------------------------^ -r- - 1 _---------------- . , No reaction between in- _ No reaction between insulation and substrate. Typical interior installations do not include a - jacket covering and a -- solvent or plasticizer environment destroys the Insulation. Cellular sponge con- -struction with low .- compressive strength. i - -- Medium compressive strength; may require metal jacket application to improve resistance from external mechanical forces (foot traffic and bumps). No reaction between insulation and substrate. High compressive strength. Low cost system. Low cost system for interior pipe and tubing to 2 inches nominal diameter; cost greater than polyurethane or fibrous glass for exterior application. Use sectional shapes for pipe; block construction - is applicable where total insulation equipment re quirements are less than 500 sq ft and sprayed foam for requirements greater than 600 sq ft. Poly urethane cost usually higher than fibrous glass or cellular plastic. Installation cost of cellular glass is 50 to 100 percent greater than other insulation materials in this temperature range. For operating temperatures of 30 to 70 F and a relative humidity range of 70 to 100 percent use K11.2 STD 8, Polyurethane Insulation or K11.2 STD 7. Cellular Plastic Insulation. Good performance in high humidity environments. . Good performance in high humidity environments. Glass fibers are non combustible; contains small amount of resin binder which is combustible. Material is combustible; rated self-extinguishing. Avoid application in concealed ceiling space. Material is combustible; rated self-extinguishing. Interior spray application requires ventilation or respiratory equipment. Non-combustible. ECONOMIC CONSIDERATION MOISTURE SAFETY CONSIDERATION CONSIDERATION 1 REMARKS Integrity of vapor barrier must be maintained or the system wilt fail. Sheet material is avail able for irregular shape equipment application (refrigeration compressors, instruments, etc.). Block construction for vessels requires insula tion support hardware; reference D03-2004, Support hardware not required for spray appli cation. Do not exceed 200 F for equipment or pipe clean-out operation. * Thermal conductivity (k) units are Bhi in. thk/hr ft,0F. Do not use on vibrating equipment. C 002244 K T 1.1 PAGE STD 1 | ISSUE 4~ TABLE II E Monsanto STANDAROS THERMAL * CONSIDERATION Insulation Standard K11.2 STD 6 FIBROUS GLASS k = 0.31 at 250 F Temperature Range 140 to 460F (60 to 236C) Insulation Standard K11.2 STD 8 CALCIUM SILICATE Insulation Standard K11.2STO 9 MINERAL FIBER Insulation Standard K11.2 STD 10 CELLULAR GLASS k = 0.40 at 260 F k = 0.28 at 250 F k = 0.60 at 250 F Hygroscopic, k greatly increased, by moisture. -s.sruij Ot M For thermal shock application consult insulation specialist. Insulation Standard K11.2STD 11 EXPANDED SILICA k = 0.40 at 250 F Insulation pH about will corrode alumi-' hum rapidly. AISoTwet insulation wilt-- jnitiate stress cor- ---- rosion of austenitic stainless steel. ---- See K1.1 STD 2. ------- --------- -- Adequate com- --- Good compressive-- Adequate com pressive strength. strength. pressive strength. High compressive strength. Good compressive strength. CHEMICAL CONSIDERATION MECHANICAL CONSIDERATION s a f e t y' CONSIDERATION ECONOMIC CONSIDERATION MOISTURE CONSIDERATION Usually lowestcost system in this temperature range. " Calcium silicate ` installation cost----- usually higher than fibrous glass or mineral fiber; equal in cost as compared to expanded silica; cost less than cellular glass insulation. Mineral fiber' installation cost-----usually higher than fibrous g'lass; how ever, cost is less than other insulation listed within this temperature range. Installation cost of cellular glass systems are 50 to 100 percent higher than other insula tion systems listed in this temperature range. High water absorptivity. High water absorptivity. High water . ^ absorptivity. Very low water absorptivity. Glass fibers are non-combustible; contains small amount of resin binder which is combustible. Non-combustible. Non-combustible. Noncombustible. Installation cost of expanded silica usual ly compares favorably with cost of calcium silicate systems. Low water absorp tivity to 375 F. Insulation formula tion contains a water repellent which degradates at temperatures above 375 F. Non-combustible. REMARKS * Thermal conductivity (k) units are Btu in. thk/hr ft10?. Water that enters the insulation system through the weather barrier tends to remain within the insulation system and will cause ' severe corrosion. Water that enters the insulation system through the weather barrier tends to remain within the insula tion system and will cause severe corrosion. C 002245. Monsanto STANDARDS Insulation Standard K11.2 STD 9 - MINERAL FIBER k = 0.40 at 600 F TABLE II F K11.1 STD ISSUE 4 PAGE 1 9 Temperature Range 4S0 to 1200 F (23S to 650 C) Insulation Standard K11.2 STD 6 - CALCIUM SILICATE k = 0.50 at 500 F Hygroscopic, k greatly increased by moisture. Insulation Standard K11.2 STD 11 - EXPANDED SILICA k = 0.52 at 500F THERMAL CONSIDERATION 2 si s Ou X <75 O2 O U . ryr--, 'I Adequate compressive strength. ; -- - - " -- Good compressive strength. Good compressive strength. MECHANICAL ECONOMIC Usually lowest cost system in tills temperature range. Installation cost of calcium . silicate is usually higher than mineral fiber systems. Installation cost of expanded silica compares favorahle with calcium silicate systems. -High water absorptivity. High water absorptivity. Very low water absorptivity to 375F. Water repellent degrades above 375 F. 'Non-combustible. Non-combustible. Non-combustible. MOISTURE CONSIDERATION CONSIDERATION CONSIDERATION CONSIDERATION SAFETY | REMARKS ' '' - ........ ............... -- * Thermal conductivity (k) units are Btu in. thk/hr ftaoF. C0Q224C- K 11.1 ' ' STD* i PAGE 10 ISSUE 4 " Monsanto STANOAROS 7. INSULATION THICKNESS Insulation thick ness tor the Thermal Insulation System Specification standards are shown in Table III as a convenience to the user who may need approximate data. Each tabulation shows the design conditions. The design conditions for elevated temperature ser vice are based on a maximum outer surface temperature limit of 140 F with an ambient temperature of 70 F and a wind velocity of 3 mph. Design conditions for low tempera ture service are noted in the thickness tables. TABLE III A. INSULATION THICKNESS (IN.) ------Rigid Fibrous Gloss System --K11.2 STD 5 Nominal Pipe - Size (in.) 30 to .100 iOOj to 149 Temperature of Pipe, up 150 200 250 to ~ ' to' to 199 249 ' '299 300 to 349 350 to 399 1/2 - 3/4 1 Us -------2------------ ----- 3 ------- -- -------- 4 6 8 -------- 10- ~ :~*r curs c f Pis >1 1 pipe sizes and temperature ranges -- -..indicated. -------- -- 12 14 " 16 18 - ------20 22 24 - * - - 400 to 450 ,* - Note: - ----- - (1) Insulation thickness is based on design conditions to hold the temperature of the insulation surface to 140 F ----- maximum, at ambient-conditions-of 70 F and a 3 mph wind, for a temperature range.of 150 F to 450 F. if 002247 Monsanto K11.1 STD ISSUE 4 PAGE i ii TABLE III B. INSULATION THICKNESS (IN.) Calcium Silicate System - K11.2 STD 6 Nominal -Pipe SiZ6 "/fn ~S 1/2 3/4 1 1>S 2 3 4 6 8 10 12 14 16 18 20 24 100 -to 199 1 1 1 1 1 1 1 1 Us Us l% 1*5 1*5 1*5 1*5 1*5 Temperature of Pipe, p | 200 300 400 500 600 700 800 900 1000 1100 to to to to to to to to to to 299 399 499 599 699 799 899 999 1099 1200 1 " 1 1 1*5 2 2 2 2*s 2% 2*s 1 - 1 1*5 1*5 2 2 2*1 2*5 2*5 3 1 1 1*5 lS* 2 2 2* j* Wiwmmm1 1 1*5 i*5 2 2 2*5 1 1 1*5 lJS 2 2*5 2*s Kail; 1 1 _ 1*5 2 2 2*5 1 1 1*5 2 2*5 ills 111 Sill 1 1 1*5 ,2 21*5 1*5 1*5 Ml 1*5 1*5 1*5 1*5 ! 1*5 1*5 1*5 1*5 1*5 1*5 1*5 1*5 1*5 1*5 1*5 1*5... 1*5 1*5 1*5 1*5 1*5 Notes: (1) Insulation thickness is based on design conditions to hold the temperature of the insulation surface to 140 F maxi mum, at ambient .conditions of 70 F and a 3 mph wind. (2) Insulation thickness shown in shaded area is double-layer, staggered joint construction. 002233 K11.1 STD PAGE 12 1 ISSUE 4 Monsanto TABLE III C. INSULATION THICKNESS (IN.) Cellular Plastic System - K11.2 STD 7 Nominal Temperature of Pipe (F) Pipe Size (in.) 0 15 to to 04 29 30 to 44 45 to 59 60 75 90 to to to 74 39 105 1/2 3/4 3/4 1/2 3/8 3/4 3/4 3/4 1/2 3/8 1 3/4 3/4 1/2 1*5 3M 3/4 3/2 ~z7W -2-------- -3/4- -3/4. 1/2 3/8 3 '3/4 3/4 l/2 3/8 4 3/4 3/4 T7T 1/2 6 3/4 3/4 1/2 1/2 Flat Surface 1 -- 1-- -3/4 1/2 Insulation thickness is based on condensation prevention of indoor piping, at a maximum ambient severity of 85 F and 70% relative humidity. Nominal Pipe Size (in.) 1/2 3/4 1 1*5 2 3 4 6 Flat Surface Tenperature of Pipe (F) 0 15 30 45 60 75 90 to to to * to to to to 14 29 44 59 74 89 105 1/2 3/8 3/8 3/8 1/2 3/8 3/8 3>8 1/2 3/8 3/8 3/8 !/2 3/8 V8 "370 1/2 3/8 V8 3/8 1/2 Vi !/2 1/2 1/2 1/2 1/2- -1/2 1/2 1/2 1/2 1/2 1/2 3/8 3/8 3/8 Insulation thickness is based on condensation prevention of indoor piping, at a maximum ambient severity of 80 F and 50% relative humidity. Nominal Pipe Size (in.) !/2 3/4 1 1*5 2 3 4 6 Flat Surface Temperature of Pipe (F) 0 15 30 45 60 75 90 to to to to to to to 14 29 44 59 74 89 105 - 3/4 3/4 _ 3/4 3/4 - - 3/4 3/4 - - 3/4 3/4 - - 3/4 3/4 - - 3/4 3/4 - - 3/4 3/4 - - 3/4 3/4 -` - 1 3/4 Insulation thickness is based on condensation prevention of indoor piping, at a maximum ambient severity of 90 F and 80% relative humidity. C 002249 ytiisii mama Monsanto STANDARDS K11.1 STD ISSUE 4 PAGE i 13 TABLE III D. INSULATION THICKNESS (IN.) Polyurethane System - K11.2 STD 8 - Nominal Pipe Size (in.) -100 to -76 Temperature of Pipe . F -75 -50 -25 0 25 to to to to to -51 -26 -1 24 49 1/2 1*5 1*5 1 1 1 1 3/4 1*5 1*5 1*5 1 1 1 1 1*5 1*5 1*5 1 1 1 1% 1*5 1*5 1*5 1 1 1 2 1*5 1*5 1*5 1 1 1 3 1*5 1*5 1*5 1 1 4 1*5 1*5 1 1 6 9p 1*5 1*5 1 .1 8 Sa* PE 1*5 - ~i*r 1~ 10 ..... - 12 1*5 1*5 1 lUl 1*5 1*5 1 14 " 16 HP* 1*5 1*5 1 *^**l53 2 1*5 1 "Flat 2 1*5 1 Surface JSSEgt 50 to 74 1 1 1 1 1 1 1 1 1 1 1 1 1 1 75 to 100 i l l l l i l l l l l i i l Notes: (1) Insulation thickness is based on condensation pre vention at a maximum ambient severity of 90 F and 80% relative humidity. ~(2) insulation thickness shown in shaded area is double layer, staggered joint construction. TABLE III E. INSULATION THICKNESS (IN.) Rigid Mineral Fiber System - K11.2 STD 9 Nominal Temperature of Pipe, F Pipe 100 200 300 400 500 600 700 800 900 1000 1100 (in.) to to to to to to to to to to to 199 299 399 499 599 699 799 899 999 1099 1200 2 1 1 1 1% 1*5 2 2*5 2*5 3 3 3*5 3 1 1 1 1*5 2 2 2*5 3 3 3*5 3*5 4 1 1 1 1*5 2 2*5 2*5 3 3 3*5 4 6 1 1 1 1*5 2 2*5 3 3 3*5 4 4*5 8 1*5 1*5 1*5 1*5 2 2*5 3 3*5 ,4 4 4*5 10 1*5 1*5 1*5 1*5 2 2*5 3 3*5 4 4*5 5 12 1*5 1*5 1*5 1*5 2 2*5 3 3*5 4 4*5 5 14 1*5 1*5 1*5 1*5 2 2*5 3 3*5 4 4*5 5 16 1*5 1*5 1*5 1*5 2 2*5 3 3*5 4 5 5 18 1*5 1*5 1*5 1*5 2 2*5 3 3*5 4% 5 , 5 Flat 1*5 1*5 1*5 1*5 2 2*5 3 3*5 4*5 5 5 Surface Note: _____ (1) insulation thickness is based on design conditions to hold the temperature of the insulation surface to 140 F maximum, at ambient conditions of 70 F and a 3 mph wind. C 002250 K11.1 STO PAGE 14 1 ISSUE 4 TABLE III F. INSULATION THICKNESS (IN.) Cellular Gloss System - K11.2 STD 10 Nominal Pipe -50 -25 0 (in.) to to to -24 -T 24 Temperature of Pipe, op 25 50 75 100 125 150 175 200 225 to to to to to to to to to 49 74 99 124 149 174 199 224 250 1/2 2*5 2 US 1 1 1 1 l 1 1 1 1 3/4 3 2*5 2 1*5 1 1 1 l 1 1 1 1 1 3 2*5 2 US 1 1 1 l 1 1 1 1 Us 3 3 2*5 2 Us 1 1 l 1 1 1 1 2 3 3 2*s 2 Us 1 1 l 1 1 1 1 3 :"3^ 3 2h 2 Us 1% 1 1 1 1 1 1 4 '3% ?? 3 2*5 2 Us Us lk l 1 1 1 1 6 3 2% 2 Us lk lk i*s 1*5 l*s 1*5 1*5 8 3 2 1*S Us lk lk 1*5 1*5 1*5 1*5 10 3 2% 1% Us lk ik 1*5 1*5 1*5 1*5 12 ';3VS 3 2*s u$ Us lk lk 1*S 1*5 1*5 1*5 14 4%~ 3 ' 2*5 Us Us lk lk 1*5 1*S 1*5 1*5 Plat r4h * ,-4%/x 3 2k Us Us lk ik 1*5 1*5 1*5 1*5 Surface Notes: (1) Insulation-thickness is based on condensation prevention at a maximum ambient severity of 90 P and 80% relative humidity for low temperature application, insulation thickness for elevated temperature service is based on design conditions to hold the ... 1 temperature of the insulation surface to 140 F maximum, at ambient conditions of 70 P and a 3 mph wind.. . (2)--lnsulatrion~thiclcness shown in shaded area is double-layer staggered joint construction. Monsanto STANDARDS TABLE III G. INSULATION THICKNESS (IN.) Expanded Silica System -- K11.2 STD 11 Nominal Temperature of Pipe, P Pipe Size (in.) 100 200 300 400 500 600 to to to to to to 199 299 399 499 599 699 700 800 900 1000 1100 to to to to to 799 899 999 1099 1200 1/2 1 1 1 1 Us 2 2 2 2*s 2% 2*j 3/4 1 r 1 1*5 1*5 2 2 2% 2% 2% 3 1 1 l 1 1*5 1*5 1*5 1 l 1 1*5 1*5 2 1 l 1 1*5 1*5 2 2k 2k 3 1 l 1 1*5 2 2 2k 4 1 l 1 1*5 2 6 1 l 1 1*5 2 k-8 1*5 1*5 l*s 1*5 '2*5^ 10 US 1*5 1*5 1*5 12 - 1*5 1*5 1*5 1*5 2 14 16 18 Plat 1*5 i*5 1*5 1*5 2 1*5 1*5 1*5 1*5 2 lim iSii 1*5 1*5 1*5 1*5 2 ^SSs wSSlillliPI 1*5 1*5 1*5 1*5 2 *jKI3Rr jsregg i^a Surface Notes: 7 "' ' (1) Insulation thickness is based on design conditions to hold he the temperature of the insulation surface to 140 F maxi mum, at ambient conditions of 70 P and a 3 mph wind. (2) Insulation thickness shown in shaded area is double-layer, staggered joint construction. ___ f-i ppryor-t Monsanto ' K11.1 STD ISSUE 4 PAGE i 15 8. BARRIER SELECTION The Thermal insula tion System Specifications contain barrier materials identified by symbols. The sym bol identifies the major material of con struction for the pipe or vessel and, in addition, identifies minor materials of construction for fittings, valves, pumps, etc. The symbols and corresponding bar rier materials are listed in Table IV. The use and application of the barrier symbols for drawings and schedules are described in Kll.l STD 2. Table V. Barrier Materials shows selective barriers for the Thermal Insulation System Specifications. The tables are developed based on available manufacturer's stan dards and typical usage for pipe, equip ment, and duct work. A numerical cost index is shown which compares cost of the various barrier systems for each Thermal Insulation System Specification. The low est cost barrier is identified by number "l*, and as barrier cost increases, numer als increase. The cost index is a rela tive guide only and should not be used for direct cost comparison. Select the lowest cost barrier for which an "X" appears in the columns representing the particular design conditions. I TABLE IV. BARRIER MATERIALS AND SYMBOLS Symbol CF CG CJ CANVAS FABRIC BARRIERS Material 8 oz canvas Pre-sized glass cloth, 7.8 oz per sq yd Pre-sized glass cloth, 7.9 oz per sq. yd. bonded to a vapor barrier. Symbol MB M& MD ME MB MS MW METALLIC BARRIERS Material .010" thk 3/16* corrugated aluminum .016" thk 3/16" corrugated aluminum .016" thk 3/16" corrugated aluminum . Q.0ATSD Vapor barrier jacket and .016" thk aluminum sheet .016* thk 1 1/4* corrugated aluminum .016" thk 3/16* corrugated 316 SS .016" thk galvanized steel, surfaced with vinyl resin; 4 mils exterior film and 2 mils interior film. Symbol FB FL FM FOIL PAPER BARRIERS Material 125 mil thk asphalt, glass cloth and aluminum foil. .001" thk aluminum foil, glass scrim and Kraft paper. White Kraft paper, glass scrim and .001" thk aluminum foil. PLASTIC RESIN BARRIERS Symbol Material PV .028" PVC sheet RA Asphalt cut-back, vapor barrier type RC Asphalt cut-back, breathing type RE Asphalt cut-back, aluminum RP Latex; PVA or acrylic RS Chlorinated rubber c 002252 K11.1 STD 1 PAGE 16 ISSUE 4 TABLE V. BARRIER MATERIALS (Select lowest cost alternative which conforms to application - "X" mark. Then review selection for serviceability in expected environmental conditions.) Monsanto STANDARDS FIBROUS GLASS K11.2 STD 5 & * JsAfr c- ^ <$ 1X 1X XX 2X X 3X X 4 X XX X 6 X XX X SXX X 6 X XX X 7XX X 8 X XX X 8 X XX X X 9 X XX X to X X X 10 X X X BARRIER FL FM CG CJ MB MC MH MO ME MW FV MS RC RP (1) ELEVATED TEMPERATURE ONLY. CALCIUM SILICATE K11.2 STD 6 & dr /////<?>/ J 11 X X ~_~ X m BARRIER CF MB ~~ _ X m X H MC IIX ~ X X MO n 2si5 X X X X MW 6XXX X ~X X 1S X --X X 4* X is 55b MS RC RP CELLULAR PLASTIC K11.2 STD 7 POLYURETHANE K11.2 STD 8 Ao* o 1X $H{ X X X X 2 XX x XXX (1) NB = NO BARRIER. WEATHER BARRIER NORMALLY NOT REQUIRED FOR INTERIOR INSTALLATION. EXTERIOR EXPOSURE REQUIRES WEATHER BARRIER. BARRIER V, 002253 . Monsanto ST ANDARDS . K11.1 STD 1 ISSUE 4 PAGE 17 TABLE V. BARRIER MATERIALS (Continued) MINERAL FIBER K11.2 STD 9 jbf/SS/S o -r <r ^ <? # co BARRIER MC CELLULAR CLASS K11.2 STD 10 jj? j (NOTE 1) (NOTE 2) (NOTE 3) lO G <) ^ C7- s# IX X 2 XX X X !W 3 XX X X X 4 XX X X X e XX X X X 6 XX X X -&V" 7 XX X X X Si 4 XX Xi 4 XX X 4 XX X lTt NOTES: 1. Low temperature barrier only. 2. Elevated temperature barrier only. . 3. Low, elevated and dual temperature barrier. EXPANDED SILICA K11.2 STD 11 /a# /////oW . tX xi 2 X X x ijmi 3 X JL X E| xi x 4XX \x HH H 6 X X X 1\ x il X X 1 1 x fig 6XX 1 1 xi C QQ22&4- K11.1 STD PAGE 18 1 ISSUE 4 9. REFERENCES The following publications and standards, in addition to insulation suppliers' catalogs, have been consulted in the preparation of the thermal insula tion standards: (1) "Thermal-^-Insulation" by John F. Malloy, Van Nostrand Reinhold Co. (1969) (2) "industrial Thermal Insulation" by Allen C. Wilson, McGraw-Hill Book Co. (1959) Monsanto STANDARDS (3) Handbook, American Society of Heat ing, Refrigeration and Air Condi tioning Engineers (4) "Climatic Atlas" U.S. Printing Office (5) "Thermal Insulation Design" Standard T1.10 STD 11 c 002255 Monsanto ST AN 0 Aft OS COATINGS AND INSULATION MANUAL THERMAL INSULATION DESIGN IDENTIFICATION AND SYMBOLS MAN. SECT PART K11.1 STD 2 ISSUE PAGE 3 OATE 1 OF i/85 2 1. SCOPE This Design Standard covers identification of thermal insulation sys tems on Drawings. - <4) he letter "D" following the insulation thickness designation (as - 5 D-6, for example) denotes a 2. IDENTIFICATION OF .THERMAL INSULATION double-layer of insulation. SYSTEMS Thermal insulation systems are -denoted on the Drawings by an -identifica tion symbol as illustrated in Figure 1. They are denoted in the Pipeline Summary and the Insulation. Summary. - Equipment by the same symbol. .. * - r ! :s < *'r. 2.1 Insulation System "Identification- "----- (5)_where required by design, two or -- more different types of insulation may be indicated. (Example, l/2"-5, 1 1/2"-10 designates 1/2" thickness of fibrous glass and 1 1/2" of cel lular glass. Materials are applied ___in the order listed.) 2.1.1 First Part The first-part of the iaentification symbol indicates the thick ness of the insulation and the type of insulation material, e.g., 1 l/2*-5. The following rules apply: -- 2.1.2 Second Part The. second part of the identification indicates the barrier material to be applied over the insula tion. The second part of the identity directly follows the first part, e.g., 1 l/2"-6MC. (1 1/2" of calcium silicate (1) Do not use decimal inches to indi-cate insulation thickness.__ (Milli- i;ciea)eters are used in metric practice.) insulation covered with an aluminum jacket barrier.) The barrier materials applica ble to the system are listed in the Ther mal Insulation System Specification. The (2) The insulation thickness does not include--the--thickness--of-- weather barrier.w ___ "barrier materials are denoted by two capi tal letters. The letters "NB" (as l/2"-7NB) denotes no barrier material application over the insulation material. For composite insulate (see Par. 2.1.1(5)) (3) Jdentification of "insulation applied "the barrier symbol follows the last insu -to piping or duct--terminates at a- lation designation: 1/2"-5, 1 l/2"-10MC. numbered equipment item jar where indicated by an insulation' termina- _2.2 Identification Symbols Symbols illus ""tion symbol as Illustrated in Figure' trates In Figure 1 are used to indicate 1. thermal insulation on engineering flow diagrams and piping drawings. ^ j'T C 003256 SOURCE T.F. STANLEY (4-6942) _________ LATEST ADDITIONS OR REVISIONS ARE SHOWN BY I I OR OUTLINING. DELETIONS ARE SHOWN BY K11.1 STD 2 PAGE 2 ISSUE 3 J--- 1 -- 5MC i CONTINUING INSULATION PIPING Monsanto STANDARDS 1 %" -- 5MC 'iXH TERMINATION OF INSULATION FIGURE 1. TYPICAL IDENTIFICATION SYMBOLS c 002257 Monsanto ST ANDAfTDS COATINGS AND INSULATION MANUAL THERMAL INSULATION DESIGN INSULATION MATERIAL PROPERTIES Design Data MAN. SECT PART Kll.l STD 3 ISSUE 3 DATE 1/85 PAGE 1 OF 9 1. SCOPE This standard lists materials propi 2. MATERIALS PROPERTIES DATA erties data for thermal Insulation and barrier materials used In the Thermal Insulation Sys------- 2.1 Insulation Materials Properties Table I tern Specifications. Additional data for other provides physlca.1 and thermal properties for common materials Is provided. materials shown In the Insulation System Spec- --------------- --------------------- *>-**. ' . -- :l IfIcatlons and a few additional materials of frequent use. TABLE I. MATERIALS PROPERTIES Insulation Characteristics ------ z ' ^Fibrous Glass K11.2 STD 6 ' Type of insulation ASTM _ Test _ Method I^clunSIUcate' "`wi.i'STD 6* " - Material Description Glass Fiber With Organic -------------- -.Binder .______ ,__ _ Reacted Hydrous Calcium Silicate Form__ . Sheet and Pips Covering Block and Pipe Covering Temperature Range (F) Thermal* Conductivity" - (BTU in. thk/hr ft2 F)----------- At Mean Temperature "" ; > Linear Shrinkage Max%. at Temp Limit .Density Ibs/Ft* "" Tensile Strength PSI Compressive Strength PSI Flexural Strength PSI Modulous of Elasticity PSI Abrasion Resistance % Wt. Loss by Tumbling Fire Exposure Flame Spread Index Smoke Density Index Water Absorption % Vol. 24 hr. Immersion Capillarity Hygroscopicity % Vol. -------- Water Vapor Transmission Perm In. Alkalinity Ph Chloride Content (PPM) Emissivity Thermal Diffusivity (FtVHr.) Specific Heat (BTU/lb/F) ........... ~0 tcr450 - -- K Temp----------- - -72, 24 " 50 - ioo . -------- _ .29 200 .35 300 100 to 1200 K Temp .38 100 .40 - 200 .47 400 .56 600 None 4-9 ------- - 3 at 10% Deformation ............ ' . " 1 """ * *" * -1.5 12 20 - 100 at 5% Deformation 35 - 10 Min Run Non-Combustible 25 50 90 None .2 90 Wicks 10% by Weight 9 Less than 30 .02 .20 10.2 200 .16 .20 Remarks --------- ---- ----- Good Strength. Absorbs Water. ASTM Test Method SOURCE T.F. STANLEY (4-6942) W22SS LATEST ADDITIONS OR REVISIONS ARE SHOWN BY | | OR OUTLINING. DELETIONS ARE SHOWN BY 5SS22; '' - ~ J : ' K 11.1 STD 3 PAG|____ 2. ISSUE 3 Monsanto STANDARDS TABLE I. MATERIALS PROPERTIES (Continued) Insulation Characteristics -Material Description Form Temperature Range (F) Thermal Conductivity (BTU in. thk/hr ft' F) At Mean Temperature ^"Ilular Plastic, K11.2STD7- Closed Cell Foamed Plastic Sheet and Pipe Covering .-BO to 220 K Temp .21 70 .28 90 3. . rv . jo ExpansionCoeffici ent Linear Shrinkage___________ Max % at 'Temp Limit Density Ibs/Ft3 Tensile Strength PSI Compressive Strength PSI Flexural Strength PSI Modulous of Elasticity PSI Abrasion Resistance % Wt. Loss by Tumbl ing Fire Exposure Flame Spread Index Smoke Density Index Water Absorption % Vol. - 24 hr. .Immersion Capillarity Hygroscopicity % Vol. Water Vapor Transmission Perm In. Alkalinity Ph Chloride Content (PPM) Emissivity ... . Thermart)iffuiVity'->(FtVHr.| Specific Heat (BTU/lb/F) *7 6 ` ' - 80 40 at 10% Deformation ' - ' -Self-Extinguishing so 500 1 '' 0 .28 .19 to .27 Type of Insulation ASTM Test Method Expanded Polyurethane Block, Pipe Covering A Spray ...------ D-1667-64 -400 to 200 -K Temp '.16 -100 .18 -50 .18 " 0 .17 50 .18 100 40X10"* 2.0 - 2.5 40-70 30-40 60-70 " . .YT ASTM Test Method D-1622 D-1623 D-1621 C-203 ' D-1692-59T Self-Extinguishing 25 and Higher Less Than 500 ' D-1692 D-1056-62 1.5 to 3.0 C-355-64 1.5 , 0355 .012 to 025 .23 Remarks I Coating Required for Exterior Exposure. Not Recommended in Confined Air Space without Fire Protection. - Foam Should not be Exposed to Sun or Weathering Elements. C 002259 Monsanto STANDARDS K11.1 STD ISSUE 3 | PAGE 3 3 TABLE I. MATERIALS PROPERTIES (Continued) Insulation Characteristics KillfiMrirFibers^ \,K11.2STD9 Material Description Form -Temperature Range (F) Thermal Conductivity (BTU in. thk/hr ft'8F) At Mean Temperature Mineral Fibers - With Inorganic Binders Block and Pipe Covering 100 to 1200 K Temp .33 100 .36 200 .42 400 - .51 ._600........ - Expansion Coefficient Linear Shrinkage Max %;at Temp Limit ' Density Ibs/Ft1 ` ;Tensile,.Strengtb PSI Compressive Strength PSI 'Flexural Strength PSI Modulous of Elasticity PSI - Abrasion Resistance % Wt. Loss by Tumbling Fire Exposure Flame Spread Index Smoke Density index Water Absorption %Vol. -24 Hr. Immersion - Capillarity Hygroscopicity % Voi. Water Vapor Transmission Perm In. Alkalinity Ph Chloride Content (PPM) Emissivity Thermal Diffusivity (FtVHr.) Specific Heat (BTU/lb/8 F) 4 - ... 15 ---------------------- 10 at 5% Deformation 40 , - -3 ' Non-Combustible ......... - -- -~ 90 Wicks .2 8 ---------------- 20 ------------ ---------- .01 .22 Type of Insulation ASTM Tost Method rCeliular GlasiTr l K11.2 STD 10 k . , Hermetically Sealed Glass Cells Block and Pipe Covering -450 to BOO K Temp .32 -50 .35 0 .41 100 .47 200 .55 300 4.6 x 10"` ASTM Test Method 9 50 100 76 180.000 - Non-Combustible .2 0 0 0 7.5 Less Than 5 .018 .20 Remarks Good Compressive Strength. C 002260 iiMgitfiEfflwiiaHii --iiitmmmi,ii K11.1 STD 3 PAGE 4 | ISSUE 3 Monsanto STANDARDS TABLE I. MATERIALS PROPERTIES (Continued) Insulation Characteristics Expanded Silica K 1.2'STD 11 Type of Insulation ASTM Test Method Material Description Form Perlite With Glass Fiber Binder And ___ Water Repellent ^ Block and Pipe Covering High Temperattre Ceramic Fiber v`!" Blanket and Bulk Temperature Range (F) - 100 to 1600 Theramal Conductivity K Temp (BTU in. thk/hr ft* F) .33 100 At Mean Temperature .38 200 .47 400 ;--.57------------ - 600 Linear Shrinkage Max % at Temp Limit 1.2 Density lbs/Ft1----- -- ------- .10 ------ - _......--- - Tensile-Strength PSI.............. - -------- --------------------------- Compressive Strength PSI 81 at 6% Deformation----------- Flexural Strength PSI - 85 ----'---------- --- --- -Modulous of Elasticity PSI -Abrasion Resistance- - -'T= % Wt. Loss by Tumbling Fire Exposure Non-Combustible Flame Spread Index Smoke Density Index -Water-Absorption --- - * ---------------------------------------- % Vol. -24 Hr. Immersion 3.7 Capillarity ----- - Hygroscopicity % Vol. Water Vapor Transmission Perm In. 18 Alkalinity Ph 9 Chloride Content (PPM) 50 Emissivity Thermal Diffusivity (Ft'/Hr.) .014 Specific Heat (BTU/lb/ F) .22 -------- ----- - . ---------------- 100 to 2300 K '* Temp .40 600 .70 1000 1.10 1400 <i>8 lb Density 3to 12 - ' .* - --- Non-Combustible ,. Less Than 50 ------------- -` .26 8 1800 F Remarks' High Temperature . And High Cost. May be Used in Combination With Low Cost Materials. ASTM Test Method <""062261 Monsanto STANDARDS K11.1 STD ISSUE 3 PAGE 3 5 TABLE I. MATERIALS PROPERTIES (Continued) Insulation Characteristics Sittvninous Rtfin r Material Description Asphalt Mastic, Cork Filler Form " -------- Temperature Range (F) Thermal Conductivity (BTLUn. thk/hr ft*'F) : At Mean Temperature Trowel or Spray Mastic -------------- .40 ^,220 K .90 v Temp Type of Insulation ASTM Test Method |Jy*hette Resin Polyvinyl Acetate Mastic, Cork Filler Trowel or Spray Mastic 40 to 170 K Temp .70 100 ASTM Test Method Linear Shrinkage Max % at Temp Limit . ___________ Density lbs/Ft* 31 Tensile Strength PSI------ r--- ' ...-------- Compressive Sttength PSI Flexural Strength PSI Modulous of Elasticity PSI _=aw- - Abrasion Resistance % Wt. Loss by Tumbl ing Fire Exposure Flame Spread Index Self-Extinguishing Smoke Density Index Water Absorption % Vol. >24 Hr. Immersion Capillarity Hygroscopicity % Vol. Water Vapor Transmission Perm In. Alkalinity Ph Chloride Content (PPM) Emissivity Thermal Diffusivity (FtVHr.) .007 Specific Heat (BTU/lb/F) Remarks Film Thickness l/, or Greater, or Films on Smooth Surfaces Such as Stainless Steel Requires a Reinforcement Membrane. Self-Extinguishing 7,5 -r - -- Film Thickness to \ M Used For Control of Condensation.on Irregular Shaped Equipment (Pumps, - Compressor, .Etc.). i fi . 0(?22S2' K11.1 PAGE 6 STD 3 ISSUE 3 Monsanto standards TABLE I. MATERIALS PROPERTIES (Continued) Insulation Characteristics ,n ^Polystyrene t Typs of Insulation ASTM Test Method V ^socyanwata7 Material Description Expanded Polystyrene Cellular Plastic Form Block and Pipe Covering Temperature RangelF)" Thermal Conductivity_______ .. (BTU in. thk/hr ft* FJ_____ ' At Mean Temperature " 0 to 175 ------K . _ Temp .22 0 .25 50 .27 10CT ------------ - -- Expansion Coefficient Linear Shrinkage Max % at Temp Limit Density. Ihs/Ft5 Tensile Strength. PSI Compressive Strength, PSI 25 x 10~*------------------ -- -- ... .~ __ .. ,, -- . 1 70 10 at 5% Deformation -- --------- . . Flexural Strength. PSI Modulous of Elasticity, PSI Abrasion Resistance % Wt. Loss by Tumbling Fire-Exposure -------- Flame Spread index Smoke Density Index Water Absorption % Vol -24 Hr. Immersion Capillarity Self-Extinguishing 1 None Hygroscopicity % Vol Water Vapor Transmission Perm In. Alkalinity Ph Chloride Content (PPM) 2.5 Emissivity Thermal Diffusivity (FtVHr) Specific Heat (BTU/lb/F) .017 * .27 - Block, Pipe Covering & Spray 100 to 300 K >' .16 - .18 .18 .17 .18 ' Temp -100 -50 0 50 100 ----------------5 x 10~* 2 30 to 40 18 to 28 35 .20X10"* 25 70 1* THK. 1.5 to 3 2 to 3 .23 Remarks Easy Fabrication And Light Weight. Material Temperature Limit May Not Be Adequate For Equipment Clean-Out Operation. --------------------------. ------------------- ASTM Test Method Monsanto STANDARDS K11.1 STO ISSUE 3 PAGE 3 7 2.2 Insulation Barrier Properties Table II provides physical data for barrier materials shown in the Insulation System Specifications. The barrier material type is identified generically and with the barrier symbols (e.g., CF, CG, CJ, etc.). TABLE II. BARRIER PROPERTIES Barrier Characteristics Material Description Font Color Temp Limit (F) Tire Exposure Flame Spread Index Smoke Density Index Smoke Toxicity Water Vapor Trans mission Perm In. Beach Puncture, oz In per In Tear Emlsslvlty 100 F Remarks Type of Barrier 8 oz Canvas (CF) filass Cloth (CG) Cotton Canvas Cloth, 7 oz per sq yd Pre-slzed 61 ass Cloth, 7.8 oz per sq yd Pliable Fabric White Pliable Fabric ______ White ------------------ -- - - -......... - Combustible Non-Combustible Glass Cloth Vapor Barrier (CJ) Pre-slzed Glass Cloth Bonded to a Plastic Film, 7.9 oz per sq yd Pliable Fabric White Non-Combustible f. ? 1 : r.'SNot a Vapor Barrier --- -- Not a . Vapor Barrier Canvas Is attached to Insulation. Surface ' Is usually painted. 215 0.60 May be painted. .03 21S 0.60 Hay be painted. Asphalt-Foil Paper (FB) Laminate of Asphalt, Glass Cloth and Aluminum Foil, 1/8* Thick, 67 lbs per sq Sheet Black 200 Combustible 0.94 Heavy Bitty Barrier, Heat Sealed Joints. 8arr1er Characteristics Material Description Form Color Temp Limit (F) Fire Exposure Flame Spread Index Smoke Oenslty Index Smoke Toxicity Water Vapor Trans mission Perm In. Beach Puncture, oz In per In Tear Emlsslvlty * 100 F Remarks Type of Barrier Foil - Glass Scrim Kraft Paper (a) Laminate of Aluminum Foil, Glass Scrim and Kraft Paper Sheet Aluminum Foil - Glass Scrim Kraft Paper (FM) Laminate of ' -Aluminum Foil, 61ass Scrim and Kraft Paper Sheet White Muftlnuar Sheet .010" (MB) 1/16* Corrugated Aluminum Sheet with Kraft-Polyetblene Film Backing Sheet Aluminum Alisnlnm* Sheet .016" (MC) 1/16* Corrugated Aluminum Sheet with Kraft-Polyethlene . Film Backing Sheet Aluminum ______ _ . 1100 Non-Combustible ---------- -----... ..___ _________ - -----1-- 1100 Non-Combustible , - NOt-4. Not a .02 .02 Vapor Barrier Vapor Barrier Bright Dull Gray Oxidized 0.05 0.07 0.11 Light Duty Barrier. Usually Applied to Sheet Insulation at the Factory for Heating and Air.Conditioning. . 215 ______ 215______ 0.60 Bright 0.05 _ Oull Gray 0.07 "Oxidized 0.11 Light Duty Barrier. Usually Applied to Sheet Insulation at the Factory. J'L THr t Jbi 1 ill Bright 0.05' Oull Gray 0.07 Oxidized 0.11 . ... - .. c 002264 K11.1 STD PAGE 8 3 ISSUE 3 Monsanto STANDARDS TABLE II. BARRIER PROPERTIES (Continued) Barrier Characteristics Material -Description Fora Cblor Temp Halt (F) Fire Exposure Flame Density Index Smoke Density Index Smoke Toxicity Vtater_Vapor Trans mission Perm In. Beach Puncture, 02 ,in per In Tear Emfssfvity 8 100 F Remarks ----------- Barrier Characteristics Material Description Form Color Temp Limit (F) Fire Exposure Flame Density Index Smoke Density Index Skoke.ToxIcIty Mater Vapor Trans mission Perm In. Beach Puncture, oz In per In Tear Im*l*ss>lvlty * 100 F Remarks . Aluminum Sheet .016* - Coated (MD) 1/16* Corrugated Aluminum Sheet with Kraft-Polyethlene Film Backing: Surface Acrylic Coated Sheet Aluminum 1100 Type of Barrier Aluminum Sheet .016* with ASJ Inner Jacket (K) im)Aluminum sheet .016* Same as System (MC) with Inner Jacket (FM) 1 1/4* Corrugated Aluminum Sheet with Kraft-Polyethlene Film Backing Sheet Alunlnum "1100 ' 1 __ Sheet Aluminum 1100 Non-Combustible .. Non-Combustible Non-Combustible Stainless Steel Sheet .010* (MS) 3/16* Corrugated Sheet - Type 316 SS Sheet Gray 1450 Non-Combustible Not a Vapor Barrier ------- ;--------------------- -------- Bright 0.05 Dull Gray 0.07 Oxidized 0.11 Coated Aluminum Used Primarily for Corrosion Protection In Coatal Areas. ...... --- (FM) used as a Vapor Barrier -------- Not a Vapor Barrier- - Bright Dull Gray Oxidized 0.0S 0.07 0.11 Used for Cold Service Requiring a Bapor Barrier. . -- Bright Dull Gray Oxidized 0.05 0.07 0.11 Corrugations Collect Liquids In a Horizon-, tal Position. Not a Vapor Barrier Bright Dull Gray Oxidized 0.24 0.37 0.82 Galvanized Steel ------.016* - Vinyl Coated (MM) ----------- Smooth Surface Coated with Vinyl Resin: 4 mils Exterior and 2 mils on Back Surface Sheet White Type of Barrier Polyvinyl Chloride Sheet .028* (PV) Asphalt Vapor Barrier (RA) Smooth Surface PVC Sheet - Solvent or Tape Sealed. Sheet 8 colors Solvent CutbackAsphalt Mastic Black 220 180 250 Non-Combustible Combustible 5 Combustible Asphalt Breathing Barrier (RC) Solvent cutback Asphalt Mastic Black 250 Combustible Not a Vapor Barrier .000015 . ,003 . ,-- .03 0.60 Higher Cost Barrier for Corrosives Environments. May Deform Slightly In Sun Light. 0.94 Corrugations collect _ 0.94 _________________ --- -- ------------------------------ ^-002265----------- - Monsanto K11.1 STD issue 3 PAGE I TABLE II. BARRIER PROPERTIES (Continued) Barrier Characteristics Material Description For* Color Asphalt Alixainum (RE) Solvent Cutback Asphalt Mastic Aluminum Temp limit (F) Fire Exposure Flame Spread Index Smote Density Index Smote Toxicity Water Vapor Trans mission Perm !h. " -; leach Puncture, oz in per in Tear Emissivity 100 F Remarks 250 Combustible .1)02 Type of Barrier latex Mastic (RF) Chlorinated Rubber Paint (RS) PVA Resin Chlorinated Rubber Resin Mastic Paint Various Various ISO 180 J 25 Not a .5 Vapor Barrier Used to Prevent Deterioration of Cellular Rubber Insulation in Weathering Exposures. _3 9 c 002266 A - Mojgaitaj STANDARDS MANUALS COATINGS AND INSULATION MANUAL THERMAL INSULATION DESIGN HEAT TRANSFER CALCULATIONS man. sect part Kll.l STD 4 ISSUE 1 DATE 5/64 PAGE 1 OF 16 r LOCATIONS STDS A ST AF A SUBS A Aom. DIV A 41 42 69 1. SCOPE This Design Standard provides equations and Tables for calculating heat loss and heat gain through thermal insulation on both flat and cylindri cal surfaces. Definitions of terms used in the equations and Tables, and convection coefficients for flat and cylindrical surfaces in elevated and low temperature services also are given. 2. USE OF THIS STANDARD Figure 1 is a Flow Chart that shows how the equations and Tables in this Design Standard are used in solving thermal insulation problems. CHEMSTR. ENTER ONE COPY IN EACH M A N U A L. SEE TABLE OP CONTENTS FOR PLACEMENT. "*> INDICATES APPROVAL OR ACCEPTANCE AT LO CATIO N. " A " AT " D IV " IN D IC ATES DIVISION-W IDE A P P R O V A L' OR ACCEPTANCE. GERING HYDRO DIV A 04 19 - 44 INORG OIV A 07 01 10 11 17 IS 26 29 as ES ORG DIV A Qt 03 06 09 ia 30 ENG PLASTIC DIV A 12 27 In W 34 31 ____________________FIGURE 1. HOW TO USE THE EQUATIONS, TABLES, AND FIGURES REFERENCES____________________________________________________________________________________________ LATEST ADDITIONS OR REVISIONS ARE SHOWN BY j | OR OUTLINING. DELETIONS ARE SHOWN BY 3 K11.1 STO 4 PAGE 2 or 16 ISSUE t STANDARDS 3. DEFINITIONS OF TERMS Terms used in this standard have the following definitions: V " Heat flux, Btu/hr, s<j ft, from bare steel surfaces. Q -Heat flux, Btu/hr, sq.ft,-at equipment or pipe surface beneath the insulation. q " Heat flux, Btu/hr, sq ft, at outer surface of insulation. - -- /, " Temperature, F, of the hot or cold surface to be insulated. ta " Temperature, F, of air surrounding the insu lation (ambient). ts " Temperature, F, of the outer surface of insulation. " 4 A/, " /, -- ta for elevated temperature service, m ta~ t, for low temperature service. " ts " ta fr elevated temperature service, m ta- ts for low temperature service. RH " Relative humidity of ambient air. R " The sum of resistances, hr, sq ft, F/Btu, throughthe insulation and' the air film surrounding the insulation, e.g., --x + --1 KO for flat surfaces. C " Convection coefficient,"' Btu/hr/sq ft,-F, used to estimate resistance through the. air film surrounding the insulation. -- " Internal resistance of a single thickness of insulation over a flat surface; x - thickness of insulation, in inches; k " conductivity of the insulation, Btu/hr, sq ft, in., at the mean temperature - * a - -jp " Internal resistance of a single thickness of insulation over a cylindrical surface; y ~ effective thickness of insulation; ' k is . defined above. NOTE: Where the sum of internal resist ances of insulation in double layer or d " Inside diameter of either the inner layer or outer layer of insulation, inches. 4. CONVECTION COEFFICIENTS An adequate treatment of convection coefficients is not within the scope of this standard. The following coeffi cients (expressed as C and defined above), are suggested for use in heat transfer equations: 4.1 Flat Surfaces The value of C for flat surfaces in still air at elevated temperatures may be con sidered 1.39 for vertical plates, 1.79 for horizontal plates facing upward, and 0.89 for horizontal plates facing downward. The value of C for flat surfaces in still air at low temperatures - may be considered 1.39 for vertical plates, 0.89 for horizontal plates facing upward, and 1.79 for horizontal plates facing downward. 4.2 Cylindrical Surfaces The value of C for cylin' drical surfaces in still air, at both elevated and low temperatures, may be considered 1.6. The value of C for cylindrical surfaces in air moving at 2 miles per hour nominal velocity, at both ele~ vated and low temperatures, may be considered 1.77. --The effect of air, moving at higher velocities is indicated in Table II, but exact coefficients are not given. - ------- - - 5. HEAT TRANSFER CALCULATIONS Heat trans fer calculations presented in this Standard do not cover personnel protection at elevated temperatures or prevention of surface moisture condensation at low temperatures. Thicknesses of insulation adequate to meet these design conditions have been calculated from equations based on the insula tion surface, and are presented in tabular form in each of the Materials Specifications for insula tion. There is no point in repeating these equations here. _l( *.compound systems is expressed as fi. + for flat surfaces, and + -^r- for cylindrical surfaces, xt and yt. always represent the inner layer of insulation, x2 and y2 always represent the outer layer; k, and kj are selected to suit the materials and mean temperatures indicated by x,, ylt x, and ya. Equations in this standard are based on the hot or cold equipment surface beneath the insulation, and are provided for use when control of process tempera ture and heat flow is the governing design factor. 5.1 Flat Surfaces The equation for calculating heat flow through a single layer of insulation over a fiat surface is: Q (1) D0 - Outside diameter of the outer layer of insulation, inches. D " Outside diameter of the inner layer of insulation, inches. Dp m Outside diameter of pipe or equipment, inches. The value of k is determined from Figures 2, 3, and 4; the value of C is suggested in Pat. 4.1. Fot increased heat loss due to wind velocity conditions, multiply q by conversion factors in Table II. c 002268 [*Km| STANDARDS Where more than one layer of insulation is applied over a flat surface, the equation becomes: K11.1 STD 4 ISSUE 1 jRAGE 3 OF 16 The value of y is given in Table V. The value of k is determined from Figures 2, 3, and 4. The value of C is suggested in Par. 4.2. For increased heat loss due to wind velocity conditions, multiply Q by conversion factors in Table II. 5.2 Cylindrical Surfaces Cylindrical insulation or pipe covering offers a path of varying-area-for-the flow of heat, and equations are more complicated than for flat surfaces. The classical mathematical treatment utilizes a log mean area for the transfer of heat. By suitable rearrangement of terms, it is possible to calculate heat flux both on the basis of the external surface of the insulation, and on the basis of the pipe or equipment surface diameter. In practice, there are uses for both methods of calculation; however, only the pipe or equipment-surface: basis is covered in this standard. ... Note that while heat fluxes q and Q are equal for flat surfaces, this is never true for cylindrical surfaces. Where more than one layer of insulation is required, or the variation of k with temperature is large and it is desirable to treat the insulation as consisting of layers of varying heat resistance, the equation becomes: 2L+*+_L[.| h C\D0j (5) 5.4 Temperature of the Insulation Surface Tempera ture of the insulation surface, ts, may be found by dividing the heat flux for the external surface of the pipe, or equipment by C to obtain the temperature difference: Q Do *lt cK (6) 5.3 Calculations for Cylindrical Surfaces Equations are based on the pipe or equipment diameter which does not vary -with insulation thickness. Calcula tions are intended to provide the rate of heat loss -or gain from or into the process fluid at the pipe or equipment wall. ---- ------------- ------ ----TM------------- Equations (1) and (2) still are applicable as long as the heat flow area or the effective thickness of insulation are adjusted to suit a cylindrical object. The common method used for this adjustment is the calculation of an effective insulation thickness, y, which takes into account the variable area in the heat flux path, 5.3.1 Calculation of y The following equation defines y: y- 1.1513 Dp log \~\ ; (3) From Paragraph 3, "Definitions":' A/j /s - ta for elevated temperature service; " ta -- ts for low temperature service. Substituting in Equation (6): q ts - ta + -- for elevated temperature service; 3_ C for low temperature service. 5:5 Square Feet to Linear Feet Where it is neces sary to determine the rate of heat transfer per linear foot of pipe or cylindrical surface, multiply Q in Equation (4) and (5) by the appropriate conversion factors in Table VI. f?0 may he used in place of P. ___ ~ 6. HEAT LOSSES FROM BARE SURFACES Many Values of y for single layer insulation in thicknesses 1", l%", 2", 2%", and 3" over piping %" through 40" pipe size; and values of y for each layer of double insulation manufacturers rate their product in terms of efficiency percentage according to results of the following equation: insulation in thicknesses 1", l`4"i 2", 2%", and 3" over thicknesses 1", 1%", 2", 2%", and 3" over Efficiency - 100 (7) piping 3" through 40" have been calculated by Equation (3) and are given in Table V. 5.3.2 Heat Flow Equations The equation for cal culating heat flux from the surface of a cylindrical object through a single layer of insulation is: Efficiency ratings so derived can be misleading because of other variables that are not considered. The concept of insulation "efficiency" is not recommended. Tables HI and IV show heat losses from uninsulated 2 k + i C \\EDlo \ flat and cylindrical surfaces at various temperature gradients. To determine the effect of wind velocity on heat loss from bare surfaces, multiply the factors LATEST -*D~DnToW5 OR REVISIONS ARE SHOWN BY OR OUTLINING. DELETIONS ARE 'SHOWN BY c 002269 K11.1 TO * PAPE 4 of 16 |mue 1 in Tables III and IV by the conversion factors in Table I. Do not use the conversion factors in Table IV to determine increase in heat loss from insulated surfaces, however. 7. INSULATION THICKNESS TO PREVENT MOIS TURE CONDENSATION AT MODERATE TEMPERA TURES The alignment diagram, Figure 5, provides a rapid means for calculating adequate thickness of insulation to prevent moisture" condensation on surfaces cooler than the ambient temperature, and under a variety of relative"Humidity conditions. Solve problems as indicated by the dotted line on the diagram, entering the chart at the Tower left TABLE I. MULTIPLYING FACTORS FOR USE WITH TABLES III AND IV Increased Heat Loss due to Wind Velocity Conditions^ Bate Surfaces.1 Temp, F, of Uninsulated Hot Surface Wind Velocity, Miles Per Hour 2% 5 n 10 15 200 300 . 400 1.43 1.72 1.40 1.66 1.36- -t.60 1.92 1.86 1.77 2.10 2.03 1.93 2.42 2.33 -2.21 - 500 600 700 800 900 1000 1.32 1.30 1.26 1.23 1.19 1.17 1.54 1.48 1.43 1.37 1.33 1.29 1.70 1.63 1.56 1.49 1.44 1.38 1.85 1.75 1.66 1.59 1.53 1.40 2.10 1.97 1.85 1.77 1.67 1.52 1100 1.15 1.26 1.33 1.40 1.52 1200 1.13 1.23 1.29 1.33 1.44 `Factors shown in this Table are averaged for fiat surfaces and for various pipe sizes, and are recommended as close enough for practical use. TABLE II. MULTIPLYING^ACTORS FOR USE WITH EQUATIONS (1), (2), (4), AND (5) Increased Heat Loss due to Wind Velocity Conditions, In sulated Surfaces.1 -- Insulation Thickness (Inches) Wind Velocity, Miles 3er Hour 5 10 15 20 25 30 1 1.07 1.09 1.11 1.12 1.13 1.14 I1/, 1.05 1.07 1.08 1.09 1.10 1.11 2 1.04 1.06 1.07 1.075 1.08 1.085 . 21/, 3 31/, 1.03 1.04 1.05 1.055 1.06 1.07 1.025 1.035 1.04 1.045 1.05 .1.06 1.02 1.03 - 1^035 1.04 1.045 1.05- 4 1.015 1.025 1.03 1.035 1.04 1.045 1.013 1.023 1.028 1.033 1.038 1.043 5 1.011 1.021 1.026 1.031 1.036 1.041 5% 1.009 1.019 1.024 1.029 1.034 1.039 6 1.007 1.017 1.022 1.027 1.032 1.037 `Factors shown in this Table are averaged for fiat surfaces and for various pipe sizes, and are recommended as close enough for practical use. RSI`STANOARDS scale.' This chart provides adequate thickness under still air conditions at moderate temperatures; since still air conditions are the most serious condition in moisture-condensation problems at these temperatures, no conversion factors for wind velocity conditions is required. This alignment diagram has been reprinted directly from the current edition of the ASHRAE GUIDE, and there is no record of results from actual field use. However, recommended thicknesses are within the range of those actually calculated and appearing in the Materials Specifications, and the approach seems adequate for the practical solution of problems. TABLE III Heat Loss from Bare Flat Surfaces under Still Ait Condi tions at 70 F Ambient Temperature. Temperature of Uninsulated Hot Surface, Btu/Square Feet, Hour Vertical Surface C- 1.394 Horizontal Surface Facing Facing Upward Downward C - 1.79 C - 0.89 100 200 300 .......--400 50 300 650 1150 67 395 880 1550 42 252 600 965 ` 500 600 700 800 1800 2650 3750 5100 2420 3570 5070 6890 ' 1510 2125 3150 4280 900 1000 1100 1200 6800 89Q0 11400 14400 8200 12100 15400 19400 5700 7500 9800 12100 - 1300 1400 1500 1600 17900 21750 26000 30500 24100 29350 35000 41200 15000 18250 21800 25600 1700 1800 1900 35500 40800 46500 48000 55000 62800 29800 34300 39000 002270 3 STANDARDS It 11.1 STD 4 2ue_I__[raos 5 or )$ TABLE IV Heat Loss from Bare Cylindrical Surfaces under Still Air Conditions at 70 F Am bient Temperature. C - 1.6 for all Cylindrical Surfaces. Temp F of Hot Surface' Pipe Size (IPS or Nominal), Inches 1 'h 2 3 4 6 8 10CK-200 . 300 - 13 76 166 400 287 500 445 600 649 -16 93 205 353 547 '801 -20 114 250 --27 159 326 34 196 432 434 613 674 955 "989"' ~T403: 753 1176 1732 48 280 620 1083 1695 2505 61 354 784 1370 2149 3179 87 503 1122 1976 3105 4604 112 644 1436 2530 3988 5927 700 800 900 1000 1100 1200 901 1218 ' 1602 1113 '1508 1984 1379 1865 2462 1960 2661 3514 2075 2644 3317 '2576 3282 4122 "3194 4080 5123 4568 5841 ,7345 2423 3295 4355 5665 7251 9133 3511 4784 6337 4467 6094 8079 6479 8858 11769 8356 11433 15211 8259 10582 13344 10545 13513 17049 15366 19740 24909 19895 25568 32293 Temp F of Hot Surface 10 pipe"Size (IPS'jpr Nominal), Inches 12 14 16 . 18 20 24 X) 100 200 300 136 791. 1769 159 930 2076 174 1009 2258 197 1142 2560 221 1282 2875 244 1416 3168 289 1683 3772 351 2042 4642 400 500 600 3114 4918 7312 3664 5809 8627 700 " 10325 800 14147 900 18812 12194 16721 22248 3989 6316 9404 4529 7160 10697 5074 8032 12010 13301 18236 24279 15124 20769 27663 16992 23346 31109 5618 8897 13270 18777 25810 34432 667910595 15825 8242 13103 19606 22375 30836 41112 27758 38299 -51107 1000 1100 1200 24621 31679 40051 29133 37501 47429 31844 40965 51856. 36257 46689 59089 40788 52539 66456 45157 58159 73691 53958 69536 88221 67126 86588 109872 NOTE: Heat loss is given in Btu's per Linear Foo< of cylindrical surface per hour; to convert to square feet, use the appropriate factor in Table VI. LATEST ADDITIONS OR REVISIONS ARE SHOWN BY | | OR OUTLINING. DELETIONS ARE SHOWN BY. ===== c 002271 Kll.l STD 4 6RAOE OR 16 ISSUE 1 TABLE V. DOUBLE-LAYER INSULATION1 BS'STANDARDS 7&U ** jt C002272 STANDARDS 69 K11.1 STD 4 ISSUE 1 |PAOE 7 OF 16~ TABLE V. VALUES OF y (EFFECTIVE THICKNESS) FOR SINGLE-LAYER AND DOUBLE-LAYER INSULATION* (Continued) Pipe Size (Inches) Nominal 0D {Dpi Factors (Note 1) Single Layer or Inner Layer Insulation Thk Outer Layer over Single Layer Insulation Thickness, Inches 1 1*4 2 2*4 3 , 1.90_ -D ,, y D y D y D y D y 1 ; .. 1 v2 0.71 5.00 0.92 2 6.63 2 % 7.63 3 " 8.63 -' 2 2.38 ... D y D y D y D y D y 1 4.50 0.76 1`4 5.56 1.01 2 6.63 1.22 2% 7.63 1.39 3 8.63 1.53 3 3.50 .. D y 1 S.56 7.63 0.81 0.55 D 1 % 6.63 y 1.12 D 2 7.63 y 1.36 D 2 % 8.63 y 1.58- D 3 9.63 y 1.77 *D- Dlt y-y, for single or inner layer; D - D0, y - y3 for outer layer. 8.63 0.77 9.63 0.65 10.75 0.85 11.75 0.76 12.75 0.90 14.00 0.85 14.00 1.06 15.00 0.97 16.00 0.89 LATES'T "A'BOITiONS'OR REVISIONS ARE SHOWN, BY | ) OR OUTLINING. DELETIONS ARE SHOWN BY 2=55= c 002273 liiiiiiBiaiiitr K 11.1 *TD 4 PASS 8 OF 16 ISSUE \ STANDARDS rWI 69 TABLE V. VALUES OF y (EFFECTIVE THICKNESS) FOR SINGLE-LAYER AND DOUBLE-LAYER INSULATION1 (Continued) Pipe Size (Inches) Nominal OD (Op) Factors (Note. 1) Single Layer or Inner Layer Insulation Thk 4 4.50 0 y 1 6.63 0.87 D IV, 7.63 y 1.19 0 2 8.63 y 1.47 V** CM 0 9.63 y 1.71 D 3 10.75 y 1.96 Outer Layer over Single Layer Insulation Thickness, Inches 1 2 0*1*,2 . . 3 , 8.63 0.59 __ ; rv 9.63 0.84 10.75 11.75 0.77 0.97 .. __ 12.75 0.88 ___ 14.00 1.09 15.00 1.00 15.00 1.24 16.00 . U.4.. 17.00 1.03 .6 6.63 D y 1 8.63 1.0.75 0.87 0.73 D n 9.63 y 1.24 D 2 10.75 y 1.60 D 2V, 11.75 y 1.90 D ' 3 12.75 y 2.17 8 8.63 D y 1 10.75 12.75 0.95 0.74 D IV, 11.75 y 1.33 D 2 12.75 y 1.68 D 2 V, 14.00 y 2.09 D 3 15.00 y 2.39 *0 D,, y - y, for single or inner layer; D * O0, y " y, for outer layer. 11.75 1.02 12.75 0.93 14.00 1.24 15.00 16.00 1.10 1.32 .17.00 1.22 17.00 1.52 18.00 1.41 19.00 1.32 14.00 1.14 15.00 1.05 16.00 1.33 17.00 1.24 18.00 1.49 19.00 1.32 19.00 1.72 20.00 1.54 21.00 1.45 C 002274 STANDARDS CHS KT 1.1 STD 4 JjSUE 1 |f*OE 9 OF TABLE V. VALUES OF y (EFFECTIVE THICKNESS) FOR SINGLE-LAYER AND DOUBLE-LAYER INSULATION' (Continued) Pipe Size (Inches) Nominal 0D (Dp) Factors (Note 1) _ Single Layer or Inner Layer Insulation__ Thk Outer Layer over Single Loyef Insulation Thickness, Inches 1 . J.*4_ 2 2*4 3 10 10.75 D 1 12.75 15.00 )6.6o y_. 0.92 0.87 1.22 D 11 >'2/ 14.00 _,.y 1.42 17.00 18.00 1.04 1.35 D y. D y.. . D y__ 2 15.00 1.79 2*4 16.00 2/14 3 17.00 2.46 ----- 19.00 1.27 20.00 1.55 21.00 1.46 21.00 1.81 22.00 1.71 23.00 1.62 12 12.75 D y 1 15.00 17.00 18.00 1.04 0.80 1.16 D '*4 16.00 y 1.45 D 2 17.00 y 1.83 19.00 1.10 20.00 1.42 21.00 1.35 22.00 1.64 23.00 1.93 D 2% 18.00 y 2.20 D 3 19.00 y 2.54 23.00 24.00 .... 1.56 1.83 25.00 1.75 14 14.00 D y 1 16.00 18.00 0.93 0.82 D i*4 17.00 y 1.36_ . D 2 18.00 y 1.76 D 2 % 19.00 y 2.14 D 3 20.00 y 2.50 *D " D,, y - y, for single or inner layer; 0 " D0, y - ya for outer layer. 19.00 1.20 20.00 1.14 21.00 1.48 22.00 1.40 23.00 1.72 24.00 1.64 24.00 2.01 25.00 1.92 26.00 1.84 c 00227S LATEST ADDITIONS Oil REVISIONS ARE SHOWN BY | | OR OUTLINING. DELETIONS ARE SHOWN BY S KIM STD 4 pAoe 10 or 16 issue 1 STANDARDS |Mlk TABLE V. VALUES OF y (EFFECTIVE THICKNESS) FOR SINGLE-LAYER AND DOUBLE-LAYER INSULATION* (Continued) Pipe Size (Inches) Nominal OD (Dp) 16 16.00 Factors (Nate 1) Single Layer or Inner Layer Insul ation Outer Layer over Single Layer Insulation Thickness, Inches Thk 1 1*4 2 2*4 3 Dy "TgjDO - '20700_ ' 21.00 0.94 0.84 1.23 --- - - D 1*4 19.00 y 1.37 22.00 23.00 1.17 1.53 D 2 20.00 y 1.79 24.00 25.00 26.00 1.46 1.79 2.10 D 2*4 21.00 y 2.18 --Dr----- -- ~2ZX>0 ..... y" ~~2^5 26.00 1.71 "" 27.00 2.01 28.00 1.93 18 18.00 D y 1 20.00 22.00 23.00 - 0.95 0.86 1.26 D 1*4 21.00 y 1.39 D 2 22.00 y 1.81 24.00 1.20 25.00 1.57 26.00 1.50 27.00 1.84 28.00 2.17 - .23.00 ___ ,, y 2.21 28.00 29.00 1.77 2.09 D 3 ~~ 24.00 y 2.59 30.00 2.01 20 20.00 D y 1 22.00 24.00 0.95 0.87 D 1 `4 23.00 y 1.40 D 2 24.00 y ~ ~ ' 1.82 D ~2%"~ "25*.00" y 2.23 D 3 26.00 y 2.62 *D " D,,y y, for single or inner layer; D " D0l y - y, for outer layer. 25.00 1.28 26.00 1.23 27.00 1.60 28.00 1.54 , 29.00 30.00 1.89 2.23 30.00 1.82 3 LOO 2.15 32.00 "~2.oe STANDARDS K11.1 STD 4 ISSUE t RAOE It "or 16 TABLE V. VALUES OF y (EFFECTIVE THICKNESS) FOR SINGLE-LAYER AND DOUBLE-LAYER INSULATION1 (Continued) Pipe Size (Inches) Nominal OD (Dp) Factors (Note I) Single Layer or Inner Layer Insulation Thk Outer Layer over Single Layer Insulation Thickness, Inches 1 IV, 2 21/, 3 24 *----- '*24^0TM ------0 -- cr\... "" D y D y D y -*y~-- 1 - -26.00 0.96 i`/. 27.00 l 1.41 2 28.00 1.85 2% 29.00 2.27 3 -- "30.00 -2.68 28.00 29.00' 0.89 1.31 ,, .. - 30.00 31.00 1.26 1.66 32.00 33.00 1.60 1.97 ----------- - -- 34.00 1.91 ----- --- 34.00 2.33 35.00 2.26 36.00 2.19 30 3Q.00 D y D ;. y D .y D y - -D y 1 32.00 0.97 IV, - 2 33.00 1.43 34.00 1.87 2Vu.. 35.00 2.31 . 3-- 36.00 2.73 34.00 0.91 35.00 1.34 36.00 1.31 37.00 1.72 37.00 1.67 39.00 2.06 40.00 2.00 . 40.00 2.44 41.00 2,37 42.00 2.31 36 36.00 D .y 1 38.00 40.00 0.97 0.92 - D IV, 39.00 y 1.44 --------- -- ----- D - -y - "y 2 ~~ 2 V, 40.00 1.90 41.00 2.34 D 3 42.00 y 2.77 *0 " D,, y " y, fot single 01 innet layer, D " D0> y - ya for outer layer. 41.00 1.37 42.00 43.00 1.33 1.76 44.00 45.00 -L72 -2.-12 --------- -46;00 2.07 --- 46.00 2.52 47.00 2.46 48.00 2.40 -..URL , .. . 002277 LATEST ADDITIONS OR'AEVIStONS ARESHOWN BY | | OR OUTLININO. DELETIONS ARE SHOWN BY = KII.1 TO 4 PAPE 12 OP 16 |tSUE 1 standards TABLE V. VALUES OF y (EFFECTIVE THICKNESS) FOR SINGLE-LAYER AND DOUBLE-LAYER* INSULATION* (Continued) P ipe Si ze (Inches) Nominal OD {Dp) Factors (Note 1) Single Layer or Inner Layer Insulation Thk Outer Layer over Single Layer Insulation Thickness, Inches ; 1 n 2 2`4 3 40 40.00 D y 1 J3"QSL ,44.00 0.99' 0.93 D 1*4 43.00 y 1.45 D, i . 44.00 y 1.91 D 2*4 45.00 y "2136 D 3 46.00 y 2.80 *D " Dlt y - yt for single or innertayer; 0 " O0, y~".y7for outer layer. 45.00 1.38 46.00 1.35 47.00 1.78 48.00 1.74 I' \r 49.00 2.16 50.00 2.12 50.00 2.60 51.00 2.52 52.00 2.46 TABLE VI. SQUARE FEET PER LINEAR FOOT OF PIPE, BARE ----Pipe Size,---- IPS or Nominal (Inches) Bare --- Pipe Size, IPS or Nominal (Inches) Bare % . .220 ......... -% -- ~ .272 1 .346 1`4 .500 2 .625 3 .917 4 1.18 6 1.74 8 2.26 10 2.82 12 3.37 14 3.66 16 18 20.............. 4.18 4.71 I,5 .-24 5 24 6.30 30 7.85 36 9.44 c 002278 -i STANDARD* (<1 + '<*> F-Mcn Temperature,-----^ tam80F, A'Btu/inch thickness/hr/sq ft/*F. K11.1 STD 4 ISSUE 1 FAOE 13 OF 16 0 200 400 600 800 1000 0 200 400 600 800 1000 0 200 400 600 600 1000 *F f F FIGURE 2. MEAN CONDUCTIVITY FACTORS FOR RIGID INSULATION MATERIALS LATciT ADOmoHi OR R~Ev7*IONS 'are SHOWN-By' 1 I OR OUTLINING. DELETIONS ARC SHOWN Y ==S== C 002279 KIM TO PAoe 14 of 16 tissue 1 STANDARDS 1.0 Fibrous Glass 0.8 _ with Bind.rs | . 0.6 _ Low D.nsity , (1 Ib/eu ft) "1 1 J| 0.4 f| b* * 0.2 0.0 ----------1------ 1____L.1..I1 1.0 0.8 _ Mineral Wool with Binders Low Donsity (5 Ib/eu ft) " ------------- ------------- -----1---------- Fibrous Glass with Bind.rs 1 _ Low Donsity (3 Ib/eu ft) j 1 jJ i Fibrous Glass without Binders . Wire-Mesh Reinforced - ll 1 i1 111 Mineral Wool without Bind.rs __ Wire-Mesh Rtinforccd Temp ^ Limit 1000 F 111 1 ! 0 100 200 300 400 500 600 F 0.6 0.4 Tmp Temp Limit ^Limit 0.2 800 F - 1200 F 0.0 ______ 1______ 1______ 1______ 1______ 1______ C 100 200 300 400 600 600 0 11 111 100 200 300 400 500 6019 . (, + /*) F " Mean Temperature,-----^--. ta " 80 F. k " Btu/inch thicknesa/hr/sq ft/*F. FIGURE 3. MEAN CONDUCTIVITY FACTORS FOR BLANKET OR BATT INSULATION MATERIALS c 002280 STANDARDS K1I.1 4STD ISSUE 1 |PAOE 15 OF li . (/, + /,,) F Mean Temperature,--------. t,, - 80 F. k " Btu/inch thickness/hr/sq ft/*F. FIGURE 4. MEAN CONDUCTIVITY FACTORS FOR FOAMED AND SPRAYED INSULATION MATERIALS .** . LATEST ADDITIONS OR REVISIONS ARE SHOWN BY ------------------------------------ C-00328-i- OR OUTLINING. DELETIONS ARE SHOWN BY K11.1 *TD 4 raoe 16 or 16 ISSUE 1 STANDARDS I--v/-- lUoMStt FIGURE 5. THICKNESS OF PIPE INSULATION TO PREVENT CONDENSATION ON OUTER SURFACE w