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www.researchprospect.com
PROPOSAL (R&D)
INUSULATION METHODS DESIGN – PROCEDURES - GUIDELINES
02/02/2014
Copyright © Research Prospect Ltd. All rights reserved.
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Contents
1. Introduction ............................................................................................................................. 3
Aims, Objectives and Research Questions ...................................................................................... 4
2. Literature Review .................................................................................................................... 4
3. Methodology ........................................................................................................................... 7
4. Considerations and Intended Outcomes ................................................................................. 8
5. References ............................................................................................................................. 10
Appendices .................................................................................................................................... 12
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1. Introduction
Insulation systems are considered to be complex systems with respect to the operational
adaptability and expected outcomes. The diverse circumstances encountered on various
processes can cause serious accidents. In case of doubt on the selection of insulation
system, guidance must be obtained from a local material specialist, engineering
companies and/or from research publications published in the recent past.
The appropriate functional sections of engineering departments and of construction
groups are usually in touch with such situation. This research report has been proposed
to be prepared to provide support in such instance, therefore extensive research which
includes primary as well as secondary data collection will be completed.
Understanding the reason for insulations and the factors that can affect the insulation
under different circumstances is an essential for the selection of insulation. The relevant
design conditions, operating temperature and any other constraints that may exist must
be taken into account, if a successful insulation system is to be achieved (Hall, 2010).
Aspects of design
Insurance of adequate communication between the designer, operating staff, contractor
and/or construction and maintenance organisation holds primary importance in any
process. Any proposed design should be as such to facilitate insulation system.
The Insulation can have an Impact on design of equipment in many ways and so it is
important to make sure that the selected insulation system is compatible with the duty.
Insulation can Impact on:
Atmospheric contamination, mechanical damage, severity of fire hazard
Thermal expansion
Life expected and/or minimum life
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Aims, Objectives and Research Questions
Following are the Aims of this research paper;
Develop Understanding of the importance of insulations
Outline the key methods of insulations currently in practice in the UK
Find out methods of improvements through detailed literature review
Complete methodological designs on Insulations
Conduct experimentations to analyze insulation techniques
Propose recommendations for future works
Following are the Objectives of this Research Paper;
Discuss and present the theoretical and practical framework of insulation methods
Discuss the adaptability of insulation
Present data of the previous completed research papers on the subject and critically
analyze the contents through practical experimentations
Complete the design guidelines on the insulation methods
Below are the Research Questions that drives the research to be completed;
What are the aspects of design in Insulation? What are the types? Methods?
Applications? Utilizations? Costs? Impacts? Research and developments?
What are possible factors that can affect the insulation?
How does the water proofing and sealing of protective finishes work?
What are the associated hazards? How can these be eliminated?
2. Literature Review
Much research has been completed in the last few decades in the field of insulation and
associated engineering (AIRAH, 2007). Abdou and Budaiui (2005) compared thermal
conductivity measurements of building insulation materials under various operating
temperatures, which highlighted the fact the insulation material selection is the primary
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step in insulation techniques. The research work completed by Anderlind and Johansson
in 1983 presented a theoretical analysis of thermal insulation through which a gas or fluid
flows. However, in this research paper, research will be conducted on the impacts of
insulation on design equipment.
The essential criterion in this research is the external temperature of the insulation system
for personal protection. The primary material types used to achieve this objective is
Calcium silicate, details of which are given as follows in the Table-1;
Pipe Nominal Size (in)
Operating Temperature range C
0 to 250 251 to 350
351to 400 401 to 450 451 to 500 501 to 550 551 to 600
0.5 ---1.0 1.0 ---1.5 2 3 4 6 to 8
25 25 25 25 25 25
25 38 38 38 38 38
25 25 38 38 38 38
25 38 38 38 38 50
25 38 38 38 50 50
25 38 50 50 50 50
25 38 50 50 50 63
Table 1: Calcium silicate insulation thickness for personal protection (source: Hall, 2010)
Temperature range: Recommended for high temperature range i.e. 200 to 600 C.
Comments: The operating upper limit should be 100 C below the BS limit, for longer exposure.
Supports: Stainless steel bands, support rings on vertical surfaces
Protective finish: Metal cladding, asbestos free cement, fire resistant mastic.
When using asbestos-free magnesia, it must be noted that it has a much lower
temperature range (320 C max.) and it tends to be more affected by spillage (ASTM,
2010; ASHRAE, 2009; ISO 6946, 2005)
Mineral wood is another popular material used for the subject purpose;
Pipe Nominal size (in)
Operating Temperature range C
0 to 250 251 to 350
0.5 to 1.5 25 25
1.5 to 8.0 25 38
Table 2: Mineral Wool insulation thickness for personal protection (source: Hall, 2010)
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Temperature range: The recommended temperature range for the use of mineral wool (glass, slab, rock)
is 0 to 350 C.
Comments: Mineral wool mattresses must not be applied to horizontal surfaces
Supports: stainless steel bands, support rings, cleats.
Protective finish: Metal cladding. (Fire resistant mastic on canvas covered slabs for resin-bonded
mineral wool)
The following aspects of design will be investigated in this research paper;
Figure 1; Aspects of Design (source: self created using MS word)
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3. Methodology
The possible factors that can affect the insulation are to be analyzed through primary as
well as secondary research. Various factors are considered in addition to the reason for
insulation. Experiments will be conducted to obtain the results through the methodology
defined in the following diagram;
Figure 2; Defining the Methodology (source: self created using MS word)
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4. Considerations and Intended Outcomes
Requirements of design and experimentations:
1. Selecting appropriate insulation types
2. Preventing warm/hot insulation from becoming wet and hence ineffective and
damaged.
3. Protection against spillage.
4. Water vapor barrier technique utilization for sub ambient system
These requirements will be applied for instances where waterproofing is the primary
precaution against stress corrosion of austenitic steel. Good practice is to leave some
gaps in sheltered regions to allow any water that enters the insulation to escape. Expert’s
advice will be sought before insulation is applied to flanged joints where the process
temperature is above 350C (Yarbrough and Graves, 1997).
The condition of the equipment will be checked if there is a reason to suspect that
insulation has become saturated, or if the standard of waterproofing appears inadequate.
This can cause corrosion under insulation.
The protective system will be developed with the ability to withstand rain, sun and
extremes of ambient temperature and care will be taken to seal gaps where the external
cladding overlaps (e.g. hangers, braches on vessels). This aspect is less important as
long as spillage is unlikely.
NOTE: Stainless steel is much more resistant to weakening in a fire situation as
compared to alternatives of carbon steel or galvanized steel.
Precautions will be taken whenever insulated austenitic steel equipment is exposed to
Temperature range of 70C to 500C (can keep the equipment wet in the temperature
range of 70C to 250C)
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When using aluminum foil as an interlayer (a preferred precaution), the temperatures of
the equipment will not be allowed to exceed 500C. Above this temperature the aluminum
foil can melt and damage the equipment, a more serious hazard (ASTM, 2010). For use
over steam tracing the foil shall not be less than 0.06mm (46smg) thickness.3.5.1,
(M5017C).
Expected Outcomes
To avoid austenitic steel from corrosion cracking, the aluminum foil shall be held in
place with stainless steel wire with all laps 50mm (2 in) minimum and formed so as to
shed water. Experimentations will be conducted to confirm this expected outcome.
The durability of different materials types to be used in the experimentations will also
be tabulated in the form conclusive results
Galvanized metal such as cladding or mesh will be allowed to come into contact with
austenitic steel surfaces. The experimentation will provide the impacts of this practice
The aluminum foil will be applied such that it completely encases the austenitic steel,
isolating it from the steam tracing.
Where it is impracticable to apply aluminum foil or where there is a possibility of
temperature rise up to 500C, optimized methods of insulations will be used. These
methods will be outlined through the results obtained from practical applications of
insulation.
Finally, design guidelines will be prepared / issued based on practical implementation
to support the activity of insulation; which will provide support to the engineers,
researchers and developers around the globe.
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5. References
o Abdou AA, Budaiui IM (2005) Comparison of thermal conductivity measurements
of building insulation materials under various operating temperatures. J Build Phys
29(2):171–184
o AIRAH (2007) Technical handbook, 4th edn. The Australian Institute of
Refrigeration, Air Conditioning and Heating, Melbourne
o American Iron and Steel Institute (1995) Thermal design and guide for exterior
walls, RG-9405
o Anderlind G, Johansson B (1983) Dynamic insulation – a theoretical analysis of
thermal insulation through which a gas or fluid flows. Swedish Council for Building
Research, Document D8
o ASHRAE (2009) Heat, air, and moisture control in building assemblies – material
properties. In: Handbook of fundamental. American Society of Heating, Refrigerating and
Air-Conditioning Engineers, Atlanta (Chap 26)
o ASTM C 1373 (2010) Standard practice for determination of thermal resistance of
attic insulation under simulated winter conditions. In: 2010 Annual book of ASTM
standards, vol 04.06, pp 793–810
o ASTM C 518 (2010) Standard test method for steady-state thermal transmission
properties by means of the heat flow meter apparatus. In: 2010 Annual book of ASTM
standards, vol 04.06, pp 152–166
o ASTM C 1303 (2010) Standard test method for predicting long-term thermal
resistance of closed-cell foam insulation. In: 2010 Annual book of ASTM standards, vol
04.06, pp 680–706
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o ASTM C 1363 (2010) Standard test method for thermal performance of building
materials and envelope assemblies by means of a hot box apparatus In: 2010 Annual
book of ASTM standards, vol 04.06, pp 741–784. http://www.ornl.gov, Dynamic thermal
performance and energy benefits of using massive walls in residential buildings
o ASTM C 1497 (2010) Standard specification of cellulose fiber stabilized thermal
insulation In: 2010 Annual book of ASTM standards, vol 04.06, pp 863–866
o Desjarlais AO, Yarbrough DW (1991) Prediction of the thermal performance of
single and multi-airspace reflective insulation materials. ASTM STP 1116:24–43
o Fine HA, Jury SH, Yarbrough DW, McElroy DL (1981) Heat transfer in building
thermal insulation: the thickness effect. ASHRAE Trans 87(Pt 2)
o ISO 6946 (2005) Building components and building elements-thermal calculation
method
o Graves RS, Wilkes K, McElroy DL (1994) Thermal resistance of attic loose-fill
insulations decrease under simulated winter conditions. Therm Conduct 22:215–226
o Hall MR (ed) (2010) Materials for energy efficiency and thermal comfort in
buildings. Woodhead, Oxford
o Siegel R, Howell JR (1971) Thermal radiation heat transfer. McGraw-Hill, New
York
o Robinson HE, Powell FJ (1957) The thermal insulation value of airspaces, Housing
Research Paper 23. U.S. Department of Commerce, National Bureau of Standards
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o Yarbrough DW, Graves RS (1997) The effect of air flow on measured heat transfer
through wall cavity insulation. J ASTM Int 4(5):94–100
Appendices
APPENDIX A:
APPENDIX B:
APPENDIX C: