Document mqb5YMEML3q7jQ2rw3gX6v6Jg

INGINIIRING STANDARD PIPING E3-3.I FITTINGS, GASKETS, and BOLTING MATERIAL SELECTION CHARTS CELANESE CORPORATION OF AMERICA Central Engineering Charlotte Office 000097 Approved June 5, 1962 CELANESE CORPORATION OF AMERICA PIPING FITTINGS, GASKETS, and BOLTING MATERIAL SELECTION CHARTS Sponsor - Chemcel ENGINEERING STANDARD E3-3.1 Issued 11/1/55 Rev. No. 1 Date 6/5/62 TABLE OF CONTENTS section 1. Scope 2, General Fitting Selection Gasket Selection 4.1 Explanation of GasketCode .5 Bolting Selection 5.1 Specification for FlangeBolting Material 5.2 Stud Bolt Dimensions ~Se No* 2 2 3 4_5 6 7 7 8-9 000098 (1) CELANESE CORPORATION OF AMERICA PIPING FITTINGS, GASKETS, and BOLTING MATERIAL JCTL?LT IITjUPTI 1TrUt1M1 PUXUUAUDVTXCt? Sponsor - Chemcel ENGINEERING STANDARD E3-3.1 Issued 11/1/55 Rev. No. 1 Dat 6/5/1 1. SCOPE This standard covers selection charts for fittings, gaskets and bolting material intended for use in designing piping systems. Manufacturers' recommendations and ASA Standards should be followed in all cases where other materials not in cluded in this standard are used. 2. GENERAL The purpose of this standard is to provide the designer and material take-off men with convenient charts to serve as a guide in the selection of fittings, gaskets and bolting materials suitable for service equivalent to the piping specified. The items shown are not ordinarily specified on piping drawings, but their specifications must be clearly set forth on the bills of material for purchasing and stores use and for use of the pipe fabricators and erectors. Use of the charts will expedite the job of material take-off men and serve as an aid in obtaining a more consistent quality of material specified in the design and fabrication of piping systems. 000099 (2) Engineering Standard E3-3.1 June 5, 1962 3. FITTING SELECTION Fittings should be selected from the following chart according to the type of pipe required. For any fittings not Included refer to manufacturers' recom mendations or ASA Piping Standards. FITTING SELECTION CHART Pipe (Code) Fittings 53 W 53 A 53 B 83 A (1-1/2" & smaller only) 120 W 120 G (3" & larger) 106 A 120 G (2-1/2" & smaller) (1)(4)*WPB Seamless Carbon Steel for use with ASTM A-106 Grade B pipe, ASTM A-234 Marking Symbol "WPB" Schedule No. "Same as Pipe" *150# Screwed Malleable Iron Galvanized Crane, Valworth, Vogt, or Grinnel 106 B AL 3 (1)(4)*WPB Seamless Carbon Steel for use with ASTM A-106 Grade B pipe, ASTM AS234 Marking Symbol "WPB" Schedule "Same as pipe" (1) Forged 6061 Aluminum Alloy Cu 42 CU 42 T B 43 B 43 T 304 310 316 317 161 S 165 S SL GL AGL Bronze Sweat Fittings 150 PSI at 500 F, Silver Solder Joints - Walworth or equal (1) *ASTM A-312 Type 304 Butt-Weld L.R. (1) ASTM A-312 Type 310 Butt-Weld L.R. (1) *ASTM A-312 Type 316 Butt-Weld L.R. (1) ASTM A-312 Type 317 Butt-Weld L.R. (1) ASTM B-161 Seamless (1) ASTM B-165 Seamless Butt-Weld (1) Saran lined Carbon Steel, any grade flan; As recommended by manufacturer As recommended by manufacturer NOTE: 1) All fittings shall be same schedule as pipe except where pressure ra is specified above. 2) For stainless steel tubing, use mitered fittings when tubing size fi tings are not available. 3) Fittings are not coded on drawings. This standard to be used primar for fitting selection and for material take-off. 4) ASTM A-105-I socket weld fittings may be substituted for 1-1/2" and smaller pipe (Symbol for socket weld fittings to be shown on drawing Standard fittings used within the Corporation. 000100 (3) Engineering Standard E3-3.1 June 5, 1962 4. GASKET SELECTION Gaskets listed in the following Chart are recommended for use with flanges of various pressure ratings and facings. The chart is set up in tabular form with a letter code to indicate the type of gasket. The letter code is applied only for ease in selecting the gaskets from this standard and is not meant to be used as a means of identification on drawings, specifications or warehouse records. Where identification of gaskets is required, it should be spelled out. The material listed is adequate to cover gasket requirements for general piping installations throughout the Corporation. It is recognized that each plant may have areas where special materials are required. These requirements should be considered "special" and a specification sheet added to the standards by the plant concerned. Gasket materials found satisfactory in some specific problem areas may be found in Engineering Standard E12-2.1. (4) Engineering Standard E3-3.1 June 5, 1962 GASKET SELECTION CHART Material Iron Iron Iron Flange or Flanged Valve Description Type Flat Face Flat Face Raised Face Rating, PSI 25 125 250 Gasket Symbol * B B A Carbon Steel Carbon Steel Carbon Steel Carbon Steel Carbon Steel Carbon Steel Flat Face Raised Face Raised Face Raised Face Ring Joint Small Tongue & Groove 150 150, 300, 400 600 900, 1500, 2500 All All B A E(1) E F g(2) Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Nickel Monel Alloy 20 Full Face Corrosion Std. ASA Raised Face Raised Face Lap Joint Lap Joint Flat Face Flat Face Flat Face 150 150, 300 600 150, 300 600 150 150 150 D C E C E B B D Bronze Karbate Aluminum Aluminum Glass or Glass Lined Porcelain Flat Face Raised Face Flat Face Raised Face Flat Face Raised Face 150, 300 150 150 125 - D J D C H J *Refer to next page for explanation of gasket symbols AND Notes (1) and (2) 000102 (5) 4.1 Explanation of Gasket Code June 5, 1962 Gasket Symbol Gasket Specification A Ring Type 1/16" Tk Preferred: B Full Face 1/16" Tk Bellmont 585 or Crane 888 C Ring Type 1/16" Tk Acceptable: Garlock 8748 or Anchor 451 D Full Face 1/16" Tk E Type 304 stainless steel spiral wound, asbestos inserted, .175" thick gasket with .125" thick metal gauge ring, ring shape, Flexitallic Style CG or equal. F Steel rings 4-6% chrome, 1/2" moly, 130 maximum Brinnell hardness, oval or octagonal ASA or API Standard. Cup grease before installation. G Lead - 1/16" thick. Ring type. b H Teflon or Teflon jacketed rubber full face J Teflon or Teflon jacketed rubber ring type (1) Where 600# flanges or valves are required by service tem peratures and pressures, gasket "E" shall be used. Where standard procedure calls for 600# flanges or valves on a service which could use flanges or valves of a lower rat ing, gasket "A" shall be used. (2) Small tongue and groove flanges shall be used only for ammonia service. Should other types of gaskets be required, assign each a code continuing with "K" and add to this sheet for construction standards. V 000103 (6!) Engineering Standard E3-3.1 June 5, 1962 5. BOLTING SELECTION Flange bolting material is selected according to the type of flanges and fac ings. A bolting code is ordinarily not required on piping drawings. The following table specifies the type of bolting material required for speci fic flanges and is followed by dimensional sheets for bolts and studs. These sheets will be of considerable value when preparing a material list as well as assuring proper installation in the field. Minimum bolting requirements shall be in accordance with ASA B16.5 and Para graph 616 of the ASA Piping Code, B31.1. 5.1 Specifications for Flange Bolting Material. Flanges and flanged valves listed below require carbon steel machine bolts equivalent to ASTM A 307 Grade B, without heat treatment other than stress relief. 1) 250# Raised Face Iron Flanges 2) Any Flat Face Iron Flange Joined with a Raised Face Flange 3) 150# Raised Face Aluminum Flanges 4) Glass, glass lined, porcelain, or porcelain lined valves or flanges 5) Cast iron split flanges for Haveg pipe All other flanges and flanged valves require heat treated carbon steel (ASTM A 261), or alloy steel (ASTM A 193) bolting material. Stud bolts are required for high temperature services. BOLT AND NUT SPECIFICATIONS* Item Description Material Thread Dimensions Stud Bolts Alloy Steel ASTM A-193 Continuous Thread Grade B-7 ASA B-1.4 ASA B-18.2 Nuts for Stud Bolts Heavy Hex Semi-finished ASTM A-194 Grade 2H ASA B-1.4 ASA B-18.2 Machine Bolts Regular Square Unfinished ASTM A-307 Grade B Coarse ASA B-l.l ASA B-18.2 Nuts for Machine Bolts Heavy Hex Semi-finished ASTM A-307 Coarse Grade B ASA B-l.l ASA B-18.2 Class 2 fit *This chart shows that alloy steel bolt studs and machine bolts are recom mended. Substitutions may be made in accordance with ASA B16.5 and ASA B31.1. 000104 (7) Engineering Standard E3-3.1 June 5, 1962 5.2 Stud Bolt Dimensions. Nominal Pipe Size 1/2 3/4 1 17172 2 3 4 6 8 10 12 14 16 18 20 24 150# FLANGED Diameter of Number of Bolt Bolts 1/2 4 1/2 4 1/2 4 1/2 4 5/8 4 5/8 4 5/8 8 3/4 8 3/4 8 7/8 12 7/8 12 1 12 1 16 To78 16 1-1/8 20 1-1/4 20 JOINTS 1/16" R.F. 2-1/2 l-Ol 2-1/2 3 3-T72 3-1/2 3-1/2 4 4-T72 5 5 5-1/2 5-f72 6 6-1/2 7 LENGTH Corr. Std.* 2 2 2 2-1/2 2-1/2 3 3 3-1/2 4 4-1/2 4-1/2 R.> - - 3 34 4-: 4-: 4-: 5 5-1 5-] 6 6 6-1 7 8 Nominal Pipe Size 1/2 3/4 1 1-1/2 2 3 4 6 8 10 12 14 16 18 20 24 300# FLANGED Diameter of Number of Bolt Bolts 1/2 4 5/8 4 5/8 4 3/4 4 5/8 8 3/4 8 3/4 8 3/4 12 7/8 12 1 16 1-1/8 16 1-1/8 20 1-1/4 20 1-1/4 24 1-1/4 24 1-1/2 24 JOINT S 1/16" R.F. 2-1/2 3 3 3-1/2 3-T72 4-1/2 4-1/2 5 5^172 6 7 7 7-1/2 8 8^172 9-1/2 LENGTH Corr. Std.* - - - - - - - - - - - R.J - - - - 4-1 5 5-1 6 6 7-1 7-1 8 8-1 9 9-1 10-1 NOTES: jau*- * Corrosion standard for use with corrosion standard stainless steel flat faced flanges. Lengths given do not include height of bolt end crowns. Lengths include thickness of two nuts. I 000105 (8) Engineering Standard E3-3.1 June 5, 1962 Nominal Pipe Size 1/2 3/4 1 1-1/2 2 3 4 6 8 10 12 14 16 18 20 24 600# FLANGED Diameter of Number of Bolt Bolts 1/2 4 5/8 4 5/8 4 3/4 4 5/8 8 3/4 8 7/8 8 1 12 1-1/8 12 1-1/4 16 1-1/4 20 1-3/8 20 1-1/2 20 1-5/8 20 57378 24 1-7/8 24 JOINTS 1/4" R.F. 3 3-1/2 3-1/2 4-172 4-1/2 5 6 7 8 8-1/2 9 9-1/2 10 11 11-1/2 13 LENGTH T& G 3 3-1/2 3-1/2 4 4 5 5-1/2 6-1/2 7-1/2 8-1/2 8-1/2 9 10 10-1/2 11-1/2 13 R.J 3-1 3-1 4-1 4-1 5-1 6 7 8 9 9 9-1/ 10-1/ 11 12 13-1/ Nominal Pipe Size 3 4 6 8 10 12 14 16 18 20 24 900# FLANGED Diameter of Number of Bolt Bolts 7/8 8 1-1/8 8 1-1/8 12 1-3/8 12 1-3/8 16 1-3/8 20 1-1/2 20 1-5/8 20 1-7/8 20 2 20 2-1/2 20 JOINT S LENGTH 1/4" R.F. T& G 6 5-1/2 7 6-1/2 8 77172 9 8-1/2 97175 9 10 10 11 10-1/2 11-1/2 11 13 13 14 13-1/2 17-1/2 17 R.J. 6 7 8 9 9-1/2 10-1/2 11-1/2 12 13-1/2 14-1/2 18 i i NOTES: Lengths given do not include height of bolt end crowns. Lengths include thickness of two nuts. 000106 PLANT ENGINEERING MANUAL REVISION RECORD INSULATION INSUL 000108 VhIELANESE PLASTICS COMPANY rishop plant DATE 11/14/74 scv. NO Ino. INSUL-1. 2. 3. 0 | A. 5. AND 6 PLANT ENGINEERING MANUAL REVISION RECORD |T Da. 1 MCVIEWCD ISSUE MTt 11/14/74 INSULATION THIS PAGE IS A RECORD OF ALL REVISIONS OF THE SPECIFICATION. EACH TIME THE SPECIFICATION IS CHANGED, ONLY THE NEW OR REVISED PAGES ARE ISSUED. FOR CONVfiNIENCE, THE NATURE OF THE REVISION IS BRIEFLY NOTED UNDER REMARKS. BUT THESE REMARKS ARE NOT A PART OF THE SPECIFICATION. THE REVISED PAGES ARE A PART OF THE SPECIFICATION AND SHALL BE . COMPLIED WITH IN THEIR ENTIRETY. REV DATE BY APPROVAL PAGES REMARKS 0 10 7`l 1 .2/1/ '5 79 Issued for Celanex Phase II Expansion 88 New Issue - 441C (3/67) 000109 ^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE 11/4/74 *V. NO. 0 NO. INSUL-1 PAGE 2 OF 88 INDEX INSULATION - MATERIALS LOGIC LOG 1. SCOPE 2. INSULATING MATERIALS 2.1 CALCIUM SILICATE 2.1.1 2.1.2 2.1.3 Description Service 2.1.2.1 Temperature Range 2.1.2.2 Components Insulated Thickness 2.2 MINERAL WOOL 2.2.1 2.2.2 2.2.3 Description Service 2.2.2.1 Temperature Range 2.2.2.2 Components Insulated Thickness 2.3 CELLULAR GLASS 2.3.1 2.3.2 2.3.3 Description Service 2.3.2.1 Temperature Range 2.3.2.2 Components Insulated Thickness Page (s) 5 5 5 5 5 5 6 6 6 6 7 -j 7 7 3 2.4 FIBERGLASS 2.4.1 2.4.2 2.4.3 Description Service 2.4.2.1 Temperature Range 2.4.2.2 Components Insulated Thickness 8 8 8 8 8 F -4 4 IB <3/67) 000110 ^^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE MO. 11/4/7* INSUL-1 tv. NO. 0 PAGE 3 OF 88 j INDEX INSULATION - MATERIALS LOGIC LOG_______ (Continued) 2. INSULATING MATERIALS (Continued) Page (2) 2.5 INSULATING CEMENT 2.5.1 2.5.2 2.5.3 Description Service 2.5.2.1 Temperature Range 2.5.2.2 Components Insulated Thickness 8 '9 9 9 2.6 CORK-FILLED MASTIC 2.6.1 2.6.2 2.6.3 Description Service 2.6.2.1 Temperature Range 2.6.2.2 Components Insulated Thickness 9 9 2.7 ASBESTOS TAPE 2.7.1 2.7.2 j 2.7.2 Description Service 2.7.2.1 Temperature Range 2.7.2.2 Components Insulated Thickness 2.8 FOAMED PLASTIC 2.8.1 2.8.2 Description Service 2.8.2.1 Temperature Range 2.8.2.2 Components Insulated 2.9 URETHANE 2.9.1 2.9.2 2.9.3 Description Service 2.9.2.1 Temperature Range 2.9.2.2 Chemical Resistance 2.9.2.3 Other Limitations 2.9.2.4 Components Insulated Thickness F-441 B (3/67) ^^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE Ll/4/74 ftEV. NO. 0 NO. INSUL-1- PAGE 4 OF 88 INDEX INSULATION - MATERIALS LOGIC LOG (Continued) 3- WEATHER--BARRIER MATERIALS 3.1 ALUMINUM 3. 1.1 3. 1.2 Description Service 3.1.2.1 Moisture Barrier 3.1.2.2 Components Jacketed 3.2 MASTIC 3. 2.1 3. 2.2 Description Service 3.3 POLYVINYL CHLORIDE (PVC) 3. 3.1 3. 3.2 Description Service 3.3.2.1 Temperature Range 3.3.2.2 Chemical Resistance 3.3.2.3 Components Jacketed 3.4 OTHER MATERIALS 4. ACCESSORIES 4.1 JOINT SEALER 4. 1.1 Description 4. 1.2 Service 4.2 GLASS CLOTH 4. 2.1 Description 4. 2.2 Service 4.3 WIRE NETTING 4. 3.1 Description 4. 3.2 Service 4.4 BANDS 4. 4.1 4. 4.2 Description Service 4.4.2.1 Aluminum Jacketing 4.4.2.2 Pipe Insulation 4.4.2.3 Vessel Insulation ooonz Page (s) .12 ^13 '13 :i3 '13 13 13 14 14 14 1 uj 14 14 -1 if i.5 -15 15 -15 15 15 15 F -44IB (3/67) QLelanese plastics company Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG OATC Ll/4/74 tcv. NO. 0 INbUL*i PAGE 5 OF 88 INDEX INSULATION - MATERIALS LOGIC LOG (Continued) 4.5 WIRE 4.5.1 Description 4.5.2 Service 4.6 SCREWS 4.6.1 Description 4.6.2 Service :16 16 16 : 16 4.7 STAPLES 4.7.1 Description 4.6.2 Service 16. 16 1. SCOPE A statement to explain the contents and logic of this section. 2. INSULATING MATERIALS 2.1 CALCIUM SILICATE 2.1.1 Description Gives type and form of pipe covering desired. Inhibitor is required since calcium silicate is sometimes used on stainless steel piping. Some calcium silicate insulation contains asbestos, CAUTION: Handling of asbestos containing materials may be hazardous to the health of the worker. Precautions are required as per OSHA 2.1.2 Service 2.1.2.1 Temperature Range Calcium silicate is used for pipe covering above the 450F limit of most fiberglass coverings. When used for applications above 1200F consult manufacturer's data for suitability of the product used. -441 B (3/67) 000113 ^^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE HO. Ll/4/74 INSUL-1 HEV. HO. 0 PAGE 6 OF 88 INDEX INSULATION - MATERIALS ________LOGIC LOG (Continued) 2.1.2.2 Components Insulated Used on small diameter equipment due to ease of application. No case of stress corrosion cracking attributable to calcium silicate insulation has been experienced in the drier non-coastal locations; therefore, inhibitied calcium silicate is used at these locations for economy. 2.1.3 Thickness Method of calculating thickness is given because rapidly changing economic conditions make a standard thickness specification impractical. Temperatures above 600F require multi-layer insulation to protect the weather-proofing and prevent excessive heat loss at the joints. 2.2 MINERAL WOOL 2.2.1 Description Gives type of covering desired. This may be altered to fit services as required by the Project Engineer. It is a non-asbestos containing material conforming to the requirements of the OSHA rulings. 2.2.2 Service 2.2.2.1 Temperature Range Mineral wool may be used up to 1200F depending on manufacturer and binder material. 2.2.2.2 Components Insulated Mineral wool does not contain chlorides which would prohibit use on stainless steel. -441 B (3/67) 000114 Qbeianese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE NO. Ll/4/74 INSUL-1 REV. NO. 0 PAGE 7 OF 88 INDEX INSULATION - MATERIALS ________LOGIC LOG (Continued) 2.2.3 Thickness Method of calculating thickness is given because rapidly changing economic conditions make a standard thickness specification impractical. Temperatures above 600F require multi-layer insulation to protect the weather-proofing and prevent excessive heat loss at the joints. 2.3 CELLULAR GLASS 2.3.1 Description Gives the acceptable material type and forms. The i acceptable form will depend on the application, local insulator preference, and installed cost. 2.3.2 Service 2.3.2.1 Temperature Range 800F is the upper limit for cellular glass insulation. 16F is the lowest temperature normally encountered in our work; however, cellular glass can be used at much lower temperatures. 2.3.2.2 Components Insulated Cellular glass insulation is used for low temperature service because it is imprevious to moisture. It is used on equipment because it is durable and light weight. Some coastal locations have experienced stress-corrosion cracking of stainless piping when insulated with inhibited calcium silicats and therefore cellular glass may be specified over stainless steel in coasta] locations or where humidity levels are normally high. F -4 4 IB (3/67) 000115 ^Kielanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE Ll/4/74 ffV. NO. 0 NO. INSUL-1 PAGE 8 OF 88 INDEX INSULATION - MATERIALS ________LOGIC LOG (Continued) 2.3.3.1 Thickness 2.4 FIBERGLASS Method of calculating thickness is given because rapidly changing economic conditions make a standard thickness specification impractical. Temperatures above 600F require multi-layer insulation to protect the weather proofing and prevent excessive heat loss at the joints. 2.4.1 Description Gives the form of covering desired. 2.4.2 Service . 2.4.2.1 Temperature Range Most fiberglass materials are limited to about 450F due to the binders. Certainteed 850 is usable to 850F. 2.4.2.2 Components Insulated Used for economy and eas of application wherever it can be used. 2.4.3 Thickness Method of calculating thickness is given because rapidly changing economic conditions make a standard thickness specification impractical. Temperatures above 600F require multi-layer insulation to protect the weather-proofing and prevent excessive heat loss at the joints. 2.5 INSULATING CEMENT 2.5.1 Description Gives the type and some acceptable brands which have been tested and found to mix well, adhere to the insulated surface, produce a smooth finish, and hold up well in service. F -4 4 IB (3/67) CBbelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE NO. Ll/4/74 INSUL-1 *CV. NO. 0 PAGE 9 OF 88 INDEX INSULATION - MATERIALS LOGIC LOG (Continued) 2.5.2 Service 2.5.2.1 Temperature Range Mineral wool insulating cement is not used in low temperature service and the upper limit varies with the product.used. 2.5.2.2 Components Insulated Used where rigid forms are impractical and to produce a smooth surface free of voids where mastic weatherproofing is used over calcium silicate, fiberglass, or cellular glass insulation. 2.5.3 Thickness Gives the thickness when used as the insulating material. 2.6 CORK-FILLED MASTIC 2.6.1 Description Gives the type of product and an acceptable brand which has been successfully used. 2.6.2 Service 2.6.2.1 Temperature Range Temperatures above and below this range justify materials with greater insulating values. 2.6.2.2 Components Insulated Used for ease of application and economy where a minimum of insulation is required. 2.6.3 Thickness Thickness will depend upon the severity of service conditions. Consult manufacturer's data. 000117 F -441 B (3/67) Gbeianese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE NO. Ll/4/74 INSUL-1 ffV. NO. 0 PAGE 10 OF 88 INDEX INSULATION - MATERIALS LOGIC LOG 2. INSULATING MATERIALS (Continued) 2.6 CORK-FILLED MASTIC (Continued) 2.6.2 Service 2.6.2.1 Temperature Range Temperatures above and below this range justify materials with greater insulating values. 2.6.2.2 Components Insulated Used for ease of application and economy \ where a minimum of insulation is l required. 2.6.3 Thickness Thickness will depend upon the severity of service conditions. Consult manufacturer's data. 2.7 ASBESTOS TAPE 2.7.1 Description Type and form desired to give good coverage and not be too wide to be applied around tubing bends. 2.7.2 Service 2.7.2.1 Temperature Range Below 180F use foamed plastic because it is easier to apply. 2.7.2.2 Components Insulated Can be easily applied around tight bends and wrapped around valves and fittings. 2.7.3 Thickness Thickness required for personnel protection and conservation of heat. F -4 4 IB (3/67) 000118 GLelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE NO. Ll/4/74 INSUL-1 REV. NO. 0 PAGE 11 OF 88 INDEX INSULATION - MATERIALS ________LOGIC LOG (Continued) 2. INSULATING MATERIALS (Continued) 2.8 FOAMED PLASTIC 2.8.1 Description Gives type and form desired. 2.8.2 Service 2.8.2.1 Temperature Range Upper temperature limit is 180F. Is economical to apply since no weatherbarrier is required. 2.8.2.2 Components Insulated Can be easily applied around bends. 2.8.3 Thickness Thickness necessary to prevent condensation in cold service is required. 2.9 URETHANE 2.9.1 Description Gives the forms of covering desired. 2.9.2 Service 2.9.2.1 Temperature Range A preferred material for low temperature.. Above 225F, it will degrade and release harmful vapors. 2.9.2.2 Chemical Resistance Urethane will be dissolved or degraded by the listed chemicals. < 4 IB (3/67) 000119 Qielanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG OATE NO. Ll/4/74 INSUL-1 AtV. NO. 0 PAGE 12 OF 88 INDEX INSULATION - MATERIALS LOGIC LOG 2. INSULATING. MATERIALS (Continued) 2.9 URETHANE (Continued) 2.9.2.3 Other Limitations Sunlight will degrade urethane and cause loss of adhesion and insulating properties. Moisture will react with and degrade it. Urethane will burn and release smoke and combustible gases. Degradation from any cause can release harmful gases which can accumulate to dangerous levels in confined spaces. 2.9.2.4 Components Insulated Spray urethane is generally economical only on large surface area vessels. 2.9.3 Thickness Method of calculating thickness is given because rapidly changing economic conditions make a standard thickness specification impractical. Normal tolerance for spray is -0, +25%. Above 3" thick spray adhesion to metal would be question able, and 3" is adequate to prevent condensate in cold service at the minimum temperature and to give negligible heat loss in hot service at the maximum temperature. 3. WEATHER-BARRIER MATERIALS 3.1 ALUMINUM 3.1.1 Description These alloys are easily obtainable and are easy to work with. These are the minimum thickness of material that can be easily handled without damage due to wrinkling. F-441 B (3/67) 00012U ^SLelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE Ll/4/74 V. NO. 0 NO. INSUL-1 PAGE 13 OF 88 INDEX INSULATION - MATERIALS LOGIC LOG (Continued) 3. WEATHER-BARRIER MATERIALS (Continued) 3.1.2 Service 3.1.2.1 Moisture Barrier To prevent corrosive attack to the aluminum due to high humidity. 3.1.2.2 Components Jacketed Type of aluminum used on straight run piping is largely plant preference. The use of aluminum elbow, valve, tee, and flange jackets will depend on economics. Jacketing of vessels and heat exchanger shells is a matter of plant preference. Corrugated aluminum is not used on horizontal vessels and heat exchangers because on a large diameter shell the corrugations would allow water to stand and seep into the insulation at circumferential laps. 3.2 MASTIC 3.2.1 Description These mastics have been used at the various plants and are preferred. 3.2.2 Service All insulation not jacketed with aluminum or pvc must be covered with a mastic weather-barrier to protect the insulation. 3.3 POLYVINYL CHLORIDE (PVC) 3.3.1 Description Describes types of material available. Ultraviolet light will imbrittle non-UV stabilized formul ations. Test methods used to describe burning properties of plastics are being revised. F-441 B (3/67) 000121 ^^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG OATE Ll/4/74 *ev. no. 0 NO. INSUL-1 PAGE 14 OF 88 INDEX INSULATION - MATERIALS LOGIC LOG (Continued) 3. WEATHER-BARRIER MATERIALS (Continued) 3.3 POLYVINYL CHLORIDE (PVC) (Continued) 3.3.2 Service (Continued) 3.3.2.1 Temperature Range Above I50F, PVC will lose dimensional stability. 3.3.2.2 Chemical Resistance Chemicals listed will dissolve or swell PVC. 3.3.2.3 Components Jacketed Lists pipe and fittings for which jacketing is available, and sheet stock for equipment. 3.4 OTHER MATERIALS Stainless steel should be used in environments corrosive tc aluminum or in which PVC or mastic are not desired. 4. ACCESSORIES 4.1 JOINT SEALER 4.1.1 Description These joint sealers have proven economical and satisfactory in service. 4.1.2 Service To completely seal the insulation to prevent moisture vapor from entering and condensing or freezing which would damage the insulation or reduce its effectiveness. 4.2 GLASS CLOTH 4.2.1 Description These materials are easy to work and have been proven acceptable in use. 000122 F -4 4 IB (3/67) ^Lelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE NO. 11/4/74 INSUL -1 RCV. NO. 0 PAGE 15 OF 88 INDEX INSULATION - MATERIALS LOGIC LOG (Continued) 4, ACCESSORIES (Continued) 4.2 GLASS CLOTH (Continued) 4.2,2 Service Asphalt impregnated glass cloth produces a better bond when used with solvent cutback mastics. 4.3 WIRE NETTING 4.3.1 Description Common company practice to use corrosion resistant material. 4.3.2 Service To prevent excessive cracking of the insulation. 4.4 BANDS 4.4.1 Description Stainless steel used for strength and corrosion resistance. 4.4.2 Service 4.4.2.1 Aluminum Jacketing Use of bands in place of screws is plant preference. 4.4.2.2 Pipe insulation Due to size wire would cut the insulation and may break. 4.4.2.3 Vessel Insulation To prevent cutting into the insulation. F -4 4 IB (3/67) 000123 Qbelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - MATERIALS LOGIC LOG DATE 11/4/74 RCV. NO. 0 NO. INSUL-1 PAGE 16 OF 88 INDEX INSULATION - MATERIALS LOGIC LOG (Continued) 4. ACCESSORIES (Continued) 4.5 WIRE 4.5.1 Description Experience proven materials. 4.5.2 Service Plant preference due to differing atmospheric corrosion potential. 4.6 SCREWS 4.6.1 Description Screw type used for ease of installation. 4.6.2 Service Use of screws in place of bands is plant prefer ence. Used in horizontal seams to prevent the aluminum from working down. 4.7 STAPLES 4.7.1 Description Standard staples are used. 4.7.2 Service Fiberglass is light enough to be held by staples, and it has enough dimensional stability to retain staples. Stapling can be faster and more economical than wire ties. F-441 B (3/67) 000124 INSUL I S3 00012b Lelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - ENGINEERS' GUIDE LOGIC LOG DATE 11/6/74 REV. NO. 0 NO. INSUL-2 PAGE 17 OF 88 INDEX INSULATION - ENGINEERS' GUIDE LOGIC LOG Poge (s) 1 SCOPE 2 ITEMS INSULATED 19 19 3 PURPOSE 3.1 HOT SERVICE 3.1.1 3.1.2 3.1.3 3.1.4 General Heat Conservation Temperature Control Personnel Protection 3.2 COLD SERVICE 19 19 19 19 19 19 4 GENERAL 4.1 SURFACES NOT INSULATED 4.2 SURFACE PREPARATION 4.3 INSULATION SUPPORT 4.4 PIPING SUPPORTS 4.5 TRACED LINES 4.6 ALUMINUM WEATHER-BARRIER 4.7 MASTIC WEATHER-BARRIER 5 DATA FORMS 5.1 HEAT INSULATION DATA FORM 20 20 20 20 20 20 20 21 21 5.1.1 INSULATION MATERIAL 21 5.1.1.1 5.1.1.2 5.1.1.3 5.1.1.4 Piping and 24" Diameter andSmaller Equipment Equipment Greater than24" Diameter Bent Pipe and Tubing Irregular Surfaces 00U12b 21 21 21 21 F -4 4 IB (3/67) Ci^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - ENGINEERS' GUIDE LOGIC LOG DATE 11/6/74 ftCV. NO. 0 NO. INSUL-2 PAGE 18 OF 88 INDEX INSULATION - ENGINEERS' GUIDE LOGIC LOG (Continued) Page (s) 5. DATA FORMS (Continued) 5.1 HEAT INSULATION DATA FORM (Continued) !i 5. 1.2 WEATHER-BARRIER MATERIALS 5.1.2.1 5.1.2.2 5.1.2.3 5.1.2.4 Straight Run Piping and 24" Diameter and Smaller Equipment Elbows Vessel and Exchanger Shells Irregular Surfaces and Equipment Heads 22 | 22 i 22 22 22 5. 1.3 5. 1.4 INSULATION SECUREMENT 5.1.3.1 5.1.3.2 5.1.3.3 Piping Through 16" Diameter Piping Greater than 16" Diameter and Equipment 24" Diameter and Less Equipment Greater than 24" Diameter ALUMINUM JACKET SECUREMENT 22 22 22 23 23 5.1.4.' 5.1.4.2 Piping and 24" Diameter and Smaller Equipment Equipment Greater than 24" Diameter 23 23 5. 1.5 REINFORCEMENT 5.1.5.1 5.1.5.2 Glass Cloth Wire Netting 23 23 23 5. 1.6 SPECIALTIES 5.2 COLD INSULATION DATA FORM 5.2.1 INSULATION MATERIALS 23 24 24 5.2.2 5.2.1.1 5.2.1.2 5.2.1.3 5.2.1.4 Piping Equipment Bent Pipe and Tubing Irregular Surfaces WEATHER-BARRIER MATERIALS uuum ~ 24 24 24 24 24 F-441 B (3/67) C^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - ENGINEERS' GUIDE LOGIC LOG DATE MO. 11/6/7- h INSUL-2 AEV. MO. 0 PAGE 19 OF 88 INDEX INSULATION - ENGINEERS' GUIDE LOGIC LOG (Continued) 1. SCOPE A statement to explain the content and logic of this section. 2. ITEMS INSULATED These drawings are the record of items requiring insulation. 3. PURPOSE 3.1 HOT SERVICE 3.1.1 General 3.1.2 States the purposes for insulating hot service piping and equipment and defines the insulation design temperature. Heat Conservation i j Factors involved in the economic calculation of insulation thickness include costs of insulation, steam generation equipment, heat energy, money, depreciation, thermal conductivity, temperature differential, pipe size, hours of operation and maintenance costs. : j j 3.1.3 Temperature Control To prevent polymerization, maintain reaction temperature, etc. 3.1.4 Personnel Protection Surface temperature of the insulation should be limited to 150F to prevent bums to personnel. Insulation specified for heat conservation will normally have a lower surface temperature. , 3.2 COLD SERVICE States the purpose and extent of cold service insulation. F -4 4 IB (3/67) CLeianese PLANT ENGINEERING MANUAL INSULATION - ENGINEERS' GUIDE PLASTICS COMPANY Bishop Plant LOGIC LOG DATE Ll/6/74 ffCV. NO. 0 *0INSUL-2- PAGE 20 OF 88 INDEX INSULATION - ENGINEERS' GUIDE LOGIC LOG (Continued) 4. GENERAL 4.1 SURFACES NOT INSULATED Specificed surfaces not to be insulated for either (1) proper fulfillment of function (nameplates, steam traps, etc.) or (2) because effort required for irregular shapes and high maintenance items is not justified. 4.2 SURFACE PREPARATION To prevent corrosion on carbon steel surfaces resulting from moisture trapped under the insulation, and to provide adhesion for spray urethane. 4.3 INSULATION SUPPORT Supports will prevent compaction or crushing of the insulation due to its own weight. 4.4 PIPING SUPPORTS Allows sufficient space for insulation below pipe (hot) and allows proper sealing of pipe to prevent condensation (cold). 4.5 TRACED LINES Using insulation one pipe size larger is an industry recognized method. An alternate method would be to dado a groove for the tracer in the line size insulation. 4.6 ALUMINUM WEATHER-BARRIER Table intended to simplify purchasing of material. 4.7 MASTIC WEATHER-BARRIER The variety of irregular shapes will require individual calculation of quantities required. F-441 B (3/67) uuui^y ^Lelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - ENGINEER'S LOG LOGIC LOG DATE Ll/6/74 REV. NO. 0 NO. INSUL-2 PAGE 21 OF 88 5. DATA POEMS To aid the engineer in the area of selection, specification, and procurement of insulation materials with a minimum of time. The two forms are designed to collect all the information required pertinent to that particular classification of insulation system. 5.1 HEAT INSULATION DATA FORM This form covers all the materials for insulating items operating at temperatures above 70F. 5.1.1 INSULATION MATERIAL The insulation materials are not limited to those specifically listed in this section. If other materials are used this paragraph lists the items to be considered in making this selection. See "INSUL-1" Section, paragraphs 2.1.1, 2.3.1, 2.4.1, 2.5.1, 2.7.1, 2.8.1, and 2.9.1. 5.1.1.1 Piping and 36" Diameter and Smaller Equipment Lists the materials and service limits normally used. See "INSUL-l" Section, paragraphs 2.1.2,- 2.2.2, 2.3.2, 2.4.2, 2.7.2, and 2.9.2. 5.1.1.2 Equipment Greater than 36" Diameter Lists the materials and service limits normally used. See "INSUL-1" Section, paragraphs 2.3.2, 2.4.2, and 2.9.2. 5.1.1.3 Bent Pipe and Tubing Lists the materials and service limits normally used. See "INSUL-1" Section, paragraphs 2.7.2 and 2.8.2. 5.1.1.4 Irregular Surfaces Gives the material and service limits normally used. See "INSUL-1" Section, paragraph 2.5.2. uuuiau a ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - ENGINEER'S LOG LOGIC LOG DATE LI/6/74 EV. NO. INSUL-2PAGE 22 OF 88 5.1.2 5.1.3 WEATHER-BARRIER MATERIALS Weather-barrier materials are not limited to those specifically listed. This paragraph lists the j factors to be considered when selecting a j weather-barrier system. See "INSUL-l" Section, paragraphs 3.1.1, 3.2.1, 3.3.1 and 3.4. ! 5.1.2.1 Straight Run Piping and 36" Diameter and Smaller Equipment- Lists the materials used and the factors j to be considered when selecting the ! material to use. See "INSUL-l" Section, ; paragraphs 3.1.2, 3.3.2, and 3.4. 5.1.2.2 Elbows Labor costs for application of mastic weather-barrier to elbows may offset the additional material cost for aluminum or PVC covers. See "INSUL-l" Section, paragraphs 3.1.2, 3.2.2 and 3.3.2. 5.1.2.3 Vessel and Exchanger Shells Lists the materials normally used. See "INSUL-l" Section, paragraphs 3.1.2, 3.2.2, 3.3.2, and 3.4 5.1.2.4 Irregular Surfaces and Equipment Heads Gives the material normally used. See "INSUL-l" Section, paragraph 3.2.2. INSULATION SECUREMENT Lists the materials normally used. See "INSUL-l" Section, paragraphs 4.4.1, 4.5.1, and 4.7.1. 5.1.3.1 Piping Through 16" Diameter Lists the materials normally used. See "INSUL-l" Section, paragraphs 4.5.2 and 4.7.2. 5.1.3.2 Piping Greater than 16" Diameter and Equipment 24" Diameter and Less Gives the material normally used. See "INSUL-l" Section, paragraph 4.4.2.2. 000131 F -4 4 IB (3/67) Qhelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - ENGINEERS' GUIDE LOGIC LOG DATE 11/6/74 ftEV. NO. 0 NO. INSUL-2 PAGE 23 OF 88 5. DATA FORMS (Continued) 5.1 HEAT INSULATION DATA FORM (Continued) 5.1.3 INSULATION SECUREMENT (Continued) 5.1.3.3 E--q--u-i-p--m--e--n-t---G--r-e--a--t-e-r---th--a--n---2-4--"---D--i-a-m---e-t-e--r Gives the material normally used. See "INSUL-1 " Section, paragraph 4.4.2.3. l i 5.1.4 ALUMINUM JACKET SECUREMENT Lists the materials normally used. Aluminum screws resist atmospheric corrosion in coastal locations. Hex head screws are used if a socket type screwdriver is used. See "INSUL-1 " Section, paragraphs | 4.4.1 and 4.6.1. 5.1.4.1 Piping and 24" Diameter and Smaller Equipment 5.1.4.2 Lists the materials normally used. See "INSUL-1" Section , paragraphs 4.4.2.1 and 4.6.2. Equipment Greater than 24" Diameter Lists the materials normally used. See "INSUL-1" Section, paragraphs 4.4.2.1 and 4.6.2. 5.1.5 REINFORCEMENT Lists the materials used and places where reinforcement is required. See "INSUL-1" Section, paragraphs 4.2.1 and 4.3.1. 5.1.5.1 Glass Cloth Lists the materials normally used. See "INSUL-1 " Section, paragraph 4.2.2. 5.1.5.2 Wire Netting 5.1.6 Gives the materials normally used. See "INSUL-1" Section, paragraph 4.3.2. SPECIALTIES For the engineers' use to specify any additional information desired. ____________________________ 000132 __ F -4 4 IB (3/67) ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - ENGINEER'S GUIDE LOGIC LOG DATE NO. Ll/6/74 INSUL-2 IVCV. NO. 0 PAGE 24 OF 88 5. DATA FORMS (Continued) 5.2 COLD INSULATION DATA FORM This form covers all the materials for insulation items operating at temperatures of 70F and below. 5.2.1 INSULATION MATERIALS The insulation materials are not limited to those listed in this section. If other materials are used; however, this paragraph lists the items to be considered in making this selection. See "INSUL-1" Section, paragraphs 2.3.1, 2.8.1, and 2.9.1. 5.2.1.1 Piping Gives the materials normally used. See "INSUL-1" Section, paragraphs 2.3.2 and 2.9.2. 5.2.1.2 Equipment Gives the materials normally used. See "INSUL-1" Section, paragraphs 2.3.2 and 2.9.2. 5.2.1.3 Bent Pipe and Tubing Gives the material normally used. See "INSUL-1" Section, paragraph 2.8.2. 5.2.1.4 Irregular surfaces Gives the material normally used. See "INUL-1" Section, paragraph 2.3.2. 5.2.2 WEATHER-BARRIER MATERIALS Weather-barrier materials are not limited to those specifically listed. This paragraph lists the factors to be considered when selecting a weatherbarrier system. See "INSUL-1" Section, paragraphs 3.1.1, 3.2.1 and 3.3.1. F -4 4 IB (3/67) 000133 000134 WBELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - APPLICATION LOGIC LOG DATE 11/7/74 NEV. NO. 0 NO. INSUL-3 PAGE 25 OF 88 INDEX INSULATION - APPLICATION LOGIC LOG SCOPE GENERAL 2.1 TIMING 2.2 SURFACE PREPARATION 2.3 DRV INSULATION 2.4 PIPING SUPPORTS 2.4.1 HOT SERVICE 2.4.2 COLD SERVICE APPLICATION PROCEDURE 3.1 STRAIGHT PIPE 3.1.1 INSULATION 3.1.1.1 3.1.1.2 3.1.1.3 3.1.1.4 Placement Joint Sealer Exposed Ends Securement 3.1.2 EXPANSION-CONTRACTION JOINTS 3.1.2.1 3.1.2.2 Location Design 3.1.3 ALUMINUM WEATHER-BARRIER 3.1.3.1 Application 3.1.3.2 Securement 3.1.4 3.1.5 MASTIC WEATHER-BARRIER PVC WEATHER-BARRIER Page fr) 27 27 27 27 27 27 27 27 27 27 27 28 28 28 28 28 28 28 28 28 F -44IB (3/67) 000135 Sdelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - APPLICATION LOGIC LOG DATE 11/7/74 REV. NO. 0 NO. INSUL-3 PAGE 26 OF 88 INDEX INSULATION - APPLICATION LOGIC LOG 3. APPLICATION PROCEDURE (Continued) Page (s 3.2 ELBOWS 29 3.2.1 3.2.2 INSULATION INSULATING CEMENT 29 29 3.2.3 WEATHER-BARRIER 3.3 FLANGES, FLANGED FITTINGS AND VALVES 29 29 3.3.1 INSULATION 3.4 EQUIPMENT 3.4.1 SHELL INSULATION 3.4.1.1 3.4.1.2 3.4.1.3 3.4.1.4 Placement Joint Sealer Securement Cork-Filled Mastic 29 29 29 29 29 30 30 3.4.2 SUPPORT INSULATION 30 3.4.3 3.4.4 3.4.2.1 3.4.2.2 3.4.2.3 3.4.2.4 3.4.2.5 General Metal Cradles Structural Steel Legs Skirts EXPANSION-CONTRACTION JOINTS WEATHER-BARRIER 30 30 30 30 30 30 30 3.5 IRREGULAR SURFACES 31 3.5.1 INSULATION 31 U 9/c) 000136 a ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - APPLICATION LOGIC LOG LI/7/74 INSUL-3 PAGE 27. OF 88 SCOPE A statement to explain the contents and logic of this section. GENERAL 2.1 TIMING To enable detection of leaks during testing. 2.2 SURFACE PREPARATION To prevent corrosion and to provide adhesion for urethane spray. 2.3 DRY INUSLATION To prevent the insulation from deteriorating or retaining moisture which would cause corrosion to the insulated surface and degradation of urethane. 2.4 PIPING SUPPORTS 2.4.1 HOT SERVICE To prevent damage to insulation due to weight of line and expansion movement. 2.4.2 COLD SERVICE To prevent condensation, freezing, and the entry of moisture where support penetrates the weatherbarrier. APPLICATION PROCEDURE 3.1 STRAIGHT PIPE 3.1.1 INSULATION 3.1.1.1 Placement To prevent heat loss at joints, F-441 B (3/67) 000137 Qbelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - APPLICATION LOGIC LOG OATE Ll/7/74 KV. NO. 0 NO. INSUL-3 PAGE 28 OF 88 3. APPLICATION PROCEDURE (Continued) 3.1 STRAIGHT PIPE (Continued) 3.1.1 INSULATION (Continued) 3.1.1.2 Joint Sealer To prevent vapor entry. 3.1.1.3 Exposed Ends To shed water and prevent moisture from reaching the insulation. 3.1.1.4 Securement To hold the insulation in place until the weather-barrier is installes. See "INSUL-4" Section, paragraphs 4.4.2.2, 4.5.2, and 4.7.2. 3.1.2 EXPANSION-CONTRACTION JOINTS 3.1.2.1 Location To maintain the required vapor seal in cold service insulation and to prevent rupture of rigid insulation in hot service. 3.1.2.2 Design An industry proven design. 3.1.3 ALUMINUM WEATHER-BARRIER 3.1.3.1 Application To prevent water from reaching the insulation. 3.1.3.2 Securement Plant preference. 3.1.4 MASTIC WEATHER-BARRIER An industry wide application procedure which has proven acceptable to Celanese. 3.1.5 PVC WEATHER-BARRIER Application me tiiods are unique to each manufacturer. -------------------------- 000138 -441 B (3/67) ^Lelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - APPLICATION LOGIC LOB DATE NO. Ll/7/74 INSUL-3 RV. NO. 0 PAGE 29 OF 88 3. APPLICATION PROCEDURE (Continued) 3.2 ELBOWS 3.2.1 INSULATION Performed elbows are used if economical. 3.2.2 INSULATING CEMENT To prevent heat loss and provide a uniform smooth surface. 3.2.3 WEATHER-BARRIER Type of barrier depends on economics and plant preference. See "INSUL-3" Section, paragraphs 3.1.3, 3.1.4, and 3.1.5. 3.3 FLANGES. FLANGED FITTINGS AND VALVES 3.3.1 INSULATION To prevent vapor entry and provide for expansioncontraction. Removable flange covers are used for high maintenance services. 3.3.2 Same logic as paragraphs 3.1.3 and 3.1.4 above. 3.4 EQUIPMENT 3.4.1 SHELL INSULATION 3.4.1.1 Placement Pipe insulation is more economical to apply. To prevent heat loss the joints are staggered. Urethane spray will normally be applied by and insulation contractor. Because of vapor and fire hazards with urethane spray, Celanese engineer and Safety Department must approve all materials, warehousing of materials, and application. 3.4.1.2 Joint Sealer To prevent the entry of moisture, see paragraph 3.1.1.2 above. F-441 B (3/67) 000139 a ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - APPLICATION LOGIC LOG DATE MO. Ll/7/74 *CV. MO. INSUL-3 PAGE 30 OF 88 3.4 EQUIPMENT (Continued) 3.4.1 SHELL INSULATION (Continued) 3.4.1.3 Securement To hold the insulation in place. 3.4.1.4 Cork-Filled Mastic Each manufacturer has their own specifications which depend on product, purpose, and service conditions 3.4.2 SUPPORT INSULATION 3.4.2.1 General To minimize heat gain, condensation, and to give an acceptable thermal gradient. 3.4.2.2 Metal Cradles Common industry practice which has proven acceptable. 3.4.2.3 Structural Steel Common industry practice which has proven acceptable. 3.4.2.4 Legs Common industry practice which has proven acceptable. I 3.4.2.5 Skirts Common industry practice which has proven acceptable. 3.4.3 EXPANSION-CONTRACTION JOINTS To allow for movement while maintaining a vapor seal. 3.4.4 WEATHER-BARRIER See paragraphs 3.1.3, 3.1.4, and 3.1.5 above. F -44IB (3/67) 000140 aELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION - APPLICATION LOGIC LOG OATE NO. 11/7/74 INSUL-3 ftCV. NO. PAGE 31 OF 88 3. APPLICATION PROCEDURE (Continued) 3.4 EQUIPMENT (Continued) 3.4.2 SUPPORT INSULATION 3.4.2.1 General To minimize heat gain, condensation, and to give an acceptable thermal gradient. 3.4.2.2 Metal Cradles Common industry practice which has proven acceptable. 3.4.2.3 Structural Steel Common industry practice has proven acceptable. 3.4.2.4 Legs Common industry practice which has proven acceptable. 3.4.2.5 Skirts Common industry practice which has proven acceptable. 3.4.3 EXPANSION-CONTRACTION JOINTS To allow for movement while maintaining a vapor seal. 3.4.4 WEATHER-BARRIER See paragraphs 3.1.3, 3.1.4, and 3.1.5 above. 3.5 IRREGULAR SURFACES 3.5.1 INSULATION Common industry procedure which has proven accept able. 3.5.2 See paragraph 3.1.4 above. F-441 B (3/67) 000141 000142 ^SaELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS OAT t 11/4/74 IIEV. NO. 0 INSUL-4 PAGE 32 OF 88 INDEX MATERIAL REQUIREMENTS 1. SCOPE .2 INSULATING MATERIALS CALCIUM SILICATE 2.1.1 2.1.2 2.1.3 Description Service 2.1.2.1 Temperature Range 2.1.2.2 Components Insulated Thi ckness 2.2 MINERAL WOOL 2.2.1 2.2.2 2.2.3 Description Servi ce 2.2.2.1 Temperature Range 2.2.2.2 Components Insulated Thickness 2.3 CELLULAR GLASS 2.3.1 2.3.2 2.3.3 Description Service 2.3.2.1 Temperature Range 2.3.2.2 Components Insulated Thickness Page (s) 37 37 37 37 37 37 37 37 38 38 38 38 38 38 38 38 38 38 39 39 2.4 FIBERGLASS 2.4.1 2.4.2 2.4.3 Description Service 2.4.2.1 Temperature Range 2.4.2.2 Components Insulated Thickness 39 39 ll 39 39 000143 F -44IB (3/67) ELANESE PLASTICS COMPANY Bi shop PI ant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS OATE .1/4/74 REV. NO. 0 NO. INSUL-4 PAGE 35 OF 88 INDEX MATERIAL REQUIREMENTS (Continued) 3. WEATHER-BARRIER MATERIALS (Continued) 3.2 MASTIC 3.2.1 3.2.2 Description Service 3.3 POLYVINYL CHLORIDE (PVC) 3.3.1 3.3.2 Description Service 3.3.2.1 Temperature Range 3.3.2.2 Chemical Restrictions 3.3.2.3 Components Jacketed ACCESSORIES 4.1 JOINT SEALER 4.1.1 4.1.2 Description Service 4.2 GLASS CLOTH 4.2.1 4.2.2 Description Service 4.3 WIRE NETTING 4.3.1 4.3.2 Description Service 4.4 BANDS 4.4.1 4.4.2 Description Service 4.4.2.1 Aluminum Jacketing 4.4.2.2 Pipe Insulation 4.4.2.3 Vessel Insulation 4.5 WIRE 4.5.1 4.5.2 Description Service 1 Page (s) ' 44 44 44 45 45 45 45 45 45 46 46 46 46 46 46 46 46 46 46 47 47 47 47 47 47 47 47 47 F -4 4 IB (3/67) 000144 CLeianese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS L------- NO. LI/4/ /4 INSUL-4 KCV. NO. 0 PAGE 36 OF 88 1 INDEX MATERIAL REQUIREMENTS (.Continued) 4.6 4.7 SCREWS 4.6.1 4.6.2 Description Service STAPLES 4.6.1 4.6.2 Description Service Page (s) 48 48 48 48 48 48 000145 ^Kielanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS OATE NO. 11/4/74 IICV. MO. 0 INSUL-4 PAGE 37 OF 88 1. SCOPE This section describes the minimum requirements for the purchase of exterior thermal insulation materials for pipe, instruments and equipment. 2. INSULATING MATERIALS 2.1 CALCIUM SILICATE 2.1.1 Description Insulation shall be a rigid hydrous calcium silicate pipe covering of sectional or segmental form, block, scored block, or beveled lag. The insulation shall contain an inhibitor to reduce the possibility of stress corrosion cracking of stainless stell. CAUTION -- If asbestos containing materials are used, then precautions as per OSHA will need to be considered. 2.1.2 Service 2.1.2.1 Temperature Range Calcium silicate is normally used for components operating in the temperature range of 451F to 1200F. For special applications, this material may be used for temperatures up to 1800F. 2.1.2.2 Components Insulated Calcium silicate is used for the insul ation of the following components operating within the above temperature o range: a. Carbon steel piping, instruments, and cylindrical carbon steel equipment. b. Stainless and alloy piping, instruments, and cylindrical equipment with a diameter of 24" or less in low humidity locations. 2.1.3 Thickness Thickness should be specified as described in INSUL-5 Section 3.1.2. Above 600F, two layers with staggered joints should be used to minimize heat loss at joints. -------------------------------------------------------- 000146 F-441 B (3/67) ^Lelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS eoat NO. 11/4/74 INSUL-4 V. NO. 0 PAGE OF gg 2. INSULATING MATERIALS (Continued) 2.2 MINERAL WOOL 2.2.1 Description Insulation shall be a segmental, mat faced, felted refractory fiber pipe covering such as MF pipe insulation, block, or blanket. 2.2.2 Service 2.2.2.1 Temperature Range MF pipe insulation is normally used for components operating in the temperature range of 451F to 1200F. 2.2.2.2 Components Insulated MF pipe insulation may be used on any equipment 36" stainless steel items. Flexible mineral wool is used in including contraction joints. Compres sion strength must be considered where the insulated surface will be walked on or where banding might compress the insulation too tightly. 2.2.3 Thickness Thickness should be specified as described in INSUL-5, Section 3.1.2. Above 600F, two layers with staggered joints should be used to minimize heat loss at joints. 2.3 CELLULAR GLASS 2.3.1 Description Insulation shall be a rigid cellular glass material in flat block, beveled lags, or pipe covering of sectional or segmental form. 2.3.2 Service 2.3.2.1 Temperature Range Cellular glass is used for components operating in the range from -450F to 800F. 000147 F -4 4 IB (3/67) Gbelanese PLASTICS COMPANY Bishop Plant plant engineering manual INSULATION MATERIAL REQUIREMENTS DATE MO. 11/4/74 MV. NO. 0 INSUL-4' PAGE 39 OF 88 2. INSULATING MATERIALS (Continued) 2.3 CELLULAR GLASS (Continued) 2.3.2 Service (Continued) 2.3.2.2 Components Insulated Cellular glass shall be used for the insulation of any equipment including stainless stell and alloys. 2.3.3 Thickness Thickness should be specified as described in INSUL-5 Section 3.1.2 for hot service or 3.2 for cold service. 2.4 FIBERGLASS 2.4.1 Description The insulation shall be sectional pipe covering, board, or blanket. 2.4.2 Service 2.4.2.1 Temperature Range Fiberglass is used for components operating in the temperature range of -60F to 450F, with one type (Certainteed 850) usable up to 850OF. In cold service, a positive vapor barrier is needed to prevent water logging of the fiberglass. 2.4.2.2 Components Insulated Fiberglass is used for all piping, instruments, and equipment. Flexible fiberglass is used in contraction joints. Compressive strength must be considered where insulated surface will be walked on or where banding might compress the insulation too tightly. 2.4.3 Thickness Thickness should be specified as described in INSUL-5 Section 3.1.2 for hot service and 3.2 for cold service. 000148 F-441 B (3/67) CLelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATIONS MATERIAL REQUIREMENTS OATC NO. 11/4/74 KV. MO. 0 INSUL-4 PAGE 40 OF 88 2.5 2.6 INSULATING CEMENT 2.5.1 Description Insulation shall be a high temperature mineral wool type insulating cement such as Eagle-Picher Super 66 or equal. 2.5.2 Service 2.5.2.1 Temperature Range Insulating cement is used for components operating at temperature of 71F and above with upper limits depending upon the material used. 2.5.2.2 Components Insulated Insulating cement is used for the insulating or irregular surfaces such as pumps and turbines. Insulating cement is also used to fill voids and smooth the surface of fabricated elbow covering. 2.5.3 Thickness Thickness should be specified the same as fiberglass or mineral wool as described in INSUL-5, Section 3.1.2. CORK-FILLED MASTIC 2.6.1 Description Insulation shall be an asphalt base mastic containing a high content of ground cork. Corkfilled mastic shall be Lion Oil Nokorode "K Kote" or approval equal. 2.6.2 Service 2.6.2.1 Temperature Range Cork-filled mastic is normally used for components operating in the temperature range of 30F to 140F. F-441 B (3/67) 000149 CLelanese plastics company Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS DAT E HO. 11/4/74 KV. NO. --2______ INSUL-4 PAGE 41 OF 88 2. INSULATING MATERIALS (Continued) 2.6 CORK-FILLED MASTIC (Continued) 2.6.2 Service (Continued) 2.6.2.2 Components Insulated Cork-filled mastic is used for the insulating of pipe and equipment to control condensation of low temperature surfaces. Cork-filled mastic is also used on piping and equipment requiring insulation for process control if the reduction in heat loss need only be 50 to 70 percent. Protective coating must be applied on carbon steel surfaces for corrosion protection. 2.6.3 Thickness Cork-filled mastic is normally applied to produce a 1/4" thickness; however, cured thickness up to 3/8" may be used, if required. ASBESTOS TAPE 2.7.1 Description Insulation shall be a woven asbestos cloth tape 1" wide x 1/8" thick. 2.7.2 Service 2.7.2.1 Temperature Range Asbestos tape is used for components operating at temperatures of 180F and above. 2.7.2.2 Components Insulated Asbestos tape is used on irregular surfaces such a bent pipe and tubing where the use of rigid insulation is considered impractical. 2.7.3 Thickness Thickness should be specified the same as cellular glass as described in INSUL-5, Section 3.1.2. F-441 B (3/67) 000150 CLelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS OATC NO. 11/4/74 INSUL-4 *CV. NO. 0 PAGE 42 OF 88 2. INSULATING MATERIALS (Continued) 2.8 FOAMED PLASTIC 2.8.1 Description Insulation shall be flexible foamed plastic tubular pipe insulation. 2.8.1 Service 2.8.2.1 Temperature Range 2.8.2.2 Foamed plastic insulation is used for components operating at temperatures of 180F and below. Components Insulated Foamed plastic is used on bent pipe or tubing where the used of rigid . _____ insulation is considered impractical. 2.8.3 Thickness Thickness should be specified as described in INSUL-5, Section 3.2. 2.9 Urethane 2.9.1 Description The insulation shall be sectional or segmental pipe covering, boards, beveled bags, shaped head segments, or foam spray. 2.9.2 Service 2.9.2.1 Temperature Range Rigid urethane is used for services from -450 to +225F. 2.9.2.2 Chemical Resistance Urethane should not be used where it will be exposed to acetone, methyl ethyl ketone, tetrahydrofuron, chloroform, ethylene dichloride, chlorine, hydrogen peroxide, or high concentration acids. 000151 F-441 B (3/67) Gbelanese plastics company Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS OATE NO. 11/4/74 REV. NO. 0 INSUL-4 PAGE 33 of 88 INDEX MATERIAL REQUIREMENTS (Continued) 2. INSULATING MATERIALS (Continued) 2.5 INSULATING CEMENT 2.5 .1 2.5 .2 Description Service 2.5.2.1 Temperature Range 2.5.2.2 Components Insulated 2.6 2.5 .3 Thickness CORK-FILLED MASTIC 2.6 .1 2.6 .2 2.6 .3 Description Service 2.6.2.1 Temperature Range 2.6.2,2 Components Insulated Thickness 2.7 ASBESTOS TAPE 2.8 2.7 .1 2.7 .2 2.7 .3 Description Service 2.7.2.1 Temperature Range 2.7.2.2 Components Insulated Thickness FOAMED PLASTIC 2.8 .1 2.8 .2 2.8 .3 Description Service 2.8.2.1 Temperature Range 2.8.2.2 Components Insulated Thickness ( 2.9 URETHANE 2.9 .1 2.9 .2 2.9 .3 Description Service 2.9.2.1 Temperature Range 2.9.2.2 Chemical Resistance 2.9.2.3 Other Limitations 2.9.2.4 Components Insulated Thickness Page (s) 40 40 40 40 40 40 40 40 j 40 40 41 41 41 41 41 41 41 41 42 42 42 42 42 42 42 42 42 42 42 43 43 43 F -44IB (3/67) 000152 a ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS DATE 11/4/74 V. NO. INSUL-4 PAGE 43 OF 88 INSULATING MATERIALS (Continued) 2.9 URETHANE (Continued) 2.9.2 Service (Continued) 2.9.2.3 Other Limitations Urethane must be protected from sunlight and moisture, it cannot be exposed to flame, it should not be used in confined spaces with poor ventilation, and it must have a continuous vapor barried (integral vapor barried bonded to metal jacketing is not adequate for a vapor barrier). 2.9.2.4 Components Insulated 2.9.3 Thickness Urethane can be used on all pipes, instruments, and equipment except in high maintenance services where the vapor barrier is likely to be punctured Spray foam can be economically used on large surface area tanks and towers. Thickness should be specified as described in INSUL-5, Section 3.1.2 for hot service or 3.2 for cold service. Maximum thickness for spray urethane is 3". WEATHER-BARRIER MATERIALS 3.1 ALUMINUM 3.1.1 Description Aluminum jacketing material shall be 5005 or 3003 alloy with H-14 temper. Sheets or rolls shall be 0.016" thick with 3/16" corrugations or 0.020" thick smooth. Jacketing both with and without attached moisture barrier are used. Aluminum elbow covers shall be 0.020" thick. Pipe sections with self-sealing lips may be economical to use on long piping runs. F-441 B (3/67) 000153 CLelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS DATE -c. 11/4/74 JICV. HO. 0 INSUL-4' PAGE 34 OF 88 INDEX MATERIAL REQUIREMENTS (.Continued) 3. WEATHER-BARRIER MATERIALS 3.1. ALOMINUM 3.1.1 3.1.2 Description Components Jacketed Page (s) 43 43 43 44 i ?J F -4 4 IB (3/67) 000154 I ^Lelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS DATE NO. 11/4/74 KCV. NO. 0 INSUL-4 PAGE 45 OF 88 3. WEATHER-BARRIER MATERIALS (Continued) 3.3 POLYVINYL CHLORIDE (PVC) 3.3.1 Description PVC pipe and fitting jacketing shall be preformed sections with a minimum thickness of 0.020". It shall be UV stabilized and rated 94 V-0 (self-extinguishing) at the thickness used by ASTM Methods D 568, D 635, or D 1433, or rated on Oxygen Index valve greater than 25% by ASTM Method D 2863. Sheet stock for vessels shall meet the same specifications as pipe jacketing. 3.3.2 Service 3.3.2.1 Temperature Range Used where surface temperature of insulation will be less than 150F and where PVC will not be exposed to other sources of heat exceeding 150F. If bonded to insulation such as urethane or fiberglass, service shall meet the temperature range of the insulation material. 3.3.2.2 Chemical Restrictions Do not use where PVC will be exposed to ketones, esters, or aromatic hydrocarbons. 3.3.2.3 Components Jacketed Used on straight pipe, elbows, ties, and valves indoors or outdoors. Sheet used on tanks and smooth wall equipment.; 3.4 OTHER MATERIALS Other weather-barrier materials such as stainless steel may be used where service conditions will not permit usage of aluminum, mastic, or PVC. F-441 B (3/67) J000155 ^Kielanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS OATE NO. 11/4/74 REV. NO. 0 INSUL-4 PAGE 46 OF 88 4. ACCESSORIES 4.1 JOINT SEALER 4.1.1 Description Joint sealer shall be an aluminum gray vapor barrier sealer such as Benjamin Foster's No. 30 - 45 or an asphalt base sealer such as Lion Oil Nokorode "Low Temp". For PVC jacketing, use joint sealer specified by jacket manufacturer. 4.1.2 Service Joint sealer shall be used on all butt edges of single layer insulation or outer layer of multi layer applications. 4.2 GLASS CLOTH 4.2.1 Description Glass cloth shall be 10 x 10 thread count such as Benjamin Foster's open weave #10, or 20 x 20 thread count asphalt impregnated glass cloth. 4.2.2 Service Glass cloth is used to reinforce mastic weather barriers. The 10 x 10 thread count cloth is used to reinforce polyvinyl acetate coatings and the 20 x 20 thread count cloth is used with solvent cutback mastics. 4.3 WIRE NETTING 4.3.1 Description Wire netting shall be 1" HEX pattern, 20 gauge Monel, 316 stainless steel, or galvanized poultry netting, depending upon environmental conditions. 4.3.2 Service Wire netting is used to reinforce insulating cement when thickness of 1 - 1/2" or greater is required. F -441 8 (3/67) 000156 aELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS DATK 11/4/74 NEV. NO. INSULT PAGE 47 OF 88 4. ACCESSORIES (Continued) 4.4 BANDS 4.4.1 Description Bands shall be 3/8", 1/2", or 3/4" wide x .020" thick stainless steel with matching double prong seals. 4.4.2 Service 4.4.2.1 Aluminum Jacketing At high humidity locations 3/8" wide bands on 9" centers are used to secure all aluminum jacketing. Self-sealing pipe jacketing is banded only on the ends of the jacket sections. 4.4.2.2 Pipe Insulation Bands 1/2" wide are used on 9" centers to secure insulation on pipe greater than 16" in diameter and equipment with a diameter of 24" or less. 4.4.2.3 Vessel Insulation Bands 3/4" wide are used on 12" centers to secure insulation on equipment with a diameter greater than 24". 4.5 WIRE 4.5.1 Description Wire shall be 16 gauge stainless stell or galvanized. 4.5.2 Service Wire is used on 9" centers to secure pipe insulation on lines through 16" diameter. Stainless steel wire is used at high humidity locations and galvanized wire is used at low humidity locations. F-441 B (3/67) 000157 <2.ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION MATERIAL REQUIREMENTS DATE MO. 11/4/74 INSUL-4 PAGE 48 OF 88 ACCESSORIES (Continued) 4.6 SCREWS 4.6.1 Description Screws shall be No. 8 x 1/2" long cadmium plated or aluminum slotted HEX head or pan head sheet metal screws. 4.6.2 Service Sheet metal screws shall be used on 6" centers to secure aluminum pipe or equipment jacketing at low humidity locations. On vertical equipment surfaces at all locations, screws are used at the horizontal laps. Screws are not used to fasten jacketing over urethane insulation. 4.7 STAPLES 4.7.1 Description Staples shall be stainless steel suitable for application with a staple gun. 4.7.2 Service Staples shall be used to fasten longitudinal seam, of rigid fiberglass pipe insulation, and to reinforce the lap fastening on fiberglass with self-sealing jacket lap. F-441 B (3/67) 000158 000159 How To Select Insulation Thickness For Hot Pipes Rising fuel costs have made traditional insulation-thickness-selection criteria obsolete. Here is a group of nomographs that can be used to choose insulation for hot pipes that will be economic under present-day and future conditions. JULES L. ABRAMOVITZ and RENE CORDERO, Allied Chemical Corp. Energy shortages and higher fuel costs have made in sulation more important Engineers must reevaluate the insulation thickness that provides optimum insulation at the most reasonable cost. A new set of standards is desirable, because the older standards have been strained beyond reasonable ex trapolation. The new standards should be simplified--by moderate sacrifices of mathematical accuracy, if neces sary--and tailored to typical plant applications. Also, the standards should provide modifying factors to adjust for most conceivable variations in design conditions. The procedures outlined in this article meet these con ditions. Although these procedures have not yet been ap plied to an actual design, test calculations have been made for numerous applications, with results that show very favorable recovery periods for the added invest ment. Only hot systems are covered in this article. (We are preparing another article on cold systems that we expect will appear in a future issue. In that situation, the new economic criteria indicate that the thicknesses needed for economic purposes are dose to those needed for func tional antisweat needs.) Evaluating the Basic Economic Forces Two major costs enter into the economics of insula tion--that of the installation itself (materials and labor), and the operating expense caused by heat loss through the insulation. A direct comparison of heat-loss costs with initial costs is possible when the initial cost is ex pressed as an equivalent annual cost Optimum economy is achieved when the annual cost of the capital invest ment plus the annual cost of the heat loss is at a mini mum. Fig. 1a through lc picture the economic phenomena described in the preceding paragraph (with insulationthickness presented as the independent variable). Fig. lc is the sum of Fig. la and lb; the theoretical thickness that achieves optimum economy corresponds to the low est point of this curve. Mathematical procedures, if properly applied to cor- Photo John-Manviiie Your capital works harder with intensive mixing. Reducing raw material costs ... increasing processing profits. Your objectives for mir-.er investments. You're a tough customer. And a good prospect for mulling. You want total dispersion of raw matej, Highest quality mixes. At lowest possir costs. Big raw material savings. Reduce maintenance, power and handling costs. You're ready to switch to mulling. Mulling affords cost-saving fulfillment of raw material potential... uses power for mixing only ... and brings your mix many steps closer to its finish. Helping to minimize costs and maximize profits. With unique kneading, smearing and spatulate actions, Simpson mulling provides intimate, intensive mixes. Total dispersion. Of varying volumes, moistures, densities and grain sizes. Uniformity of texture, moisture ... of all physical properties. You're tough. We'll prove we're tough. Investigate opportunities to pre-evaluate your investments in Simpson Mix-Mullers* or Multi-Mulls* through lab tests under your supervision. Send for Performance Laboratory Bulletin (PL-70). Write: National Engineering Company, 20 N. Wacker Dr., Chjcago, III. 60606. Nationa Engineering Company CHEMICAL ENGINEERING/JULY 21,1975 Circle 41S on Reader Service Card 000161 >7 red basic data, will indicate one specific value for this optimum. However, owing to the wide JJ-shape^of the M curve(Fig. le), commercially available thicknesses tha|| are.slightly greater or less than the theoretical one. will* yield a system whose life-economy differs only slightlys from the theoretical minimum. Hence, even though"the* "optimum thickness" may be impractical,, the overall^ economy is essentially the same with the next higher, ?r-* lower, commercial thickness, a Engineering Impact of New Economic Criteria The economic thicknesses indicated by the new proce dure are, in most cases, nearly double those calculated by older standards. It is apparent that the new standard can not be applied (practically) to the repair or replacement of damaged insulation in existing installations. In most cases, existing spacing and available pipe-rack space would prohibit the change. To test the value of the new criteria, a recent installa tion that was designed under the old standard was re evaluated in light of the new criteria. The initial cost of applying the thicker insulation (at the time of construc tion) was estimated as $75,600. With current fuel prices, the incremental fuel saving would have been about S25,000/yT. Unfortunately, as in most cases, hindsight could not be usefully employed.' Using the Insulation Nomographs The assumptions that have been built into the follow ing nomographs for hot insulation are listed below: Assumptions affecting the value ofheat losses: Overall conversion efficiency, fuel to useful heat-- 72%. Annual hours of operation of insulated system-- 8,760. Average annual ambient temperature--45 to 75'F. Capital cost of heat-generating equipment, realized over a 15-yr life span--negligible. Effect of wind on heat loss of well-insulated outdoor pipe and equipment--negligible. Assumptions affecting equivalent annual cost of capital investment in insulation: Anticipated service life--15 yr. Annual cost of money--10%. Annual cost of maintenance of insulation-negli gible. The overalll conversion efficiency (the first item noted) incorporates an 80% efficiency (based on higher heating value) of heat-generation equipment, which is typical of modem oil-burning boilers in the medium-size range, and the use of 10% of the steam produced (or the equiva lent value in electrical energy) to drive auxiliaries and otherwise serve the boilers. The annual cost of money is obviously subject to change in today's fluctuating money markets. (We will explain later how to adjust for such changes.) User Inputs There are five user-selected variables: Pipe size. Operating fluid temperature. Raw fuel cost--projected at plant's mid-life. Insulation material. Installed cost of insulation. For the sake of simplicity, the installed cost of insula tion is based on one thickness (1 Vi in) ofjacketed insula tion applied to one pipe size (2V4 in). This is the only in- stalled-cost figure needed, no matter what the actual pipe size or insulation thickness. There is a separate nomograph of each pipe size or limited group of pipe sizes. On each, an array of curves (for various fuel costs) has been drawn for calcium sili cate, and another array for fiber glass, each within the temperature range of its normal application. Where there is a preference for such application, the calcium silicate lines may be projected to temperatures below 350"F. For mineral wool, use the fiber-glass lines. For this ap plication they can be projected (as straight lines) to tem peratures as high as 1,000`F. The projected curves can also be used with fiber-glass having higher temperature limits. (Continued on p. 96) \, I COST of insulation, a: Cost of thermal losses, b: Cost of investment, c: Total yearly cost--Fig. 1 CHEMICAL ENGINEERING/JULY 21,1975 59 000162 INSULATION THICKNESS . . . Installed cost of ` 100^*^200 ^300' 1'A-in jacketed insulation'?': ^ on a 214-in ips. pipe. S/ft ;>t-. : ' - EXAMPLE lor use of subsequent nomographs (or determining optimum thickness of insulation--Pig. 2 , Example of Selection of Insulation Thickness For an application when calcium silicate insulation is preferred. See Fig Z Given: a. Pipe size--10-in Solution: a. Use 1 0-in pipe curvos b. Fluid tempantura-275*F . c. Mstarial-CaSi d. Raw-fuel cost S2.85/lD* b. Project CaSi curvos to lower tamperaturt region c Enter at 275*F and proceed vertically to CaSi curvet d. Intersect $2J)5 curve (by interpolation) e. Local installed coat--$6/ft (for 1%-in on 2K-in pipe) . Proceed horizontally to S4 cost line and follow sloping lines to $S can line f. Find economic insulation f. Proceed horizontally and road 3.1-in Answer Use 3-in insulation at closely approximatini the optimum. tjmpsniHfcy|>jgi .f3eSpre% 'Adjusting for Higher Fuel Costs .*: , . J'-Jy For fuel cons above $3/10* Btu, proceed followe: " Givee: ' vTalutiea: srf***, a. Pipe size-tO-in b. Fluid tmiperature-SOirF " c. Material-CaSi '0.-(Jet 10-in pipe s _>... .- i-nr. fccEntarFig. 2at S t ProiaedverticaByl - . curvae ,.<*! d. Raw-fuel cott-St/10*Btu d IntmctOeunm i *s-*$r------- '''.ri'Vrv>Vi7aodplot a Local installed con-S8/ft (for IK-in insulation on 2JHo pipe). WIV* if'.1* Sn e.FoUowioping mats] . ^ ' Mnd/ji . f. Find economic Insulation - ~ V'.'.f.'' Proceedt vs-.~v eneveilahle ftiduaeu^ ___________________ ' -- JULY 21,1975/CHEMICAL ENGINEERING) 000163 |BHiiiiBsi3**Bsi*aB*Ba*B*saBBBBaBBBa*BBBBaBBBBBmsiBBaBBBBBBa------ ',PBa4BB*B!0S*.dateBSiailsSeaSa*g*<Sia'M!S.'S;SaBa.^<<MeSt!aBBBBBdaBB:aaBBaSaaiBaBB4IataBsaiiaaa>Bag*BaBBaBBdaaBaBBeBBaBBfjBnlBBMBBiBBaBgBauBgiBeniaBnBlalBBnaBNllBBaagNBBBBaBaaBgtBJnIBBr'BB*B'a`-BB-BB--B-*j itJc*-iMxj3c*tiaBaaaBBEsss*^Bsda*atanBaw4aaa-'Bu.^ajae-B:aaaajj*s:Ba*Nniast;aaa.aasaiaaaeaaiais.rsats*rssa^na.sa2sB-aesr^etivBa>atcasBaiBs*.aiinie9iBai*aasMaarMua'>5ed<auBi^sBaa3)ca9aaSaiaaas?ar>Bs?MaBttia<atBatae;CiaaaicjBB*a^aBBaa*B5'aaBssaaaaaiaBaaaaaasa'aiaaaa'ajsat.aefaiaaaaisBB)Baaa(BsBaaaaaBaaaaBBaaaaaaHaBBaeaaaaBaaa*jasaaaaaaBaBaBaa*aaaBaBia9BaaaMaaBaBaaaaaa9aBBviaaBiaaBawBaaaaaaaBBBaanaawBBaBaBaBaaiBaa>a'_B*BaBoaaaa__-aaaaaaaar_aBaaaaBi_BBaBas;5a_aBaBBBB5aaaaaaaB*aa,a?B1Baaa**;aBBB'aBaaMaaaBBia-a-SBa-ama'a-BH'a-a-~asB-gBB-a-a-Ba-~aBn-nS-aa'a-B-Baa-nIii 13.T 44irtirait for 2-Inipt. a za.sessitfs aes ftv adjusting for *' ******? ^PP- irataited cost factor .***** *4 - J ; rj9B__aTCsF*^***4**>oH*o*a**aa-a*j^i*\*^?*-Z__x_ kis ;*., #* c.; * * 3 r - dH-;-r7ra* .:r5u*i5tU*s`t*i?*r32tf-= .J **M&aSi*<l'*tfa 9 .?US;- ' ,3l4? ?Sti.ii02i muUn1BSrIIB9>~1 isaiU f-SdMtd****.* TfeOtVwfflSiPa f^d4U9lt_!KJZana. .uamisvauBai (ravftMIB j c* Ja. MBaS*;! .^Haaaaaaaaaai*aaaAaMM --------aaauaaiuaaasiraaaM iaaaea9Maaaait3saaA93<j^ "~iaaBBaaBBa*ttaaaaa33ia .^laaaaaaaaaaaaaaa* a s a* _____ laBBaaBaaaaaBBaaaaaaaasa lawMaaBBaaaawaansiaaaaaaiaMa *2!rv ,^_5Rf*tw3C^%8 l?Sr*.4* ... tm^ss -Ijj^uavi2&rs*gr*ti<**( raJ"r*it fffaimjTtneAWMifse 8as*HBtffiiM*aa**a; BtaBaHri-'a?`aTa'iaiBaaaaa*aaaaaaaaajg%;J_ig,, isaBaasaas"*^ -.:&`W*L'MttaaVSaftif*dtt9M*aai..i.M....S....B..... a.,i,MflB, ,, V..al.a.M_a__a*_a_._.aM_._a--0_-a-_-Sa_--_a-8_--a.9-.-.a-B----eflaalBsBaHBBaaaaaaa J,,. ~#,f^)acjfotadJrmiL.. orta2)Hni^pip*$ c? ' ; Required Insulation thickness, in Installed cost of 100 IJWn jackatad insulation on a2K-m ip*, pipe, t/fl CHEMICAL ENGINEERING/JULY 21, 1975 300 400 5do' eooT .,,--.- Pipeline fluid-tamperature, * v-- ;,. 46-75* year round i *- ' . ' . ' - - `^'-K . .. .a... .. ..i. : . .. ------ lidtoiu -1;A JsiW-U v-*l 91 000164 INSULATION THICKNESS 92 JULY 21,1975/CHEMICAL ENGINEERING 000165 Required Insulation thickness. In 5TaaBi*BasMcq*JH . ^ Sa**aB****;:*snta*iiL _4 ___________ i*aaaMaKafitaUaHaMaMBaB0paaar39S'**eed&r*'?a*s*LLl.-?v$: ____ '74 ^___ iHaMai0UiniivuttaiMits9^inKai|<. vj i0aaiBaaBBaaaBauBaaBaaBBaa9atf*sg3*Kr* laBaaBaaaBaaaaaaaattBaaaattaaaasa&avBSffaaks&tf f__l_m___a___ii_i_M_ [aaMnmiiaiaiaaaBBtaaanaamaiaimaaiaiBaauBiafatiaMM8tfaifBlsaia!f*lswHPV-t.';f IK K m on . 254-in ip*, pip*, */ft vaattMttaaasaaff ai,v a mn<is<>tg!^it|,t i ___________ ________________________________ ttIiS?SSSSSiIiillSSiiiSilS*S**SSSt**IB*a*2|*2g**|2f77' XmXiSo^oo < jgfaife. gfes^fei.-; > ' tn-t >&,*'' .......* ' _ T.f"* " ^ "^4"tf***r >>*ri w rmsas isss smnnt 5*9K1 su"'a;war*?ni-adRkBfia?i*aai m!iDBSOatcaafssBa3ii*tvtBBttMf9fBaaaa*aBt3atfNm*Raaiaaa*ssAa*3aavHanatitstB3fPst*fvatsfatlBMai(stB9fa*faiaa8afBiist4*asi'-ai.i.i:i-as rna*n r**Be5a*Sf Miatr s :iv- .4 n a-ftra-'n;*! >;* - X*iLsrsKrt`atttJ`tt3*9jo' wjieSBa*--3*uea:%Cl*ss*inaK&tesn:&a,taSafntaf4i53*ssVn.,ticiia.--A9**f.cma.iti3tE..it.aa7ri*s--_5*a.-kpr-fM4.*T:h2,TW*c*-a9{Brs;j*r4--wB#s.t^a7^o*!6*AsTIr0.ipIKtiOt9A._f.5.fwk*_*sc.Su^.M*A*I9*'T*-?j*3SB^saMJ:B:9r<B_if*q3M*__5a*9aw_9s_t4tsaag__f^s9_a*fj_m_ilj?t9w__rtisB#-q-_aiay-Uaaa-iBvava^-A-aaa*-]ga9s!-1-ifi*ai-f-rr-*.fa.a\-ts*Ms-Fn.a*B&S*s9T;.Va3*a^n4*9tcc?w.4*t^w*B<j**p54*^*W*j:f*3rss-*N*5iKk*t^'i'SAA4cvef-.ta*>r^Jj-??^*rp.-r--r'V:Pf*.*V>^-"#*-*.'-..--Wi'-*v-*'<:a.">*-*i-*T'?s-j.p--9*'*y.*.:.-/*-.f,*i .4 fctfiZttS n:i<9w?#Ka9 ***es?ii>^..r*a* i-r-^^r-- '"...... . ^ 43BBtt99a**9?4^i>^'-4faii5^W*' r ft <* 9 "J i V *c r:?.^ 4 -, .* * #eajr#: If*t l#!l|dltfflic>nl aummamnavam"*"** a**9aa*^w?*?<:* i- :v;v-'.s' w;tt-A9af<ctfct<#* zb*** i !4*T ^ .. V- a S rtS tt *3 R* * *5W ?***> * *3 * * y-3 SA * < -'XKkfa*? .Vii5Cr}~*-su*fcwrf^4. -*T* -/ -1u'#f-' * 4*i1t~rr 3 ^ u,-* 4* n?:< a ;is* *xss k * * r: ^ .: < .9<* y rs-Ay*?*ssftJ[i:iisSSrS- tft^8..X............. ' Jlf ?#* :rv ' su: aaKJ*64iriW;g?g.*vtJ^t?3y?y5iiffg,xa'ii - s"?a;&;*^. *i*. ^: *v: - '>^'''r.'r3^^--^a^.- tt s^r ii6.^iaa |f4 " 31* .? 1CS? Z ft. 3 irCT ^5 9? 215 -.7 ^ *J * > -S?K - * JfS`:':t*5laAT65|.<? Vfifc 'pesfhe.jiorniuierd.v y.v pataot Kiendjfcefgbg .... gl>-s.................... ^UKV***p:'b 1^500 Fj iSB 9HiS **-43-fewt'4T-i-.^i9':><-5* ,w*i4-1.^A';n-.a*^S>Wt'aV'*^vB5A.;iCVy.1a^r.'f;;p'.*'S< .' . ^ -T - -e 1 *-4 10>in ipt t Intuited con of 100 200 300 400 500 600 700 800 900 1,000 1,100 1.200 154-in jacketed insulation on a 254-in ips. pipe. S/ft Pipeline Fhiid-temperatuns. F vs 46-75* year round ambient >.">>- CHEMICAL ENGINEERING/JULY 21,1975 93 000166 INSULATION THICKNESS i Installed cost of 114-in jacketed insulation on a 2%-in ips. pipe. S/ft 94 - .*-v. :< Y . .&-- r **.:*. "*: a .5 *& - v*. - -^z:*s-<ae:*i'z? ->s*ttss*S5a -re 1 ssissa^aBBasaBsatf ' ~ '* J'v V'f'ri; t'r-ta'reSEC:reaS3B-r'.-.-5 > i- .* tf r *>v.^s; v a < * r '"s 5- *sb srabjt : ;- **>:> irr.<rii,'--:t.5!.55BSCE*lSB-(aB!Bi. Calciumsilicata. ;.*yr2E,wsasMann!BM.V':''i .*s*ss-n-n'iw3an c^ibic . ** partita (for mineral .' wool extandfiberglass cmvaupto 1,000** i l ll&'.lfrr20> ndi^wJ -*"'. yj S"u* "i.iijfl y * v; * * * s**s it -t *a t?s * aar, 300 400 500 800 700 800 . Pipefina fluid-temperature, "p ^ -. .Vi' 45*75*year round ambtienntt .; !v ^aja3fct4jjiflaaag - > 900 T,000 1,100 1.200 vY*v'tV' 9!*28s&2i V-- r.'.r tiu! JULY 21,1973/CHEMICAL ENQIHoiin 000167 1--------------------------*4 Vvii,', Spedffed Annual Interest {FactorA)--TaW* f L 1.'.. V - -* - ... . . - i. ' V *5'. ^ " '" I Amorli/.ition Value of A for Vdriuus fnirn.'s! Annu.il. Periuci. Yr 6.0 6.5 70 7.5 8.0 8.5 9.0 95 100 10 b 110 115 12.0 1 1.060 1.065 ,3.070 #1075 - ill080'7t-1085 1090' ,CUH5-. ^i.ioo. 4306 '1.110 ^-t.iiiK. irt20 *. 2 0.5454 05433.,05531. .05569 05600 0.5646 05685 05723 05762 05801 05839 *05878 05917 3 03741 03776 83811 - .03845 03880 .03915 02961 03986 04021 04057 04092 0.4128 04163 4 02886 02919 02952 02986 .03019 03053 03087 03121 02155 03189.02223 03258 ! 03292 ' h 02374 02406 02439 02472 02505 , 02538 0.2571 02604 02838 02672 02706 02740 02774 6 02034 02066 02088 02130 02163 .02263 nrr^ 02263 02296 02330 02364 02398 02432 7 01791 01823 01856 01888 01921 01954 01987 02020 0.2054 02088 02122 02157 02191 8 01510 01642 01675 01707 01740 01773 0.1807 01840 01874 01909 0.1943 0.1978 02013 9 01470 01502 01535 01568 01601 01634 0.1668 0.1702 0.1736 01771 0.1806 0.1841 0.1877 10 01359 01391 .01424 . 01457 01490 01524 01558 01593 . 0107.01663 0.1698. 01733 \O1770_ 1 01268 ` 01301 01334 01367 01401 01435 0.1469 01504 0.1540 01575 01611 01648 01684 12 01193 01226 01259 01293 01327 01362 01397 01432 01468 01504 01540 01577 01614 13 01130 01163 01197 01231 Q.1265 01300 0.1336 0.1372 0.1407 01444 0.1482 0.1519 01557 14 01076 01109 01143 01178 01213 01248 01284 f 01321 0135L 01395 0.1432 0.1470 01509 TO O1930 91064 01098 01133 01169 01204 01241 ' 0.1277 B 01352 01391 01429. jL1468 ' 16 00990 01024 01059 01094 01130 01166 01203 01240 01278 01316 -01355*'01394* 01434 17 00954 00989 01024 '01060 01096 01133 01170 01208 '01247 01285 01325. 01364 01405 18 00924 0.0959 00994 01030 01067 0.1104 01142 0.1180 01219 01259 01299 01339 01379 19 00896 00932 00968 01004 01041 01079 0.1117 0-1156 01195 01235 01278 0131*8 01358 20 00872 00908 00944 0.0981 01019 01057 0.1095 01135 01175 01215 012560129^01339 21 00850 00886 90923 00960 00998 01037 01076 01116 01156. 01197 ' 01238 01280 01322 22 00830 00867 00904 00942 00980 01019 01059 0.1899 01140 01181 01223 01285. 01308 23 00813 00850 00887 00925 00964 01004 01044 01084 01126 01167 01210 07252. 01285 24 00797 00834 90872 0.0910 00950 00990 01030 01071 01113 O1155'01198 01241/ 01285 V 26 00782 00820 00858 00887 0.0937 00977 01018 0.1060 01102 01T44 01187 01231 01275 CHEMICAL ENGINEERING/JULY 21, 1975 000168 95 INSULATION THICXNESS . . . Observe that Fig. 2 shows a 14-in minimum insulation thickness-this is common to all the nomographs. Several manufacturers have indicated that they are discontinuing insulation material thinner than 14 in. in recognition of dwindling user interest. It is probable that 14-in insula tion will soon be the thinnest competitively available. The nomographs also indicate maximum recom mended insulation thicknesses. These maxima vary with the pipe size, and are in recognition of the economic im pact of excessive thickness in such areas as pipe-rack ca pacity, pipe support problems, and the like. These max ima are based solely on our engineering judgments. Adjusting for Variations in Assumptions Corrections to fit conditions other than those assumed are made by adjusting one or more of the plotted vari ables which, when applied to the nomographs, will indi cate the optimum insulation thickness. Hour* of Operation and Efflciancy--To adjust for fewer than 8,760 hr/yr operation, or for overall effi ciency other than 72%. multiply "Raw fuel cost per mil lion Btu" by: (hours of operation/8,760) (72%/% efficiency) Ambient Temperature Other Than 45-75"F--For higher ambients, subtract from "Pipeline-fluid tempera ture" the quantity: Ambient - 60 For lower ambients, add to "Pipeline-fluid temperature" the quantity: 60 - Ambient Service Lite, Maintenance, Coat of Money--To adjust for a service life of other than 15 vr, a cost of money other than 10%, or appreciable insulation maintenance. multiply "Installed cost of 14-in jacketed insulation on a 24-in pipe" by: (A + AO/0.1315 where A is the uniform annual payment needed to reach unit value over the expected service life, while paying a specified annual interest (read from Table I)- AT is the ex pected average annual maintenance charge, expressed as a decimal part of the installed cost. (0.1315 is the uniform annual payment at 10% for 15 years, the assumed condi tions for the nomograph.) Fuel Coate Above $3--For applications where pro jected raw-fuel costs exceed S3/106 Btu, adjust curve val ues by using Table 11. The resultant thicknesses will ex ceed, in many cases, the maxima established on the nomographs. As stated previously, the maxima are engi neering judgments, and the user is advised to weigh physical space considerations against overall operating economy. Differing Energy-Coat Levels--Applications will arise where a portion of the plant's piping owes its tempera ture level to conventional combustion of fossil fuels, while other streams are heated by significantly differing energy sources such as low-pressure waste steam, exhaust gases and direct-fired calciners. The user is encouraged to apply appropriate raw-fuel costs and efficiency adjust ments for each distinct system to derive maximum ben efit from this article. Cylindrical Equipment--Cylindrical equipment of less than 30-in. O.D. may be treated as pipe of approximately the same O.D. # Reference* "Econ-I-How to Determine Economic Thickness of Thermal Insu lation," Thermal Insulation Manufacturers Assn., 7 Kirbv Plaza. Ml Kisko, NY 10549. 1973. King, Reno C.. Crocker. Sabin, eds.. "Piping Handbook." 5th ed.. Mc<5raw-Hill. New York. 1967. Meet the Authors M Jules L. Abramovna is a Mocnanical Design Engineer in tfta Corporal# Engtnoor- ng Oapt. ot Allied Chemical Corp.. P O Box 224SA. Momstown. NJ 07960 Ho received his B S m mocnanical engineering from Nowar* Collogo of Engmoor' mg. and hi* M S in mochanica) engineering from Pairtotgh Dickinson Untversrty Bono Cordoro * a Mocnanical Oowgn Engmoor for Allied Gnomical Corp. at Morristown. N j Ho received nit 8 ME degree from Catholic University and hia M M A E from the University of Oeiaware. Ho n a regwtered Professional Engi neer m trie state of Now jersey. a JULY 21,197S/CHEMICAL ENGINEERING *0, f , T j*ri''MfMd vapor condemn - ]' appraeMilv*t wall L tamparature. T *--. -\.. Vanal it unitulatad. Con- - tainad liquid foult or solidifia* at wall tamparature. .1 , - vqpo\_' .. . 4\ ' v >\ - ++' ~ -:r. vatodry Of ouuida turfac* - 3 ~k film only, bv u*ing Eq. (7b) -. ~ (HnWvitv,K required. ^ .and (4b). Temperature correction - ; factor, W - 14) Film rasittanct of both containad liquid and vapor . adjacent to fouled surface. -Fio. 1 with tamparature . correction factor W * 0.4; and wind velocity or "T""" " amitaivity correction aa required. Heat Iota through fouling layer and adjacent air film by " 'using Eq. 14a) or (8). ' I' Vaaaal it unintulatad, and . '. contains stagnant liquid or dry vapor. Fig. 1 with temperature Heat lost through inside-fluid ^ correction factor, W, obi ~ film and adjacent air fHm ..- . , tainad from table for type by using Eq. (6) or (6a), (7) , ' ^ ' ' of contained material; and and (4). -------- . .-f-.T,. -i. wind velocity or amitaivity------ ;.___ '- -- - -% -- - ^- correction at required.-------- ------- Vaaaal it insulated with calcium plicate or similar material. Film resistance of both obm f. Fig. 2 with wind-velocity tainad liquid and vapor'* ' correction factor obtained ~ adjacent to insulated surface. . - from table. Insulation - .. thickness may be obtained ' - ' "from Fig. 2. Haat lots through insulation and adjacent sir film by using Eq. (7a) and (31. Insulation Saves Energy Shortcut graphical methods allow rapid evaluation of heat losses from uninsulated and insulated vessels. Depending on the temperature difference between vessel and ambient air, the method also sets the required thickness of outside insulation. RICHARD HUGHES and VICTOR DEUMAGA, The Badger Co. Accurate calculations for determining the heat flow between the contents of a vessel and its surroundings are often complex. Multiple resistances in senes are usually present in the heat-flow path. In addition, conduction, convection and radiation flows may be simultaneously involved. And there may be heat flow by evaporauon and condensation within the confines of the vessel. Therefore, the particular assumptions and simplifica tions involved in the method used to calculate heat losses must be understood, and the accuracy of the method must be consistent with a particular requirement. For example, a simple shortcut approximation will usuallv indicate whether outside insulation of a given thickness is required. On the other hand, it is often desir able lo accurately check a final design (sometimes at CHEMICAL ENGINEERING/MAY 27. 1974 varying ambient or internal tank conditions) to determine the average annual heal losses. Accordingly, we will present two methods of heat-loss calculation: 1. A rapid graphical method that can be used for ex ploratory evaluation of heat losses. 2. A more accurate algebraic method that is suitable for a computerized solution if multiple calculations are required. Graphical Method Is Rapid We can obtain an approximate value for the unit heat loss from Fig. 1 or 2. The unit heat loss when multiplied by the surface area under review yields the overall hourly 000170 HEAT LOSSES . . . Temperature difference, 000171 UNINSULATED tanks have heat losses that depend on nature of tank contents. Values in chart are for wind velocity of zero, surface emis-'vity of 0.9. and ambient air temperature of 70F--i 96 MAY 27, 1974/CHEMICAL ENGINEERING INSULATED tanks, covered with calcium silicate, have heat losses based on negligible resistance to heat flow on process side. Values in chart are for wind velocity of zero, emissivity of 0.8, ambient air temperature of 70F--Fig. 2 heat loss. A summation of the discrete losses through the tank roof and tank side, exposed to both liquid and vapor, gives the total hourly heat loss to the atmosphere. In addition, heat loss from the bottom of the tank to the ground is easily calculated from Eq. (5) to complete the heat-loss approximation. Table I summarizes conditions for which Fig. I and 2 are recommended. Fig. 1 is used to approximate heat losses from uninsu lated tanks. A table of correction factors for temperature difference is included to compensate for common internal resistances to heat flow. In addition, the unit heat loss is divided into a convection and a radiation component. This allows rapid, independent correction for wind velocity and surface emissivity, if required. Fig. 1 also contains a total unit-heat-loss curve at zero wind velocity and 0.9 radiation emissivity. Fig. 2 is used to approximate heat losses from insulated tanks. A table of recommended insulation thickness for CHEMICAL ENGINEERING/MAY 27, 1974 various temperature ranges is included, and wind-loss correction factors at the recommended insulation thick ness are given. Analysis of Algebraic Method Heat losses from tanks are calculated by using the natural-convection heat-transfer relations for the sides and roof of the tank, and the conduction heat-transfer relation for the bottom where the tanks rest on the ground. The total heat loss, QT, is divided into four compo nents: Qt = Ql + Qv + Q + Qa (11 where QL is heat loss from liquid in tank to atmosphere through sidewall; Qv is heat loss from vapor in tank to atmosphere through sidewall; QK is heat loss from vapor 000172 HEAT LOSSES . .. in tank to atmosphere through roof; and Qa is heat loss from liquid in tank to ground through the bottom of the tank. Table I summarizes conditions for which specific equa tions are recommended to calculate the component heat losses. Hsat Losses: Sidewall and Top The method for calculating side and top heat losses, Ql, Qv and Qt, is essentially the same. In all cases, heat loss is calculated through two series resistances to heat transfer. These resistances are; (1) the tank inside-film or the tank insulation, and (2) the air film (when insulation is used, the inside-film resistance is neglected). Note that in all cases the tank wall itself is neglected as a separate resistance. If the tank is fabricated of heat-transfer-resistant material, then the wail itself can be treated as an insulation layer. Similarly, if appreciable fouling or so lidification occurs within the tank, the fouling layer be comes equivalent to an insulation layer. The usual individual and overall relationships for heat transfer are given by: <?/<= 9. +? = ? = U(T, - TA) = ht(Tt - Tw) = (k,/X,XTw - T,) = hA(T, - Ta) (2) When the tank surface under consideration is insulated, the unit heat loss, q, is given by: q = (VJT.xr, - T,) = hAcr, - ta) (3) Note that the inside-film resistance is neglected, and Tw = T{. The inside liquid-film resistance can also be neglected, even in the absence of insulation, if the liquid contents are agitated. In this case, a direct resolution is possible by using Eq. (4b). Similarly, the inside vapor-film resistance can be neglected if appreciable condensation occurs in the portion of the tank's surface that is exposed to vapors. When the tank surface under consideration is not in sulated, the unit heat loss, q, is given by: q = A,(Tt - 7V) = hA(Tw - Ta) (4) For either insulated or uninsulated tanks, the method of computation is the same. The air temperature, TA, and the tank-contents temperature, 7",, are known. Individual film heat-transfer coefficients [as defined by Eq. (6) and (7)] are used, together with insulation resistance, where applicable, to calculate the remaining unknown interme diate temperature, 7), in Eq. (3), or Tw in Eq. (4), and hence to calculate the unit heat loss. The total heat loss is then calculated as the product of the unit heat loss and tank surface area under consideration. When the tank surface is coated internally with a foul ing or solidified layer, the unit heat loss is found from a modification of Eq. (4), which is: 9 = (1 /R^T, - TV) = hA(Tw - Ta) (4a) When the inside-film resistance is small and the tank surface is insulated, the unit heat toss becomes a particular case of Eq. (4), which is: 9 = hA(Tt - Ta) (4b) M Nomenclature A Area of heat transfer, ft* C Specific heat, Btu/(lbX*F) D Diameter of tank, ft g Gravity acceleration, 4.17 x 10* ft/h1 ,. H Tank height, ft. l , hmt+rtMftr ueth c. e*T, k Thermal conductivity, Btu/fhXft^'F/ft) P Pressure, psia Q Heat transferred. Btu/h 9 Unit heat transferred, Btu/fliXft2) R Fouling factor, (hrXftJX'F)/Btu T Temperature, *F V Overall heat-transfer coefficient, Btu/(hXfl*X'F) V Wind velocity, mph W Temperature-difference correction factor X Thickness, ft ff Coefficient of volumetric expansion, 1/*F < Emissivity It Viscosity, lb/(hXft) P Density, lb/ftJ Subscripts A Environment a Radiation c Convection F Fluid film G Ground i Tank content 7 Insulation L Liquid M Insulation mean 71 Roof r Fouling layer T Total V Vapor W Tank wall Hmt Lossm: From Bottom of Tank When a tank rests on the ground, the heat loss through the bottom, Qa, is given by: Qa = 2D1c0(7^ -- Tg) (5) Eq. (5) was derived [7] from an equation given by McAdams (J]. The inside-film resistance to heat transfer is neglected. If the tank is mounted aboveground, the bottom tank surface, A0, is then added to the side-surface, AL, when calculating QL by Eq. (3) or (4). Finally, QT is found as the sum of the component heat losses from Eq. (1). -__ , 000173 Film Coefficients and Fouling 1 Inside liquid-film coefficient for a liquid in contact with the tank surface (h{ = hL) is given by: &! (6) was derived [2] from an equation given by McAdams [4], Inside vapor-film coefficient for a vapor in contact with the tank surface (hi = hY) is given by: hT = 9.686 x 10-`iP0-\Ty)--\Tv - Fw)-a (6a) MAY 27, 1974/CHEMICAL ENGINEERING /C\ Eq. (6a) is a particular case of Eq. (6), and can be used for both nitrogen and air at moderate temperatures (SO to 400*F) and pressures (0 to 500 psig). When the vapor present is appreciably different from air, the vapor-film coefficient is calculated from Eq. (6) by using vapor-film physical properties. For a condensing vapor, the vaporfilm resistance is neglected, and hence the coefficient is not calculated. The outside air-film coefficient is calculated from one of the following equations. When the tank surface is uninsulated, Eq. (7) is recom mended for substitution into Eq. (4): hA = 0.296(Tw - I.28F + l)172 + (Tw + 460y _ /TA + 460\4 V 100 / l 100 / 0.174 Tw-Ta (7) Eq- (7) includes a wind-velocity correction factor and a radiation loss factor [5]. When the tank surface is insulated, Eq. (7a) is recom mended for substitution into Eq. (3): hA = 0.296<r( - Ta)V*{\.2V + l)^2 + 0.174< Ta + 460 y 100 t,-ta (7a) Eq. (7a) differs only from Eq. (7) in that the surface temperature of the insulation, 7}, is used instead of the tank-wall temperature, Tw. In either case, Eq. (3) or (4) is then solved by trial and error for the intermediate temperature, T, or Tw, which is then used to calculate the unit heat loss, q. When the tank surface is uninsulated and the liquid- film or vapor-film resistance for the material contained in the tank is small, Eq. (7b) is recommended for substi tution into Eq. (4b): hA = 0.296(7; - Ta)1'*( 1.28K + 1)I/J + (T, +460\ ,Ta + 460 y \ 100 / V 100 / O.I74< Tt - Ta (7b) For these conditions, Eq. (4b) can be used directly to calculate the unit heat loss, q. If the thickness of the fouling layer can be estimated, the inside fouling factor used in Eq. (4a) can be calculated from: Rt = XJK (*) The thermal conductivity, kr, is usually taken as the fluid thermal conductivity at the mean temperature across the fouling layer. Temperatures and Physical Properties Initially, we can assume that the intermediate temper ature, Tw or T,, is midway between 7" and TA. The inside fluid properties are used at the average inside-film tem perature of (T, + Tw)/2. Similarly, outside properties at the average outside-film temperature of (Tw + TA )/2 are CHEMICAL ENGINEERING/MAY 27, 1974 &'Wj) Mwptwft, cwbon, -Rid brick and tflcKconcrete - r+ojs f-vea;. sa-oas l^fcon, dark pelme ; |S. brawn, eraanh^fc^j^ifttf.'. i^OJBS - 0J6 L 0.76 -0.90 or IWn-oaam SridtA*^ JafS ?:' >-Y* -.vtW&VL' ,ta, paint or pepcr.&jtf'iwM j. . r. V & ~ otter, wtiltnndi.^'^ :;OJB8-0J6 - ' 0.S0-0.7B afc^(w4aWUj4*a(, ctwnraliim,.- C-OCQ-0.04 }0.0R -0.10 ... Ltouracfc-JAAUBAg^quIOc. (Waadna. VantHaMne, Afe-Cow dtUonlna tMdil.* Own. B. p. S3, Amarlean Sac, of H--tlna. dladrdfadm and AirCowdMonlnc itjlniia Maw York,1t0. used to evaluate physical properties for the film coeffi cients in Eq. (4). When the tank is insulated, the average insulation temperature, TM, becomes (Tt + T,)/2. Similarly, the average outside-film temperature becomes: (7} + TA)/2. These average temperatures are used to evaluate physical properties for the film coefficients in Eq. (3). For greater accuracy, the average film temperatures can be recalculated by using 7} or Tw, as found from Eq. (3) and (4). Hence, a new heat loss can be obtained by using physical property data at the new average film tempera ture. Problem Illustrates Procedures A fuel oil at 12" API at 60*F with a viscosity of 50 SSF (Saybolt seconds furol) at 122*F is stored at 300*F in a 20-ft-dia. by 30-ft-high carbon-steel tank at atmospheric pressure. The oil level in the tank is 18 ft Air temperature is 70*F. Let us calculate heat losses to the environment for the following two cases: Core 7--Total surface of the tank is uninsulated and black. Wind velocity is 0 mph. Surface eraissivity of tank is 0.9. Thermal conductivity of ground is 0.8 Btu/(h) (ft2X*F/ft). We will begin the computations by finding the heat loss from the wetted inside surface of the tank. The wetted area is: Al = itDHl = ir(20X18) = 1,130 ft2 A(7; - Ta) = (300 - 70) = 230*F From Fig. !, we find the unit heat loss to be 664 Btu/ (h)(ft2) for this temperature difference. Therefore: Ql = ALqL = 1,130(664) = 750,320 Btu/h 000174 99 HEAT LOSSES . . . Ncxl we calculate the heat loss from the dry inside surface and roof surface of the tank: Ay = trDHy + Iff)2/4 Ay = *<20X30 - 18) + *(20)74 Ay = 754 -4- 314 = 1,068 ft2 \TW = (Tt -TA)W = 230(0.20) = 46`F. Note that IV is the temperature-difference correction fac tor for a noncondensing vapor (Fig. 1). For this temperature difference, we find the unit heat loss from Fig. 1 to be: 84.3 Btu/(h)(ft2). Hence: Qy = Avqr = 1,068(84.3) = 90,030 Btu/h Assuming that T0 = TA, we substitute the appropriate quantities into Eq. (3) to find Q0 as: Qo = 2(20X0.8X300 - 70) = 7,360 Btu/h Therefore, the total heat loss is: Qt = Ql + Qy + Qo Qt s 750,320 + 90,030 + 7,360 = 847,710 Btu/h Alternatively, we can find the exact solution by using the algebraic equations. After making the necessary cal culations, we find that: Qt = Ql + Qr + Qo Qy = 750,980 + 135,782 + 7,360 = 894,122 Btu/h Case 2--Roof of tank is uninsulated and is coated with aluminum painL Side-wall is insulated with calcium sili cate, or equivalent, and has a surface emissivity of 0.8. Wind velocity is 30 mph. Tank contents are not agitated. Thermal conductivity of ground is 0.8 Btu/(h)(ft2)( F/ft). As in Case 1, the wetted surface of the tank, AL, is 1,130 fL2 This represents the interior circumferential area of the tank wetted by the fuel oil to a height of 18 ft. Heat loss from the vessel wall to ambient air is a function of: AT, = (7V - Ta) = (300 - 70) = 230F From Fig. 2, we find the recommended insulation thickness to be 1 % in, and the wind-velocity correction factor to be 1.10. Also, from Fig. 2, we find that the unit heat loss, corrected for wind velocity, becomes: qL = 46(1.10) = 50.6 Btu/fhXft2) Hence: QL - ALqL = 1,130(50.6) = 57,178 Btu/h Now, we calculate the heat loss from the insulated dry-side surface: Av = *(20X30 - 18) = 754 ft2 4(T,, - TA) = 230*F qy = 46(1.10) = 50.6 Btu/(hXfl2) Qy = Ayqr 3 754(50.6) = 38,152 Btu/h In order to calculate the heat loss from the uninsulated roof, we must use Fig. 1. We find that Ag = *(20)2/4 = 314 ri,2 and that surface emissivity = 0.4 from Table II. \TW = (7J - Ta)W = 230(0.20) = 46'F Using this corrected temperature difference and Fig. 1, we find that the unit heat loss for radiation and convection (correcting the radiation loss for an emissivity of 0.4 and the convection loss for the wind velocity) is: q, 3 54.2(0.4) = 21.7 Btu/fhXft2) qc = 35.5f(1.28X30) + l]172 = 2228 Btu/lhKft2) ?* = ?.+?,= 2I-7 + 22Z8 = 244 5 Btu/fhXft2) Hence: Qt - AtqM = 314(244.5) = 76,773 Btu/h Heat loss to the ground is the same as Case 1, i.e. Q0 = 7,360 Btu/h. Therefore, the total heat loss is the sum of the compo nent parts, or: Qr = 57,743 + 38,529 + 76,773 + 7,360 Qt = 180,405 Btu/h Again, we can calculate a more-exact answer by using the algebraic equations. For this case: Qy = 54,419 + 36,279 + 49,887 + 7,360 Qt = 147,945 Btu/h This problem illustrates the ease with which rapid ap proximations to heat loss can be made. # References 1. Stuhlburg, D., How to Design Tank Heaung Coils, Petrol. Refiner, Apr 1959. p. 143. 2. Ibid p. 146. 3. McAdams, W. H.. "Heat Transmission," 3rd ed.. p. 54, McGraw-Hill. New York, 1954. 4. Ibid. p. 172. 5. Malloy, J., Thermal Insulation." p. 35. Van Nostrand Reinhold, New York. 1969. 6. "Heat Insulation Manual," pp. 72-79, Pabco Div., Fibreboard Corp., Emeryville, Calif. Meet the Authors < Richard E. Hugh-- <s a process supervisor with The Badger Co., One Broadway. Cambridge, MA 02742, h )omad Badger in 1959 and hat a wtda rang# ot experience in chemical and petroleum processes. He has IBS in chemical engineering from the University of Wrtwatersrand. South Afnca. and an M.S. in chemical engineering from Vale University He is a memoer of AlChE. Victor Oeumega is a process design engineer with The Badger Co.. Cambridge, MA 02142. He joined Badger in 1972. and has experience in vinyl chionda, acrylonitrile and pntnaile anhydride processes He has a B.S. in chemical enqineanng from Pratt institute, and an M S in chemical engineering from Mas sachusetts institute of Technology 000175 100 MAY 27, 1974/CHEMICAL ENGINEERING o I MILLION BTU MILLION BTU PER YEAR .. .. -from - .UNIMSULA ED PIPE, i-LANGES, AND VALVES.., (9p Percent Fuel Recovery)-- .Lj I 75 150 225 300 375 450 525 600 675 750 825 900 F. FLOWING MEDIUM 40-* 000176 5 QLelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO. 11/4/74 INSUL-5 *CV. NO. 0 PAGE 49 OF gg INDEX ENGINEERS' GUIDE 1. SCOPE 2. ITEMS INSULATED 3. PURPOSE 3.1 HOT SERVICE 3. 1.1 3. 1.2 3. 1.3 3. 1.4 General Heat Conservation Temperature Control Personnel Protection 3.2 COLD SERVICE 4. GENERAL ' 4.1 SURFACES NOT INSULATED 4.2 SURFACE PREPARATION 4.3 INSULATION SUPPORT 4.4 PIPING SUPPORTS 4.5 TRACED LINES 4.6 ALUMINUM WEATHER-BARRIER 4.7 MASTIC WEATHER-BARRIER 5. DATA FORMS 5.1 HEAT INSULATION DATA FORM 5. 1.1 Insulation Material 5.1.1.1 5.1.1.2 5.1.1.3 5.1.1.4 Piping and 24" Diameter and Smaller Equipment Equipment Greater than 24" Diameter Bent Pipe and Tubing Irregular Surfaces Page (s) 52 52 52 52 52 52 53 53 53 53 53 54 54 54 54 54 54 54 55 55 56 56 57 F-4 4IB (3/67) 000177 CLelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO 11/4/74 INSUL-5 *EV. NO. 0 PAGE 50 OF 88 INDEX ENGINEERS' GUIDE (Continued) Page (s) 5. DATA FORMS (Continued) 5.1 HEAT INSULATION DATA FORM (Continued) 5.1.2 Weather-Barrier Materials 57 5.1.2.1 5.1.2.2 5.1.2.3 5.1.2.4 Straight Run Piping and 24" Diameter and Smaller Equipment Elbows Vessel and Exchanger Shells Irregular Surface and Equipment Heads 57 58 58 58 5.1.3 Insulation Securement 58 5.1.3.1 5.1.3.2 5.1.3.3 Piping Through 16" Diameter Piping Greater than 16" Diameter and Equipment 24" Diameter and Less Equipment Greater than 24" Diameter 58 59 59 -tr *--l in Aluminum Jacket Securement 5.1.4.1 5.1.4.2 Piping and 24" Diameter and Smaller Equipment Equipment Greater than 24" Diameter 59 59 59 5.1.5 5.1.6 Reinforcement 5.1.5.1 5.1.5.2 Glass Cloth Wire Netting Specialties 60 60 60 60 COLD INSULATION DATA FORM 5.2.1 Insulation Material 5.2.1.1 5.2.1.2 5.2.1.3 5.2.1.4 Piping Equipment Bent Pipe and Tubing Irregular Surfaces 60 60 60 61 61 C1 000178 F-441 B (3/67) CKielanese PIASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO. 11/4/74 INSUL-5 *CV. NO. 0 PAGE 51 OF 88 INDEX ENGINEERS' GUIDE (Continued) Page (s) Table I - Coverage Table for Aluminum Jacketing, Bands, Clips & Screws 52 Heat Insulation Data Form No. DF-1 63 Cold Insulation Data Form No. DF-2 64 Figure I - Heat Loss From Uninsulated Pipe, Flanges, and Valves How To Select Insulation Thickness for Hot Pipes Insulation Saves Energy 000179 QLelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO 11/4/74 INSUL-5 REV. NO. 0 PAGE 52 OF 88 1. SCOPE This section describes the guidelines to be considered by the engineer in designing and selecting insulation. 2. ITEMS INSULATED Pipelines, valves, instruments and equipment to be insulated are defined on the mechanical flowsheets and/or piping drawings. 3. PURPOSE 3.1 HOT SERVICE 3.1.1 General Hot service insulation serves four purposes: heat conservation, temperature control, personnel protection, and condensation prevention. The temperature used to determine the need for insulation or insulation thickness is the normal operating fluid temperature. One exception to this is when piping or equipment has internal insulation or refractory lining, the temperature that determines insulation thickness is the metal temperature. Composite insulation (one layer of one type of insulation and one layer of a second type) can be used where economical. 3.1.2 Heat Conservation Operating temperatures of 100F or greater justify insulation for heat conservation. Since energy costs, money costs, and installed insulation costs can vary widely, no single table for economic insulation thickness can be constructed. For pipe, economic thickness can be determined by using the graphs in the article "How to Select Insulation Thickness for Hot Pipes", Chemcial Engineering, July 21, 1975. J. L. Abramovitz and R. Cordero, or by using the computer program T 2013 developed j by CCTC. For tanks, heat loss can be estimated j from Figure I of the article "Insulation Saves Energy", Chemical Engineering, May 27, 1974, R. Hughes and V. Deumagh or calculated using the equations in the same article. Economic thickness can be calculated using net present value. Program T 2013 can also be used to determine heat loss and . economic thickness. For flanges and values, heat loss can be estimated from Figure I, "Heat Loss in Million BTU per Year from Uninsulated Pipe, Flanges and Values". Insulation thickness will normally | be the same as used on associated piping. j 000180 F-441 B (3/6?) Qbelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO 11/4/74 *CV. NO. 0 INSUL-5 PAGE 53 OF 88 3. PURPOSE (Continued) 3.1 HOT SERVICE (Continued) 3.1.2 Heat Conversation (Continued) More extensive help in specifying economic thickness can be found in ECON-1, the Economic Thickness Manual supplied by Thermal Insulation Manufacturers Association. 3.1.3 Temperature Control In some cases piping or equipment which would not be insulated for heat conservation will require insulation for close process temperature control. 3.1.4 Personnel Protection Operating temperatures above 150F justify protective insulation. Insulate piping or equipment to a height of 7 ft. above the operating level, or wherever there exists the probability of human contact. 3.2 COLD SERVICE Cold service insulation serves two main purposes; to minimize heat gain, and to prevent condensation on the cold surface. All components in cold service insulation systems shall be insulated. Insulation manufacturers publish tables showing required thickness to prevent condensation under various temperature and humidity conditions. Composite insulation is commonly used in cold services. 4. GENERAL 4.1 SURFACES NOT INSULATED Unless specifically called for on the mechanical flowsheets or piping drawings, the following hot surfaces do not require insulation. Apparatus Nozzles (unless piping into nozzle Insulated) Nameplates Steam Traps Expansion Joints Glass Surface on Sight Glasses is (/9/C) 8lfrfr-J 000181 ^Lelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE 11/4/74 REV. NO. 0 NO. INSUL-5 PAGE 54 OF 88 4. GENERAL 4.2 SURFACE PREPARATION Refer to "INSUL-6" Section, paragraph 2.2. 4.3 INSULATION SUPPORT Insulation on vertical pipe shall be supported near the bottom of the run, if required. Additional supports will be used at intervals dependent upon the insulation materials being used. Insulation on vertical vessels shall have insulation supports or the stiffening rings may be used to provide the supports. 4.4 PIPING SUPPORTS Refer to "INSUL-6" Section, paragraph 2.4. 4.5 TRACED LINES Pipe requiring steam or water tracing should be insulated. Provisions shall be made to allow room for teh tracer tubing, such as using insulation one'pipe size larger than line size. Insulation must be able to withstand operating temperature of the fluid in the tracing. 4.6 ALUMINUM WEATHER-BARRIER See Table I for coverage. 4.7 MASTIC WEATHER-BARRIER Individual requirements should be calculated. 5. DATA FORMS Data forms for the specification of specific materials to be used for the design, purchase and application of an insulation system are as follows: Form DF-1 Heat Insulation Data Form Form DF-2 Cold Insulation Data Form To expedite filling out the data forms, numbers appear on the forms that correspond to the following paragraphs. -441 B (3/67) 000182 ^Lelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE OATE MO. 11/4/74 ftCV. MO. 0 INSUL-5 PAGE 55 OF 88 5. DATA FORMS (Continued) 5.1 HEAT INSULATION DATA FORM 5.1.1 INSULATION MATERIAL The selection of an insulation material for a particular application must take into consideration such factors as operating temperature, temperature limits of the materials, availability of material, cost, required thickness, and maximum allowable surface temperature and heat loss. The materials listed below for a given service are those normally used by the Plastics Company. See "INSUL-4" Section, paragraphs 2.1.1, 2.2.1, 2.3.1, 2.4.1, 2.5.1, 2.6.1, 2.7.1, 2.8.1, and 2.9.1 for description, service, and thickness for these materials. 5.1.1.1 Piping and 24" Diameter and Smaller Equipment Carbon steel piping and small diameter equipment is insulated with urethane material, see INSUL-4, Section 2.9.2, for operating temperatures up to 225F, or with fiberglass material, see "INSUL4", Section 2.4.2, for operating temperatures up to 450F. Above 450F either calcium silicate, see "INSUL-4" Section 2.1.2, mineral wool insulation, see "INSUL-4" Section 2.2.2. Certainteed 850 fiberglass, see "INSUL-4" Section 2.4.2, or cellular glass, see "INSUL-4" Section 2.3.2 is used. The upper temperature limit varies with the different materials, and for operating temperatures above this limit special high temperature materials may be required. Alloy piping and small diameter equipmen is also insulated with urethane material see "INSUL-4" Section 2.9.2, for operating temperatures up to 225F, or with fiberglass material, see "INSUL-4" Section 2.4.2, for operating temperature: up to 450F. Between 450F and 800F cellular glass, calcium silicate, mineral wool, or certainteed 850 fiber glass is used, see "INSUL-4" Sections 2.3.2, 2.1.2, 2.2.2, and 2.4.2. Above 000183 F-44IB (3/67) Qbelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS* GUIDE OATE MO. 11/4/74 *CV. MO. 0 INSUL-5 PAGE 58 OF 88 5. DATA FORMS (Continued) 5.1 HEAT INSULATION DATA FORM (Continued) 5.1.1 INSULATION MATERIAL (Continued) 5.1.1.1 Piping and 24" Diameter and Smaller Equipment 800F, material must be specified to meet the requirements of temperature and yet not contribute to the initiation of stress corrosion cracking. Long straight piping runs can economically use insulation factory bonded to aluminum or PVC jacketing. Valves, flanges, and ells are insulated with fabricated sections of the same material used on associated piping, or with flexible fiberglass or mineral wool or with asbestos tape, see "INSUL-4" Sections 2.4.2, 2.2.2, and 2.7.2, 5.1.1.2 Equipment Greater than 24" Diameter Large diameter equipment is insulated with urethane, see "INSUL-4, Section 2.9.2, for operating temperatures up to 225F (large storage tanks or towers may justify spray-on urethane), with fiberglass board, see "INSUL-4" Section 2.4.2, up to 450F, with certainteed 850 fiberglass board, see "INSUL-4" Section 2.4.2, up to 850F, or with cellular glass, see "INSUL-4" Section 2.3.2, for operating temperatures up to 800F. Above 850F material must be specified to meet the requirements of the application, see Section 5.1.1. 5.1.1.3 Bent Pipe and Tubing Bent pipe and tubing is insulated with foamed plastic insulation, see "INSUL-4" Section 2.8.2, for operating temperatures up to 180F. Above 180F, use asbestos tape, see "INSUL-4" Section, 2.7.2. {Preinsulated tubing can be purchased on reels like electrical cable). F-44IB (3/67) 000184 ^Kielanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO 11/4/74 KCV. NO. 0 INSUL-5 PAGE 57 OF 88 5. DATA FORMS (Continued) 5.1 HEAT INSULATION DATA FORM (Continued) 5.1.1 INSULATION MATERIAL (Continued) 5.1.1.4 Irregular Surfaces Irregular surfaces are insulated with insulating cement, see "INSUL-4" Section 2.5.2. Insulated boxes are used around installations such as control valves, pump headers, instruments, etc., where operability, inspection, or maintenance would be hampered by individual insulation of all components, and around equipment like banks of double pipe heat exchangers where the insulated box is more economical. 5.1.2 WEATHER-BARRIER MATERIALS Weather-barriers used are aluminum, see "INSUL-4" Section 3.1.1, mastic. Section 3.2.1, PVC, Section 3.3.1, and special types. Section 3.4. The material used varies with the component insulated, environment, type of insulation, labor and material costs, and plant preference. For type "E" specify the brand or type of mastic. Type "F" is used for specials such as plastic, stainless, etc. 5.1.2.1 Straight Run Piping and 36" Diameter and Smaller Equipment All locations use aluminum jacketing, see "INSUL-4" Section, 3.1.2. Material cost and plant preference dictates the choice of smooth or corrugated type. Coastal locations use jackets with moisture-barrier over calcium silicate insulation. PVC pipe jacketing, see "INSUL-4" Section 3.3.2, can be used below 150F, and snap fit molded jackets are available for valves, tees, and elbows. For indoor use where pipe will not be exposed to water or foot traffic, insulation with a factory applied all service jacket is satisfactory. Jacket temperature must be maintained between -10 and +150F for bonding to remain effective. 000185 F-441 B (3/67) ^Lelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE OATC NO 11/4/74 HCV. NO. 0 INSUL-5 PAGE 58 OF 88 5. DATA FORMS (Continued) 5.1 HEAT INSULATION DATA FORM (Continued) 5.1.2 WEATHER-BARRIER MATERIALS (Continued) 5.1.2.2 Elbows Material and labor cost and plant preference will dictate the choice of mastic, see "INSUL-4" Section 3.2.2, aluminum, see "INSUL-4" Section 3.1.2, or PVC, see "INSUL-4" Section 3.3.2, weather-barrier for elbows. 5.1.2.3 Vessel and Exchanger Shells The weather-barrier used on vessel and exchanger shells is mastic, see "INSUL-4" Section 3.2.2, or aluminum, see "INSUL-4" Section, 3.1.2, or PVC, see "INSUL-4" Section 3.3.2. If aluminum is used on horizontal shells it should be smooth type. 5.1.2.4 Irregular Surfaces and Equipment Heads Mastic is used on irregular surfaces where aluminum jacketing is impractical, see "INSUL-4" Section 3.2.2. 5.1.3 INSULATION SECUREMENT The insulation is secured by using staples, see "INSUL-4" Section 4.7.1, galvanized or stainless steel tie wire, see "INSUL-4" Section, 4.5.1, or stainless steel bands, see "INSUL-4" Section, 4.4.1. 5.1.3.1 Piping Through 16" Diameter Coastal locations use stainless steel wire and non-coastal locations use galvanized wire, see "INSUL-4" Section, 4.5.2. Staples, see "INSUL-4" Section, 4.7.1, can be used to secure fiberglass insulation if the insulation will be covered with a jacket which is banded. All service jackets with self-sealing laps are reinforced with staples. F-44IB (3/67) 000186 ^^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO. 11/4/74 INSUL-5 REV. NO. Q________ _______ PAGE 5,0F 88 5. DATA FORMS (Continued) 5.1 HEAT INSULATION DATA FORM (Continued) 5.1.3 INSULATION SECUREMENT (Continued) 5.1.3.2 Piping Greater than 16" Diameter and Equipment 24" Diameter and Less For large diameter pipe and small diameter equipment use 1/2" wide bands, see "INSUL-4" Section, 4.4.2.2. 5.1.3.3 Equipment Greater than 24" Diameter For large diameter equipment use 3/4" wide bands, see "INSUL-4" Section, 4.4.2.3. 5.1.4 ALUMINUM JACKET SECUREMENT Aluminum jacket material is secured by the use of stainless steel bands, see "INSUL-4" Section, 4.4.1, or sheet metal screws, see "INSUL-4" Section 4.6.1. Aluminum screws may be preferred at coastal locations. Choice of Hex head or Pan head depends on tool used by insulators. 5.1.4.1 Piping and 24" Diameter and Smaller Equipment For securing jacket material on piping and small diameter equipment 3/8" wide bands, see "INSUL-4" Section 4.4.2.1, or sheet metal screws, see "INSUL-4" Section 4.6.2, are used depending on material and labor costs, and plant preference at a particular location. For long piping runs, aluminum jacketing with self-locking features can be used to eliminate or reduce banding require ments . 5.1.4.2 Equipment Greater than 24" Diameter For securing jacket material on large diameter equipment 3/8" wide bands, see "INSUL-4" Section 4.4.2.1, or sheet metal screws, see "INSUL-4" Section 4.6.2, are used depending on material and labor costs, and plant preference at a particular location. The horizontal laps on vertical equipment at all plants are secured with screws. 000187 -441 B (3/67) VBielanese PLASTICS COMPANY Bishop Plant plant ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO. Ll/4/74 ACV. NO. 0 INSUL-5 PAGE 60 OF 5. DATA FORMS (Continued) 5.1 HEAT INSULATION DATA FORM (Continued) 5.1.5 REINFORCEMENT Glass cloth reinforcement, see "INSUL-4" Section, 4.2.1, is required for mastic weather barrier. Wire netting reinforcement, see "INSUL-4" Section 4.3.1, is required for thick applications of insulating cement. 5.1.5.1 Glass Cloth Specify the type and weave of glass cloth to be used, see "INSUL-4" Section 4.2.2. 5.1.5.2 Wire Netting Specify the material, see "INSUL-4" Section, 4.3.1, depending on avilability and cost. 5.1.6 SPECIALTIES This space is used to specify special materials, items to be insulated, thickness tables or brand names desired to complete the Insulation Data Form. 5.2 COLD INSULATION DATA FORM 5.2.1 INSULATION MATERIAL The selection of an insulation material for a particular application must take into consideration such factors as operating temperature, temperature i limits of the materials, availability of materials,, cost, required thickness, minimum allowable surface temperature, and maximum heat gain. The materials normally used by the Plastics Company are cellular glass, see "INSUL-4", 2.3.1, urethane, see "INSUL-4 Section 2.9.1, and foamed plastic, see "INSUL-4" Section 2.8.1. Foamed plastic is mainly used on bent pipe and tubing but may be used for any i application where compressive strength is not | required. i 5.2.1.1 Piping 000188 Cellular glass, see "INSUL-4" Section j 2.3.2, and urethane, 2.9.2 are used to insulate pipe and small diameter equipment, see "INSUL-4" Section 2.3.2. F-44IB (3/67) ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE OATE NO. 11/4/74 INSUL-5 REV. NO. 0 PAGE 61 OF88 5. DATA FORMS (Continued) 5.2 COLD INSULATION DATA FORM (Continued) 5.2.1 INSULATION MATERIAL (Continued) 5.2.1.2 Equipment Cellular glass, see "INSUL-4" Section, 2.3.2, and urethane, 2.9.2, are used to insulate equipment. 5.2.1.3 Bent Pipe and Tubing Foamed plastic is used to insulate bent pipe and tubing, see "INSUL-4" Section, 2.8.2. 5.2.1.4 Irregular Surfaces Cellular glass, see "INSUL-4" Section 2.3.2, and urethane, 2.9.2, are used to box in and insulate irregular surfaces. Loose or flexible insulation materials are used to fill voids around flanges, manhole covers, valves, and enclosed equipment. 5.2.2 WEATHER-BARRIER MATERIALS Weather-barriers used are aluminum, see "INSUL-4" Section 3.1.1, mastic, see "INSUL-4" Section 3.2.1, and PVC, see "INSUL-4" Section 3.3.1. The material used varies with the component insulated, environment, labor and material costs, and plant preference. For Type "E" specify the brand or type of mastic to be used. Type "F" is used for specials such as plastic, stainless, etc. F-441 B (3/67) 000189 ^^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO. 11/4/74 REV. NO. 0 INSUL-5 PAGE TABLE I COVERAGE TABLE FOR ALUMINUM JACKETING , BANDS, CLIPS , & SCREWS I. NO. OF SQUARE FEET OF JACKETING* PER LINEAL FOOT OF INSULATED PIPE (COMPENSATING FOR 3" OVERLAP PER LIN. YD. & 3" LAP ON CIRCUM- FERENCE PIPE SIZE 1" 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 3 1/2" 4" 4 1/2" 5" 6" 7" 8" 10" 12" 14" 15" 16" 18" 20" 22" 24" 26" 28" 30" 32" 34" 36" 1.08 1.14 1.22 1.32 1.39 1.52 1.66 1.84 1.99 2.13 2.27 2.43 2.73 3.02 3.30 3.59 3.91 4.48 4.84 5.12 5.41 5.98 6.55 7.12 7.69 8.26 8.83 9.40 9.98 10.55 11.12 1 1/2" 2" 1.37 1.43 1.50 1.60 1.67 1.81 1.95 2.13 2.27 2.41 2.56 2.72 3.02 3.30 3.59 3.88 4.20 4.77 5.12 5.41 5.69 6.27 6.84 7.41 7.98 8.55 9.12 9.69 10.26 10.83 11.40 1.65 1.71 1.79 1.89 1.96 2.09 2.23 2.41 2.56 2.70 2.84 3.00 3.30 3.59 3.88 4.16 4.48 5.05 5.41 5.69 5.98 6.55 7.12 7.69 8.26 8.83 9.40 9.98 10.55 11.12 11.69 2 1/2" 3" 1.94 2.00 2.08 2.17 2.24 2.38 2.52 2.70 2.84 2.98 3.13 3.29 3.59 3.88 4.16 4.45 4.77 5.34 5.69 5.98 6.27 6.84 7.41 7.98 8.55 9.12 9.69 10.26 10.83 11.40 11.97 2.22 2.28 2.36 2.46 2.53 2.66 2.81 2.98 3.13 3.27 3.41 3.57 3.88 4.16 4.45 4.73 5.05 5.62 5.98 6.27 6.55 7.12 7.69 8.26 8.83 9.40 9.98 10.55 11.12 11.69 12.26 3 1/2" 4" 2.51 2.57 2.65 2.74 2.81 2.95 3.09 3.27 3.41 3.55 3.70 3.85 4.16 4.45 4.73 5.02 5.34 5.91 6.27 6.55 6.84 7.41 7.98 8.55 9.12 9.69 10.26 10.83 11.40 11.97 12.54 2.80 2.86 2.93 3.03 3.10 3.23 3.38 3.55 3.70 3.84 3.98 4.14 4.45 4.73 5.02 5.30 5.62 6.19 6.55 6.84 7.12 7.69 8.26 8.83 9.40 9.98 10.55 11.12 11.69 12.26 12.83 5" 3.37 3.43 3.50 3.60 3.67 3.80 3.95 4.13 4.27 4.41 4.55 4.71 5.02 5.30 5.59 5.87 6.19 6.76 7.12 7.41 7.69 8.26 8.83 9.40 9.98 10.55 11.12 11.69 12.26 12.83 13.40 6" 3.94 4.00 4.07 4.17 4.24 4.38 4.52 4.70 4.84 4.98 5.12 5.39 5.59 5.87 6.16 6.44 6.87 7.34 7.69 7.98 8.26 8.83 9.40 9.98 10.55 11.12 11.69 12.26 12.83 13.40 13.97 CO 00 & CM, ! ! ! II. III. IV. Banding - Number from above Table X 1.3 gives feet of banding per foot of insulated pipe Clips - (Feet of insulated pipe) X (1.3) = Clips required Screws - (Feet of insulated pipe) X (3) = Screws required i F-44IB (3/67) ^Jacketing commonly available in rolls 36 " x 100'. 48" x 100 ' . Also available 000190 ________________ i ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE HEAT INSULATION DATA FORM NO. DF-1 11/4/74 *CV. NO. INSUL-5 PAGE 63 OF 88 5.1.1 Insulation Material 5.1.1.1 Piping and 36" Diameter and Smaller Equipment Carbon Steel to 4 5 0WF, 451F to F, F to F, toA4li5o0&F, 451F to F, F to F, 5.1.1.2 Equipment Greater than 36" Diameter To 800F 801F to op. 5.1.1.3 Bent Pipe and Tubing to 180F above 180F 5.1.1.4 Irregular Surfaces_______________ 5.1.2 Weather-Barrier Materials Used Shall be One of the Following Types: Type A - .016" thick aluminum with 3/16" corrugations and without moisture barrier Type B - .016" thick aluminum with 3/16" corrugations and with moisture barrier Type C -.020" thick aluminum smooth without moisture barrier Type D - .020" thick aluminum smooth with moisture barrier Type E - mastic with glass cloth reinforce ment Type F - 5.1.2.1 Straight Run Piping and 36" Diameter and Smaller Equipment C.S. to 450F type_____,451F to_____ type Alloy to 450F type____ ,451F to_____ type 5.1.2.2 Elbows C.S. to 450F type_____,4 51F to_____ type_ Alloy to 450F type,451F to____ type" of to "of to" F type "F type F to F type_ "F to" "F type" 5.1.2.3 Vessel and Exchanger Shells Horizontal Type________________ Vertical Type 5.1.2.4 Irregular Surfaces and Equipment Heads Type______________ 5.1.3 Insulation Securement 5.1.3.1 Piping Through 16" Diameter,Wire Ties or Staple 5.1.3.2 Piping Greater Than 16" Diameter & Equipment 24" Diameter and Less, V Wide Bands F-441 B (3/67) 5.1.3.3 Equipment Greater Than 24" Diameter, 3/4" Wide Bands 5.1.4 Aluminum Jacket Securement 000191 J aELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO. 11/4/74 INSUL-5 MV. NO. PAGE 64 OF 88 5.1.4.1 5.1.4.2 5.1.5 5.1.5.1 5.1.5.2 5.1.6 HEAT INSULATION DATA FORM NO. DF-1 (Continued) Piping and 24" Diameter and Smaller Equipment Equipment Greater Than 24" Diameter_____________ Reinforcement Glass Cloth Wire Netting Specialties ____________________________________________ 5.2.1 5.2.1.1 5.2.1.2 5.2.1.3 5.2.1.4 5.2.2 5.2.2.1 5.2.2.2 5.2.2.3 5.2.2.4 5.1.3 5.1.3.1 5.1.3.2 5.1.3.3 COLD INSULATION DATA FORM NO. DF-2 Insulation Material Piping, Equipment, Bent Pipe and Tubing, Irregular Surfaces, Weather-Barrier Materials Used Shall be One of the Following Types: Type A - .016" thick aluminum with 3/16" corrugations without moisture barrier Type B - .020" thick aluminum smooth without moisture barrier Type C - mastic with glass cloth rein forcement Type D - ______________________________________________ Straight Run Piping and 24" Smaller Equipment Type Elbows Type Vessel and Exchanger Shells Horizontal Type________________ Vertical Type Irregular Surfaces and Equipment Heads Type_______ Insulation Securement Piping Through 16" DiameterWire Ties or Staples Piping Greater than 16" Diameter & Equipment 24" Diameter & Less, V Wide Bands Equipment Greater than 24" Diameter, 3/4" Wide Bands 000192 F-441 B (3/67) Qbeianese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION ENGINEERS' GUIDE DATE NO. 11/4/74 INSUL-5 *EV. NO. 0 PAGE 65 OF 88 5.1.4 5.1.4.1 5.1.4.2 5.1.5 5.1.6 COLD INSULATION DATA FORM NO. DF-2 (Continued) Aluminum Jacket Securement Piping and 24" Diameter and Smaller Equipment Equipment Greater than 24" Diameter_____________ Glass Cloth Reinforcement__________________________ Specialties_____________________________________________ 000193 000194 Aelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS INDEX APPLICATION REQUIREMENTS DATE NO. 11/4/74 REV. MO. 0 INSUL-6 PAGE 66 OF 88 SCOPE GENERAL 2.1 TIMING 2.2 SURFACE PREPARATION 2.3 DRY INSULATION 2.4 PIPING SUPPORTS 2.4.1 HOT SERVICE 2.4.2 COLD SERVICE APPLICATION PROCEDURE 3.1 STRAIGHT PIPE 3.1.1 INSULATION 3.1.1.1 3.1.1.2 3.1.1.3 3.1.1.4 Placement Joint Sealer Exposed Ends Securement 3.1.2 EXPANSION-CONTRACTION JOINTS 3.1.2.1 3.1.2.2 Location Design 3.1.3 ALUMINUM WEATHER-BARRIER 3.1.3.1 3.1.3.2 Application Securement 3.1.4 MASTIC WEATHER-BARRIER 3.1.5 PVC WEATHER-BARRIER 3.2 ELBOWS 3.2.1 INSULATION 3.2.2 INSULATING CEMENT 3.2.3 WEATHER-BARRIER Page (s) 68 68 68 68 68 68 68 68 69 69 69 69 69 69 69 69 69 70 70 70 70 70 71 71 71 71 71 000195 F-44IB (3/67) ^^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS DATE NO. 11/4/74 INSUL-6 REV. NO. 0 PAGE 67 OF 88 j INDEX APPLICATION REQUIREMENTS (Continued) 3 APPLICATION PROCEDURE (Continued) 3.3 FLANGES, FLANGED FITTINGS AND VALVES 3.3.1 INSULATION 3.3.2 WEATHER-BARRIER 3.4 EQUIPMENT 3.4.1 SHELL AND HEAD INSULATION 3.4.1.1 3.4.1.2 3.4.1.3 3.4.1.4 Placement Joint Sealer Securement Cork Filled Mastic 3.4.2 SUPPORT INSULATION 3.4.2.1 3.4.2.2 3.4.2.3 3.4.2.4 3.4.2.5 General Metal Cradles Structural Steel Legs Skirts 3.4.3 EXPANSION-CONTRACTION JOINTS 3.4.4 WEATHER-BARRIER 3.5 IRREGULAR SURFACES 3.5.1 INSULATION 3.5.2 WEATHER-BARRIER SUGGESTED APPLICATION DRAWINGS, AD-1 THROUGH AD-11 Page (s) | j ! i 72 72 72 72 72 72 73 73 73 73 73 73 73 74 74 74 75 75 75 75 76 F 441B (3/67) 000196 PLANT ENGINEERING MANUAL 'x Vbelanese INSULATION PLASTICS COMPANY Bishop Plant APPLICATION REQUIREMENTS DATE NO. 11/4/74 REV. NO. 0 INSUL-6 PAGE 68 OF 88 1. SCOPE 1 This section describes the application of the thermal insulation described in the material requirements section. 2. GENERAL j 2.1 TIMING Insulation shall not be applied to any flanged, machined, or welded surfaces until they have passed all field test?, includinghydrostatic, and have been released for insulatio. by thefield engineer. j 2.2 SURFACE PREPARATION The pipe, instruments or equipment to be insulated shall be cleaned of all oil, water, and other foreign matter before insulation is installed. Insulated carbon steel surfaces operating under 140F shall have a protective coating on the steel. All metal surfaces must be primed before application of urethane spray insulation. 2.3 DRY INSULATION All insulation shall be protected from moisture before and during application. If applied insulation should get wet before it is jacketed, it shall be thoroughly dried by heating the line or by other means before it is sealed with weatherproofing. 2.4 PIPING SUPPORTS 2.4.1 HOT SERVICE Insulated piping shall be supported on shoes 4" above the BOP of the uninsulated piping, unless specified higher when thicker insulation will be used. 2.4.2 COLD SERVICE Low-temperature piping below 32F shall be supported on outside of insulated surfaces if possible, with metal cradle to provide for adequate support and distribution of weight. Cradle shall be secured with at least two insulation bands looped about cradle and insulation When pipe is suspended with hangers attached directly to the pipe, the hanger shall be insulated the same as the adjoining pipe. Insulation shall extend up the hanger for a distance of four times the specified thickness. _______________________________ 000197 F-44IB (3/67) ^^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS DATE NO. 11/4/74 *ev. no. 0 INSUL-6 PAGE 69 OF 88 3. APPLICATION PROCEDURE 3.1 STRAIGHT PIPE 3.1.1 INSULATION 3.1.1.1 Placement Pipe insulation shall be applied with tightly butted end joints in a staggered position. Additional layers, where specified, shall be applied in the same manner as the first layer, with side and end joints staggered over joints of preceding layer so that no two joints coincide, except where they cross at right angles. 3.1.1.2 Joint Sealer All butt edges and ends of the outer layer of cold service insulation shall be buttered with joint sealer before application. The joints shall be drawn together when the insulation is applied so that only a very thin, vapor-tight coat separates the sections of insulatio 3.1.1.3 Exposed Ends Exposed ends are to be beveled and covered with aluminum pipe bevels and flashed with high temperature sealer or they may be weatherproofed with fiberglass cloth and mastic. 3.1.1.4 Securement Secure the insulation with tie wire or bands depending upon the pipe diameter. Fiberglass can be stapled instead of fastened with wire, and fiberglass with self-sealing jacket can be press sealed and the lap reinforced with staples. 3.1.2 EXPANSION-CONTRACTION JOINTS 3.1.2.1 Location Expansion-contraction joints should be installed in cold service piping, and in hot service piping above 700F, if specified, in both horizontal and vertic straight run piping for each 50 ft. 000198 F-441 B (3/67) ^^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS DATE NO. 11/4/74 IVCV. NO. 0 INSUL-6 PAGE 70 OF 88 3. APPLICATION PROCEDURE (Continued) 3.1 STRAIGHT PIPE (Continued) 3.1.2 EXPANSION-CONTRACTION JOINTS (Continued) 3.1.2.1 Location (Continued) When flanged fittings or valves occur within this limit, expansion-contraction joint shall be provided for in the flang cover only. 3.1.2.2 Design Expansion-contraction joint shall be V space between adjoining pipe insulation sections. Appropriate compressible insulation, such as flexible fiberglass or thermal wool, shall be packed into the space. Insulation cover over the joint shall be the specified thickness on each side of the 1/2" space. To provide for slip joint construction, the joint cover and adjoining pipe insulation shall be coated with joint sealer prior to application. 3.1.3 ALUMINUM WEATHER-BARRIER 3.1.3.1 Application Aluminum jacketing shall be applied with longitudinal and circumferential joints lapped 2" minimum. Joints shall be positioned to shed water and be away from prevailing wind. 3.1.3.2 Securement Jacketing shall be secured with bands, see "INSUL-4" Section, 4.4.2, or screws, see 4.6.2. 3.1.4 MASTIC WEATHER-BARRIER Outer surface of insulation shall receive an adhesive coat of mastic. While still tacky, reinforcing glass cloth shall be stretch taut and thoroughly embedded in the coating, care being exercised that the weave is not stretched and that the cloth is overlapping approximately 1 1/2". Before the surface becomes dry to touch, a second coating shall be applied and allowed to dry. Total 000199 F-441 B (3/67) CLelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS DATE *0 11/4/74 INSUL-6 *V. MO. 0 PAGE 71 OF 88 3. APPLICATION PROCEDURE (Continued) 3.1 STRAIGHT PIPE (Continued) 3.1.4 MASTIC WEATHER-BARRIER (Continued) ' dry thickness of coating shall be a minimum of 1/8"! Cloth shall not be visible on the finished surface. 3.1.5 PVC WEATHER-BARRIER PVC weather barrier is usually supplied already bonded to straight pipe insulation sections. It is fastened by clamping self-sealing closure on the longitudinal seam and sealed with a solvent or glue. Butt end joints are covered with vinyl tape to form a vapor seal. It is also supplied in rolls bonded to insulation for equipment insulation. Sheets are fastened to equipment surface with mastic and welded pins. Joints are sealed with solvent or glue and taped with PVC tape. Jacket is banded with stainless bands. 3.2 ELBOWS 3.2.1 INSULATION If preformed elbows are not used, fabricate elbow cover from mitered segments of pipe covering secured with wire ties, or wrap with flexible insulation secured with wire ties. 3.2.2 INSULATING CEMENT When mastic weather-barrier is specified, insulatin cement is used over fiberglass, calcium silicate, cellular glass, urethane, or mineral wool insulation to give the surface a smooth finish and to fill all cracks and voids. 3.2.3 WEATHER-BARRIER Aluminum or mastic weather-barrier shall be applied in accordance with 3.1.3 and 3.1.4 above. PVC weather-barrier is usually snapped on with self sealing closure or with metal snaps, with mastic used on the seam and vinyl tape or metal bands used to clamp it to adjoining pipe jacketing. -441 B (3/67) 000200 Qielanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS OATE NO 11/4/74 Htv. MO. 0 INSUL-6 PAGE 72 OF 88 3. APPLICATION PROCEDURE (Continued) 3.3 FLANGES, FLANGED FITTINGS AND VALVES 3.3.1 INSULATION Insulation shall be prefabricated and shall extend over adjacent pipe insulation so as to provide a slip joint at each end. All joints shall be sealed as per 3.1.1.2 above, and insulation is secured with wire or bands depending upon pipe diameter. Where specified, flange covers shall be removable. 3.3.2 WEATHER-BARRIER Aluminum or mastic weather-barrier shall be applied; in accordance with 3.1.3 and 3.1.4 above. j 3.4 EQUIPMENT 3.4.1 SHELL AND HEAT INSULATION 3.4.1.1 Placement Equipment shells shall be insulated with pipe insulation where diameter is small enough (generally 36"). Block or blanket insulation is used on large diameter shells and on heads. Block insulation shall be applied to shell using standard broken joing method, starting with alternate full and half length lags. Application of lags shall start at one end, proceeding circumfer entially and then axially. Each lag shall be tightly butted against adjacent lags. Blanket insulation shall be draped around horizontal vessels. On vertical vessels, it can be applied in horizontal wraps or vertical strips. Where multi-layer pipe, block, or blanket application is required, all joints shall be staggered over joints of the preceding layer. Urethane spray is used on very large surface area tanks and towers. It is applied in a manner approved by the Celanese Project Engineet and Safety Department. Specific materials and storage of materials must also be approved. F-441 B (3/67) 000201 ______________ aELANESE plastics company Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS DATE 11/4/74 MCV. MO. INSUL-6 PAGE 73 OF 88 1 3. APPLICATION PROCEDURE (Continued) 3.4 EQUIPMENT (Continued) 3.4.1 SHELL AND HEAT INSULATION (Continued) 3.4.1.2 Joint Sealer Joint sealer shall be applied to cold service insulation in accordance with 3.1.1.2. 3.4.1.3 Securement Secure pipe, block, and blanket insulation with bands. Blanket insulation on vertical surfaces is further secured by impaling on metal pins welded to the vessel shell. Pin spacing is as needed for the specific insulation, generally 16 to 24" centers, 3.4.1.4 Cork Filled Mastic Spray apply to desired thickness in accordance with manufacturer's recommendations. 3.4.2 SUPPORT INSULATION 3.4.2.1 General Supports of equipment in cold service require insulation to the extent shown below. Application is the same as for the shell of the equipment. 3.4.2.2 Metal Cradles 3.4.2.3 Where equipment is supported on metal cradles, insulation shall be carried down over cradles to concrete or to a distance four times the specified thickness from the junction of the vessel and the insulated cradle, which ever is less. The top of the concrete is to be coated with joint sealer before application of insulation. Structural Steel 000202 When equipment is supported by structura steel beams, insulation shall be extended not iess than four times the F-44IB (3/67) ^tiELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS OATE NO 11/4/74 REV. NO. 0 INSUL-6 PAGE?4 OF 88 3. APPLICATION PROCEDURE (Continued) 3.4 EQUIPMENT (Continued) 3.4.2 SUPPORT INSULATION (Continued) 3.4.2.3 Structural Steel (Continued) specified thickness in each direction, measured from the junction of the equipment and the insulated support lug. Thickness of insulation over steel supports shall be one-half that specifie for the equipment. Thickness of insulation over support lugs to be the same as body insulation. 3.4.2.4 Legs Where equipment is supported by legs, insulation shall extend over structural legs and the down legs a distance of four times insulation thickness, but not less sthan 12". Thickness shall be as specified for body of equipment. Body insulation shall be brought up to and butted firmly against tank leg flange. Space between flanges and webs of structural members shall be filled with block cemented in place with adhesive. 3.4.2.5 Skirts Where equipment is supported by skirts, insulation shall be applied inside and outside as part of equipment area, insulation to extend downward from junction of inside of skirt with insulated bottom head a distance of not less than one foot. Thickness shall be as specified for body of equipment. Nuts shall be secured to the bottom head and the inside of the skirt to allow insulation attachement. 3.4.3 EXPANSION-CONTRACTION JOINTS Longitudinal contraction of cold service vessels shall be provided for by installing expansioncontraction joints below insulation supports. Joint sealer shall be applied to surfaces of insulation to provide proper slip joint where movement is likely to occur. 000203 F-441 B (3/67) ^Lelanese PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS DATE NO. 11/4/74 *CV. NO. 0 INSUL-6 PAGE 75 OF 88 3. APPLICATION PROCEDURE (Continued) 3.4 EQUIPMENT (Continued) 3.4.4 WEATHER-BARRIER Aluminum, mastic, or PVC weather-barrier shall be applied in accordance with 3.1.3, 3.1.4 or 3.1.5 above. 3.5 IRREGULAR SURFACES 3.5.1 INSULATION Irregular surfaces in hot service shall be insulated with insulating cement. Insulating cement shall be applied with a trowel on the surface to be insulated, filling all depressions for entire depth to eliminate voids of any nature. Care shall be exercised that the thickness of each application will be no greater than that which will set on vertical surfaces without excessive cracking upon drying. When sufficiently dry, additional applications may be made as required to build cement to full specified thickness. Where specified thickness of cement insulation exceeds 1 1/2", cement shall be reinforced with one layer of wire netting for each additional 1 1/2", or a part thereof, uniformly embedded midway between metal and finished surface. Irregular surfaces in cold service shall be insulated by boxing in with equipment insulation. 3.5.2 WEATHER-BARRIER Mastic weather-barrier shall be applied in accordance with Section 3.1.4 above. F-44IB (3/67) 000204 a ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS OATE 11/4/74 rev. mo. INSUL-6 PAGE 76 OF 88 AD-1 AD-2 AD-3 AD-4 AD-5 AD-6 AD-7 AD-8 AD-9 AD-10 AD-11 SUGGESTED APPLICATION DRAWINGS Piping Insulation Support and Flange Cover Insulation Horizontal Contraction Joints Cold Insulation Pipe Hangers and Supports Cold Piping Hanger and Hanger Insulation Cold Pipe Anchor Insulation Vertical Equipment Insulation Vessel Insulation - Removable Manhole Cover Cold Horizontal Equipment Insulation - Cradle Cold Equipment Structural Steel Support Cold Equipment Skirt and Bottom Insulation Valve Insulation Page (s) 77 73 79 gg g^ g2 gg 34 35 gg 37 F-441 B (3/67) 000205 ^^ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS DATE 11/4/74 REV. NO. u PIPING INSULATION SUPPORT AND FLANGE COVER INSUL-6 PAGE 77 OF 88 AD-1 R emovable type flange cover Vertical Piping 000206 F -44IB (3/67) F-4416 (3/67) ^jaELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS OATE 11/4/74 MCV. NO 0 NO. INSUL-6 PAGE 7 8 OF 88 AD-2 | i j INSULATION HORIZONTAL CONTRACTION JOINTS ^^ELANESE PtASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS OATE NO. 11/4/74 INSUL-6. REV. NO. 0 PAGE 79 OF 88 AD-3 COLD INSULATION - PIPE HANGERS AND SUPPORTS No-re : A r a* PoK p/Ff. SFSFS TO 6' A . !6"fof put nzes ~ro 24" A * 24' fof ///* stzec to 3 000208 F-44IB (3/67) ^Obelanese PLASTICS COMPANY Bi shop PI ant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS OAT 11/4/74 NEV. NO. 0 NO. INSUL-6 . PAGE 80 OF 8g AD-4 COLD PIPING HANGAR AND HANGAR INSULATION F-441 B (3/67) 000209 %2ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPUCATION REQUIREMENTS COLD PIPE ANCHOR INSULATION DATE NO. 11/4/74- INSUL-6. AEV. NO. 0 PAGE 81 OF 88 AD-5 000210 C^EIANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS OATC 11/4/74 KCV. NO. 0 INSUL-6. PAGE 82 OF 88 AD-6 VERTICAL EQUIPMENT INSULATION -441 B (3/67) 000211 U. plant engineering manual ^SOBELANESE INSULATION PLASTICS COMPANY APPLICATION REQUIREMENTS BishoD Plant --------------------------- DATE NO. 11/4/74) INSUL-6 ev. no. 0 PAGE 83 OF 88 AD-7 VESSEL INSULATION - REMOVABLE MANHOLE COVER 44 B (3/67) CLelanese plastics company Bishop Plant PLANT ENGINEERING MANUAL INSULATION DATE " INSUL-1, 2, 3, 11/4/74 4, 5V AND 6 ftEV. NO. 0 PAGE 88 OF 88 NOTES TO USERS The Insulation Section consists of three basic information packages: requirements for vendors, guidelines for engineers, and requirements for application of the insulation. A Logic Log is provided for each section to explain the reasoning for inclusion of each portion of the section. Any alterations of a section shall also include alteration of the Logic Log for that paragraph or section. These sections have been identified as "INSUL1", "INSUL-2" and "INSUL-3". The Material Requirements and Engineers' Guide sections, identified as "INSUL-4" and "INSUL-5", respectively, will be supplied to a potential vendor for his consideration and to aid in his supplying of materials and expertise for Plastics Company jobs. The Application Requirements section, identified as "INSUL-6", will be supplied to a contractor when bids are being obtained for jobsite maintenance or construction. This section should be used strictly as a guideline and may be changed consistent with good engineering practices and the approval of the Project Engineer. This section should not be construed to prohibit continual testing and evaluation of any insulation material. INDEX INSULATION INSUL-1 INSUL-2 INSUL-3 INSUL-4 INSUL-5 INSUL-6 Insulation - Materials - Logic Log Insulation - Engineers' Guide - Logic Insulation - Application - Logic Log Insulation - Material Requirements Insulation - Engineers' Guide Insulation - Application Requirements Page (s) 000213 -441 B (3 /6 7 ) @BELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS OATC REV. NO. 0 NO. INSUL-6 PAGE 86 OF 8 AD-10 COLD EQUIPMENT SKIRT AND BOTTOM INSULATION F -4 4 IB (3/67) 000214 <2.ELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS VALVE INSULATION DATE 11/4/74 *CV. MO. INSUL-6 PAGE 87 OF 88 AD-11 .AWOMIUUM SMtCTINfr 000215 ^SELANESE PLASTICS COMPANY Bishop Plant PLANT ENGINEERING MANUAL INSULATION APPLICATION REQUIREMENTS DATE NO. 11/4/74 INSUL-6 REV. NO. 0 PAGE 35 OF 88 AD-9 COLD EQUIPMENT STRUCTURAL STEEL SUPPORT Sunport Beam 000216 -441 B (3/67)