Document OpnOyZmxMVVDqpg8Mr3dwoV1
Memorandum
Engineer mg, Department Sun Francisc'*, <':>} i l'wrn : April , ly/li
Evaluation of Insulation Materials
MESSRS: R. C. ANDKESEN J. E. HAYDEN J. R. MASSON R. F. MUELLER W. SCARBOROUGH R. L. SMITH
Attached is Drewing GT-D-25673-1 - "Standard Insulation Item Numbers." This
revision reflects the results of recently completed Materials Laboratory tests.
Two additional insulation brands, Keene Thermasil and Cary Temp 1500, have been
added for intermediate and high temperature service, for both piping and equip
ment. Also, for very high temperature service, the "hold" hss been removed
from J-M Superex 2000 and B&W Kaowool for piping, and from B&W Keowool for equip
ment. The specific notes on the drawing effecting these changes are tabulated
on Attachment "B." All insulation materials shown on this drawing are asbestos
free.
--
Detailed results of the Materials Laboratory tests are summarized in the report. Attachment "C." Our conclusions from these tests are:
1) Calcium Silicate and Perlite Insulation
Thermo-12, Kaylo-10, CalTemp N.A., and Thermasil are acceptable to 1200F. Carey Temp 1500, a perlite material, is an acceptable substitute to 1500F. Kaylo-10 had more shipping breakage than the other brands. A comparison of some of the properties important to selection and use is made in Attachment "D."
2) Mineral Wool Insulations
The Forty-Eight mineral wool for both piping and vessel insulation deter iorated badly in fire-resistance tests, and should be limited as described under fire resistance. Epitherm 1200 insulation was OK in the same fire tests.
For column and vessel insulation we believe calcium silicate is a better choice for long-term performance. We have only about 16 months' exper ience with mineral wool block and only on a few vessels. We are concerned that the mineral wools will compress and sag over the years under normal bending loads as the insulation binder deteriorates at high temperatures.
For piping, Company experience shows that mineral wool has adequate dura bility as long as lines are not walked on or otherwise abused. Additionally, the better "K-factor" of mineral wool reduces ripe spacing and eliminates
the need to change our normal pipe spacing practices.
oo^ouu:
Messrs. R. C. Atulresen, et el
April
3) Fire Resistance
All the calcium silicates, the perlite, and Epitherm 1200 mineral wool have satisfactory fire resistance. The Forty-Eight insulation deter iorated badly in the tests and should be limited in use.
We recommend that Forty-Eight mineral wool should not be used on columns and vessels under fire conditions. We also recommend that Forty-Eight insulation should not be used on chrome-moly vessels, exchangers, and piping which can suffer serious metallurgical changes if exposed to a fire. For piping, we consider Forty-Eight insulation adequate except on lines which are so large that their volume must be considered in sizing relief valves on interconnected equipment.
U) Insulation for Stainless Steel
All the insulations listed are acceptable for use on stainless steel. After additional review, we concluded a primer is not Justified under insulation on stainless. Instead we recommend that insulation for stain less should get extra attention to be certain that weatherproofing details are good and will keep the insulation dry.
RDS/EHE:dps Attachments A,B,C & D
cc: ETM w/l DRL " FGS " EHE RDS RLP " DMJ JGK/FEJ w/l
D. R. LOEER
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ATTACHMENT B
LIST OF REVISIONS APPEARING IN DRAWING GT-D-2yj73-J "STANDARD INSULATION ITEM NUMBERS"
Insulation - Sectional for Hot Piping For Intermediate Temperatures 10QF-65CF (single layer) and High Temperature 65O-IOOOF (double layer): Note A2(a)-IV adds Keene Thermasil
*
Note A2(c)-1 adds Perlite Carey Temp 1500 For Very High Temperatures, HOOF and above:
Note A3(a) and A3(b) removes hold on J-M Superex 2000 and B&W Kaowool. Insulation Block for Hot Equipment For Intermediate Temperatures IOO-65CF (single layer) and High Temperatures 65CSF-100QF (double layer) : Note B2(a)-IV adds Kenne Thermasil Note B2(c)-i adds Perlite, Carey Temp 1500 For Very High Temperatures, llOOF and above: Note B3(b) removes hold on B&W Kaowool
CHEV BB 012148
ATTAC HMENT C
memoka:jdl\.t
Richmond, California January 17, 1974
EVALUATE PIPE AND VESSEL INSULATION MATERIAL Materials Lab File: M-283.02
MR. E. H. EDWARDS:
The attached report covers the evaluation of insulation materials for service from 450F to 1200F. Five calcium silicates and two mineral wool and one fiberglass materials were tested.
Our test results indicate that some mineral wool insulations, namely Epitherm 1200, will perform better in nearly every category than the calcium silicates except in the load carrying capabilities. All of the mineral wool and fiberglas materials compress when walked upon or put under pressure. They all soak up water when wet but regain their normal characteristics when dried out. All of the insulations were found to have a high percent of leachable chlorides. Accordingly, it is recommended that austenitic stainless steels be coated with a high temper ature silicone paint (Mobile Chem 37J-1, Triangle Paint P-260 or equal) prior to insulating. Additional effort to insure a waterproof jacket would be desirable. All the insulations performed quite well in the fire test except for 40/8 which disintegrated quite rapidly. The calcium silicates and Epi-Therm 1200 glazed at the surface but the insulation appeared to be unaffected.
Based on the tests run and from visual examination of the materials, the Careytemp 1500 and Thermo-12 appear best of the calcium silicates. Eagle Picher mineral wool insulation appears a little easier to apply on pipe than the 40/8 Pipe Insulation; however, there is little, or no, difference between the Eagle Picher and 40/8 block insulation except in the fire test, and for this reason the Epi-Therm would be recommended over the 40/8. Owens-Corning Fiberglas is excellent for temperatures up to 450F, both for preformed pipe insulation and block.
PEJ/jhh
cc: RDS/RLP
File: M-283.02
(^VYW-w J7 G. KERR
CHEV BB 012149
MATKlvIALS LAAOKATOKY UiCHMONb
tut. and vi;:;kf.i. ilAAXATJON NATKKlAhJANHAKY 17, ,'W4
nil: K-263.02
Five i-.ilo him silicate, two inincral wool and one fiberglanr; ir.nulntion materials v.to evaluated for service from 450F to 1200F. Factors considered in this test inelwvic weight loss at the test temperatures, thickness loss using a designated loading at test temperatures, chloride leaching and the effect of the pH factor when subjected to water immeroion.
The following materials were tested:
a. Johns-Manville Company - Thermo 12
b. Owens-Corning Company - Kaylo-10
%
c. Fiberboard Products - Caltemp N.A.
d. Keene Building Products Corp. - Thermasil
e. Celotex Corporation - Careytemp 1500
f. Eagle Picher Company - Epi Therm 1200
g. 40/8 Insulation - 40/8 MF Pipe Insulation
h. Owens-Corning Company - Fiberglas 25 ASJ
All of these insulation materials, except Nos. f and h are block insulation. Nos. f and h are preformed pipe insulation. However, both Eagle Picher and Owens-Corning Company make block type insulation of the same material as the pipe insulation.
1. K-Factors
The "K" factors (in UTU-in/hr/sq.ft./V) for the various materials tested, as obtained from the manufacturers are as follows:
in Temp. Thermo-12 Kaylo-10 i
100 .38 --
200 .41 .38
300 .44 .45
400 .48 .50
500 .52 .56
600 .57 .62 700 .63 .70
800
--
--
Caltemp N.A.
.288 .343.400 .450 .505 .560 .615 .670
Thermasil
.31
--
.41
--
.51
--
.61
Careytemp Epi Therm 40/8 MF Fib .tv, las
1500
1200
25 AM J
--
.42
--
.51
--
.64
.215 .250 .300
.365 .440 .510
--
--
.275
--
.335
--
.44 .53
to
.260
The above Information indicates mineral wool has slightly better insulating
qualclcs than the calcium silicate and all five of the calcium silicates have
about the same Insulating qualities.
CHEV
BB 012150
2
2. Physical Chnr ac Lcr i:; t_i c_s
2.1 JOHNS-MANV1LI.r THERMO-]2 (Max. temperature application - 1500F)
A ilcnse calcium silicate reinforced with fibers. Less pliable than some others, does not break easily in shipment, dusts when cut, but less than some oLhers. Hard to indent with a stick.
2.2 OWENS-CORKING KAYL0-10 (Max. temperature application - 1200F)
A relatively hard calcium silicate with mineral fibers. Breaks easily in shipment. Ten percent or more of Kaylo-10 pieces examined were broken in shipment. Dusts badly when cut, moderately pliable, hard to indent with a stick.
2.3 FIBERBOARD PRODUCTS CO. (PABCO) CAL-TEMP N.A. (Max. temperature application - 1200F)
A calcium silicate with mineral fibers. Soft and easy to indent with a stick. Very pliable and dusts badly when cut. Appears to have a lower amount of fiber reinforcement than some others. Does not break easily in shipment.
2.4 KEENE COMPANY THERMASIL (Max. temperature application - 1200F)
This is Cal-Temp N.A- made under license from Pabco. The insulation is practically identical in every way to Cal-Temp N.A.
2.5 CELOTEX CARYTEMP 1500 (Max. temperature application - 1500F)
A low density pearlite and fiber insulation. Hard to indent with a stick. Very low dust when cut, moderately pliable but has good rigidity and resists cracking and breakage in shipment. Because of its low density it floats in water.
2.6 EAGLE PICHER CO. EPI-THERM 1200 - (Max. temperature application - 1200F)
A soft mineral wool material held together with a water repellant phenolic ester. It holds its shape well and has no tendency to break in shipment. It packs down when compressed. It wets rapidly in water, but when dried out, regains its original characteristics.
2.7 40/8 INSULATION CO. tion - 1200F)
40/8 MF PIPE INSULATION (Max. temperature applica
A mineral wool material, softer than Eagle Picher. The blocks are glued to a thin resin impregnated fiberglas backing. The fibers are similar to Eagle Picher but the binder resin appears to be a phenolic type that burns out at a high temperature. This material packs down under compression and wets in water just like Epi Therm 1200.
2.8 OWENS-CORNING CO. FIBERGLAS 25ASJ (Max. temperature application -- 450F)
This is a glass fibers mat held together with a phenolic binder. At
temperatures above 450F, the binder appears to burn away leaving the
fibers loose with no support.
_ C^HEV
BB 012151
3
3. Temperature lVst.s
All insulation materials were subjected to temperature tests at 450F, 900F and 1200F (if recommended for these temperatures) and the weight loss and deflection under a loading of 40.8 lbs. per sq. ft. were recorded except as indicated below.
BRAND
2 Weight Loss
30 days 0 450F
30 days 0 900F
10 days 0 1200F
Z Thickness Loss
30 days 0 450F
30 days @ 900F
Thermo-12 Kaylo-10 Caltcmp N.A. Thermasil Careytemp 1500 Epi Therm 1200 40/8 MF Fiberglas 25ASJ
5.8 15.5
9.7 7.0 8.0
(1) (1) (3)
9.6 20.4 15.1 12.0 10.0
-
14.0 24.4 27.5 21.0 11.0
3.4 4.6
**
2.7 3.5 2.9 2.9
1.0 1.5 1.0 2.0 1.0 1.6 (2) (2) (2)
> Material tested 0 12OOF only due to expected low weight loss and lack of furnace space.
(2) Mineral wool and fiberglass should not be subjected to any loading conditions and therefore was not tested.
(3) Recommended only for 450F maximum - specimen not tested due to J.ack of furnace space.
4. PH Factor
2-inch square samples of.each brand of insulation were submersed in a beaker of distilled water for 120 hours to determine the effect on the pH factor. The distilled water had an initial pH of 7.2.
BRAND
pH
ThermQ-12 Kaylo-10 Caltemp N.A. Themasil Careytemp 1500 Epi Therm 1200 40/8 MF Fiberglas 25ASJ
8.6 8.4 8.8 8.9 7.7 7.6 7.8 8.5
5. Chloride Leaching
The chloride content was investigated from samples of each insulation furnished. Test work was performed in the Materials Laboratory and at Chevron Research by the following methods:
CHEV BB 012152
A
Materials I.abor.it ory
A cu.in. of insulation were placed in 500 ml. of distilled water for a period of 30 days. The chloride content was analyzed by the Socal Chemical Laboratory by adding to the aqueous solution, HNO-j (nitric acid) and titrated potentiometrically with A8NO3 (silver nitrate;.
Chevron Research
Test No. 1 Basic chloride content - Chloride is extracted from the insulation by stirring a one gram sample for 15 to 20 minutes in 50 ml of distilled water plus 1 to 1 IINO3 at room temperature. 50 ml of Isopropyl alcohol is added and the solution is filtrated potentiometrlcally with 0.02 AgNO-j.
Test No. 2 - Effect of hot water at 200F upon insulation. One gram 6ample*plus 30 ml distilled water stirred for five minutes at 200F. Water decanted and filtered through a five micron Millipore filter. The remaining asbestos in the beaker was washed three times with ten ml of distilled water each time and the washings filtered through the five micron Millipore filter. The combined filtrates were titrated for chloride by then adding 5 ml 1:1 HNO^ plus 50 ml of isopropyl alcohol.
The chloride contents determined from the above tests were as follows:
Col. 1
Col. 2
Col. 3
Trade Name
Materials Lab chlorides extractable by water @ room temperature
Chev. Research chlorides in insulating material
Chev. Research chlorides extractable by water @ 200F
Thermo-12 Kaylo-10 Caltemp N.A. Thermasil Careytemp 1500 Epi Therm 1200 A0/8 MF Fiberglass 25ASJ
3 ppm 2 ppm 15 ppm 11 ppm 3 ppm A ppm
-
2 ppm
6A6 ppm <( 100 ppm
333 ppm 185 ppm <1 100 ppm 299 ppm 360 ppm'l) <^100 ppm
556 ppm </_100 ppm
360 ppm 291 ppm 100 ppm 257 ppm -ClOQ ppm 100 ppm
(1) A0/8 mineral wool contains a considerable amount of sulfides which evolve as H2S when acid is added to the sample. The amount, 360 ppm could include the H2S which is also titratable with AgN03.
CHEV BB 012153
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7. Conclusions
These test results indicate that the mineral wool insulations will perform better in nearly every category than the calcium silicates except in the load carrying capabilities. Where insulation can be readily damaged by personnel traffic or other mechanical impact conditions consideration should be given to adequately jacketing mineral wool installations or consider the calcium silicates with a suitable waterproof type jacket.
In reviewing the manufacturer's literature, mineral wool appears to have slightly better insulating qualities than the calcium silicates. All of the calcium silicates have about the same insulating qualities. The calcium silicates also have a larger weight loss at their rated maximum application temperature than the mineral wool but all will perform at the temperatures claimed by the manufacturer. The calcium silicates also tend to change the neutralization of water (towards alkalinity) to a greater degree than mineral wool although our tests do not show a disastrous trend with any of the materials tested.
All of the insulations were found to have a high percent of leachable chlorides. Hot water (200F) tended to release all of the available chlorides inherent in the insulation as noted in paragraph 5, columns 2 and 3. At ambient temperatures, the chlorides are released at a considerably slower rate (column No. 1) but are high enough to^give concern with use on austenitic stainless steels.
Until insulations are provided chloride free, austenitic stainless steel piping should be coated with a high temperature silicone paint prior to insulating. Additional effort to insure a waterproof jacket would also be desirable.
All of the insulations performed quite well in the fire tests except 40/8 which disentegrated quite rapidly. The balance of the insulations glazed at the surface but appeared to be unaffected underneath.
PEJ/JED/jhh
J. E. DAVIS
CHEV BB 012155
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