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power JULY 19S3 I " /...$&. /JA -;<S 7''v,V7.,m -dm th ' g floor at ill's Warrn, jj 'lant . ->;* - v JUSTIN R WHITING PLANT of Consumers Power Co, near Erie, Mich. Unifs No. 1, 2 operating. No. 3 building Early stage in insulation application around corner in spection door on boiler. Lath, studs, tie wires ready Smart Insulation Methods Cut Cost In Modern Statione proper - *': place for eying,} y LL VOLVED and Distributors iters valves er works supplies nditioning systems 'ER * JULY 1953 The key to better insulation in any plant is good applica tion of suitable materials. This is especially true in today s high-pressure .high-temperature stations where the right materials and methods cut costs from start to finish of installation; and during every day the plant runs. Here's a picture story showing many of the methods chosen for a 1480-psi 1000-F reheat station of Consumers Power Co. Erie. Mich. Starting at the boiler we follow steam flow to superheater, main steam line and turbine, stopping at each to see the insulation application tech niques selected. Though any insulation saves Btu's. the right material correctly applied does far more. Its maintenance cost is lower, appearance neater, life longer. The insulation shown here is Kavlo (hydrous calcium silicatel but many of the modern installation methods pictured are suitable for other high-temperature insulating materials. For more pictures, turn page 73 inspection door is now almost completely surrounded with insulation. Tie wires have been pulled through, fastened Casing helps protect the job Mft km !- "V ;J ir;` i INSULATION coniinutd 8 Securing tie wires for block insulation on boiler super- 1 A Here half-nuts are being applied to a welded stud on the heater wall. Block joints pointed with insulating cement * " recirculating-air duct. Stucco lath is over insulation 74 ENGINEERING AND MANAGEMENT SECTION POWER JU cks in place, .s from tubes 6 Metal straps tie insulating blocks to mesh on back wall H Air-heater inspection door showing corner beading, lath of air heater. Note the expansion joint at lower right * and tie wires. Metal strops (not shown) ore also used Many Application Methods Are Used in Insulating a Modern Boiler Careful planning and accurate fitting insure a tight job, good for many years of service. In this photo story, neat finish shows work quality over blocks, iock insulated ed stud on the >ver insulation POWER JULY 1953 ENGINEERING AND MANAGEMENT SECTION turn page - 111 <j vs 4 i s/1 * conzmuea Induced-Draft Fan and Main Steam Lines Take Two Layers of High- f O Start of block application to main steam lines showing O the tie wires that hold the blocks to frames on pipes Second layer of block insulation is wired to main steam lines. Pointing cement already applied to first layer 76 ENGINEERING AND MANAGEMENT SECTION POWER jrface clean 4 A Steam at 1 000 F leaves boiler from two secondary outlet i "7 From tubes, steam flows through these main lines before 1 0 headers having seven 5-in, tubes. Two layers on tubes * * entering turbine. Frames on lines will support blocks ! Temperature Insulation, Have Smooth, Well-Finished Exteriors steam layer POWER OA Specially notched block being applied to the expansion Ai Finished expansion joint in vertical steam lines running "V joint in the insulation surrounding the main steam lines * between boiier and turbine. The work is neat and clean JULY 1953 ENGINEERING AND MANAGEMENT SECTION turn page INSULATION continued 26 High-pressure end of turbine for No. 2 unit with insu lation applied. Casing over insulation completes the job Details of Whiting Plant Insulation Table below gives schedule o thick nesses chosen for various temperatures and pipe sizes at Whiting. All high-tem perature insulation is Kaylo (hydrous calcium silicate) preformed for applica tion on flat and curved equipment and pipes in the plant. Pipe insulation is nested; that is, out side diameter of first layer is a size that permits second layer to fit snugly. Fas tening method varies with surface insu lated, wires, studs and lath being used as illustrated. Pipes and valves are fin ished with canvas and cement to give a smooth exterior, easy to paint and keep clean at all times. Expansion joints in pipe, duct and flat-surface insulation are specially con structed and carefully located to insure freedom of movement without danger to the insulation. Metal corner beads pro tect block edges, give a neat and true finish of lasting quality. Though only high-temperature insula tion is illustrated here, a number of other materials are used in the 40-90 F range. Table below shows typical speci fications for them. With Units No. 1 and 2 operating, and No. 3 nearing completion, experience proves the application methods illus trated give good service. Insulation Thickness for Various Pipe Sizes and Temperatures 24 Second layer, finish and expansionjoint covering on the reheat lines 25 Insulation and supports for main steam and reheat lines, Unit No. 1 Degrees, F 150- 350 350- 450 450- 550 550- 650 650- 800 800- 900 900-1000 1000-1200 40-60 60-90 60-90 40-90 Pipe Sizes in inches, With High and Low Temperatures i/2- H High Low i-m/2 2-4 High Low High Low 5-3 High Low 10- 14 16 & over High Low High Low _ 1 -- 1 --1 -- 1'4 _ 11-4 _ T/z -- 1^2 -- 1 '4 -- 1 '4 --2 -- 214 -- 214 --2 2_ 2_ 2_ 2_ -- 2 --2 -- 214 --3 --3 2 -- 1V4 114 2 V'2 2 114 214 2 -- 114 2 1V4 214 1H 2'4 2 214 2 -- 2 2 21.-4 2 21i 2'4 214 3 1 '4 1V4 2 2<4 2>4 214 3 2'/4 3 3 2'2 -- 114 114 2 214 2',4 214 3 3 3 314 Two ',4-in. layers of antisweat covering (well water and drinking water) One layer of 1-in. wool felt (river water) Cork spray built up to a minimum of 14-in. thickness Sheet-metal protective covering Asbestos-cloth protective covering Waterproof cement 1 i | One layer 1-in. hair felt tied on with jute twine or No. 14 Copperweld wire on 6-in. centers, 1-2-in. asbestos cement; poultry netting with 1-4-in. water proof cement finish 78 ENGINEERING AND MANAGEMENT SECTION POWER <1