ProRox

Industrial insulation

Process Manual
Technical guidelines for the insulation of industrial installations

Overview ROCKWOOL Technical Insulation System solutions

1.2 Insulation of piping
1.2.1 Insulation with pipe sections

23
30 1.2.7 Insulation of valves and anges 42

1.2.2 Insulation with load-bearing mats

32

1.2.8 Insulation of pipe elbows and T pieces

44

1.2.3 Insulation with wired mats

34

1.2.9 Reducers

45

1.2.4 Insulation support

36

1.2.10 Expansion joints

46

1.2.5 Cladding

38

1.2.11 Tracing

47

1.2.6 Pipe hangers and pipe support

41

1.2.12 Foot trafc

48

1.3 Insulation of vessels

49

1.6 Insulation of boilers

1.6.1 Insulation of re tube boilers

69
69

1.4 Insulation of columns

55

1.6.2 Supercritical steam generators

71

1.7  Insulation of ue gas ducts 77 1.5  Insulation of storage tanks 61

1.8 Cold boxes

84

Contents
1. System solutions
1.1 Planning and preparation 1.2 Insulation of piping 1.3 Insulation of vessels 1.4 Insulation of columns 1.5 Insulation of storage tanks 1.6 Insulation of boilers 1.7 Insulation of ue gas ducts 1.8 Cold boxes

7
11 23 49 55 61 69 77 84

2. Theory
2.1 Norms & Standards 2.2 Product properties & test methods 2.3 Bases for thermal calculations

87
90 110 122

3. Tables
3.1 Units, conversion factors and tables 3.2 Product properties insulation and cladding materials 3.3 Usage tables

127
130 142 145

4. Products
ProRox PS 960 ProRox PS 970 ProRox WM 950 ProRox WM 960 ProRox MA 520 ALU ProRox SL 920 ProRox SL 930 ProRox SL 950 ProRox SL 970 ProRox SL 980 ProRox SL 580 ProRox LF 970 ProRox GR 903 ProRox Rocktight

167
169 169 170 171 172 173 173 174 174 175 175 176 176 177

Dear customer,
ROcKwOOl Technical Insulation is a known entity in the insulation market. Specialists such as yourself often willingly turn to our products and expertise in industrial and marine & offshore insulation (with ProRox & SeaRox product families). We have now packaged that expertise into a practical guide: the 'Industrial Insulation Process Manual. This new manual offers a transparent overview of our ProRox product range, including our thermal, re-resistant and acoustic insulation solutions for technical installations in the process & power generation industries. The Process Manual is a handy and compact instrument which is very convenient to consult. Fold-out sections take you straight to the right page, whether you are looking for straightforward piping insulation or for more complex applications for columns, tanks and boilers. In addition to the many pictures and photographs, a whole range of tables and diagrams clarify the information provided. Keep this manual close by. It is a helpful tool for theapplication of our ProRox insulation solutions inaprocess environment. Should you need any furtherinformation about a specic application, procedure or practical problem, please consult www.rockwool-rti.com or contact your local ROcKwOOl Technical Insulation representative.

Rafael Rodriguez Managing Director ROCKWOOL Technical Insulation

 ROCKWOOL Technical Insulation

ROCKWOOL Technical Insulation an independent organisation within the ROCKWOOL Group - is a leading supplier of high quality stone wool products in the industrial insulation market. With the ProRox & SeaRox lines for the industrial market and for the marine and offshore industry, our experts provide a full range of products and systems for the thermal, acoustic and resafe insulation of technical installations. With this respect, ROCKWOOL Technical Insulation continuously monitors the market developments. For over 75 years we have managed to provide high value products and expert advice through research, innovation and intensive training of all our staff. We are committed to providing the best service to you.

TE
ZEICH

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INRZEUGNISSE AU L L ER ALW O

Founding partner of EIIF ROCKWOOL Technical Insulation was one of the founding partners of the European Industrial Insulation Foundation European Industrial Founding Partner Insulation Foundation (EIIF), which has established itself as a resource for industries that need to reduce CO emissions.

The ROCKWOOL Technical Insulation Process Manual

Know-how for designers, engineers, site supervisors and managers of industrial plants
Energy keeps the world in motion. Without it, everything would come to a standstill. The global economy is dependent upon a secure, efcient supply of energy. Over eighty percent of the energy currently being consumed however is obtained from non-renewable resources. And those resources are becoming increasingly scarce, whilst at the same time the demand for energy is exploding. This means that owners, designers and operators of large, industrial plants are challenged with the task of reducing their energy consumption as much as possible in order to ensure the long term sustainability of their operations. Solar energy is just one of the possible alternatives. Through, for example, solar power plants we already succeed in converting concentrated sunlight very efciently into electricity. And this is just one of the solutions that can help us drive down fuel consumption and carbon emissions. On top of that, insulation signicantly reduces the energy needed to manufacture a product or provide a service. Nowadays there are a great many efcient insulation systems that enable scarce energy reserves to be put to the best possible use. The ROcKwOOl Technical Insulation Process Manual illustrates these systems both theoretically and practically. This process manual targets designers, installers and managers of industrial plants and provides them an overview of the possible modern insulation techniques for, by way of example, chemical or petrochemical installations and power stations. Based on current standards and regulations the manual provides accessible, practical guidelines for the implementation of numerous insulation applications. Restriction of thermal losses to an absolute minimum, including during transfer or storage, can considerably reduce the energy consumption of industrial plants. This also results in a reduction in carbon dioxide (CO) emissions, which are created each time fossil fuels such as coal or gas are burnt and which, as a greenhouse gas, is responsible for the global increase in temperature. From an environmental perspective, adequate insulation of industrial plants is a signicant means of reducing (CO) emissions. This measure pays off in two ways, because within the framework of the EU Emission Trading Scheme, CO reduction equally signies a reduction in emission costs.

In addition, the right insulation keeps temperatures, for example in pipes and storage tanks, within strict tolerances, thereby ensuring reliable process efciency. At the same time, adequate insulation protects the plant itself. Modern insulating materials can thoroughly protect plant components from moisture and associated corrosion. Installation and process maintenance costs can be reduced considerably and the effective lifetime ofindustrial plants can be successfully maximised. Furthermore, industrial insulation also provides a signicant contribution to personal protection. Optimum insulation reduces process temperatures and noise in the industrial environment to an acceptable level, to the limits generally regarded in the industry to be those required for a safe and comfortable working environment. With a complete range of techniques and insulation systems, ROcKwOOl Technical Insulation offers designers and construction supervisors optimum tailored solutions for the petrochemical, energy, ship building, offshore and processing industries.

In the 'Flow of Energy' diagram on the following page, you will nd an overview of all of the sectors in which ROcKwOOl Technical Insulation is active, like the process industry and marine & offshore. All of our ProRox (and SeaRox) products, such as pipe sections, slabs, wired mats and lamella mats, as well as loose insulating wool, full the highest quality and safety standards and comply with the strictest, and therefore safest, re safety classes. Stone wool is non ammable up to temperatures of approximately 1,000C and therefore provides a crucial contribution towards passive re protection. As a supplement to this process manual, ROcKwOOl Technical Insulation also regularly provides infor mation about technical innovations, product solutions and recent and relevant documents available online at our website www.rockwool-rti.com. The process manual is a guideline and can only provide general advice for specic instances in the eld of plant and processes. For these instances, ROcKwOOl Technical Insulations experts are available to provide advice during the design, engineering and implementation phases. Please nd our contact details on the back cover of this manual.

ROCKWOOL Technical Insulation, Flow Of Energy

ROCKWOOL Technical Insulation, Flow Of Energy

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Business Areas:
ProRox insulation for industry: Our ProRox product line covers all our thermal, re-resistant and acoustic insulation solutions for technical installations in the process industry. SeaRox insulation for shipbuilding and offshore: SeaRox comprises the full marine and offshore product line. This sharp focus enables us to combine our expertise and extensive experience like never before to develop outstanding insulation solutions for our customers.

Industrial Residential Petrochemicals Marine

Non-residential

Offshore End Products

ProRox SeaRox

ProRox
Industrial insulation

System solutions

1. System solutions
Table of contents
1.1.1  Decision criteria for the design of an insulation system A. Functional requirements B. Safety aspects C. Economics D. Environmental E. Corrosion Prevention 1.1.2 Design & planning of the insulation work 1.1.3 Corrosion prevention 1.1.4 Storage of insulation materials

1.1 Planning and preparation

11
11 12 16 17 18 18 19 19 22

1.2.1 Insulation with pipe sections 1.2.2 Insulation with load-bearing mats 1.2.3 Insulation with wired mats 1.2.4 Insulation support 1.2.5 Cladding 1.2.6 Pipe hangers and pipe supports 1.2.7 Insulation of valves and anges 1.2.8 Insulation of pipe elbows and Tpieces 1.2.9 Reducers 1.2.10 Expansion joints 1.2.11 Tracing 1.2.12 Foot trafc

1.2

Insulation of piping

23
30 32 34 36 38 41 42 44 45 46 47 48

1.3 1.4 1.5 1.6

1.6.1 1.6.2

Insulation of vessels Insulation of columns Insulation of storage tanks

Insulation of re tube boilers Supercritical steam generators

49 55 61 69
69 71

Insulation of boilers

1.7.1  Installation of the insulation systems for ue gas ducts 1.7.2 Cladding of ue gas ducts 1.7.3 Acoustic insulation of ue gas ducts

1.7

Insulation of ue gas ducts

77
77 80 83

1.8

Cold boxes

84

10

1. System solutions
1.1 Planning and preparation
The design of a suitable insulation system for technical installations is a major factor for its economical operation, functionality, security, durability and environmental impact. Additionally, the installation-specic heat losses are specied for the entire life cycleof the plant. Corrections at a later stage, such as subsequently increasing the thickness of the insulation, for example, may no longer be possible due to lack of space. Corrections at a later stage may also entail a far greater investment compared to the original planning. Continually rising energy costs are also often overlooked factors when dimensioning the insulation. Insulation thicknesses that are designed to last take energy price increases into account. They form an important criterion for the economical operation of the installation after just a few years. We have an obligation to future generations to treat our environment with care. Correctly dimensioned insulation systems constitute an important contribution to environmental protection, carbon dioxide (CO) reduction and to economic success, because: CO reduction is also an economical operation, as it lowers the costs for CO emission certicates. Nowadays, conservational and economical operations are no longer conicting ideas, but on the contrary, theyare two inseparable parameters.

1.1.1.  Decision criteria for the design of an insulation system

Selecting a suitable insulation system depends on the following four parameters: A. Functional requirements  a. Object dimensions b. Operation of the installation c. Operating temperatures d. Permissible heat losses or temperature  changes ofthe medium e. Frost protection f. Ambient conditions g. Maintenance and inspection B. Safety aspects  a. Personal protection b. Fire protection c. Explosion prevention d. Noise reduction within the plant C. Economics  a. Economical insulation thickness b. Pay-back time D. Environment  E. Corrosion prevention 

11

1.1 Planning and preparation

A. Functional requirements
a) Object dimensions The space requirements of the insulation must be taken into account when the installation is being designed and planned. Therefore, the insulation thicknesses should be determined in the early planning stages and the distances between the individual objects should be taken into account in the piping isometrics. To guarantee systematic installation of the insulation materials and the cladding without increased expense, observe the minimum distances between the objects asspecied in the following illustrations.

Minimum distances between vessels and columns (dimensions in mm)

12

Minimum distances between insulated pipes (dimensions in mm)

Minimum distances within range of pipe anges (dimensions in mm)

a = distance ange to normal insulation a 50 mm x = bolt length + 30 mm s = insulation thickness

13

1.1 Planning and preparation

A. Functional requirements
b) Operation of the installation To select a suitable insulation system, the operating method of the installation must be considered. A basic distinction is made between continuous and interrupted operation. With continuous operation, the operating temperatures are constantly above or constantly below the ambient temperatures. The interrupted operating method, also referred to as intermittent or batch operation, is characterised by the fact that the installation is switched off between each operating phase and during that time can assume ambient temperatures. For special applications, so called dualtemperature systems, the operating temperature alternates between above or below the ambient temperature. c) Operating temperature The appropriate insulation material should be resistant to the intended operating/peak temperatures. Thisproduct property is assessed by the maximum service temperature (also see Chapter 2.3 Product properties). d)  Permissible heat losses or temperature changes ofthemedium With many technical processes, it is essential that media in vessels, columns or tanks do not fall below a specic lower temperature limit, otherwise chemical processes will not proceed as intended or the media will set and can no longer be pumped or extracted. Over-cooling can lead to the precipitation of, for example, sulphuric acid in exhaust and ue gas streams, which furthers corrosion in the pipes or channels. With owing media, it is essential to ensure that the temperature of the medium is still at the desired level at the end of the pipe. The thermal insulation is designed according to these requirements. Under extreme conditions (for example, lengthy periods of storage, longtransport routes or extreme temperatures), installing tracing may be necessary, to ensure that the media is kept within the required temperature limits. Use Rockassist, a thermo-technical engineering calculation program, to ensure the optimum engineering and design of these insulations. More information can be found on our website www.rockwool-rti.com. For special situations please contact ROCKWOOL Technical Insulation for further guidance.

Inside buildings, uninsulated or poorly insulated parts of installations can heat the room climate unnecessarily. This leads to higher room temperatures, which can have a negative effect on the working environment - both for the people who work long hours under these conditions and for the electronic components. In addition to the increased heat losses, further energy consumption is required to air condition the rooms. The design of the insulation and the related reductions in terms of heat losses from parts of installations should be relevant to the entire infrastructure and use of the building.

14

e) Frost protection Installations that are situated outside are at risk from frost in the winter. In addition to the undesirable malfunctioning of installations, installations also risk damage caused by the expansion of frozen water. Adequate measures so called frost protection - must be taken to protect the installation from freezing. Insulation can reduce heat losses and postpone the moment at which the installation freezes. Insulation alone, however, cannot indenitely prevent the installation from freezing. Installing additional tracing may be necessary between the object and the insulation. To prevent freezing, the insulation must be designed so that the density of heat ow rate of the insulated object is less than the heat conducted by the tracing.

corrosion of the insulated installation components. Cladding must be installed to prevent the ingress of moisture into the system. However, with installations situated outside with operating temperatures < 120 C or with installations operating intermittently, there is a high risk of moisture accumulation. This is caused by moisture condensing from the ambient air inside the cladding. For this reason, retain an air space of at least 15mm between the insulation and the cladding. Inaddition, drainage and ventilation holes of minimum 10 mm diameter and at intervals of maximum 300 mm should be provided on the underside or at the lowest point of the cladding. Ifnecessary, the insulation and cladding must resist chemical inuences that develop within the environment. g) Maintenance and inspection To avoid complicating routine maintenance and inspection work unnecessarily with the insulation, maintenance-intensive areas must be taken into account, especially when designing the insulation work. Removable insulation systems, such as removable coverings and hoods, could be tted in such areas, for example. Easily removable covering systems are also recommended for anges and pipe ttings. These coverings are generally fastened with quick-release clamps, which can be opened without special tools. The insulation of xtures such as anges or pipe ttings must be interrupted at a sufcient distance to allow installation or dismounting to be carried out. In this case, take the bolt length at ange connections into consideration. The connection of the insulation should have an extremity and any xtures in the range of the insulation, including the interruption in the installation, should be insulated with removable coverings.

f) Ambient conditions Select an insulation system that offers long-lasting resistance to the surrounding environme nt. Atmospheric inuences: wind, rain  Mechanical loads such as vibrations or  foottrafc Corrosive environment (close to the sea,  chemicals,) Prevent the ingress of moisture into the insulation system. Moisture accumulation in insulation increases thermal conductivity and the risk of

15

1.1 Planning and preparation

B. Safety aspects
a) Personal protection Surface temperatures in excess of 60 C can lead to skin burns, if the surface is touched. Therefore, all accessible installation components should be designed to prevent people being exposed to the risk of injury by burns. The insulation applied to such plant components must ensure that surface temperatures in excess of 60C do not occur during operation. Use our Thermo-technical engineering program Rockassist to calculate the required insulation thickness. All of the operational parameters must be known to achieve a reliable design, including, for example, the temperature of the object, the ambient temperature, air movement, surface materials, distance from other objects, etc. the nature and scope of the re prevention measures together with the building supervisory board, the re brigade, insurance companies and the operator. As a basic principle, consider the fact that the re load in a building or technical installation can be considerably increased by ammable insulation materials. On the other hand, non-ammable insulation materials such as mineral wool, which has a melting point of >1,000 C, not only have a positive impact on the re load, but in the event of a re, also constitute a certain re protection for the installation component. Installation components with tracing, in particular, which use thermal oil as a heat transfer medium, have an increased risk of catching re in the event of a leak. In this case, ensure that the thermal oil cannot penetrate into the insulation material. c) Explosion prevention If there is a risk of re and explosion, the surface temperature of the object and the cladding must be considerably lower than the ignition temperature of the ammable substance and/or gas mixtures. This requirement also applies to

Note As the surface temperature depends on a set of physical parameters, which cannot always be calculated or estimated with any degree of certainty, the surface temperature is not a guaranteed measurement. Also refer to Technical Letter No. 5 ofthe German BFA WKSB The problem of guaranteeing surface temperatures. If the required protection (temperature) cannot be achieved by insulation, apply additional protective devices, such as safety guards or enclosement of theobject.

b) Fire protection The general re protection requirements imposed on structural installations are usually dened within the local Building Codes or the specications of plant owner. Structural installations must be designed, built, modied and maintained to prevent the outbreak of a re and the spread of re and smoke. In the event of a re, the rescuing of people and animals and effectively extinguishing the re must be made possible. During the design of the installation, it is vital to determine

16

thermal bridges, such as pipe mounting supports, supporting structures and spacers etc. With regard to insulation systems, explosion protection can only be achieved with a doubleskin covering. A doubleskin covering is a factory made cladding that has been welded or soldered to make it air proof and diffusion-resistant. In addition special (local) explosion regulations must be observed.

C. Economics
In the industry there are two grades of insulation. The rst grade focuses on reducing heat losses and the prevention of injuries to people operating or working nearby the installations. The second grade of insulation, the so called economical insulation thickness focuses on signicant heat loss reduction and as a result achieving a better return on investment. a) Economical insulation thickness Insulation reduces the heat losses from the object. Thethicker the insulation, the greater theheat reduction and consequently, the more energy is saved. However, the investment and expenditure, e.g. for depreciation, interest rates and higher maintenance costs also rise ifthe insulation thickness is increased. At a certain insulation thickness, the sum of the two cost ows reaches a minimum. This value is known as the economical insulation thickness. Aqualitative curve of a similar costs function is shown below.

In explosive areas electrostatically charged substances like unearthed cladding or non-conductive plastics must be earthed. For further guidance please consult the German guideline BRG 132 (previously ZH 1/200 "Static Electricity"). d) Noise protection The guidelines for noise in the ordinance and workplace are stated in the local regulations and standards. Generally, the level of the guideline values depends on the nature of the activity, such as: ARAB (Belgium)  ARBO (Netherlands)  Code du travail (France)  The sound propagation of installation components can be reduced using insulation systems. The nature and effect of the sound insulation depend onthe frequency and the sound pressure level.

Costs

Economical insulation thickness

Total costs

Insulation costs Heat loss costs Insulation thickness

The German VDI guideline 2055 describes in detail various calculation methods used to determine the economical insulation thickness. The energy costs cannot be based solely on the current price. Developments over recent years indicate that substantial increases in energy prices are also anticipated for the future.

17

1.1 Planning and preparation

C. Economics
Increasing energy prices are tending to bring about a shift in economic insulation thicknesses towards larger thicknesses. b) Pay-back time In addition to the economical insulation thickness, another frequently used economical parameter is the return on investment period (ROI), also referred to as the payback period. This is dened as the period within which the cost of the insulation is recuperated through savings on heat loss costs. Costs of the insulation annual saving

D. Environmental
The burning of fossil fuels, such as coal, oil or gas, not only depletes the available primary energy sources, but also, due to the emission of carbon dioxide (CO) into the atmosphere, places aburden on the environment. The increasing CO concentration in the Earths atmosphere plays a signicant part in the global increase in temperature, also referred to as the greenhouse effect. CO absorbs the thermal radiation emanating from the earths surface andin doing so reduces the dissipation of heat into space. This will lead to a change in the worlds climate with as yet inestimable consequences. Reducing CO emission can only beachieved through more efcient management of fossil fuels. Increasing the insulation thicknesses is essential for the reduction of CO emissions. Also refer to the Technical Letter No. 6 of the German BFA WKSB High rate of return on environmentally friendly insulation layer thicknesses. Reducing CO emissions also has a positive nancial benet for businesses within the context of the EU emissions trading scheme. The benets of increased insulation thicknesses in technical installations are twofold, as the costs for both energy consumption and CO emissions are decreased.

ROI period =

[a]

In the case of technical insulation systems, the return on investment period is generally very short, often being much less than one year. Considering only the return on investment period, however, can be deceptive, as this approach disregards the service life of the installation. With long-life installations, it is advisable to select higher insulation thicknesses, even if this means accepting a longer return on investment period. Throughout the entire service life of the installation however, the increased insulation thickness results in a signicantly higher return on the investment in insulation and achieves a much more economic operation of the installation.

E. Corrosion Prevention
See chapter 1.1.3

18

1.1.2  Design & planning of the insulation work

Requirements with regard to the later insulation works must already be included in the design and construction phase of industrial plants. It is therefore advisable to involve all project managers at an early stage, to preclude unnecessary and unprecedented problems during the insulation works from the outset. All preparatory works must be completed according to the relevant insulation standards such as DIN 4140, AGI Q05, BS 5970 and the CINI manual. The following preconditions must be fullled: If necessary, work has been carried out on the  object to protect against corrosion Tracing and technical measurement equipment  have been installed The minimum distance between the objects  hasbeen observed (see illustrations on pages 12and 13) The surface displays no coarse impurities  Mounting supports have been installed on the   object to accommodate the support structure (For further guidance please consult AGI Q153, BS 5970 or the CINI manual) Collars and sealing discs have been tted to  theobject (For further guidance please consult AGI Q152, BS 5970 or the CINI manual) Taps on the object are long enough to ensure   that anges lie outside the insulation and can be screwed on without hindrance Supports are designed so that insulation,   watervapour retarders and cladding can be professionally installed The insulation can be applied without any   obstacles (e.g. by scaffolding) Welding and bonding work has been carried out   on the object The foundations have been completed  

1.1.3 Corrosion prevention

National economies are damaged to a great extent due to the lack of, or inadequate forms of, protection against corrosion. This considerably reduces the service life of industrial plants, and more frequently, essential shutdown or overhaul work impairs the efciency of the installation. It is commonly, but wrongly, assumed that the insulation system also protects an installation against corrosion. For each installation it must be determined whether protection against corrosion is required and, if so, which are the appropriate measures. Generally, the design of the insulation system & corrosion protection will depend on the following parameters. Operation of the installation  - Continuous operation - Interrupted/intermittent operation - Operation involving varying temperatures Operating temperatures of the installation  Metals used  - Non-alloy or low-alloy steel - Austenitic stainless steel - Copper External inuences upon the installation  - Internal/external - Environment of the installation (chemically  aggressive?) The best practices may vary per country and/or standard. The design of the corrosion protection is often carried out in accordance with EN ISO 12944-1 to7 Coating materials Protection against the corrosion of steelwork by means of coating systems. However, since this standard does not adequately take into account the specic features of protecting against corrosion in insulation systems, the require ments of AGIQ151 Protection against corrosion in the case of hot and cold insulation in industrial plants must also be considered.

19

1.1 Planning and preparation

1.1.3 Corrosion prevention
DIN 4140 DIN 4140 states the following advice relating to protection against corrosion: I   n the case of cold insulation, if the object is made of non-alloy or low alloy steel, it must be protected against corrosion. I   n the case of objects made, for example, of austenitic stainless steel or copper, the installation must be tested in each individual case by the planner to determine whether protection against corrosion is necessary. O   bjects made from austenitic stainless steel do not require protection against corrosion if the temperature never even for a short period exceeds 50 C CINI Manual Insulation for industries CINI recommends applying corrosion protection prior to the insulation work at any time. I   n all phases, pay attention to CUI (corrosion under insulation) prevention: design, construction, paint & coating work, application of the insulation system, inspection and maintenance. Equipment and piping sections like nozzles and supports etc. should be designed and maintained to prevent ingress of water into the insulation system. The paint specications are split up into: Construction material - (carbon steel, stainless steel) -  Temperature ranges from minus 30 C to 540 C) with special attention to the temperature range between -20 C and 150 C. The corrosion protection can be achieved using  aluminium foil wrapping, thermal sprayed aluminium (so called TSA) or paint. Protection against corrosion may be omitted in the case of installations operating continuously under extremely cold conditions (< -30 C) Application Before applying the corrosion protection coating with the most layers, the surface must be free from grease, dust and acid and, for better adhesion, the priming coat should be roughened. Blasting is recommended as a surface preparation method (with austenitic stainless steel, use a ferrite free blasting abrasive). Observe the corresponding processing guidelines of the coating manufacturer. If metals with different electrochemical potentials, such as aluminium and copper, come into contact with one another, there is a risk of electrochemical corrosion. If necessary, this can be avoided using insulating, intermediate layers such as non- metallic straps. The presence of moisture will increase the development of electrochemical corrosion.

Note Protection against corrosion should be  applied in the case of all installations made from non-alloy or low-alloy steel where the operating temperatures are below 120 C. Protection against corrosion may be omitted in the case of: Installations operating continuously under   extremely cold conditions (below -50 C) such storage tanks, as well as Insulated surfaces of power plant compo  nents, such as boiler pressure components, ue gas and hot air ducts and steam pipe systems with operating temperatures that are constantly above 120 C.

BS 5970 Guidance is given in BS 5970 relating to austenitic stainless steel that is insulated with any type of insulation For temperatures of up to 500C, aluminium foil of not less than 0.06 mm thick to be applied to the steel surface, arranged to shed water with overlaps of not less than 50 mm at the joints.

20

The table further on this page, which has been derived from the standard DIN 4140, indicates the initial risks of electrochemical corrosion in cases where various combinations of metals are used.

Note The table does not take into account forms  ofcorrosion with other root causes, such as stress corrosion. For further information, see Chapter 2.3 Product properties AS-quality.

Material Metal Surface ratio in proportionto ombinationmaterial c Small Large Small Large Small Large Small Large Small Large Small Large Zinc Aluminium

Combination material Ferritic steel Lead Austenitic stainless steel H L H L H L H M L L Copper

Zinc

L L L L L L L L L L

M L L L L L L L L L

M L L L L L L L L L

H L H M H L L L L L

H L H H L L H M M L -

Aluminium

Ferritic steel

Lead Austenitic stainless steel Copper

L - Light or little corrosion to material M - Moderate corrosion to material, for example, in very humid atmospheres H - Heavy electrochemical corrosion to material Observation: The table shows the corrosion of the material, and not that of the combination material. Light means: small-scale in proportion to the combination material, heavy means: large-scale in proportion to the combination material. Example 1: Material is a zinc galvanised screw in combination material, a cladding made from austenitic stainless steel: Row zinc small: H heavy corrosion of the screw. Example 2: Material , a cladding made from austenitic stainless steel screwed on with a screw galvanised with combination material zinc: Row austenitic stainless steel large. L the corrosive attack upon the austenitic steel is light.

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1.1 Planning and preparation

1.1.4 Storage of insulation materials
Incorrect storage of insulation materials outdoors can mainly due to moisture cause the insulation to deteriorate. Moisture in insulation materials has the following negative inuences. The thermal conductivity of water is approximately 25 times greater than that of air, which is present in cells or between the bres in insulation. An increase in moisture therefore results in an increase in the thermal conductivity of the insulation and, correspondingly, a decrease in theinsulation efciency. Even a moisture content of 1 % can result in an increase of thermal conductivity by 25 %. A higher moisture also means a signicantly higher weight, which, as a rule, is not taken into account in the static design of an insulation system. Moisture causes many types of corrosion that virtually never develop in a dry system. The major types of corrosion in relation to insulation technology are oxygen, electrochemical and stress corrosion. Insulation materials for austenitic components, which in stainless steel quality are manufactured with a low chloride ion content, irrecoverably lose this property when moisture is introduced. Insulation materials must be protected against moisture when stored, during installation and when tted. If storage in a closed structure is impossible, protect the insulation material from weather inuences by covering it with waterproof material. Ensure the insulation is not in direct contact with theoor; otherwise it may become wet as a result of ground moisture.

22

1. System solutions
1.2 Insulation of piping
Piping plays a central role in many industrial processes in chemical or petrochemical installations such as power plants, as it connects core components such as appliances, columns, vessels, boilers, turbines etc. withone another and facilitates the ow of materials andenergy. Toguarantee a correct process cycle, the condition of the media within the pipes must remain within the set limitations (e.g. temperature, viscosity, pressure, etc.). In addition to the correct isometric construction and fastening of the piping, the piping insulation also has an important function. It must ensure that heat losses are effectively reduced and that the installation continues to operate economically and functionally on a permanent basis. This is the only way to guarantee the maximum efciency of the process cycle throughout the design service life without losses as a result of faults.

ROCKWOOL ProRox products for pipe insulation

ROCKWOOL Technical Insulation offers a wide range of high-quality stone wool insulation products for the insulation of industrial plants. All products are part of our extensive ProRox range for technical insulation. With this specic eld of application in mind we developed our pre-formed pipe sections, load bearing mats as well as various wired mats for pipe insulation. All these products are easy to install and contribute to a high level of efciency, functionality and reduced heat losses. Continuous internal and external inspection and high levels of quality assurance ensure the consistently high quality ofall ROCKWOOL Technical Insulation products. The examples of use below cannot fully take into account the particular circumstances of the construction-related factors. Determine whether the products are suitable for the corresponding application in each individual case. If in doubt, consult the ROCKWOOL Technical Insulation experts. The applicable standards and regulations must also be observed. A few examples follow: D   IN 4140 (Insulation works on technical industrial plants and in technical facility equipment) A   GI Q101 (Insulation works on power plant components) C   INI-Manual Insulation for industries  BS 5970 (Code of practice for the thermal insulation of pipework, ductwork, associated equipment and other industrial installations)
23

Requirements for industrial piping

The basic efciency and productivity factors of piping for the processing industry include energy efciency, dependability and reliability under different conditions, inaddition to the functionality of the process control, anappropriate structure that is suitable for the operating environment, as well as mechanical durability. The thermal insulation of piping plays a signicant role in fullling these requirements.

Thermal insulation
The functions of proper thermal insulation for piping include: Reduction of heat losses (cost savings)   Reduction of CO emissions   Frost protection   Process control: ensuring the stability of   theprocess temperature Noise reduction   Condensation prevention   (Personal) protection against high temperatures  

1.2 Insulation of piping

Hot insulation systems
Principally, a thermal insulation structure for piping consists of an appropriate insulating material, usually covered by sheet metal cladding. This protects the object and the insulation from external inuences such as the weather of mechanical loads. Spacers are also essential with insulation such as wired mats, which do not offer sufcient resistance to pressure to hold the weight of thecladding and other external loads. These spacers transfer the cladding loads directly onto the object. In thecase of vertical piping, support structures are tted totake on the loads of the insulation and the cladding. Ingeneral, support structures and spacers form thermal bridges. Selecting a suitable insulation system depends on numerous parameters. These are described in greater detail in Chapter 1.1. Regarding the different forms of piping insulation, a fundamental distinction can be drawn between the following insulation systems. and costs. The lack of spacers and unforeseen gaps minimises heat losses and the risk of personal injuries due to hot spots on the cladding. At temperatures above 300 C, the provisional application of spacers must be determined in each individual case. Pipe sections are always precisely tailored to the corresponding pipe diameter to minimise the risk of convection and processing defects. ROCKWOOL pipe sections are available in diameters of 17 to915 mm.

Insulation with pipe sections

Generally, the best insulation is achieved using ProRox Pipe Sections. The sections can be used up to temperatures of 640C. They are supplied ready split and hinged for quick and easy snap-on assembly and are suitable for thermal and acoustical insulation of industrial pipe work. Due to their excellent t and high compression resistance pipe sections can often be applied in asingle layer without any additional spacers. If multiple layers are required, ROCKWOOL Technical Insulation can also supply double layered - so called nested - pipe sections. This reduces installation costs considerably. Also the number of thermal bridges, which have a negative inuence on the insulation, is greatly reduced, while a lower thickness may be applied compared to wired mats. Using pipe sections for the insulation of pipes results in considerably reduced installation time

Insulation with load-bearing mats

Load bearing mats, such as ProRox MA 520 ALU, are the latest development in the insulation sector. ProRox MA 520 ALU is a stone wool insulation mat (with a special bre structure) bonded onto breglass reinforced aluminium foil. The exible application makes the mats easy to cut. Typical applications include: p   ipe diameters DN 350, or; p  iping with a high number of shaped pieces such as elbows or T-joints. ProRox MA 520 ALU can be applied up to temperatures of 300 C. Their high compression resistance means, that in many cases, load bearing mats can be applied without any additional spacers.

24

Consequently the number of thermal bridges, which have a negative inuence on the insulation, is greatly reduced.

Insulation with wired mats

Wired Mats, such as ProRox WM 950, are lightly bonded stone wool mats, usually stitched with galvanized wire onto a galvanized wire mesh. Pipe insulation with wired mats has been a time-tested universal solution for many decades now. Due to their exibility and high temperature resistance, wired mats can be easily cut and mounted onto the piping. These wired mats are ideal for application in situations where the use of pipe sections or load bearing mats is difcult or impossible: t  emperatures above 300 C p   ipe diameters DN 350, p   iping with a high number of shaped pieces such as elbows or T-joints. Wired mats have a relatively low resistance to pressure and from a practical point of view should only be mounted in combination with spacers or support structures. Because of the resulting thermal bridges, better insulation performances are often achieved in thelower and middle temperature range (up to 300 C) with pipe sections or load bearing mats rather than with wired mats.

The result is considerably reduced installation time and costs. The lack of spacers and unforeseen gaps minimises heat losses and the risk of personal injuries due to hot spots on the cladding. Load-bearing mats are tailored to the corresponding length of the pipe circumference on site and are fastened with clamps.

25

1.2 Insulation of piping

Comparison of the different insulation systems
The particular advantage of pipe sections and load-bearing mats lies in the fact that support structures are not required and therefore thermal bridges caused by the insulation are minimised or removed. On the other hand, wired mat systems have their advantages due to their maximum service temperature in the case of hot face insulation. The advantages of pipe sections and load-bearing mats at a glance are: It is not necessary to install spacers or support  structures. Faster application without the interference of  spacers. Both products offer an even, rm surface for  installing the sheet cladding.  he lack of spacers gives rise to lower heat T losses. It yields an even surface temperature across  the sheet cladding. In comparison to wired mats, a more shallow  insulation thickness can be applied. Theoperating costs of the installation decrease as a result of lower heat losses. Generally speaking, a spacer or support structure functions as a thermal bridge, as a result of which theheat loss in the total insulation is increased considerably.

Insulation system with a spacer ring

1. Pipe - 2. Insulation: ProRox Wired Mats - 3. Cladding - 4.Spacer ring

Insulation system without a spacer ring

1. Pipe - 2. Insulation: ProRox Pipe Sections or Load bearings mats: ProRox MA 520 ALU - 3. Cladding

26

Required insulation thicknesses

If the three insulation systems are compared, taking into consideration similar heat losses, clear advantages are seen with regard to the insulation thicknesses with systems using pipe sections or load-bearing mats. These do not use spacers, in contrast to insulation systems made using wired mats. The table below shows the required insulation thicknesses taking into account the following boundary conditions: Medium temperature: 250 C  Ambient temperature: 10 C  Wind speed: 5 m/s  Cladding: Aluminium-zinc  Heat loss: 150 W/m  Application of spacers in the case of wired mats 

Minimum insulation thickness Pipe sections Nominal diameter DN NPS (inch) Pipe diameter mm ProRox PS 960 Load bearing mats ProRox MA 520 ALU Wired mats ProRox WM 950

50 80 100 150 200 250 300 350

2 3 4 6 8 10 12 14

60 89 108 159 219 273 324 356

30 30 40 60 70 90 100 110

n.a. n.a. n.a. n.a. 100 130 140 (2*70) 160 (2*80)

n.a. n.a. n.a. n.a. 120 150 180 (2*90) 200 (2*100)
n.a. = not applicable

Multiple layer insulation

27

1.2 Insulation of piping

Selection of pipe insulation systems
Generally, the best insulation is achieved using ProRox Pipe Sections. The sections are quick and easy to install. Their excellent t and high compression resistance means pipe sections can be applied in a single layer without any additional spacers. They also have a lower insulation thickness. Load bearing mats, are usually applied for the insulation of large pipe diametres and shaped pieces like elbows and T-joints. Generally, wired mats are applied within the higher temperature range (T > 300 C). Generally speaking, a spacer or support structure functions as a thermal bridge, as a result of which the heat loss in the total insulation is increased considerably. The design of an insulation system depends upon many factors such as the dimensions, mechanical loads, safety aspects, economics, etc. Consequently this also requires a considered selection of the insulation material. Use the application matrix on the next page as a guide.

Comparison ProRox pipe sections and load-bearing mats  offer theadvantage that spacers are generally not required. ProRox pipe sections and load-bearing mats are applied more quickly without the inter ference of spacers. Both products offer an even, rm surface  for installing the cladding. The lack of spacers creates lower heat  losses It yields an even surface temperature   across the cladding In comparison to wired mats, a more  shallow insulation thickness can be used. With a same insulation thickness, the operational costs of the installation decrease as a result of lower heat losses.

28

Pipe sections Application Temperature (C) < 300 C Piping 300 C - 600 C > 600 C Short sections, (many) elbows, valves, anges < 300 C 300 C - 600 C 600 C - 660 C ProRox PS 960

Load bearing mats ProRox MA 520 ALU

Wired mats ProRox WM 940 ProRox WM 960

Piping with tracing City heating pipes D 356 mm D > 356 mm

Note:

= most optimal product

29

1.2 Insulation of piping

1.2.1 Insulation with pipe sections
Generally, the best insulation is achieved using ProRox Pipe Sections. The sections can be used up to temperatures of 640 C. They are supplied ready split and hinged for quick and easy snapon assembly and are suitable for thermal and acoustic insulation of industrial pipe work. Their excellent t and high compression resistance means pipe sections can be applied in a single layer without any additional spacers or support structures. Consequently the number of thermal bridges, which have a negative inuence on the insulation, is greatly reduced, while a low thickness may be applied compared to wired mats. The result is considerably reduced installation time and costs. The lack of spacers and unforeseen gaps minimises heat losses and the risk of personal injuries due to hot spots on the cladding. At temperatures above 300 C, the provisional application of spacers must be determined in each individual case. ProRox Pipe Sections are available in a wide range of diameters, ranging from 17 to 915 mm. Note Due to their low thermal conductivity, better thermal insulation values can be achieved with pipe sections than, for example, with wired mats. With insulation on straight pipe sections, a combination of both products in the same insulation thickness is therefore not advisable. If this combination is essential, for example, in the case of bends or shaped pieces, it is vital to select the correct insulation thickness. This is the only way to guarantee that no unexpected, potentially hazardous surface temperatures occur.

Insulation thicknesses to guarantee protection against contact

The table below is an initial guide to help select suitable insulation thicknesses for the guards. Itisbased on the following boundary conditions: Ambient temperature: 25 C  Wind speed: 0.5 m/s  Cladding: galvanised steel bright  Maximum surface temperature: 60 C  Insulation: ProRox PS 960 pipe sections 

External diameter Nominal diameter DN 25 50 80 100 150 200 250 300 NPS (inch) (mm) <200 250 300 350 400 450 500

1 2 3 4 6 8 10 12

33,0 60,3 88,9 114,3 168,3 219,1 273,0 323,9

30 30 30 30 30 30 30 30

30 30 30 30 40 40 40 40

30 40 40 40 50 50 60 60

40 50 50 60 60 70 70 70

50 60 60 70 80 80 90 90

60 70 80 80 90 100 110 110

70 80 90 100 110 120 130 130

Multiple layer insulation: the thicknesses mentioned above should be seen as an indication. In the event of differing boundary conditions, please contact the ROCKWOOL Technical Insulation sales team. The thermotechnical engineering program Rockassist can be used to design the insulation according to the specic requirements.
30

Installation Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details. The ProRox PS 960 pipe section is mounted directly onto the pipe to form a close t. With horizontal pipes, the lengthwise joint of the pipe section should be turned towards the underside at the 6 oclock position. With vertical pipes, the lengthwise joints should be staggered at an angle of 30 to one another. Secure the pipe sections with galvanised binding wire or with steel bands. With an insulation thickness exceeding 120 mm (or temperatures > 300 C), install the insulation in at least two layers. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered.

Support structures and spacers

Spacers are not generally essential in insulation systems with pipe sections. With pipes that are exposed to large mechanical loads (e.g. strong vibrations) and/or temperatures above 300 C, determine whether a spacer ring is required in each individual case With pipes that have been installed vertically, with a height in excess of four metres, t support structures to transfer the dead load of the insulation system onto the pipe. Attach the rst support ring to the lowest point of the vertical pipe. The distance between the support rings should not exceed approximately four metres.

1. Pipe - 2. Insulation: ProRox Pipe Sections 3. Clamp or binding wire - 4. Sheet cladding 5. Sheet-metal screw or rivet

31

1.2 Insulation of piping

1.2.2 Insulation with loadbearing mats
Load bearing mats (such as ProRox MA 520 ALU) are the latest development in the insulation business. ProRox MA 520 ALU is a stone wool insulation mat (with a special bre structure) bonded onto breglass reinforced aluminium foil. The exible application makes the mats easy to cut. Load bearing mats are ideal for application as pipe insulation in situations where the use of pipe sections is difcult. For instance where pipe diameters DN 350, or in case of a high number of shaped pieces such as elbows or T-joints. ProRox MA 520 ALU can be applied up to temperatures of 300 C. Due to the high compression resistance, load bearing mats can be applied without additional spacers in many cases. Consequently, the number of thermal bridges which have a negative inuence on the insulation, is greatly reduced. The result is considerably reduced installation time and costs. The lack of spacers minimises heat losses and the risk of personal injuries caused by hot spots on the cladding. Load-bearing lamella mats are precisely tailored to the corresponding length of the pipe circumference on site and are fastened with clamps.

Insulation thicknesses to guarantee protection against contact

The table below is an initial guide to help select suitable insulation thicknesses for the guards. It is based on the following boundary conditions: Ambient temperature: 25 C  Wind speed: 0.5 m/s  Cladding: galvanised steel bright  Maximum surface temperature: 60 C  Insulation: ProRox MA 520 ALU 

External diameter Nominal diameter DN 200 250 300 400 500 NPS (inch) (mm) 100

Temperature of the medium (C) 150 200 250 300

8 10 12 16 20

219,1 273,0 323,9 406,4 508,0

30 30 30 30 30

30 30 30 30 30

30 30 40 40 40

50 50 50 50 50

60 60 70 70 70

The thicknesses mentioned above should be seen as an indication. In the event of differing boundary conditions, please contact the ROCKWOOL Technical Insulation sales team. The thermo technical e ngineering program Rockassist can be used to design the insulation according to the specic requirements.

32

Installation Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details. Cut the mats to the required length, based on the external insulation diameter (pipe diameter + two times the insulation thickness). Fasten the mat rmly to the pipe with steel bands. Ensure that the mats form a tight joint and that no lengthwise joints or circular joints are visible. The joints of the individual mats are securely taped with self-adhesive aluminium tape. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered.

Support structures and spacers

Spacers are not generally essential in insulation systems with load bearing mats. With pipes that are exposed to large mechanical loads (e.g. strong vibrations), determine whether a spacer ring is required in each individual case. With pipes that have been installed vertically, with a height in excess of four metres, t support structures to transfer the dead load of the insulation system onto the pipe. Attach the rst support ring to the lowest point of the vertical pipe. The distance between the support rings should not exceed approximately four metres.

1. Pipe - 2. Insulation: ProRox load bearing Mat - 3. Self-adhesive aluminium tape - 4. Steel bands - 5. Sheet cladding 6.Sheet-metal screw or rivet

33

1.2 Insulation of piping

1.2.3 Insulation with wired mats
Pipe insulation with wired mats has been a time-tested universal solution for many decades now. Due to their exibility and high temperature resistance, wired mats can be easily cut and mounted onto the piping. These wired mats are ideal for application on large pipe diameters and shaped pieces as elbows or T-joints. Wired mats have a relatively low resistance to pressure and from a practical point of view should only be mounted in combination with spacers. Because of theresulting thermal bridges, better insulation performances are often achieved in the lower and middle temperature range (up to 300C) with pipe sections or load bearing mats rather than with wiredmats.

Insulation thicknesses to guarantee protection against contact

The table below is an initial guide to help select suitable insulation thicknesses for the guards. It is based on the following boundary conditions: Ambient temperature: 25 C  Wind speed: 0.5 m/s  Cladding: galvanised steel bright  Maximum surface temperature: 60 C  Insulation: ProRox WM 950 

External pipe diameter Nominal diameter DN 200 250 300 400 500 NPS (inch) (mm) 100 200

Temperature of the medium (C) 300 400 500 600

8 10 12 16 20

219,1 273,0 323,9 406,4 508,0

30 30 30 30 30

35 34 40 40 40

65 65 70 75 75

95 105 105 115 120

135 145 150 160 165

150 190 200 215 225

Multiple layer installation : the thicknesses mentioned above should be seen as an indication. In the event of differing boundary conditions, please contact the ROCKWOOL Technical Insulation sales team. The thermo technical engineering program Rockassist can be used to design the insulation according to the specic requirements.

34

Installation Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details. Cut the mat to a length so that it can be tted to the pipe with slight pre stressing. Wire the closing joints (lengthwise and circular) of the mats together using steel wire (0.5 mm thickness) or secure with mat hooks. Stainless steel pipes and pipes with an operating temperature > 400 C can only be insulated with wired mats with stainless steel stitching wire and wire netting to prevent galvanic corrosion cracking. With an insulation thickness of more than 120 mm (or temperatures >300 C), apply multiple layer insulation. If the insulation is assembled in multiple layers, the lengthwise and crosswise joints of the individual insulation layers must be staggered. If mechanical loads are anticipated, use steel straps to secure the wired mats.

1. Pipe - 2. Insulation: ProRox Wired Mat- 3. Joint edge closed with mat hooks - 4. Sheet-metal cladding 5.Sheet-metal screw or riveted bolt - 6. Spacer ring

Support structures and spacers

As wired mats do not offer sufcient resistance topressure to bear the weight of the cladding, spacer or support structures should be applied. More information can be found in 1.2.4. With pipes that have been installed vertically, witha height in excess of four metres, t support structures to transfer the dead load of the insulation system onto the pipe. Attach the rst support ring to the lowest point of the vertical pipe. The distance between the support rings should not exceed approximately four metres.

1. Pipe - 2. Insulation: ProRox Wired Mats - 3. Stitching of the joint edge with binding wire - 4. Sheet cladding 5. Sheet-metal screw or riveted bolt - 6. Spacer ring

35

1.2 Insulation of piping

1.2.4  Insulation support A. Spacers
The purpose of spacers is to keep the cladding at a predetermined distance from the pipe. Spacers are essential when the insulation (e.g. wired mats) cannot bear the mechanical load of the cladding. The use of spacers is generally not necessary ifpipe sections or load bearing mats are used. Use a support structure or spacers on pipes where mechanical loading (e.g. strong vibrations) of the insulation is expected and/or the temperature is higher than 300 C. Spacer rings usually consist of metal rings on which the sheet cladding rests, and metal or ceramic bars used as spacers, which rest on the pipe. Elastic spacers such as Omega clamps are frequently used to reduce the transference of vibrations. With steel spacers, apply at least three bars, whereby the maximum distance measured as circumference of the external ring must be a total of maximum 400 mm. With ceramic spacers, apply at least four bars at a maximum permissible distance of 250 mm. Dimension spacers of support construction The number of spacers depends on the insulation, temperature and the mechanical load. Use the following intermediate distances as a guide.
Horizontal piping Vertical piping

Insulation system

300 C > 300 C 300 C > 300 C

Pipe sections Load bearing mats Wired mats

none none 1m

3 to 4 m 3 to 4 m 1m

none none 1m

5 to 6 m 5 to 6 m 1m

1. Pipe - 2. ProRox Insulation - 3. Spacer - 4. Thermal dividing layer - 5. Cladding

1. Pipe - 2. ProRox Insulation - 3. Spacer - 4. Thermal dividing layer - 5. Support ring

The spacers on pipes are located under the circular joint of the cladding. On shaped sections such as pipe elbows, spacers are tted at the start and at the end. If the external distance between the two spacers exceeds 700 mm, place additional spacers between the two.

36

B. Support construction
The purpose of support structures is to transfer the mechanical load of the insulation system and the forces affecting the insulation system onto the object. Support structures are essential in the case of vertical piping. In addition to the static and dynamic forces, changes in piping length and support structures due to temperature must also be taken into account when dimensioning. Support structures are fastened to mounting supports, which are welded to the pipe beforehand, or are mounted directly onto the pipe via a clamping action with so-called double clamping rings. With temperatures above 350 C, the support structures must be made of high-temperature steels. The table below is an initial dimensioning guide, and shows the weight of the insulation system against the nominal width of the pipe and the insulation thickness. The table accounts for an insulation with an apparent density of 100 kg/m, including the spacer and a 1.0 mm strong galvanised sheet (11 kg/m).

1. Support ring - 2. Bar - 3. Rivet or screw connection 4. Thermal decoupling - 5. Clamping screw - 6. Screw nut - 7. Internal clamping ring

Weight of the insulation (kg/m. pipe)

External diameter Nominal NPS diameter (inch) DN 15 25 50 65 80 100 200 300 500 700 1 2 2 3 4 8 12 20 28 mm Weight of insulation ystem in s relation to different insulation thicknesses kg/m kg/m kg/m kg/m kg/m kg/m kg/m kg/m kg/m kg/m kg/m
2

Insulation thickness in mm 30 40 50 60 80 100 120 140

21,3 33,7 60,3 76,1 88,9 114,3 219,1 323,9 508,0 711,0

4 4 5 6 7 8 12 17 25 34 15

5 5 7 7 8 9 14 19 28 37 16

6 7 8 9 10 11 16 21 31 41 17

8 8 10 10 11 12 18 24 34 44 18

11 12 13 14 15 16 23 29 40 52 20

15 15 17 18 19 21 28 35 47 60 22

19 20 22 23 24 26 33 41 54 69 24

24 25 27 28 29 31 39 47 62 78 26

planar surface

37

1.2 Insulation of piping

1.2.5 Cladding
Suitable cladding should be applied to protect the insulation from weather inuences, mechanical loads and (potentially corrosive) pollution. Selecting the appropriate cladding depends on various factors, such as working loads, foot trafc, wind and snow loads, ambient temperatures and conditions.  luminium is used outdoors, because it is easy A to t and more cost-effective than stainless steel and does not tend to corrode under common weather conditions. In corrosive environments, aluminised steel,  stainless steel or glass reinforced polyester (grp: e.g. ProRox Rocktight) is used as cladding. Stainless steel is recommended for use in environments with a re risk. The surface temperature of the cladding is  inuenced by the material type. The following applies as a general rule: the shinier the surface, the higher the surface temperature. To exclude the risk of galvanic corrosion, only  use combinations of metals that do not tend to corrode due to their electrochemical potentials (also see page 21 in section 1.1). For acoustic insulation, a noise absorbent  material (bitumen, mylar foil) is mounted on the insulation or inside the cladding. To reduce the risk of re, limit the surface temperatures of the cladding to the maximum operating temperature of the noise absorbent material.

Note An insulation system resistant to foot trafc  must not become permanently damaged if a person weighing 100 kg, (weight including any tools being carried) walks across it. It is not designed to bear additional loads, such as the placing of heavy equipment. For the purpose of the safety regulations, a durable insulation is not considered to be a walkable surface!

When selecting the appropriate cladding, take the following points into account: As a general rule, galvanised steel is used in  buildings due to its mechanical strength, re resistance and low surface temperature (in comparison to an aluminium cladding).

Max. surface temperature Cladding material Areas at risk Corrosive of re environment < 50 C < 60 C >60 C

Aluminium sheet Aluminium/zinc coated steel sheet Galvanised steel sheet Austenitic stainless steel sheet Aluminised steel sheet Plastic-coated steel or aluminium Glass bre-reinforced polyester (e.g. ProRox Rocktight) Coatings/mastics Foils

90 C 80 C

The thickness of the metal sheet depends on the pipe diameter and the type of the metal. With special acoustic requirements, a larger thickness ( 1 mm) is generally used.
38

Recommended sheet thickness and overlaps regarding cladding made from at sheets (conform CINI)
Minimum thickness of metal cladding sheet (recomended by CINI) External diameter of the insulation (mm) < 140 130 - 300 > 300 Aluminium (CINI 3.1.01) Aluminised steelsheet (CINI 3.1.02) 0,56 0,8 0,8 Alu-Zinc coated steel sheet (CINI 3.1.03) 0,5 0,8 0,8 Zinc coated steelsheet (CINI 3.1.04) 0,5 0,8 0,8 Austenitic stainless steel sheet (CINI 3.1.05) 0,5 0,8 0,8

0,6 0,8 1,0

The recommended sheet thickness deviates to a certain level per standard/country. The thickness recommended by CINI is shown in the table above. See section 3.2.2 for the thickness according to DIN 4140 and BS 5970. To reduce the risk of galvanic corrosion, it is very important to use the correct screws, straps etc. See the table on page 17 for more information. The basic guidelines are: Fasten sheet cladding on lengthwise joints with  at least six sheet metal screws or blind rivets every metre. Place the screws or blind rivets equidistantly.  Ifscrews or rivets are tted in two rows, do not stagger the screws or rivets. The cladding can also be held in place with  corrosion-resistant straps instead of screws orrivets. Do not use aluminium screws. 

The following applies as a general rule for thermal insulation: the shinier a surface is (lower emissivity), the higher the surface temperature. The following example shows the various surface temperatures that depend on the cladding: Diameter: DN 100 (114 mm)  Temperature of the medium: 500 C  Place of installation: Interior (Wind speed  0.5m/s) Insulation: ProRox WM 940, wired mats;   thickness: 100 mm Various cladding materials  - Aluminium sheet - Galvanised steel sheet, bright - Stainless steel - Paint-coated plastic cladding

Inuence of the cladding on the surface temperature

In addition to the insulation thickness, the thermal conductivity of the insulation and the ambient conditions (for example temperature and wind), the surface temperature of insulation is also inuenced by the emissions ratio of the cladding.

Surface (cladding) temperature C

Aluminium cladding

Galvanised steel, bright

Stainless steel

Paint-coated Plastic cladding

39

1.2 Insulation of piping

1.2.5 Cladding Cladding in corrosive environments
To guarantee the functionality of a technical insulation, it is important to protect it against atmospheric inuences and prevent the ingress of moisture into the insulation. Moisture in the insulation system increases thermal conductivity, thereby reducing the effectiveness of the thermal protection. It also poses a high risk of corrosion to the component. In certain applications, the cladding system is also expected to offer chemical resistance, as well as being resistant to cleaning methods such as steam blasting. Alongside the insulation and construction, selecting a suitable cladding system is very important as it forms the basis for a long service life, low maintenance costs and low heat loss of a technical insulation. ROCKWOOL Technical Insulation has therefore developed an innovative cladding system for technical insulation: ProRox Rocktight. exposed to ultraviolet (UV) light. Once hardened, ProRox Rocktight is watertight and forms a mechanical protection for the insulation. The advantages: Long service life:   ProRox Rocktight creates a sealed, watertight cladding for ROCKWOOL insulation systems. This minimises damage caused by atmospheric inuences or general wear and tear. ProRox Rocktight is resistant to many chemical substances and forms a mechanical protection for the insulation. Easy to clean:  Insulation systems cased in ProRox Rocktight can be cleaned with steam-jet air ejectors, without the risk of water penetrating the insulation and causing damage. Low start-up costs:  The cutting and processing take place directly on site. This avoids costly prefabrications, as is the case with sheet cladding. Flexible applications:  ProRox Rocktight can be used for cold and thermal insulation of underground and aboveground pipes, for example in offshore plants. Its high exibility enables application on complex, shaped objects. ProRox Rocktight is characterised by easy processing. It can be cut easily using a knife directly on site and, as an unhardened ProRox Rocktight mat is highly exible, it can be simply shaped to cover complex geometric shapes such as pipe elbows, T-joints or pipe ttings. ProRox Rocktight has a protective foil on both sides. It is supplied in rolls in cardboard packaging. The roll is also wrapped in black foil that is resistant to UV light. The underside (the side facing the object) is covered with a dark foil and has a rough, self-adhesive surface. The at surface of the outside is covered with a white foil. After each use, place the roll in the sealed cardboard packaging to minimise the risk of hardening caused by daylight or UV light. ProRox Rocktight requires a dry, clean (ventilated)

ProRox Rocktight a durable protection for insulation

ProRox Rocktight is a breglass reinforced polyester mat, which hardens when exposed to ultraviolet (UV) light. The material contains resins, glass bres and a special lling agent and is (unprocessed) protected against UV rays by foils on both sides. ProRox Rocktight is soft and exible when unprocessed. Itcan be cut or trimmed in any shape and easily mounted onto the insulation in this state. Thepolyester then hardens when
40

work environment. For outdoor applications, tents should be erected if necessary, to protect the unhardened ProRox Rocktight mat from UV light.

Pipe support in direct contact with the piping

Note High temperatures: ProRox Rocktight can  be used in temperatures of up to 90 C. In case of higher temperatures, t an end-cap to lower the temperature. Chemical resistance: ProRox Rocktight is  resistant to numerous chemicals. Expansion joints: t expansion joints to  accommodate expansion of the ProRox Rocktight material and the steel pipe.

1. Pipe - 2. Insulation: ProRox PS 960 pipe section 3.Sheet cladding - 4. Pipe clamp - 5. Pipe saddle

Pipe support not in direct contact with the piping

1.2.6 Pipe hangers and pipe supports

There is a wide range of solutions for pipe hangers and pipe supports. The following illustrations show the possibilities described below for insulation systems: Pipe hangers in direct contact with the piping   Pipe supports in direct contact with the piping   Pipe supports not in direct contact with the   piping (commonly used with cold insulation systems)

1. Pipe - 2. Insulation: ProRox PS 960 pipe sections - 3.Sheet cladding - 4. Load-bearing insulation 5.Seal - 6.Stirrup - 7. Pipe saddle

Pipe hangers in direct contact with the piping

A basic rule applying to all pipe attachments is that the insulation system (i.e. the insulation and cladding) must not be damaged if the piping expands. Damage to the cladding of outdoor installations, in particular, can allow the ingress ofmoisture in the material.The result may be permanent damage of the insulation system andas a consequence high heat losses, and dangerously high surface temperatures and corrosion etc.

1. Pipe - 2. Insulation: ProRox Pipe Sections 3.Collar - 4. Sheet cladding - 5. Pipe hanger
41

1.2 Insulation of piping

1.2.7 Insulation of valves and anges
Heat losses incurred through non insulated xtures such as valves and anges are substantial, even at low temperatures. Refer to Table A14 of the VDI guideline 2055 for information about heat losses from non-insulated pipe ttings and anges (see section 3.3.11). The table states that an uninsulated valve (DN100), located outside loses almost as much heat at 100 C as 36 metres of uninsulated piping. The temperature of the medium can also decrease to such an extent at non-insulated ttings or anges, that process critical temperatures are reached, at which point for example, the medium will start to crystallise. Valves and anges should therefore be insulated as much as possible. To avoid damage during inspection or repairs, the insulation for valves and anges is designed with removable coverings or hoods, to allow rapid disassembly. Removable coverings or hoods are usually insulated from the inside with wired mats (e.g. ProRox WM 940). The coverings are fastened to the object with lever fastenings, which are xed directly onto the covering or on to straps. Take the following conditions into account when designing insulated coverings for ttings and anges: T   he overlap distance of the insulated covering over the insulated pipe should be at least 50mm. T   he pipe insulation should end at the anges, leaving a gap equal to the bolt length + 30 mm and should be closed off with a lock washer so the ange can be loosened without damaging the insulation. W   ith valves, an extended spindle should preferably be tted horizontally or below the pipe to prevent leakage along the spindle shaft. T   he cladding must be tted to prevent the ingress of moisture in the insulation. On inclined or vertical piping, for example, mount rain deectors above the removable coverings. If the ingress of moisture into the insulation is unavoidable, make 10 mm. diameter drain holes in the removable covering.

1. Pipe - 2. Insulation: ProRox Wired Mats- 3. Cladding - 4. Sheet-metal screw or Rivet - 5.Swage- 6.Drainage opening - 7. Strap - B 50 mm - A= bolt length + 30 mm

Leakages
With pipes where a leaking uid content could A number of possible design options for insulation systems for pipe ttings and anges follow:

1. Pipe - 2. Insulation: ProRox Wired Mats - 3. Cladding4. Sheet-metal screw or rivet - 5. Rain deector - 6. Lock washer - 7. Straps - 8. Rain deector - B 50 mm - A = bolt length + 30 mm

42

1. Pipe - 2. Insulation: ProRox Wired Mats - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Swage - 6.Drainage opening - 7. Straps B 50 mm 1. Pipe - 2. Insulation: ProRox Wired Mats - 3.Sheet 4. Sheet-metal screw or rivet - 5. Rain deector 6. Lock washer - 7. Straps - 8. Lock washer B 50 mm - A = Screw length + 30 mm

1. Pipe - 2. Insulation: e.g. ProRox Wired Mats 3.Cladding - 4. Sheet-metal screw or rivet - 5. Swage6.Drainage opening - 7. Straps B 50 mm A = Bolt length + 30 mm

the removable covering, mount ange straps with a leak detection tting around the ange. Flange bands can also prevent ammable products from penetrating into the insulation material and can help prevent the outbreak of re.

1. Pipe - 2. Insulation: e.g. ProRox Pipe Sections 3. Cladding - 4. Sheet-metal screw or rivet - 5. Removable coverings (insulated from the inside with e.g. ProRox Wired Mats) - 6. Swage

1. Pipe - 2. Insulation: ProRox Wired Mats - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Swage - 6.Flange band - 7. Leak detection tting - 8. Clamps

damage the insulation or the coating system in

43

1.2 Insulation of piping

1.2.7 Insulation of valves and anges
pipe elbow with clamps or binding wire. Joints between the individual segments are plugged tightly with loose ROCKWOOL.

1. Pipe - 2. Insulation: ProRox Wired Mats - 3. Cladding - 4. Sheet-metal screw or rivet - 5. Collar - 6. Collar - 7. Clamps - 8.Rain deector - 9. Leak detection tting - B 50 mm - A = bolt length + 30 mm

1. Pipe - 2. Insulation: ProRox Pipe Sections 3.Cladding - A and B = Segmented pipe sections

1.2.8  Insulation of pipe elbows and Tpieces

The cladding of elbows and T-pieces is susceptible to damage, due to expanding or vibrating pipes. There is a particular risk of moisture penetrating damaged swage connections in the cladding, if the object is located outdoors. For the insulation of shaped pieces, we recommend using the same insulation in the same thickness as used for the pipe.

Insulation of pipe elbows with wired orload bearing mats

If the piping is insulated with wired mats or load bearing mats, shaped pieces such as pipe elbows or T-pieces are generally insulated with the same mats. In this case, the mats are cut into so-called sh-shaped elbow segments. These are mounted onto the pipe elbow to seal the elbow. With wired mats, all the joints (both circular and lengthwise joints) are sewn together with binding wire or mat hooks. Spacers are required at least at the start and end of the elbow (for more details, please see page 34). Load-bearing mats are xed to the pipe elbow with metal or plastic straps. Any gaps between theindividual segments are plugged up with looseROCKWOOL. Secure the joint edges with self-adhesive aluminium tape.

Insulation of pipe elbows with ROCKWOOL pipe sections

For the insulation of pipe elbows with pipe sections (e.g. ProRox PS 960), the pipe sections are cut into segments and tightly tted onto the pipe elbow with the lengthwise joints facing downwards. The angular division of the segments should correspond to the radius of the pipe elbow. The pipe section segments are fastened to the
44

The diagrams below show how the sheet is mounted onto shaped pieces.

1.2.9 Reducers
Pipes that branch out with many outlets reduce the pipe diameter. Examples of how to install reducers follow:

1. Pipe - 2. ProRox Insulation - 3. Cladding - A to C: Elbow segments of mats 1. Pipe - 2. ProRox Insulation - 3. Cladding - 4. Sheetmetal screw or rivet- 5.Swage - 6. Reducer

1. Pipe - 2. ProRox Insulation - 3. Cladding

1. Pipe - 2. ProRox Insulation - 3. Cladding - 4. Sheetmetal screw or rivet- 5.Swage - 6. Reducer

1. Pipe - 2. ProRox Insulation - 3. Cladding 4. Drainage opening - 5.Edging with mastic compound
45

1.2 Insulation of piping

1.2.10 Expansion joints
In thermal insulation systems, large differences between the piping and the cladding temperature can occur. The materials used for the pipe, insulation, insulation support and cladding also have different thermal expansion coefcients. Thisleads to different thermal elongations of the various components in the insulation system, which must be allowed for using constructive measures. The elongation l can be determined as follows:
l = l t 1. Pipe - 2. Insulation: ProRox Wired Mats 3. Cladding- 4. Aluminium foil - 5. Cover sheet - 6. Mat pin with clip - 7. Spacer

In this formula, l corresponds to the length of the pipe, t corresponds to the difference in temperature between the cold and warm pipe (or cladding) and a corresponds to the linear thermal e xpansion coefcient (see tables in chapter 4).

To compensate for thermal expansion of the cladding, install the expansion joints shown below.

Example for the thermal elongation of steel

l(mm)/m
0,55 1,10 1,65 2,20

t
50 100 150 200

If below expansion joints for thermal length compensation have been built into the pipe, the insulation system bellows, thereby compromising the compensatory effect. The expansion bellows are covered with a sheet that is then insulated (see diagram). With temperatures above 300 C, do not use galvanised sheets due to the risk of galvanic corrosion (cracking).

Cladding 1. Pipe - 2. Insulation: ProRox Wired Mats - 3. - 4. Sheet-metal screw or rivet - 5. Swage - 6.Metal strap - 7. Circumferential seam

46

1.2.11 Tracing
When media are transported over long distances, in particular, the media inside the piping can spoil, set or be at risk from frost in the winter. Insulation can reduce heat losses and postpone the moment at which the installation freezes. Insulation alone, however, cannot indenitely prevent the installation from freezing. Installing additional tracing may be necessary between the object and the insulation. A distinction is made between pipe tracing and electrical tracing. In pipe tracing systems, a heating pipe is tted parallel and close to the media pipe. Steam, warm water or thermal oil ows through the tracing pipes as a heat transfer medium. Electrical tracing consists of cables mounted onto the pipes. These cables heat the pipes Traced pipes can be insulated with pipe sections or mats. Ensure that no insulation occupies the space between the tracing and the pipe; otherwise the heat transfer will be hampered. Pipes are therefore often wrapped in aluminium foil. If pipe sections are used, select a correspondingly larger internal diameter of the pipe section. With vertical piping, sealing the end of each pipe section with loose ROCKWOOL is recommended to prevent convection (chimney effect). The diagrams on the right show various design options.
1. Pipe - 2. Insulation: ProRox Pipe Sections - 3.Electrical tracing - 4. Aluminium foil - 5. Cladding

1. Pipe - 2. Insulation: ProRox load bearing Mats or Wired Mats - 3. Tracing - 4. Aluminium foil - 5.Cladding

1. Pipe - 2. Insulation: ProRox Pipe Sections 3. Tracing- 4. Binding tape - 5. Cladding

47

1.2 Insulation of piping

1.2.12 Foot trafc
Avoid walking on insulated pipes, as this can damage the insulation. Damage caused by foot trafc includes dented sheet cladding and gaps at the sheet seams. Water can penetrate the insulation through these gaps and cause lasting damage to the entire insulation system. The result is often greater heat losses and corrosion.

Note An insulation system resistant to foot trafc must not become permanently damaged if a person weighing 100 kg, (weight including any tools being carried) walks on it. It is not designed to bear additional loads, such as the placing of heavy equipment. For the purpose of the safety regulations, a durable insulation is not considered to be a walkable surface.

1. Pipe - 2. Insulation: ProRox PS 970 Pipe Sections 3. Reinforcement sheet - 4. Cladding - 5. Sheet-metal screw or rivet - 6. Joggle

In special applications, reinforcing the cladding is recommended, e.g. using a reinforcement sheet. Pipe insulation systems resistant to foot trafc require an insulation material with a high mechanical strength (e.g. ProRox PS 970 pipe sections). Using other insulation materials such as wired mats, which are not resistant to pressure, is not recommended, as the sheet cladding only rests on the spacers and tends todent when walked upon.

48

1. System solutions
1.3 Insulation of vessels
Vessels are a major component in installations for various procedures in almost all elds of industry. Many production processes require different substances that are stored in vessels and used in the individual processes later in the procedure. The vessels primarily store liquid, solid or gaseous substances, which are added to the process as and when required. Raw materials, fuels or end products are usually stored in large storage tanks. It is often important to store the substances within certain temperature limits. If the temperature is too high or too low, the substance can spoil or set, or lose its owing properties and become incapable of being pumped or discharged. Insulation is therefore a major factor in the functionality of procedural processes. Italso has the following purposes: Reduces heat losses   Guarantees protection against contact by   minimising the surface temperature Reduces cooling of the stored substance, so it   remains uid and does not set Prevents the vessel from freezing (with   additional tracers) Prevents heating of the stored substance (for   example, through solar radiation) The vessels used in the different industrial processes are so varied that the examples of use cannot fully take into account the particular circumstances of each case. Determine whether the products and construction described are suitable for the corresponding application in each individual case. If in doubt, consult the ROCKWOOL Technical Insulation Sales Team. The applicable standards and regulations must also be observed. A few examples follow: DIN 4140 (Insulation works on industrial plants   and building services installations) AGI Q05 (Construction of industrial plants)   AGI Q101 (Insulation works on power plant   components) CINI-Manual: Insulation in industry    BS 5970 (Code of practice for thermal insulation of pipe work, equipment and other industrial installations)

 efore starting the insulation works, B ensurethat all preparatory work on the objecthas been completed. Refer to Chapter 1.1 for details.

Insulation systems for vessels

An insulation system for a vessel generally consists ofthefollowing components: Insulation   Support construction and a spacer   Water vapour retarder with cold insulation   systems Cladding   The actual operating temperature (above or below ambient) is essential for the design of the insulation work. The following chapters concentrate on hot insulation.

49

1.3 Insulation of vessels

Selection and installation of the insulation
Selecting the appropriate insulation depends on the operating method, the installation temperature, the dimensions and the location of the vessel. Typical insulation materials are ProRox Load Bearing Mats (MA520 ALU) and ProRox exible and semi rigid boards like the SL920 and SL930. Since vessels are often located outdoors, it is important to select insulation with a low thermal conductivity and excellent water repellent properties. The insulation is usually fastened to the cylindrical vessels with steel straps. These should be made from stainless steel and should be closed with buttery nuts or quick release fasteners. The strap measurements and intervals for cylindrical objects shown in the table on the next page have proved useful in many projects.

1. Vessel inlet - 2. Crane hooks - 3. Vessel head 4. Expansion joint - 5. Manhole - 6. Tapping point 7. Identication board - 8. Vessel base- 9.Vessel outlet - 10. Fitting insulation - 11.Flange - 12.Vessel leg

Minimum radius ROCKWOOL Technical Insulation slabs Product 25 ProRox SL 920 ProRox SL 930 ProRox SL 960 400 400 500 40 500 500 700 50 700 700 1000 Insulation thickness (mm) 60 900 1000 1500 70 1100 1200 2000 80 1300 1500 2500 100 1800 1900 2500 120 2000 2400 2800

50

External insulation diameter

Internal insulation layer strap measurement

External or single layer insulation strap measurement 16 x 0.5 mm 19 x 0.5 mm

Distance between the straps

200 tot 1800 mm > 1800 mm

13 x 0.5 mm 16 x 0.5 mm

250 mm 250 mm

In a wide variety of applications, these values can only beused as reference values. In each individual case, determine whether different strap measurements and intervals should be used. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered (socalled masonry bond). For temperatures up to 300 C, ProRox MA 520 ALU for horizontal applications, semi rigid boards like ProRox SL 930 or ProRox WM 940 - wired mats are usually used to insulate vessels with at vertical walls. In this case, the insulation is attached with welding pins and spring plates. On at surfaces, attach the wired mats using minimum six pins per m, and minimum ten pins per m on the underneath. Observe the following when pinning the insulation: W   ith insulation thicknesses 120 mm, use pins with a minimum diameter of 4 mm. W   ith insulation thicknesses ranging from 130 to230 mm, use pins with a minimum diameter of 5 mm. W   ith insulation thicknesses 240 mm, use pins with a minimum diameter of 6 mm. I   f the cladding rests directly on the insulation without a gap between the two, the pins must be 10 mm shorter than the insulation thickness. Fasten each insulation layer with straps and clips. 

With wired mats, all the lengthwise and crosswise joints must be sewn or wired together, or joined with six mat hooks per metre. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered. The following illustrations show a number of typical methods of insulating vessels.

Insulation of a crane hook

1. Cladding - 2. Insulation: ProRox Wired Mats or Load Bearing Mats - 3.Crane hooks - 4. Insulation covering for the crane hook

51

1.3 Insulation of vessels

Selection and installation of the insulation
Insulation of a vessel base

1. Insulation: e.g. ProRox Wired Mats - 2. Support construction - 3. Mounting support - 4. Conical column head5. Vessel outlet - 6. Vessel leg

1. Insulation: ProRox load bearings Mats - 2. Flange inlet for safety valve - 3. Vessel lling nozzles 4. Conical head - 5. Vessel drawdown - 6. Conical head with manhole - 7. Vessel leg

52

Insulation of a conical head

Support constructions and spacers

The application of support constructions and spacers on vessels is essential. The objective of support constructions is to bear the weight of the insulation system and to bear the weight above mounting supports on the object to be insulated. The spacers keep the cladding of the insulation at a predetermined distance. On vertical pipes, the substructures often assume the function of the support construction and spacer. The design specications are illustrated in Chapter 1.4. Thecorresponding requirements for support constructions and spacers can be found in CINI and the AGI guidelines Q153 and 154. Before commencing the insulation works, t mounting supports to the vessels to which the support constructions are tted. The shape, construction and measurements of mounting supports for support constructions must enable the insulation to be tted during assembly. Use the design loads specied in DIN guidelines 1055-4 and 1055-5 to dimension the mounting supports and the support constructions and spacers.

Insulation of a conical head with a manhole

Cladding
The cladding of vessels protects the insulation against mechanical inuences and the weather. There is a wide range of different at and proled sheets available. See Chapter 3.2 for an overview. Flat sheets are primarily used to clad smaller vessels. With large-scale insulation systems, at sheets can only bear small, static loads exerted by the wind. It is therefore essential to reduce the distance between the support structures. The result will be a higher number of support structures and thermal bridges. On large surfaces, at sheets are more likely to buckle or dent, leading to optical damages, than proled sheets. To improve the stability and optical characteristic, the sheets can be canted diagonally (cambered).

Insulation of vessel outlet

53

1.3 Insulation of vessels

Selection and installation of the insulation
Preferably use proled sheets for vessels with a large surface area. They offer structural advantages and can accommodate expansions that are perpendicular to the direction of the swage. The disadvantage is that pipe protrusions are more complex from a structural perspective. Using proled sheets is only recommended with cladding with a low number of protrusions. Design proled sheet casings so that rainfall is deectedsafely. Alongside the insulation and construction, selecting a suitable cladding system is very important as it forms the basis for a long service life, low maintenance costs and low heat loss of a technical insulation. ROCKWOOL Technical Insulation has therefore developed an innovative cladding system for technical insulation: ProRox Rocktight.

ProRox Rocktight for durable protection

ProRox Rocktight is a bre glass reinforced polyester mat, which hardens when exposed to ultraviolet (UV) light. The material contains resins, glass bres and a special lling agent and is protected against UV rays by foils on both sides. ProRox Rocktight is soft and exible when unprocessed. The polyester then hardens when exposed to ultraviolet (UV) light. Once hardened, ProRox Rocktight is waterproof and formsa mechanical protection for the insulation. Pleasesee Chapter 1.2. for more details about processing ProRox Rocktight.

Cladding in moist or corrosive environments

To guarantee the functionality of a technical insulation, it is important to protect it against atmospheric inuences and prevent the ingress of moisture into the insulation. Moisture in the insulation system increases thermal conductivity, thereby reducing the effectiveness of the thermal protection. It also represents a high risk of corrosion to the component. In certain applications, the cladding system is also expected to offer chemical resistance, as well as being resistant to cleaning methods such as steam blasting.

54

1. System solutions
1.4 Insulation of columns
Columns are pillar-shaped vessels, which are mainly used in the (petro) chemical industry for distillation or the extraction of substances. They often form the key elements in chemical or petrochemical plants. The processes in columns often only operate at certain temperatures. The insulation of columns plays an important role in their functionality. Reduces heat losses   Guarantees protection against contact by   minimising the surface temperature Reduces the cooling of the stored substance, so   it remains uid and does not set Ensures the column remains at the necessary   process temperatures Prevents heating of the stored substance (for   example, through solar radiation) The columns used in the different industrial processes are so varied that the examples of use below cannot fully take into account the particular circumstances of the construction-related factors. Determine whether the products and construction described are suitable for the corresponding application in each individual case. If any doubt, consult the ROCKWOOL Technical Insulation Sales Team. The applicable standards and regulations must be observed. A few examples follow: D   IN 4140 (Insulation works on industrial plants and building services installations) A   GI Q101 (Insulation works on power plant components) C   INI-Manual: Insulation in industry  BS 5970 (Code of practice for thermal insulation of pipe work, equipment and other industrial installations)

Before starting the insulation works, ensurethat all preparatory work on the object hasbeen completed. Refer to Chapter 1.1 for details.

Insulation systems for columns

An insulation system for vessels and columns generally comprises the following components: I   nsulation S   upport construction and a spacer W   ater vapour retarder in the case of cold insulation systems C   ladding The temperature of the columns, in particular, has asignicant impact on the optimal insulation system. Thischapter focuses on the insulation of hot columns.

55

1.4 Insulation of columns

Insulation systems for columns

Selection and installation of the insulation

Selecting the appropriate insulation depends on the operating method, the installation temperature, the dimensions and the location of the vessel or column. Insulation materials like ProRox MA 520 ALU load bearings mats or ProRox WM940 wired mat are primairily used for the insulation ofcolumns. Since columns are often located outdoors, it is important to select insulation with a low thermal conductivity and excellent water repellent properties. The insulation is usually fastened to the columns with steel straps. These should be made from stainless steel and should be closed with buttery nuts or quick release fasteners. The strap measurements and intervals for cylindrical objects shown in the table on the next page have proved useful in many projects.

1. Column head - 2. Reinforcement ring - 3. Expansion joint - 4. Working platform - 5. Identication board 6. Column base - 7. Column skirt

56

External insulation diameter

Internal insulation layer strap measurement

External or single layer insulation strap measurement 16 x 0.5 mm 19 x 0.5 mm

Distance between the straps

200 tot 1800 mm > 1800 mm

13 x 0.5 mm 16 x 0.5 mm

250 mm 250 mm

In a wide variety of applications, these values can only be used as reference values. In each individual case, determine whether different strap measurements and intervals should be used. If the insulation is assembled in multiple layers, thejoints of the individual insulation layers must bestaggered. The following illustrations show a number of typical methods of insulating columns.

Insulation of a reinforcement ring

1. Support construction - 2. Mounting support 3. Reinforcement ring - 4. Insulation: e.g. ProRox MA 520 ALU load bearing mats - 5.Cladding

Insulation of conical column head

1. Supporting construction - 2. Mounting support

57

1.4 Insulation of columns

Selection and installation of the insulation
Insulation of a column base

Fire protection in column skirts

The re protection quality of a column primarily depends on the re resistance of the column support frame. The ROCKWOOL Technical Insulation ProRox solutions offer proven re protection solutions for column support skirts. If you have any questions, please consult the ROCKWOOL Technical Insulation Sales team.

1. Skirt: Column support frame - 2. Sliding cover

Insulation of manhole on the column head, vertical connection

Insulation of manhole, horizontal connection

1. Manhole - 2. Insulation: e.g. ProRox MA 520 ALU load bearing mats - 3. Cladding - 4. Sheet-metal screw

58

Various methods for pipe penetrations

Support constructions and spacers

The application of support constructions and spacers on columns is essential. The objective of support constructions is to bear the weight of the insulation system and to bear the weight above mounting supports on the object to be insulated. The spacers keep the cladding of the insulation at a predetermined distance. On columns, which are always perpendicular, the substructures often assume the functions of the support construction and spacer. The corresponding requirements for support constructions and spacers can be found in AGI guidelines Q153 and Q154.

Before commencing the insulation works, t mounting supports to the column to which the support constructions are tted. The shape, construction and measurements of mounting supports for support constructions must enable the insulation to be tted during assembly. Use the design loads specied in DIN guidelines 1055-4 and 1055-5 to dimension the mounting supports and the support constructions and spacers.

59

1.4 Insulation of columns

Support constructions and spacers

1. Object wall - 2. Mounting support - 3. Metric bolting - 4. Bar - 5. Omega clamp - 6. Thermal separating layer

Cladding
The cladding of columns protects the insulation against mechanical inuences and the weather. There is a wide range of different at and proled sheets available. See section 3.2.2 Cladding materials for an overview. Further details are also provided in Chapter 1.3 Insulation of vessels.

Ladder support cleats

ProRox Rocktight for durable protection

The ProRox Rocktight cladding system has proven its value in moist and corrosive environments. SeeChapters 1.2 and 1.3 for more details.

side view

front view

60

1. System solutions
1.5 Insulation of storage tanks
The availability of raw materials, fuels and the storage of end products is critical in almost all elds of industry. Generally, large tanks are used for raw materials, fuels and end products. Small tanks or vessels (see chapter 1.3) are used to temporarily store (semi) products. Toconserve the substance and ensure the stability and safety of the production process, it is important to keep the temperature inside the tank between certain temperature limits. Therefore the industrie sets high standards for theconditioning temperature of storage tanks. Wegive some examples: In the food industry, a milk cooling tank is a  large storage tank used to cool and hold milk at a cold temperature until it can be packed and transported to the end-users. Storage facilities for liqueed gasses such as  LNG, operate at very low temperatures up to -168C. Avoid evaporation or expansion of the liqueed gas, as this can result into safety problems. In the petrochemical industry, many storage  facilities operate at high temperatures of 30C 220C to avoid uids, such as bitumen, spoiling or setting - which could result in problems with pumping or discharging from thetank. Conclusion: Therefore, insulation of storage tanks is a major factor in the functionality of storage facilities. It also serves the following purposes: Costs savings: Insulation signicantly reduces   the heat and the so-called breathing losses of the substance. The pay-back time for the hot insulation is, even at lower temperatures (30C), usually less than 1 year, whereas the lifetime of the insulation may be many years. Environment: In addition to the cost savings   achieved, reduced heat losses will also lead to lower CO emission. Reduced breathing losses of hazardous substances prevents damage to our environment.
P  rocess control: Insulation will prevent tanks

from freezing or being heated by solar radiation. It will also reduce the cooling of the stored substance, preventing it from setting and remaining in a solid form. In both cases additional heating or cooling may be applicable. S   afety: A re resistant insulation reduces the risk of a re outside the tank igniting a ammable medium. It is also protection against contact by minimising the surface (contact) temperature of the tank.

Properly designed insulation work mainly depends on the isometrics and location of the storage tank, type of uid and the purpose of the insulation. Even though the following examples of use are restricted to hot thermal insulation for outdoor application, the types of storage tanks used are so varied that the examples cannot fully take into account the particular circumstances of each case. Determine whether the products and construction described are suitable for the corresponding application in each individual case. If in doubt, consult the ROCKWOOL Technical Insulation Sales Team.
61

1.5 Insulation of storage tanks

The applicable standards and regulations must also be observed. A few examples follow: D   IN 4140 (Insulation works on industrial plants and building services installations) A  GI Q05 (Construction of industrial plants) A  GI Q101 (Insulation works on power plant components) C   INI-Manual: Insulation in industry  BS 5970 (Code of practice for the thermal insulation of pipework, ductwork, associated equipment and other industrial installations)

Insulation selection
Storage tanks are located outdoors, so it is important to select a material with a low thermal conductivity and excellent water repellent properties. ProRox semi rigid slabs such as ProRox SL930, are mainly used to insulate tank walls. Applying a less water repellent, non pressure-resistant insulation like Wired Mats is not generally recommended. If foot trafc can occur, a pressure-resistant slab such as ProRox SL 580 is applied for the insulation of the tank roof. If applying a product which is resistant to foot trafc is impossible, apply a support structure, where needed, to protect the insulation boards. For temperatures above 100C applying the insulation in at least 2 layers (so called masonry bond) is recommended.

1. No insulation: strong convection - 2. Insulation: reduced convection - 3. Insulation: e.g. ProRox SL930 semi rigid slabs

Construction
Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details. Outdoor storage tanks are continuously exposed to the environment. Wind causes both pressure and delamination, which can easily result in damage to the insulation protection usually aluminum sheeting. Consequently, the aluminum sheeting is blown away and rain water can leak into the insulation. Water accumulation can cause corrosion resulting in severe corrosion of the tank, leakage of the substance inside etc. Correct precautions are necessary to ensure the quality and life-time of theinsulation. Many systems can cope with the demands. The appropriate system will greatly depend on the diameter, temperature tank, the surrounding environment and thepossibilities to use scaffolding/rope access when mounting the insulation. In addition, the plant owner may have specic requirements. Determine whether the products and construction described are suitable for the corresponding application in each individual case. If in doubt, consult the ROCKWOOL Technical Insulation Sales Team.

Insulation of tank roofs

Insulating a tank is not easy. Corrosion of the tank roof can occur if the insulation is not properly installed and maintained. Therefore, many companies tend not to insulate the tank roof. A common assumption is that the still air above the hot uid acts as insulation of the tank roof. This assumption is, however, not entirely correct. Due to the difference in temperature between the hot uid and the non-insulated tank roof there is fairly strong convection, which results into considerable heat losses. Tank roof insulation is feasible if the proper insulation material and mounting and xing methods are applied.

62

1. Insulation: e.g. ProRox SL 930 semi rigid slabs - 2. Stainless steel bands (weather proong)- 3.Stainless steel bands4. Support ring - 5. Protrusion - 6. Cladding - 7.Roof/wall connection

Cladding
A metal cladding is generally applied for the tank wall and roof. Thanks to its light weight, low costs and ease of installation, aluminium is commonly applied as cladding. In special circumstances (re rating, corrosive environment etc) other materials such as stainless steel or ProRox Rocktight may be used. Please note the comments under 1.2.6 and watertight covering in this section.

63

1.5 Insulation of storage tanks

Support rings
With vertical applications, the weight of the insulation can damage the insulation layer below. To avoid damaging the insulation, t horizontal support rings is higher than 4metres. The distance between the support rings should not exceed 3 metres. The construction should be built so that leakage water can be expelled from the insulation.

Expansion
Large storage tanks expand due to changes in temperature and if the substance stored is lled or discharged (so called bulging). These factors can increase/decrease the tank diameter.

1500 mm 1 1500 mm 1 50 50 0m 0m

Example: The diameter of a storage tank - 20 m, Avg T 220C - will increase approx. 60 mm. This consequently increases the tank circumference by approx. 180 mm. To avoid stress/tension on the insulation protection (aluminium sheeting) selecting a exible insulation material such as ProRox SL 930 is important. For high temperatures, anticipate further expansion by tting proled sheeting.

1. Tank wall - 2. Spacer - 3. Insulation: e.g. ProRox SL930 semi rigid slab

Ladders and manholes

The necessary space requirements for the insulation must be taken into account when designing and planning the installation. The distance between the ladder and the tanks should be large enough to make installing insulation afterwards possible. Insulate manholes so they can still be used frequently without damaging the insulation.

15

00

mm

15

00

mm

Tank wall and tank base connection

1. Horizontal support ring - 2. Spacer - 3. Fixing

When a tank is lled, stress may occur at the welded seam between the wall and base of the tank. For inspection purposes the rst 50 cm of the tank wall should not be insulated. The rst support ring is usually welded above this level and constructed so that leakage water can be expelled from the insulation.

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Connection tank wall - tank roof with railing

1. Tank wall - 2. Insulation: e.g. ProRox SL 930 semi rigid slabs - 3. Support ring - 4. Cladding - 5. Welded seam

>

Tank wall and tank roof connection

A rainwater shield is tted at the seam between the tank wall and tank roof to prevent leakage into the tank wall insulation. Weld the safety guard / railing on this rainwater shield. Connection tank wall - tank roof

1. Tank wall - 2. Insulation: e.g. ProRox SL 930 semi rigid slabs - 3. L-prole - 4. Rain deector - 5.Support strip - 6. Tank roof - 7. Insulation: e.g. ProRox SL 580 compression resistant slabs - 8. Railing - 9. Not insulated roof

1 2 4

1. Tank wall - 2. Insulation: ProRox SL930 semi rigid slabs - 3. Tank roof - 4. Cladding (aluminium) 5. Deector
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1.5 Insulation of storage tanks

Protrusions within tank walls
Protrusions within the tank wall insulation may lead toleakage of rainwater or pollution with chemical substances. Keep the number of protrusions to a minimum. Insulate any remaining protrusions as indicated below.

Finishing of tank roofs

Similar to tank wall insulation, many constructions are possible for tank roof insulation. Theappropriate system greatly depends on the tank diameter and the nature of the seam with thetank wall. In addition, the plant owner may have specic requirements. The insulation is generally cladded with aluminium sheeting, rivetted or in radial segments. As tank roofs arevulnerable to delamination, screws may be damaged (pulled loose). If welding the roof is not possible, the steel radial segments in the centre of the roof can be hooked together in a ring around the perimeter of the roof. Turnbuckles are used to keep the radials correctly tensioned. In many cases, the most critical aspect of tank insulation is preventing the leakage of rainwater inside the insulation. Water accumulation can cause corrosion resulting in severe corrosion of the tank. Correct precautions are necessary to ensure the quality and life-time of the insulation.

1. Finishing with aluminium cladding - 2. Finishing with steel radial segments - 3. Insulation: ProRox SL Slabs

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A: welded steel bar attached on the roof with a stainless steel strip

Protrusions within tank roofs

Protrusions within the tank roof insulation may lead to leakage of rainwater or pollution with chemical substances due to overlling of the tank. Keep the number of protrusions in the tank roof to a minimum. If this is not possible, apply the construction stated below.

B: applying ProRox insulation

C: Finishing with aluminium cladding

1. Tank roof - 2. Cladding - 3. Insulation: ProRox SL 580 compression resistant slabs - 4. Aluminium nishing strip - 5. Bolts and rivets (stainless steel) - 6. Strip (stainless steel) - 7.Weld - 8.Welded steel bar

1. Sealing tape - 2. Insulation: e.g. ProRox MA 520 ALU load bearing mats - 3. Perforated sheet (ventilation)

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1.5 Insulation of storage tanks

Foot trafc
Tank roofs are subject to foot trafc. To ensure the insulation system is resistant to foot trafc, apply a pressure-resistant slab such as ProRox SL 580. If the radius of the tank roof is too large to allow the use of a rigid board, use a more exible slab such as ProRox SL 930 in combination with a (local) metal support construction. The walkways need to be clearly marked.

Watertight covering
Conventional systems for tank roof insulation are often sensitive to weather damage (water, wind, etc.) and the effect of chemicals. The costs of maintenance, and the consequently lower operational safety, are often higher than the (energy) cost-savings that are realized by the insulation. For this reason, many tank roofs, especially in the lower temperature ranges, are not insulated. P   roRox Rocktight is applied directly on ROCKWOOL tank roof insulation on site. As direct cladding supports are no longer needed, it ts seamlessly to all parts of the tank and has an unequalled hardness and mechanical strength (e.g. can be walked upon). I   n situations exposed to high wind stresses, a special cable construction can be applied. This will hold the insulation in place under the most extreme weather conditions. A   n anti-slip coating is available that can easily be applied to ProRox Rocktight. T   he absence of cladding supports virtually eliminates any risk of corrosion under the insulation. T   his ensures perfect protection to the insulation and storage tank, which guarantees the durability of the insulation. For more information please contact our ROCKWOOL Technical Insulation staff.

ProRox Rocktight for durable protection P   roRox Rocktight is a breglass reinforced polyester mat positioned between two sheets of foil. The material contains resins, glass bres and a special lling agent. It is soft and exible when unprocessed. It can be cut or timed in any shape and easily mounted onto the insulation in this state. The polyester then hardens when exposed to ultraviolet (UV) light. Once hardened, ProRox Rocktight is absolutely watertight and forms a mechanical protection for theinsulation.

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1. System solutions
1.6 Insulation of boilers
Hot water boilers and boilers for the production of water vapour under high pressures are considered to be steam boilers. As a generic term, boiler is used to denote steam generators and hot water installations. Insulating boilers has the following purposes: Reduces heat losses and increases the   efciency of the boiler Guarantees protection against contact by   minimising the surface temperature Prevents heating of the compartment air in the   boiler house, which guarantees an acceptable working The design and functionality of the boilers on the market is so varied that the examples of use cannot fully take into account the particular circumstances ofeach case. Determine whether the products and construction described are suitable for the corresponding application in eachindividual case. In if doubt, consult the ROCKWOOL Technical InsulationSales Team. The applicable standards and regulations must also be observed. A few examples follow: DIN 4140 (Insulation works on industrial plants   and building services installations) AGI Q101 (Insulation works on power plant   components) CINI-Manual: Insulation in industry    BS 5970 (Code of practice for thermal insulation of pipe work, equipment and other industrial installations)

1.6.1 Insulation of re tube boilers

Fire tube boilers are often used in small and medium-sized industrial plants, where small and medium-sized mixtures of hot water or water vapour are required at low pressures. These boilers are used in the technical building appliances of large complexes, such as hotels, hospitalsetc. The re tube boiler consists of a horizontally positioned cylindrical casing body with diameters of up to four metres. The interior generally contains a corrugated ame tube, where a fuel, which is usually oil or gas, is burnt. At the end of the boiler are so called reversing chambers, where the ue gas is reversed and pumped back through the boiler. Depending on the design, the boiler will have one or more gas ues, connected at the rear or the front base through the reversing chamber. The chamber surrounding the gas ues and the re-tube is lled with the water to be heated.

69

1.6 Insulation of boilers

1.6.1 Insulation of re tube boilers
Fire tube boiler

1. Boiler casing - 2. Insulation: ProRox Load Bearing Mats or Wired Mats - 3. Cladding - 4. Flame tube - 5. Fire tube - 6. Reversing chamber

Applying load bearing mats such as ProRox MA 520 ALU is a proven solution in the insulation of ame tube-smoke tube boilers. These mats are easily mounted onto the horizontal, cylindrical boiler surface and are easily fastened to the boilers with metal straps. Metal spacers, which always create thermal bridges, can be omitted. Due to the compression resistance of at least 10kPa, the cladding can be mounted directly onto the Duraex insulation. Alternatively, if the sheet cladding is tted so closely that it can adopt this function, the fastening straps can be omitted. The insulation is characterised by a consistent rigidity and surface. Due to the lack of spacers, itguarantees an even surface temperature without temperature peaks (so called hot spots), which pose a hazard in the form of skin burns.

The balanced surface temperature prole also accounts for the thermography of a ame re tubeboiler shown on this page. Wired mats are generally used toinsulate the area of reversing chambers and are secured with pins and springclips. The thermography of a ame tube-smoke tube boiler, which is insulated with ProRox MA 520 ALU. (Source LOOS INTERNATIONAL, Loos Deutschland GmbH) The areas insulated with ProRox MA 520 ALU show an even temperature distribution without visibly, increased hot spots. The right image shows the position of the thermographic camera. Reading point Sp1 has a temperature of 21.7 C; reading point Sp2 is 21.2 C and reading point Sp3 is 22.8 C.

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1.6.2 Supercritical steam generators

In the modern energy and heat economy, super critical steam generators, which burn fossil fuels such as mineral coal, brown coal and anthracite etc. are used to generate steam to operate steam turbines. In current utility steam boilers, up to 3,600 t steam is generated per hour under pressures of 300 bar and steam temperatures of 620 C. The most common type is the Benson boiler, that is operated by forced circulation (with boiler feed pumps). In contrast to re tube boilers, the water or vapour is not located in the vessel, but in pipes, which are tted in gas-tight, welded tube-n constructions and form the walls of the boiler. Generally constructed as single-pass or two-pass boilers, these boilers reach levels of up to 160 m, depending on the fuel used. The bottom contains the furnace, where nely ground fuel is burned. The ue gases ow through the boiler and heat the water in the pipes, thereby causing it to evaporate. The boiler casing is suspended on a frame and can compensate for any thermal expansions that occur during operation (vertical and horizontal expansions). These types of expansions must be considered during the design of the insulation system. The diagram on the right shows the most important technical components in the insulation of a boiler.

Insulation works on a re tube boiler with ProRoxMA 520 ALU

Buckstays
So-called buckstays are tted horizontally at regular intervals around the boiler. Buckstays are reinforcement elements, which prevent the boiler from bulging. Adistinction is made between hot buckstays, which are located inside the insulation, and cold buckstays, which are located outside the insulation sections.

Dead spaces
Dead spaces are located in front of the boiler wall or boiler roof, where installation components such as collectors, distributors or pipes are tted. The dead spaces are located inside the insulation.

71

1.6 Insulation of boilers

1.6.2 Supercritical steam generators Handles
Handles are reinforcement elements, which are tted vertically between the buckstays and bear the vertical loads exerted on the buckstays on the boiler wall. Handles can be located inside and outside the insulation sections.

Installation of the insulation system for utility steam generators

The following product characteristics are important when selecting a suitable insulation system for utility steam generators: The insulations used must be non combustible.   The maximum service temperature of the   insulation must be higher than the operating temperature of the installation component to be insulated. The thermal conductivity must be specied as a   function of the temperature. The (longitudinal) air ow resistance must be as   high as possible. High ow resistances reduce convection in the insulation. In addition to protection against contact and the maximum permissible surface temperatures of 60C, industrial parameters such as efciency factors must beconsidered during the design of the insulation thickness. The AGI guideline Q101 Insulation works on power plant components recommends that the insulation layer thicknesses for power plant components is designed for a maximum heat ow rate density of 150 W/m. In view of rising energy prices and the socio political target of CO-emission reductions, this generally recommended value is, however, subject to critical analysis. From an economic and environmental perspective, a design parameter of well below 150W/m is often sensible. ProRox Wired Mats have proven invaluable in the insulation of utility steam generators over the years. They are exible and can be easily mounted onto the various geometries or surface structures. ROCKWOOL wired mats are non combustible, have high maximum service temperatures and exhibit a low degree of thermal conductivity across the entire temperature range. The insulation is assembled in multiple layers, comprising two to three layers of insulation. TheProRox Wired Mats with a maximum service temperature of 680 C are a tried and tested solution asa rst insulating layer in upper temperature ranges, as are often encountered in

1. Boiler roof - 2. Dead space - 3. Cross bar - 4. Collector- 5.Boiler support tube - 6. Boiler wall 7.Buckstay - 8.Handles - 9. Burner port - 10. Boiler funnel

72

dead spaces. The further layers of insulation are constructed with ProRox WM 950 or WM 940 wired mats, depending on the temperature of the adjacent layer. In accordance with AGI guideline Q101, galvanised wire netting and galvanised stitching wire in wired mats can only be heated up to a temperature of 400 C. With tempera tures above 400 C, austenitic stainless steel wire netting and stitching wire must be used. Toreduce the convection in the insulation of vertical constructions such as boilers, onlyuse insulations that exhibit an air ow resistance of50 kPa s/m. Diagram of a boiler insulation system with wiredmats

walls), the pins cannot be xed to the pipes, but must be welded onto the bars between the pipes. Observe the following when pinning the insulation: W   ith insulation thicknesses 120 mm, use pins with a minimum diameter of 4 mm. W  ith insulation thicknesses ranging from 130 to230mm, use pins with a minimum diameter of5mm. W  ith insulation thicknesses 240 mm use pins with a minimum diameter of 6 mm. I  f the cladding rests directly on the insulation without a gap between the two, the pins must be 10 mm shorter than the insulation thickness. F  asten each insulation layer with clips. With wired mats, all the lengthwise and crosswise joints must be sewn or wired together, or joined with six mat hooks per metre. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered. The following illustrations show a number of typical methods of insulating vessels.

Diagram of a boiler insulation system with wired mats with a gap between the insulation and sheet cladding

1. Tubed wall - 2. Insulation: ProRox Wired Mats 3. Fastening pins with spring plates - 4. Cladding

Before starting the insulation works, ensure that all preparatory work on the object has been completed. Refer to Chapter 1.1 for details. The wired mats are fastened to at surfaces with at least six pins per m, and on the underside with at least ten pins per m. The pins are either welded directly onto the surface of the object or are screwed into nuts. With nned walls (tube-n

1. Finned pipe - 2. Insulation: ProRox Wired Mats3. Fastening pins with spring plates - 4. Aluminium foil if necessary - 5. Metal cladding (e.g. proled sheet)
73

1.6 Insulation of boilers

1.6.2 Supercritical steam generators
Diagram of a wired mats boiler insulation system with nogap between the insulation and sheet c ladding

Barriers
The following diagrams show two designs for vertical barriers. Depending on the temperature or structural requirements, the barrier can be manufactured from sheet metal (0.5 mm) or aluminium foil (80m). Thebarrier must be fastened to the object on the heated side and must reach to the cladding on the cold side. Fill interstices with loose rock wool. Where the insulation is constructed in multiple layers, cascade thebarriers.

1. Tube wall - 2. Insulation: ProRox Wired Mats 3.spring plates - 4. Aluminium foil if required 5.Cladding (e.g. proled sheet)

Convection in the insulation

With vertical insulation constructions in particular, where cavities can form on the heated side between the object and the insulation, there is an increased risk of heat losses caused by convection in the insulation. This risk equally applies to nned walls, as an insulation that follows the contours of the object, in which the cavities in the area of the bars are sealed, cannot always be secured. Take the following measures to prevent convection:
 C  onstruct vertical barriers at intervals of 5 to 8 m.  O  nly use insulations with a longitudinal ow

1. Boiler wall - 2. Insulation: ProRox Wired Mats- 3. Fill with loose rock wool - 4. Convection barrier sheet - 5. Aluminium foil ifrequired - 6.Metal cladding - 7.MF prole lling - 8. Z-prole separating sheet

resistance of 50 kPa s/m. F   itting an aluminium foil between the individual insulation layers and/or on the exterior is recommended.

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Insulation of the buckstays

Buckstays that are exposed to heat are insulated and tted with a casing. An example follows.

Buckstays that are exposed to cold are generally not insulated and not cladded. An example follows.

Buckstays exposed to heat on a boiler wall

Buckstays exposed to cold on a boiler wall

1. Boiler wall - 2. Insulation: ProRox Wired Mats3.Fill up with loose ll ROCKWOOL - 4. Support construction - 5. Buckstay exposed to heat 6. Aluminium foil if required - 7. Cladding/Preformed sheet - 8. Internal buckstay cover, made from black sheet - 9. Mat pins with clips - 10. Aluminium foil barrier - 11. Flat sheet cladding

1. Boiler wall - Insulation: ProRox Wired Mats- 3.Mat pins with clips - 4. Buckstay deectors- 5.Aluminium foil if required- 6. Metal cladding/proled sheet 7. Substructure - 8. Cold buckstay - 9.Boiler handle

75

1.6 Insulation of boilers

1.6.2 Supercritical steam generators Insulation of dead spaces
Dead spaces located in front of the boiler wall or roof containing installation components, are enclosed with cladding, to which the insulation is then mounted. Use a non-scaling sheet with a minimum thickness of one mm. Fasten the sheets to appropriate, structurally measured substructures so that the thermal expansions can be accommodated. The insulation is secured to the dead space sheeting with pins as described above. An example of dead space insulation follows.

Support construction and spacer

There are various options available to attach support constructions and spacers to boilers. They can be mounted directly onto the boiler, to auxiliary constructions, to buckstays, cross bars or handles. When selecting the support construction and spacer and the corresponding attachment option, a design matching must take place between the insulator and the plant manufacturer. With power plant components with temperatures above 350 C, use high temperature orreproof steel.

Dead space for boiler wall collector

Cladding
With power plant components with large surface areas, such as utility steam generators, proled sheets are used as cladding material for structural, economic anddesign reasons. The open spans, overlaps and connections correspond to the prole. Refer to the instructions of the relevant proled sheet manufacturer. When selecting a suitable cladding material, consider the following parameters: corrosion, temperature resistance, type of construction and architectural design. The contractor and customer should consult about this matter. Galvanised steel sheeting is generally used for the insulation of utility steam generators, which are usually located inside buildings.

1. Boiler wall - 2. Insulation: ProRox Wired Mats 3. Fill up with loose ll ROCKWOOL - 4. Support construction - 5. Dead space sheeting- 6. Aluminium foil if required - 7. Metal cladding/Preformed sheets 8. Support construction and spacer

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1. System solutions
1.7 Insulation of ue gas ducts
Burning fossil fuels produces ue gases, which are guided through ue gas ducts through the various cleaning stages, such as denitrication (DENOX) desulfurization (DESOX) and dust removal (EN), discharged into the atmosphere. Large sections of ue gas ducts are often located outdoors. They are subject to an extent to both internal and external extreme conditions. The effects of external atmospheric inuences, such as wind and rain, as well as varying ambient temperatures on the ue gas duct, can lead to intense cooling of the ue gases internally, and therefore to the accumulation of sulphuric acids, which facilitate corrosion. Insulation systems on ue gas ducts have the following purposes: Reduce heat losses in the ue gas, thereby  preventing sub-dew point (acid or water dew point) conditions in the ue gas on the interior surfaces of the ue gas duct. This also minimises the corrosion risk. This also applies to areas with structural thermalbridges, such as support constructions, reinforcements etc. Reduce the heat losses in ue gas channels of   heat recovery systems Personal protection   Adherence to technical specications with  regard to noise Designs are so varied in terms of their size and geometry, as well as the materials and layers used, that the examples of use below cannot fully take into account the particular circumstances of the construction-related factors. Determine whether the products and construction described are suitable for the corresponding application in each individual case. If in doubt, consult the ROCKWOOL Technical Insulation Sales Team. Furthermore, the applicable standards and regulations must be observed. A few examples follow: D   IN 4140 (Insulation works on industrial plants and building services installations) A   GI Q101 (Insulation works on power plant components) C   INI manual: Industrial insulation  BS 5970 (Code of practice for thermal insulation of pipe work, equipment and other industrial installations)

1.7.1  Installation of the insulation systems for ue gas ducts

ROCKWOOL wired mats have been a proven solution for rectangular ue gas ducts for many years. They are exible and can t onto different geometries and surface structures. ROCKWOOL wired mats are non-ammable, have high maximum service temperatures and exhibit a low thermal conductivity across the total temperature range. Secure the wired mats to the rectangular ducts with welding pins and spring clips. Before the welding pins are tted, a bonding procedure should be determined by the plant manufacturer and insulator, which does not damage any corrosion coating present on the inside and outside of the ue gas duct. For example, it may be advisable to t the welding pins before constructing the corrosion coating. The wired mats must be secured to at surfaces with at least six pins per m, and on the undersides with at least ten pins per m. Observe the following when pinning the insulation: W   ith insulation thicknesses 120 mm, use pins with a minimum diameter of 4 mm. W  ith insulation thicknesses ranging from 130 to 230mm, use pins with a minimum diameter of 5mm. W  ith insulation thicknesses 240 mm use pins with a minimum diameter of 6 mm.
77

1.7 Insulation of ue gas ducts

1.7.1  Installation of the insulation systems for ue gas ducts
I  f the cladding rests directly on the insulation

without a gap between the two, the pins must be 10 mm shorter than the insulation thickness. F   asten each insulation layer with clips. With wired mats, all the lengthwise and crosswise joints must be sewn or wired together, or joined with six mat hooks per metre. If the insulation is assembled in multiple layers, the joints of the individual insulation layers must be staggered. To reduce convection in the insulation, tting barriers is recommended, for example made from steel, at intervals of 5 to 8 m when working on large vertical surfaces. The barrier must be effective across the entire section of insulation up to the cladding. The recommended insulation for round ue gas ducts, where temperatures are below 300 C, is load-bearing mats ProRox MA 520 ALU. These are mounted directly onto the ue gas duct and are fastened with straps. Afastening with welding pins and spring clips is generally not required in this instance.

Preventing temperature drops on theinside wall

To prevent a drop in temperature on the inside wall in the area of reinforcement proles, they must always be insulated. The insulation thickness required depends on factors such as the size and geometry of the proles, the temperature level and rate of ow within the ue gas duct and the operating method. Complex calculations may be required to determine the insulation thickness. These are usually established by the plant manu facturer, who is aware of the installation parameters. When starting up the installation, a brief drop in temperature below the dew point of the ue gas is unavoidable on the inside wall of the duct.

Reduction of stress due to temperature in the reinforcement proles

The operating method of the installation inuences the problem of stress in the reinforcement proles caused by temperature. Less critical is the steady operation, where the ue gas temperature does not change with the passage of time. Generally, stresses due to temperature are not critical if the implementation principles outlined in the AGI guideline Q101 are observed: The insulation thickness across the reinforce ment elements should be of the same thickness as the insulation on the ue gas duct. In the case of ducts with reinforcing ribs up to a  height of 100 mm, the thickness of the insulation layer across the ribs must measure at least one third of the insulation thickness required for the duct.

Insulation of reinforcement elements

Large ue gas ducts are tted with reinforcement proles to stabilise the duct. These can consist of double T-girders, hollow sections or reinforcing ribs and form potential thermal bridges. This may cause the following problems: The thermal bridges cause an increased heat  ow and lead to a temperature decrease on the inside wall of the ducts. Temperature variations between the inner and  exterior lead to stress in the proles. If the tensile forces become too great, this can lead to deformations and breaking of the welding.

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Insulation of reinforcing ribs

1. Duct wall - 2. Insulation: ProRox Wired Mats- 3. Reinforcing ribs - 4. Welding pins with clips - 5. Metal cladding

In the case of non-steady operation, for example, when starting up the installation causes uctuating ue gas temperatures , measures must be taken if necessary to allow even heating of the reinforcement proles. The temperatures on the duct wall, as well as on the inside of the reinforcement element, increase rapidly when the installation is started up, whilst the outside of the prole remains cold at rst and only heats up after a longer delay. This leads to temperature differences, which can cause undue stressing of the component. The extent of the temperature differences depends on numerous parameters. Afew examples follow: The operating speed inuences the speed at   which temperature of the ue gas increases and the temperature difference in the reinforcement element. High temperature differences occur in the case   of large proles. The shape of the reinforcement proles inu  ences an even temperature distribution. Thick walled proles, for example, do not warm up as evenly as thin walls. The different thermal conductivities of the   materials used and the heat transfer rates lead to an uneven temperature distribution. To reduce the temperature differences, the insulation must be structurally designed to enable as much heat as possible to be transported by means

of radiation and convection from the duct wall to the external ange of the reinforcement proles. The following shows the design details for a prole insulation system.

Insulation of reinforcing ribs

1. Duct wall - 2. Insulation: ProRox Wired Mats - 3. Metal cladding: corrugated sheet - 4. Reinforcing element- 5. Supporting construction and spacer - 6. Aluminium foil (optional) - 7. Welding pins/clips

This type of design is generally recommended for proles measuring up to 240 mm in height.

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1.7 Insulation of ue gas ducts

1.7.1  Installation of the insulation systems for ue gas ducts
Insulation of reinforcing element with cavity and covering sheet

1.7.2 Cladding of ue gas ducts

Due to their size and the associated high demands placed upon the exural rigidity of cladding, ue gas ducts are encased with proled sheets such as trapezoidal sheets. Flat sheets, which are generally cambered, can also be used. The claddings are secured to the ue gas duct using substructures. With ducts located outdoors with ue gas temperatures of < 120 C, an air space of at least 15 mm should be left between the cladding and insulation. On clear nights, especially, there is a risk that thermal radiation in space (the small surface of the ue gas duct radiates on an endlessly large surface space), will cause the surface temperature of the cladding to fall below the dew point temperature of the ambient air. The atmospheric humidity from the ambient air can then condense on the inside of the cladding. Therefore, the insulation and cladding must not be allowed to touch. To drain the water, drill drainage or ventilation holes at the lowest point on the underside. With round ue gas ducts, which are constructed with the spacer free insulation ProRox MA 520 ALU, corrugated straps or bubble wrap are inserted between the insulation and sheet cladding as a spacer. If the duct is located outside, the upper surface ofthe cladding should have a gap of 3 %. Thefollowing pages show two examples for the cladding of a ue gas duct with a pent or gabled roof.

1. Duct wall - 2. Insulation: ProRox Wired Mats 3. Reinforcing element - 4. Covering sheet - 5. Support construction and spacer - 6. Aluminium foil (optional) 7. Welding pins/clips - 8. Metal cladding: corrugated sheet

In the case of proles measuring above 240 mm in height, a covering sheet should also be installed. The heat transfer from the duct wall to the external ange is therefore not impeded and the cavities do not need to be insulated. The prole insulation described leads to increased heat losses through convection in the case of vertical steel girders. As a result, barriers for example in the form of sheets welded into the reinforcement elements must be tted at intervals of approximately 3 to 5 m to reduce convection.

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Duct located outdoors with a cladding constructed as apent roof

1. Duct wall - 2. Insulation: ProRox Wired Mats - 3.Support construction and spacer - 4. Welding pins/clips5.Metal cladding: corrugated sheet - 6. Extension (trapezoid)- 7. Z-shaped spacer

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1.7 Insulation of ue gas ducts

1.7.2 Cladding of ue gas ducts
Duct located outdoors with a cladding constructed as a saddle roof

1. Duct wall - 2. Insulation: ProRox Wired Mats- 3. Support construction and spacer - 4. Welding pins/clips - 5.Metal cladding: corrugated sheet - 6. Extension (trapezoid) - 7. Z-shaped spacer - 8. Support construction - 9. Ridge

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1.7.3 Acoustic insulation of ue gas ducts

The thermal insulation of ue gas ducts inuences the propagation of airborne noise and structure-borne noise. The effects of this depend on many factors, such as the frequency, the noise pressure level and the structure. The following structural measures inuence the acoustic properties of an insulation system: Changing the insulation layer thickness and/or   the apparent density of the insulation Changing the clear distance between the ue   gas duct and the cladding Acoustic decoupling of the cladding from the   ue gas duct using elastic elements within the support construction and spacer (e.g. omega clamp, rubber elements, steel wool pads) Increasing the basic weight of the cladding   through the choice of material or sheet thickness Internal coating of the cladding with sound-   deadening materials Construction of the insulation in multiple   layers, with at least two separate insulating layers and cladding

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1. System solutions
1.8 Cold boxes
Many industrial applications use gases such as oxygen, nitrogen and argon. These gases are obtained using cryogenic gas separation technology, whereby air is condensed and converted into a liquid. Afterwards, thevarious elements can be separated using fractional distillation. So-called air separation plants are characterised by an extremely low temperature of as low as approximately -200C. In addition to the risk of water and ice forming at this cryogenic temperature, there is also the risk of pure oxygen condensing against the cold parts of the system. The presence of oil and grease may be enough tocause the high concentration of oxygen to spontaneously combust. This is obviously an extremely hazardous situation. The presence of oil and grease must therefore be avoided at all times. It is vitally important to well insulate all cold parts of the system, such as vessels and pipes. Strict specications regarding the insulation are therefore essential. A frequently applied standard for the insulation of air separation plants is the AGI Q 118 standard insulation work on air separation plants. Thisstandard describes in detail the various parts of theinstallation and theinsulation to be applied. Theconstruction method naturally depends on the application. Thefollowing instructions are limited tothe insulation of so-called cold boxes.

Choice of insulation
The choice of insulation material depends on avariety of parameters, including the user requirement, standards (e.g. AGI Q118), the operating temperature and the accessibility of the installation. In many cases, mineral wool bres are used (e.g. ROCKWOOL ProRox GR 903), which contain a very low proportion of organic substances- the so-called Linde Quality. This can be easily injected into the vessel and has a very long lifespan. The material is easily removed for inspection purposes.

Fitting the insulation

In compliance with the AGI Q118 standard, the bres are tted manually or using an injection technique. The hollow spaces in the installation must be free of water and other liquids and contaminants. All lling openings (and non-lling openings) must be sealed. An optimum result is achieved by pulling the packaged, loose bres apart before injecting or shaking them into the vessel. The ProRox GR 903 must be injected or shaken into the unit in even layers. If necessary, the wool can then be tamped to achieve the required density. To avoid damage to the installation, manually lling certain parts of the installation may be advisable. The ultimate

Cold boxes
An important component in gas separation plants are the so-called cold boxes. Cold boxes are (pressure) vessels that hold a gas or liquid at a very low temperature. The distinctive feature of cold boxes is the double-wall construction, which allows the insulation to be tted between the inner and outer walls. The cold box is sealed after the insulation has been tted, so the insulation can no longer come into contact with, for example, water, snow, dust and contaminants.

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density of the tted wool depends on how it is tted. Densities of at least 150 kg/m3 are feasible. The ofcial requirement according to the AGI Q118 standard is 160 to 200 kg/m3. The procedure is outlined step by step as follows: 1.  Create a trial set up by lling a 60 x 60 x 60 cm crate with an evenly distributed layer of loose wool, with a thickness of 300 - 400 mm. Then have a man of average weight compact this layer by treading on it. Repeat this process until the box is full. Calculating the quantity of wool used (in kg) afterwards allows the feasible density to be determined. This also gives a good idea of the tamping method required in order to achieve an effective lling density. 2.  Before starting to ll the cold box, ll the installation with air to create a slight over pressure. This will make any possible leaks, which can occur during thetamping process, audible. 3.  The cold box is lled with an evenly distributed layer of ROCKWOOL ProRox GR 903 granulate, with a thickness of 300 mm - 400 mm. Tamp down this layer until a density is reached that corresponds to the density in step 1. 4.  Repeat step 3 until the cold box is completely lled. Check the lling density by regularly calculating the number of kilograms used in relation to the lled volume. The pressure required to achieve a certain density depends on the procedure that has been followed.

Note As ROCKWOOL ProRox GR 903 Granulate may  settle after a while or the shape of the cold box may alter due to temperature uctuations, take into account that the unit will need tobe relled.

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Notes

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ProRox
Industrial insulation

Theory

Theory

2. Theory
Table of contents
2.1
2.1.1 Overview of different norms & standards 2.1.2 Insulation specicationt a) CINI Guideline b) PIP - guidelines c) ASTM standards d) European standardisation (CEN) e) CE-mark f) DIN standards & guidelines g) AGI guidelines h) BFA WKSB guidelines i) FESI guidelines j) ISO standards k) VDI 2055 guideline l) British Standard (BS) m) Norme Franaise (NF) n) Document Technique Uni (DTU) 2.1.3  Relevant guidelines & standards for the technical insulation industry in Germany 2.1.4  Relevant guidelines & standards for the technical insulation industry within the Benelux

Norms & Standards

90
90 91 91 92 93 94 95 95 96 97 97 98 98 99 100 102 103 110

2.2  Product properties & test methods

2.2.1 Fire behaviour 2.2.2 Thermal conductivity 2.2.3 Maximum service temperature 2.2.4 Water Leachable chloride content 2.2.5 Water repellency 2.2.6 Water vapour transmission 2.2.7 Air ow resistance 2.2.8 Compression resistance 2.2.9 Density

110
110 112 115 118 119 121 121 122 122

2.3

Bases for thermal calculations

122

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2.1 Norms & Standards

2.1.1  Overview of different norms &standards
There are numerous standards, guidelines and specications for the planning, design and construction of technical insulation systems. These regulations must be observed to guarantee the functionality, economic operation and safety ofa technical installation, as well as a long service life. Industrial plants are built and maintained according toa range of requirements, detailed in numerous technical standards that cover all design and equipment requirements. An overview of the commonly used standards, guidelines and specications is mentioned below.

Internal plant owner or contractor specications

Detailed technical requirements for design, procurement, construction, and related maintenance based on a companys experience (so called best practices), e.g.: Shell  : DEP British Petroleum : BP  Mobil standards : MS  Exxon standards : ES  These specications often refer to industrial guidelines and society standards.

General-specic or site standards

General project or maintenance standards for common materials and equipment adopted by owners and contractors. Often, national, countryspecic standards & guidelines are observed, e.g.: Saudi Operation Specification: SOS Petroleum Development Oman: POD

Society standards
Published standards from an accredited standards developer. Common examples are ASTM, European Standard (EN), DIN. Often related to product performance.

Industrial guidelines for insulation

In many cases, industrial guidelines are established to ease and to reduce the development & maintenance time and effort of specications sharing best practices. They contain detailed technical requirements for design, material selection/approval. These specications often refer to society standards and industrial guidelines. Typical examples in industrial insulation are DIN 4140, AGI Q101, PIP, CINI.

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2.1.2 Insulation specication

The insulation specication is part of the plant owner or contractors specication. It generally contains: Guidelines for preparation prior to the  insulation work Material specications  Mounting instructions per application  The insulation specication also often includes the guidelines for corrosion protection. Similar to other specications, the insulation specication often refers tosociety standards and/or industrial guidelines. The detailed lay-out per specication will depend on the type of application, the plant owner, contractor and country specic requirements. A more detailed explanation of the most common standards, guidelines and specications is given in the following documents. a) CINI guideline b) PIP guideline c) ASTM standards d) European standardization e) DIN standards & guidelines f) AGI guidelines g) BFA WKSB guidelines h) FESI guidelines i) ISO standards j) VDI 2055 guideline k) British Standard (BS) l) Norme Franaise (NF) m) Document Technique Uni (DTU) The wide variety per country, application and plant owner means these documents cannot convey the entire content and so cannot claim to be complete. For specic applications, please contact our ROCKWOOL Technical Insulation sales team for advice.

a) CINI Guideline
CINI is a Dutch association, in which various companies active in the technical insulation of industrial plants have united to develop uniform material and design guidelines. When compiling these standards, CINI works closely with many decision makers from within the insulation sector. The CINI Standards are guidelines, yet they do not constitute national standards. Nevertheless, the CINI standards are often adopted by operators and design engineers in the Benelux countries, as well as by international companies operating in the petrochemical industry, for example, Shell. They are often used by operators and design engineers as guidelines on tendering procedures for insulation works. The CINI standards also are grouped into material standards and design rules. The validation of the material properties isbased on ASTM and AGI guidelines. More information is available via www.cini.nl

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2.1 Norms & Standards

2.1.2 Insulation specication
CINI 2.2.01 CINI 2.2.02 Insulation materials (Material standards) CINI 2.2.03 CINI 2.2.04 CINI 2.2.05 CINI 2.2.06 CINI 3.1.02 Cladding (Material standards) CINI 3.1.03 CINI 3.1.04 CINI 3.1.05 CINI 3.1.11 CINI 1.3.10 CINI 4.1.00a CINI 4.2.00 Processing guidelines CINI 4.3.00 CINI 4.4.00 CINI 4.5.00 CINI 7.2.01 Stone wool boards: ROCKWOOL (RW) slabs for the thermal insulation of equipment Wired mats: ROCKWOOL (RW) wire mesh blankets for the thermal insulation of large diameter pipes, at walls and equipment Pipe sections: ROCKWOOL sections and prefabricated elbows for the thermal insulation of pipes Loose wool: Loose rock wool without binder for the thermal insulation of valve boxes and the specication stufng of insulation mattresses Lamella mats: ROCKWOOL lamella mats for the thermal insulation of air ducts, pipe bundles and equipment Aluminium faced pipe sections: ROCKWOOL sections with reinforced pure aluminium foil facing for the thermal insulation of pipes Aluminised steel sheeting: Aluminised steel cladding for the nishing of insulation Alu-zinc coated steel sheet: Alu-zinc steel cladding for the nishing of insulation Galvanised steel sheet: Continuous hot dip (Sendzimir) galvanised steel cladding for the nishing of insulation Austenitic stainless steel: Stainless steel cladding for the nishing of insulation GRP: Weather resistant UV-curing glass bre-reinforced polyester (GRP) General processing guidelines: Installation instructions for the thermal insulation of hot pipelines and equipment (insulated with mineral wool) Pipes: (Overview) piping insulation details Columns: (Overview) insulation/nishing details overview columns Vessels: (Overview) insulation/nishing detail overview vertical vessels Heat exchangers: (Overview) insulation/nishing details overview horizontal heatexchangers Vessels: (Overview) insulation/nishing details for tanks (operating t emperature from20C to 180C Corrosion protection: Corrosion protection under insulation

b) PIP - guidelines
Process Industry Practices (PIP) is a consortium of mainly US-based process industry owners and engineering construction contractors who serve the industry. PIP was organised in 1993 and is a separately funded initiative of the Construction Industry Initiative (CII) and the University of Texas at Austin. PIP publishes documents called Practices. These Practices reect a harmonisation of company engineering standards in many engineering disciplines.

Specic Practices include design, selection and specication, and installation information. Some of the best practices are mentioned below. INIH1000 - Hot Insulation Installation Details  INSH1000 - Hot Service Insulation Materials  and Installation Specication More information is available via www.pip.org

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c) ASTM standards
ASTM International (ASTM), originally known as the American Society for Testing and Materials, is an international organisation that develops and publishes voluntary standards for a wide range of materials, products, systems and services. ASTM is older than other organisations for standardisation, such as BSI (1901) and DIN (1917), however it differs from these in that it is not a national standard-setting body. This role is performed in the USA by the ANSI Institute. Nevertheless, ASTM plays a predominant role in the specication of standards in the USA and for many international projects particularly in the Middle East, Asia and South-America.

The ASTM standards are grouped into materials standards and validation standards for product properties. International tenders for the insulation of industrial plants often refer to relevant ASTM standards. The ASTM annual book of standards comprises 77volumes. The corresponding standards for insulation are incorporated into ASTM Volume 04.06 Thermal insulation; Building and environmental acoustics. Arelevant extract is shown below. More information is available via www.astm.org

ASTM C592 Materials ASTM C547 ASTM C612 ASTM C335

Wired mats: Standard specication for mineral ber blanket insulation and blanket-type insulation (Metal-mesh covered) (Industrial type) Pipe sections: ROCKWOOL sections. For the thermal insulation of pipes. Standard specication for mineral ber pipe insulation Slabs: ROCKWOOL (RW) slabs for thermal insulation of equipment. Standard specication for mineral bre block and board thermal insulation Testing of the thermal conductivity (pipe sections): Standard test method for steady-state heat transfer properties of pipe insulation Testing of the thermal conductivity (slabs): Standard test method for steady-state heat ux measurements and thermal transmission properties bymeans of the guarded hot plate apparatus test method Testing of the maximum service temperature: Standard test method for hot-surface performance of high-temperature thermal insulation Testing of the ame propagation on surfaces: Standard test method for Surface Burning characteristics of Building Materials Thermal insulation for use in contact with austenitic stainless steel Evaluating the inuence of thermal insulations on external stress corrosion cracking tendency of austenitic stainless steel Chemical analysis of thermal insulation materials for leachable chloride, uoride, silicate plus sodium ions Determining the water vapor sorption of unfaced mineral ber insulation Standard practice for estimate of the heat gain or loss and the surface temperatures ofinsulated at, cylindrical, and spherical systems by use of computer programs

ASTM C177

ASTM C411 Product properties ASTM E84 ASTM C795 ASTM C692 ASTM C871 ASTM C1104/ C1104M Thermal c alculations ASTM C680

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2.1 Norms & Standards

2.1.2 Insulation specication d) European standardisation (CEN)
In order to remove technical barriers to trade, the European Union decided to develop uniform European product standards. These product standards describe the product properties, as well as the methods of testing for these properties. The minimum requirements for certain product properties still remain a national responsibility and are laid down in each individual country. The EU issues orders in the form of mandates to CEN (the European Committee for Standardisation), which the CEN uses to develop relevant standards. For ROCKWOOL, this product standard is the EN14303 Thermal insulation products for building equipment and industrial installations Factory-made mineral wool (MW) products specication. Following ratication, a European standard must be adopted as it stands by the national standardization organizations as a national standard. Deviating national standards must be retracted. Each European standard adopted is published in each EU country with a national prex, e.g. in Germany: DIN-EN-XXXX; in England (British Standard): BS-EN-XXX.

Product properties, test standards

Product property Thermal conductivity (Piping) Thermal conductivity (Boards) Water vapour diffusion resistance coefcient AS quality Standard EN ISO 8497 Description Heat insulation Determination of steady-state thermal transmission properties of thermal insulation for circular pipes Thermal performance of building materials and products Determination of thermal resistance by means of guarded hot plate and heat ow meter methods - Products of high or medium thermal resistance Thermal insulating products for building applications Determination of water vapour transmission properties Thermal insulation products for building equipment and industrial installations Determination of trace quantities of water-soluble chloride, uoride, silicate, sodium ions and pH Thermal insulating products for building equipment and industrial installations Determination of short-term water absorption by partial immersion of preformed pipe insulation Thermal insulating products for building equipment and industrial installations Determination of maximum service temperature Thermal insulating products for building equipment and industrial installations Determination of maximum service temperature for preformed pipe insulation Thermal insulating products for building applications Determination of compression behaviour Acoustics; Materials for acoustical applications; Determination of airow resistance (ISO 9053:1991)

EN 12667

EN 12086 EN 13468 Replaces AGIguideline Q135 EN 13472 Replaces AGIguideline Q136 EN 14706 (for at products) EN 14707 (for piping) EN 826 EN 29053 Determination of airow resistance

Hydrophobic treatment

Maximum service temperature Compression resistance Air ow resistance

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e) CE-mark
The CE marking as it is legally called since 1993 (per directive 93/68/EEC) (abbreviation of French: Conformit Europenne, meaning "European Conformity" is a mandatory conformity mark for products placed on the market in the European Economic Area (EEA). With the CE marking on a product the manufacturer ensures that the product conforms with the essential requirements of the applicable EC directives. Legally, the CE marking is no quality mark. But from August 2012 on, only technical insulation products which comply with the European product standards (see 2.1.2d) and bear the CE mark may be sold in Europe. A mandatory frame-work will then apply for the key product features of technical insulation materials such as thermal conductivity, resistance to water vapour transmission, re behaviour, tolerances etc. The performance of a mineral wool product is summarized in a designation code, which can be found on the labels of the individual products. E.g. for mineral wool: MW EN 14303-T2-ST(+)680-WS1-CL10-pH9 T2 = Thickness tolerance  ST = Maximum service temperature  CS = Compressive strength  WS = Water absorption  CL = Trace quantities of water soluble chloride  pH = Level of the pH  The main advance of the CE-mark and related European standards is that a higher level of transparency is achieved. This will allow speciers, distributors and installers to make a quick and direct comparison between the available products in todays market place.

indicate that standardisation covered many elds, not just industrial products. In 1975 the DNA was nally renamed DIN. Since 1975, it has been recognised by the German government as the national standards body and represents German interests at international and European level. The acronym DIN is often wrongly expanded as Deutsche Industrienorm (German industry standard). This is largely due to the historic origin of the DIN as NADI. The NADI indeed published their standards as DI-Norm (Deutsche Industrienorm, German industry standard). Designation The designation of DIN standards shows its origin. D   IN # is used for German standards with primarily domestic signicance or designed as a rst step toward international status. E   DIN # is a draft standard and DIN V # is a preliminary standard. DIN EN # is used for the German edition of  European standards. DIN ISO # is used for the German edition of ISO  standards. DIN EN ISO # is used if the standard has also  been adopted as a European standard. DIN standards for the validation of insulation materials can be found under European standards. DIN 4140 Insulation work on industrial installations gives guidelines for the validation of insulation material, mounting and xing. This standard applies to insulation works on industrial plants. These are production and distribution plants for the industry and for technical building appliances, (e.g. appliances, vessels, columns, tanks, steam generators, pipes, heating and ventilation systems, air conditioning units, refrigeration units and hot water installations). With requirements relating to re protection, the relevant standards or national technical approvals must be observed. This standard does not apply to insulation works performed on building shells, interior walls and inserted ceilings, neither in the shipbuilding and vehicle manufacturing industry, nor within the control area of power plants.
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f) DIN standards & Guidelines

Deutsches Institut fr Normung e.V. (DIN; in English, the German Institute for Standardization) is the German national organisation for standardisation and is that countrys ISO member body. DIN is a registered association (e.V.), founded in 1917, originally as Normenausschuss der deutschen Industrie (NADI, Standardization Committee of German Industry). In 1926, the NADI was renamed Deutscher Normenausschuss (DNA, German Standardization Committee) in order to

2.1 Norms & Standards

2.1.2 Insulation specication g) AGI
Arbeitsgemeinshaft Industriebau e.V. (AGI) isaGerman association of manufacturers, engineering companies and universities. AGI was founded in 1958 to establish a common platform to exchange best practices within Industry. These practices, which are summarised in the
Material standards and designguidelines AGI Q02: Insulation works on industrial installations Terms AGI Q03: Construction of thermal and cold insulation systems Insulation works of industrial plants AGI Q05: Construction of industrial plants Bases, design, requirements with regard to the interfaces of plant components and insulation AGI Q101: Insulation works on power plant components Construction AGI Q103: Insulation works on industrial plants Electrical tracing AGI Q104: Insulation works on industrial plants Tracing systems with heat transfer media AGI Q132: ROCKWOOL as insulation forindustrial plants

AGIguidelines (so called Arbeitsbltter) are established in cooperation with the German DIN, VDI and CEN members for insulation. The most relevant standard for insulation work is shown on the next page. More information is available via www.agi-online.de.
Field of application/scope

The terms used in the AGI Q working documents are dened in this working document. This working document applies to insulation works performed on industrial installations. The working document classies works into thermal insulation works for operating temperatures above the ambient temperature and cold insulation works for operating temperatures below the ambient temperature. This working document has been compiled for planners and designers who have to design the industrial plants, including the essential thermal or cold insulation. It examines, in particular, the interfaces between plant construction and insulation. Working document Q 101 applies to insulation works performed on power plant components such as steam generators and ue gas cleaning systems, pipe systems and steel ues This working document applies to insulation works performed on industrial plants with electrical tracing. This working document applies to insulation works performed on industrial installations, which are heated and/or cooled by means of heat transfer and/or refrigerant media, for example in tracing pipes or half pipe sections. This working document applies to rock wool insulation, which is used for thermal, cold and acoustic insulation of technical industrial plants and technical building appliances. This working document applies to corrosion protection coating systems for the surfaces of industrial plants, such as appliances, columns and pipes, which are insulated against heat and cold loss. Since the DIN EN ISO 12944 standard provides no explanations with regard to protecting insulation systems against corrosion, this working document should be considered as a supplement to standard DIN EN ISO 12944. This working document does not apply in respect of adhesive primers. This AGI working document applies to objects where the insulation must be protected against moisture and, above all, against the ingress of liquids, (e.g. water, heat transfer oil). AGI working document Q 153 applies to the design and construction of mounting supports. They transfer the loads of the insulation onto the support constructions on the object. AGI working document Q 154 applies to the construction of support constructions.

AGI Q151: Insulation works Protecting thermal and cold insulation systems on industrial plants against corrosion

AGI Q152: Insulation works on industrial plants Protection against moisture penetration AGI Q153: Insulation works on industrial plants Mounting supports for support constructions AGI Q154: Insulation works on industrial plants support constructions

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h) BFA WKSB
Deutsche Bauindustrie is a German branch organization within the building & construction industry. Part of this organization is the so called Bundes Fach Abteilungen {(BFA) - technical departments} who are specialized in the technological developments and lobby activities within a specic area of technical expertise. One of them, the so called BFA WKSB {Bundes Fach Abteilung Wrme-, Klte-, Schall-und Brand Schutz}, represents the branche members interests in industrial insulation, acoustic insulation and re proong in buildings. As well as lobbying towards the various organizations and the German government, they recommend best practices and provisions as stated in the so called technical letters. These practices are established in cooperation with DIN, AGI, CEN, FESI and testing bodies like FIW. The most important technical letters for hot insulation are shown below.

i) FESI
FESI, Fdration Europenne des Syndicats dEntreprises dIsolation is the European Federation ofAssociations of Insulation Companies. FESI was founded in 1970 and is the independent European Federation representing the insulation contracting sector. FESI promotes insulation as one of the best, themost cost effective and sustainable manners to save energy. FESI represents the insulation associations from 16 European countries whose members are active in insulation for industry, commercial building sectors, ship insulation, soundproong, re protection and others. The most important FESI documents (guidelines, recommendations) are shown below.

Document

Description Working Manual: System for measure ment and recording for industrial insulation cladding (English translation of BFA WKSB letter no. 4 and 2). Problems associated with the w arranty of specied surface temperature. ( English translation of BFA WKBS, technical letter no. 5) "High protability through ecologically based insulation thicknesses". (English translation of BFA WKBS, technical letter no. 6) "Principles of metal corrosion". (English translation of BFA WKBS, technical letter no. 3 and 2) A industrial Acoustics B Building acoustics Code of Guarantee "Problems of thermal stress in metal reinforcements of large-dimensional objects with elevated service temperatures". (English translation BFA WKSB technical letter Nr. 1, 2.) Basics of Acoustics Product characteristics Acoustic insulation, absorption, attenuation

04 Technical Letter Field of application/scope 05

1 3 4 5 6 9 10 11

Problems of thermal stress in metal reinforcements of large-dimensional object with elevated service temperatures Prevention of metal corrosion System for measurement and recording for industrial insulation cladding. Problems with the warranty of specied surface temperatures High protability through ecologically based insulation thicknesses Methods of measuring Measuring point for thermal insulation Moisture in insulation systems

06

09

A1

11

More information is available via www.bauindustrie.de

A2 A3

More information is available via www.fesi.eu

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2.1 Norms & Standards

2.1.2 Insulation specication j) ISO
The International Organization for Standardization (Organisation internationale de normalisation), widely known as ISO, is an international-standardsetting body composed of representatives from various national standards organizations. Founded on 23 February 1947, the organisation promulgates world-wide proprietary industrial and commercial standards. It is headquartered in Geneva, Switzerland.[1]. While ISO denes itself as a non-governmental organization, its ability to set standards that often become law, either through treaties or national standards, makes it more powerful than most non-governmental organizations. In practice, ISO acts as a consortium with strong links to governments. Most of the ISO standards for insulation focus on the testing of material properties and are embedded in, for instance, EN standards. More information is available via www.iso.org warm water pipes in technical building equipment with respect to Germany, are laid down in the regulations concerning energy-saving heat insulation and energy-savings in buildings (EnEVEnergy Saving Ordinance). The considerations expressed in this guideline may lead to other insulation thicknesses. Withregard to heat insulation in the construction industry, both the EnEV and DIN standard 4108. Legalrequirements must be observed with regard to there performance of insulation and the re resistance classes of insulation, such as federal state building regulations [Landesbauordnungen] and the piping system guidelines of thefederal states [Leitungsanlagen-Richtlinien der Bundeslnder]. The VDI guideline 2055 also serves as a benchmark for thermo technical calculations and measuring systems in relation to industrial and building services installations and for guarantees and conditions of supply with regard to those installations. The guideline covers in detail the calculation of heat ow rates, the design of the insulation thickness according to operational and economic aspects, the technical warranty certicate and the technical conditions in respect of delivery quantities and services. Furthermore, the guideline examines measuring systems and testing methods (forquality assurance). The VDI 2055 consists of: Part 1: Bases for calculation  Part 2: Measuring, testing and certication of  insulation materials Part 3: Conditions of supply and purchasing of  insulation systems

k) VDI 2055
Verein Deutscher Ingenieure (VDI) (English: Association of German Engineers) is an organisation of engineers and natural scientists. Established in 1856, today the VDI is the largest engineering association in Western Europe. The role of the VDI in Germany is comparable to that of the American Society of Civil Engineers (ASCE) in the United States. The VDI is not a union. The association promotes the advancement of technology and represents the interests of engineers and of engineering businesses in Germany. VDI 2055 is the most important guideline for technical insulation. The scope of the guideline includes heat and cold insulation of technical industrial plants and technical building equipment, such as pipes, ducts, vessels, appliances, machines and cold stores. The minimum insulation thicknesses for heat distribution and

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l) British standard
British Standards are produced by BSI British Standards, a division of BSI Group that is incorporated under a Royal Charter and is formally designated as the National Standards Body (NSB) for the UK. The standards produced are titled British Standard XXXX[-P]:YYYY where XXXX is the number of the standard,P is the number of the part of the standard (where the standard is split into multiple parts) and YYYY is the year in which the standard came into effect. British Standards currently has over 27,000 active standards.

The following table provides an overview of the standards and regulations that must be taken observed when insulating industrial plants with ROCKWOOL insulation. On the one hand, they are grouped according to product and material standards, which establish the different insulation properties, and on the other hand, according to validation and design rules.

Standard BS 5970:Code of practice for thermal insulation of pipework and equipment in the temperature range of -100 C to +870 C

Description This British Standard code of practice describes aspects of thermal insulation for pipework and equipment in the temperature range 100 degrees C to +870 degrees C. The installation techniques described in this standard can be used outside the temperature range indicated, however, it isrecommended that for such applications specialist advice is sought. This standard explains the basic principles that should be followed in selecting insulating systems for specic requirements. This British Standard describes a method for specifying requirements for thermal insulating materials on pipes, tanks, vessels, ductwork and equipment for certain dened applications and conditions within the temperature range -40 degreesC to+700 degrees C. It gives the hermal insulation recommended thickness and required performance of t material for various applications. Colours for identifying pipes conveying uids in liquid or gaseous conditionin land installations and on board ships. Colour specications inaccordance with BS 4800. Physical and chemical requirements, dimensions and nishes for pipe ections generally for use at elevated temperatures. s Species composition, moisture content, physical and chemical requirements for mineral bre mattresses, faced on one or both sides withexible metal mesh. Composition, moisture content, physical and chemical requirements, and standardsizes. Products are divided into four groups according to thermal conductivity and temperature range.

BS 5422: Method for specifying thermal insulating materials for pipes, tanks, vessels, ductwork and equipment operating within the temperature range -40 C to +700 C

BS 1710 Specication for identication of pipelines and services BS 3958-Part 4: Thermal insulating materials. Bonded preformed manmade mineral bre pipe sections BS 3958-Part 3: Thermal insulating materials. Metal mesh faced manmade mineral bre mattresses BS 3958-Part 5: Thermal insulating materials. Specication for bonded man-made mineral bre slabs

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2.1 Norms & Standards

2.1.2 Insulation specication
Test methods
Part 4, Non combustibility test for materials Part 6, Methods of test for re propagation of products Part 7, Method for classication of the surface spread of ameproducts Determination of dimensions, squareness and linearity of preformed pipe insulation Determination of trace quantities of water soluble chloride, uoride, silicate, sodium ions and pH Determination of water vapour transmission properties of preformed pipe insulation Determination of the apparent density of preformed pipe insulation Determination of the coefcient of thermal expansion Determination of short term water absorption by partial mmersion of preformed pipe insulation i Determination of thermal resistance by means of guarded hot plate and heat ow meter methods. Dry and moist products of medium and low thermal resistance Determination of thermal resistance by means of guarded hot plate and heat ow meter methods. Products of high and medium thermal resistance Determination of thermal resistance by means of guarded hot plate and heat ow meter methods. Thick products of high and medium thermal resistance

BS 476-4Fire test on building materials

BS EN 13467Thermal insulating products for building e quipment and industrial installations BS EN 13468Thermal insulating products for building equipment and industrial installations BS EN 13469Thermal insulating products for equipment and industrial installations building BS EN 13470Thermal insulating products for equipment and industrial installations building BS EN 13471Thermal insulating products for equipment and industrial installations building BS EN 13472Thermal insulating products for equipment and industrial installations building BS EN 12664Thermal performance of building materials and products BS EN 12667Thermal performance of building materials and products BS EN 12939:2001Thermal performance of building materials and products

m) NF (Norme Franaise) mark

The NF mark is an ofcial French quality mark, issued by the Association Franaise de Normalisation (French Association for Standardization, AFNOR), which certies compliance with the French national standards. The use of the NF mark has been entrusted to AFNOR Certication (a subsidiary of the AFNOR Group). The NF quality mark is not a trademark as such, but is a collective certication mark. It carries undisputable proof that a product satises the safety and/or quality specications dened within the corresponding certication standard. More information is available via www.afnor.org
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This standard consists of: French, European or international standards  Supplementary specications regarding the  product or service and the quality system in place in the company as comprised in the certication rules, specic to each product or service. The certication standards are drawn up in collaboration with all relevant stakeholders: manufacturers or service providers, trade organisations, consumers, public authorities and technical bodies. Compliance with French standards is mandatory in France for all supply or construction contracts for public authorities (government contract).

NF EN ISO 7345 July 1996 NF EN ISO 9251 July 1996 NF EN ISO 9288 July 1996 NF EN ISO 8497 December 1996 NF EN ISO 9229 September 2007 NF EN ISO 12241 October 1998 NF EN ISO 13787 August 2003 NF EN 12667 July 2001 Property NF EN 8497 September 1996 NF EN 12939 March 2001 NF EN 14303 October 2005 NF EN 1609 July 1997 NF EN 13472 December 2002 NF ISO 2528 S eptember 2001 NF EN 12086 November 1997 Test standard NF EN 12087 November 1997 NF EN 12087/A1 January 2007 NF EN 14706 February 2006 NF EN 14707/IN1 March 2008 NF EN 14707+A1 March 2008 NF EN 1602 July 1997

Thermal insulation Physical quantities and denitions Thermal insulation Heat transfer conditions and properties of materials Vocabulary Thermal insulation Heat transfer by radiation Physical q uantities and d enitions Thermal insulation Determination of steady-state thermal transmission properties of thermal insulation for circular pipes Thermal insulation Vocabulary Thermal insulation for building equipment and industrial installations Calculation rules Classication index P 50-730 Thermal insulation products for building equipment and industrial installations - Determination of declared thermal conductivity Thermal performance of building materials and products Determination ofthermal resistance by means of guarded hot plate and heat ow meter methods Products of high and medium thermal resistance Thermal insulation - Determination of steady-state thermal transmission wproperties of thermal insulation for circular pipes (ISO 8497:1994) Thermal performance of building materials and products Determination ofthermal resistance by means of guarded hot plate and heat ow meter methods Thick products of high and medium thermal resistance Thermal insulation products for building equipment and industrial installations - Factory made mineral wool (MW) products Specication Thermal insulating products for building applications - Deter mination of short term water absorption by partial immersion Thermal insulating products for building equipment and industrial installations Determination of short term water absorption by partial immersion of preformed pipe insulation Sheet materials Determination of water vapour transmission rate Gravimetric (dish) method Thermal insulating products for building applications Determination of water vapour transmission properties Thermal insulating products for building applications - Determination of long term water absorption by immersion Thermal insulating products for building applications - Determination of long term water absorption by immersion Thermal insulating products for building equipment and industrial installations Determination of maximum service temperature Thermal insulation products for building equipment and industrial installations Determination of maximum service temperature for preformed pipe insulation Thermal insulation products for building equipment and industrial installations Determination of maximum service temperature for preformed pipe insulation Thermal insulating products for building applications Determination of the apparent density

General

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2.1 Norms & Standards

2.1.2 Insulation specication
NF EN 1602 July 1997 Test standard NF EN 826 September 1996 NF EN 13468 September 2002 NF EN 13162 February 2009 NF P75-101 October 1983 Thermal insulating products for building applications Determination of the apparent density Thermal insulating products for building applications Determination of the apparent density Thermal insulation products for building equipment and industrial installations - Determination of trace quantities of water soluble chloride, uoride, silicate, sodium ions and pH Thermal insulation products for buildings Factory made mineral wool (MW) products Specication Thermal insulation for building purposes Denition Insulation work Thermal insulation of circuits, appliances and accessories from-80 C to +650 C - Part 1-1: contract bill of technical clauses - Part 1-2: general criteria for selection of materials - Part 2: contract bill of special clauses (Commercial reference for standards NF DTU 45.2 P1-1, P1-2 and P2) Industrial installations thermal insulation of tanks coating support Cryogenic vessels Methods for performance evaluation of thermal insulation Cryogenic vessels Methods for performance evaluation of thermal insulation Steel sheet and strip either coil coated or organic lm counterglued or colaminated for building purposes Aluminium and aluminium alloys Sheet, strip and plate - Part 1 - 4 Stainless steels Technical delivery conditions for sheets and strips of corrosion resistant steels for general purposes. Part 1-5

Insulating materials

NF E86-303 Assembly

May 1989 NF EN 12213 March 1999 XP P 34-301

Covering

NF EN 485 NF EN 10088-2

* Please consult the other parts for further details regarding corrosion protection of steel structures.

n)  Unied Technical Document (Document Technique Uni, DTU)

Object and scope of the DTUs A DTU comprises a list of contractual technical stipulations applicable to construction work contracts. The specic documents included in the works contract, in accordance with the specications for each individual project, must specify all of the required provisions that are not outlined within the DTU, or all those deemed relevant for inclusion by the contracting parties, as a complement to or in deviation from those specied in the DTU. In particular, the DTUs are generally unable to suggest technical provisions for performing work on buildings constructed using outdated techniques. The establishment of technical clauses for contracts of this type results from a reection on the part of those parties who are responsible for designing and implementing the work. Where it proves to be pertinent, these clauses are based on the content of the DTU, as well as on all knowledge acquired in practice in relation to these outdated techniques.

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The DTUs refer to construction products or procedures for the execution of works, the ability of which to satisfy the technical provisions of the DTUs is known through experience. Where this document refers to that effect to a Technical Evaluation or Technical Application Document, or to a product certication, the contractor may suggest products to the contracting authority that benet from current testing methods in other Member States of the European Economic Area, which they deem to be compa rable and which are certied by accredited organisations, by the organisations that are signatories to E.A. agreements, or in the absence thereof, which evidence their compliance with the EN 45011 standard. The contractor must then supply the contracting authority with the evidence needed in order to evaluate the comparability. The conditions under which the contracting authority shall accept such an equivalent are dened within the Contract Bill of Special Clauses of this DTU. More information is available via www.afnor.org

2.1.3 R  elevant guidelines & standards forthe technical insulation industry in Germany
The German system of standards and regulations is primarily composed of the following constituents: DIN (German Institute for Standardisation) standards, VDI (Association of German Engineers) guidelines, AGI (German Working Group for Industrial Construction) working documents, VDI quality assurance, and RAL (German Institute for Quality Assurance and Certication) quality marks. Furthermore, there are additional regulations for special elds of application, such as working standards on the part of the operator, which must be observed. Most of the standards, regulations and guidelines are adapted within the local project specications. The following table shows an overview of the standards and regulations that must be observed when insulating industrial plants with ROCKWOOL insulation. On the one hand, they are grouped according to product and material standards, which establish the different insulation properties, and on the other hand, according to validation and design rules.

103

2.1 Norms & Standards

2.1.3 R  elevant guidelines & standards forthe technical insulation industry in Germany
Material standards and design guidelines AGI Q02: Insulation works on industrial installations Terms AGI Q03: Construction of thermal and cold insulation systems Insulation works ofindustrial plants AGI Q05: Construction of industrial plants Bases, design, requirements with regard to the interfaces of plant components and insulation AGI Q101: Insulation works on power plant components Construction AGI Q103: Insulation works on industrial plants Electrical tracing AGI Q104: Insulation works on industrial plants Tracing systems with heat transfer media AGI Q132: Rock wool as insulation for industrial plants AGI Q151: Insulation works Protecting thermal and cold insulation systems on industrial plants against corrosion Field of application/scope

The terms used in the AGI Q working documents are dened in this orkingdocument. w This working document applies to insulation works performed on industrial installations. The working document classies works into thermal insulation works for operating temperatures above the ambient temperature and cold insulation works for operating temperatures below the ambient temperature. This working document has been compiled for planners and designers that have to design the industrial plants, including the essential thermal or cold insulation. In examines in particular the interfaces between plant construction and insulation. Working document Q 101 applies to insulation works performed on power plant components such as steam generators and ue gas cleaning systems, pipe systems and steel ues This working document applies to insulation works performed on ndustrial plants with electrical tracing. i This working document applies to insulation works performed on industrial installations, which are heated and/or cooled by means of heat transfer and/or refrigerant media, for example in tracing pipes or half pipe sections. This working document applies to rock wool insulation, which is used for thermal, cold and acoustic insulation of technical industrial plants and technical building appliances. This working document applies to corrosion protection coating systems for the surfaces of industrial plants, such as appliances, columns and pipes, which are insulated against heat and cold loss. Since the DIN EN ISO 12944 standard provides no explanations with regard to protecting insulation systems against corrosion, this working document should be considered as a supplement to standard DIN EN ISO 12944. This working document does not apply in respect of adhesive primers. This AGI working document applies to objects where the insulation must be protected against moisture and, above all, against the ingress of liquids, (e.g. water, heat transfer oil). AGI working document Q 153 applies to the design and construction of mounting supports. They transfer the loads of the insulation onto the support constructions on the object.

AGI Q152: Insulation works on industrial plants Protection against moisture penetration AGI Q153: Insulation works on industrial plants Mounting supports for support constructions

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AGI Q154 Insulation works on industrial plants support constructions

AGI working document Q 154 applies to the construction of support constructions. This standard applies to insulation works on industrial plants. These are production and distribution plants for the industry and for technical building appliances, (e.g. appliances, vessels, columns, tanks, steam generators, pipes, heating and ventilation systems, air conditioning units, refrigeration units and hot water installations). In the event of requirements with regard to re protection, the relevant standards or national technical approvals must be taken into account. This standard does not apply to insulation works performed on building shells, interior walls and inserted ceilings, neither in the shipbuilding and vehicle manufacturing industry, nor within the control area of power plants. The scope of the guideline includes heat and cold insulation of technical industrial plants and technical building equipment, such as pipes, ducts, vessels, appliances, machines and cold stores. The minimum insulation thicknesses for heat distribution and warm water pipes in technical building equipment are laid down with respect to Germany in the regulations concerning energy-saving heat insulation and energy-saving plant engineering in buildings (Energy Saving Ordinance) [Energieeinsparverordnung, EnEV]. The considerations expressed in this guideline may give rise to other insulation thicknesses. With regard to heat insulation in the construction industry, both the Energy Saving Ordinance and DIN standard 4108. Legal requirements must be taken into consideration with regard to the re performance of insulation and the re r esistance classes of insulation, such as federal state building regulations [ Landesbauordnungen] and the piping system guidelines of the federal states [Leitungsanlagen-Richtlinien der Bundeslnder]. The VDI guideline 2055 serves as a benchmark for thermo technical calculations and measuring systems in relation to industrial and building services installations and for guarantees and conditions of supply with regard to those installations. The guideline covers in detail the calculation of heat ow rates, thedesign of the insulation thickness according to operational and economic aspects, the technical warranty certicate and the technical conditions in respect of delivery quantities and services. Furthermore, the guideline examines measuring systems and testing methods (for quality assurance purposes also). The VDI 2055 guideline consists of 3 parts: Part 1: Bases for calculation Part 2: Measuring, testing and certication of insulation materials Part 3: Conditions of supply and purchasing of insulation systems Following the completion of the ofcial draft of Part 1, the nal editorial draft is being compiled. The nal version is expected to be published in the second quarter of 2008.

DIN 4140: Insulation works on technical industrial plants and technical buildingappliances Construction of thermal and cold insulation systems

VDI 2055: Thermal and cold insulation of technical industrial plants and technical building equipment

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2.1 Norms & Standards

2.1.3 R  elevant guidelines & standards forthe technical insulation industry in Germany
The following table cites a number of important test standards for the product properties of insulation materials.

a) Test standards (Germany)

Building material class (Fire performance) Melting point Thermal conductivity (Piping) Fire performance of building materials and building components Part 1: Building materials, terms, requirements and tests Fire performance of building materials and building components Part 17: Melting point of rock wool insulations Heat insulation Determination of steady-state thermal transmission properties of thermal insulation for circular pipes Thermal performance of building materials and products Determination of thermal resistance by means of guarded hot plate and heat ow meter methods - Products of high or medium thermal resistance Thermal insulating products for building applications Determination of water vapour transmission properties Thermal insulation products for building equipment and industrial installations Determination of trace quantities of water-soluble chloride, uoride, silicate, sodium ions and pH Thermal insulating products for building equipment and industrial installations Determination of short-term water absorption by partial immersion of preformed pipe insulation Thermal insulating products for building equipment and industrial installations Determination of maximum service temperature Thermal insulating products for building equipment and industrial installations Determination of maximum service temperature for preformed pipe insulation This test procedure veries whether the insulation is free from paint wetting impairment substances (e.g. silicon) Thermal insulating products for building applications Determination of compression behaviour Acoustics; Materials for acoustical applications; Determination of airow resistance (ISO 9053:1991)

DIN 4102-1 DIN 4102-17 DIN EN ISO 8497

Thermal conductivity (Boards)

DIN EN 12667

Water vapour diffusion resistance coefcient AS quality

DIN EN 12086 DIN EN 13468 Replaces AGI Q135 DIN EN 13472 Replaces AGI Q136

Hydrophobic treatment

Maximum service temperature

DIN EN 14706 (for at products) DIN EN 14707 (forpiping) According to VW test 3.10.7 DIN EN 826 DIN EN 29053 Determination of airow resistance

Absence of silicon Compression resistance

Air ow resistance

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b)  Insulation code number according to AGI Q132

AGI guideline Q132 lays down the material properties and the requirements that are imposed on rock wool insulation for industrial installations. The insulation materials are denoted with a ten-gure code number (so called Dmmstoffkennziffer), consisting of ve

pairs of digits. In this case, the rst pair of digits 10 represents rock wool. The further pairs of digits represent the: Delivery form  Thermal conductivity group  Maximum service temperature group  Apparent density group 

Rock wool insulation

Delivery form

Thermal conductivity

Maximum service temperature Group C

Nominal apparent density Group kg/m3

Group

Type

Group

Form

Group

Delivery form

10

Rock Wool

01 02 03 04

Wired mats Lamella mats Lamella mats load-bearing (Pipe) sections (Pipe) elbows Felts Mats Slabs Segments Loose wool

01 02 03 04

Limit curve 1 Limit curve 2 Limit curve 3 Limit curve 4

10 12 14 16

100 120 140 160

02 03 04 05

20 30 40 50

05 06 07 08 09 10

05

Limit curve 5

72 74 76

720 740 760

06 07 08 09 10 11 12 13 18 99

60 70 80 90 100 110 120 130 180 *

* The digits 99 apply only to (pipe) sections.

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2.1 Norms & Standards

2.1.3 R  elevant guidelines & standards forthe technical insulation industry in Germany
Using ROCKWOOL wired mat with a density of 80kg/m3 asan example results in the following insulation code: 10.01.02.64.08 Apparent density 80 kg/m3 Maximum service temperature 640C Limit curve of the thermal conductivity Limit curve 2 Delivery form Wired mats Rock wool pecication. The ofcial implementation of this s standard is expected to take place in 2009. Following ratication, a European standard must be adopted as it stands by the national standardisation organisations as a national standard. Deviating national standards must be retracted. Each European standard adopted is published in each EU country with a national prex, e.g. in Germany: DIN-EN-XXXX; in England (British Standard): BS-EN-XXX. The (as of yet) unratied standards are denoted with the letter pr (for proof) e.g. prEN-14303.

d) Quality Assurance
It is essential that, in addition to the design quality, the product properties guaranteed by the insulation manufacturer, for example, the thermal conductivity or temperature resistance, are adhered to during processing in order to guarantee the faultless operation of a thermal or cold insulation constructed according tooperational and economic criteria. Well-known insulation manufacturers guarantee this through extensive internal and external quality control. The VDI2055 guideline Thermal and cold insulation ofindustrial installations and building equipment regulates this voluntary quality assurance. The VDI 2055 quality assurance of insulation products is classied as a quality control, consisting of an external and internal quality control, as well as a certication of insulation materials for industrial installations. The property values specied on the product data sheets, prospectuses or price lists of the manufacturer, such as the thermal conductivity or maximum service temperature for example, form the basis for the quality control. As a result , a user or producer of VDI 2055 quality assured insulation products can safely assume that even publicised property values are subject to a quality control. When the product conforms to the properties specied by the manufacturer in the product data

c) European standardisation
In order to remove technical barriers to trade, the European Union decided to develop uniform European product standards. These product standards describe the product properties, as well as the methods of testing for these properties. The minimum requirements for certain product properties still remain a national responsibility and are laid down in each individual country. The EU issues orders in the form of mandates to CEN (the European Committee for Standardisation), which the CEN uses to develop relevant standards. The majority of orders have now been commissioned and initial harmonised standards, such as the insulation standards for structural engineering (DIN EN 13262), have been published. The European product standards for technical insulation are currently being compiled. For rockwool, this product standard is the prEN14303Thermal insulation products for building equipment and industrial installations Factory-made mineral wool (MW) products
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sheets, the certication body grants the manufacturer the right to use the certication mark Checked in accordance with VDI 2055. The following text outlines the product properties that must, at the very least, be controlled in the case of a mineral wool insulation product, in order for the VDI 2055 inspection mark to be granted: Thermal conductivity as a curve ( = f(t) or f(tm))  Dimensions (length, width, depth)  Apparent density  Maximum service temperature  In addition, the following product properties are usually controlled externally: Fire performance  Hydrophobic properties  Water-soluble chloride content (AS quality)  Internal quality control The manufacturer takes samples during production and tests for the relevant product properties. For properties such as thermal conductivity, indirect measurement methods can also be used. The manufacturer must have a quality management procedure in place, which instigates the measures required to rectify the defect in the event of deviations from the reference values. External quality control For the purposes of external quality control in accordance with VDI 2055, the manufacturer must enter into a supervision contract with a leading testing body, such as the FIW (Research Institute for thermal insulation materials). The external quality control is made up of the following elements: Auditing of the internal quality control  Verication of the labelling of the products  Product testing 

Certication Upon correct implementation of the internal and external quality control of insulation products manufactured according to VDI 2055, DIN CERTCO developed a certicate with regard to conformity to VDI 2055, to the data sheets of the VDI AG Quality Control and to the technical data of the manufacturer.

e) RAL quality mark

ROCKWOOL stone wool insulation products bear the RAL quality mark. They are therefore subject, in addition to the stringent criteria of the quality assessment and test specications of the Mineral Wool Quality Community [Gtegemeinschaft Mineralwolle e. V.], to continuous inspections, which guarantee compliance with the criteria of the German legislation governing hazardous substances and with the EU directive. In accordance with both the German and European standards, bio-soluble ROCKWOOL stone wool offers outstanding thermal, cold, acoustic and re protection whilst meeting a high safety standard.

f)  No prohibition on manufacture andusage

The German federal government has laid down criteria for the appraisal of mineral wool insulation products in the Ordinance on Hazardous Substances [Gefahrstoffverordnung] and the Chemicals Prohibition Ordinance [ChemikalienVerbotsverordnung]. Products not meeting these criteria cannot be manufactured and used in Germany. ProRox stone wool insulation products full these requirements. The prohibition on manufacture and usage does not apply to ProRox stone wool insulation products. Studies have shown that stone wool is a safe product to live and work with; it is amongst the most well-documented and tested of all building materials. A Safe Use Instruction Sheet (SUIS) from ROCKWOOL Technical Insulation Group is available upon request.

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2.1 Norms & Standards

2.1.4  Relevant guidelines & standards for the technical insulation industry within the Benelux
The local system of standards and regulations in the Netherlands and Belgium focuses primarily on building construction. The Dutch CINI manual is adopted as a general guideline for mounting and xing by the majority of industry owners and construction engineers. Product testing often refers to AGI, DIN and European standards. Refer to the previous chapters for more information.

2.2  Product properties & test methods

The requirements for technical insulation are high and varied. Piping, boilers, storage tank require insulation materials with particular properties. Although the application and type of products may vary, the basic denition of all product properties is the same. 2.2.1 Fire behaviour 2.2.2 Thermal conductivity 2.2.3 Maximum service temperature 2.2.4 Water leachable chloride content 2.2.5 Water repellency 2.2.6 Water vapour transmission 2.2.7 Longitudinal air ow resistance 2.2.8 Compression resistance 2.2.9 Density The relevant standards, guidelines and project specications are explained in 2.1. The following text outlines the most important product properties of mineral wool insulation products for insulation of technical installations.

2.2.1 Fire behaviour a) Introduction

The re load in a building or technical installation is increased considerably by ammable/combustible insulation materials. Non-combustible insulation materials such as mineral wool, with a melting point higher than 1000 C, on the other hand, not only have a positive impact on the re load, but also constitute a certain form of re protection for the insulation installations. Often one confuses re resistance with reaction to re. Fire resistance indicates how well a building component, for instance, can hold back the re and prevent it from spreading from one room to another for a stated period of time. Does it function as a re shield or not? Fire resistance is an extremely important characteristic. For example, a vessel containing ammable liquids. Serious accidents/explosions can occur if a vessel is not protected against re from the outside.

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Reaction to re indicates the smoke development

and combustibility / ammability if the insulation is exposed to re.

b) CEN standards
A distinction is generally made between non-combustible and combustible building materials. The insulation materials are exposed to re. The ammability and smoke development and droplets of melted insulation are observed and rated. The classication of insulation materials depends on the relevant re standards. In the second half of the 20th century, almost every country in Europe developed their own national system for re testing and classication of building materials in particular. The European Community has developed a new set of CEN standards. The Reaction to re classes test three properties: spread of re, smoke intensity and burning droplets. Spread of Fire The building components are classied in class A1, A2, B, C, D, E and F. Additional classications provide information on products tending to produce smoke and burning droplets or particles. Class A1 products are non combustible. They  willnotcause any sustained aming in the non combustibility test. Class A2 product must not show any sustained  aming for more than 20 seconds in the non combustibility test. The A2 products have to be tested for re contribution, smoke intensity and burning droplets. Class B product aming must not spread more   than 150 mm in 60 seconds, when evaluated by a small ame test. Class B products have to be tested for re contribution, smoke intensity and burning droplets Class C product contributes to ashover after   10 min. Class D product contributes to ashover after 2   min. Class E product for less than two minutes.  Class F is not tested. 

Smoke intensity Smoke intensity is only tested in the classes from A2 toD. There are 3 intensity levels; s1, s2 and s3. Smoke intensity is vital for people trapped in a burning building. The major cause of death in these circumstances is smoke inhalation. Burning droplets Burning droplets are also tested on building materials inthe classes A2 to E. There are three classes. No droplets (d0). Droplets that burn out in less than 10 seconds (d1) and droplets that burn for more than 10 seconds (d2). ROCKWOOL products Due to its nature, mineral wool is non combustible. Therefore all products are classied as class A1.

c) Project specications
Many industrial plant owners still refer to the old local standards or American (ASTM) Standards. Some of the most important examples are stated below. For projects outside Europe, especially, many plant owners tend to use the American ASTM E84 or the Canadian equivalent UL723. Both standards solely focus on the surface burning characteristics (ame propagation across the surface of insulation materials). In Germany, the building material classes for insulation materials for technical insulation are classied according to DIN standard 4102-1. A distinction is made between non ammable building materials in class A1 and A2, and ammable building materials in classes B1 to B3. A1 non-ammable  A2 non-ammable  B1 ame resistant  B2 normally inammable  B3 highly ammable (cannot be used in  Germany)

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2.2 P  roduct properties & test methods

2.2.1 Fire behaviour
Alongside the implementation of the European product standards for technical insulation, the European building material classes, the Euroclasses, are also being implemented. In that case, the products are classied in accordance with the standard DIN EN 13501-1 Fire classi cation of building products and building elements Part 1: Classication using test class data from reaction to re tests in combination with the specications of the European product standard. Other local (often building) standards may apply occasionally. e.g.: NEN 6064: Netherlands  NFP 92507 (class M0) France  BS 476: United Kingdom  The ROCKWOOL Technical Insulation Sales Team can advise designers and manufacturers of installations who are faced with such requirements. Many of the ProRox insulation materials are tested and/or certied in accordance withseveral local and international standards forreaction to re.

2.2.2 Thermal conductivity

The heat-insulating effect of insulation materials is specied in terms of the thermal conductivity . is conveyed in the physical unit W(m.K). It indicates the quantity of heat Q that, in t amount of time and at a temperature difference of T, ows across the thickness l through the surface A. = Ql = [J] [m] J = = A t T [m] [s] [K] msK W mK

The unit of thermal conductivity is shown in terms of J/(msK) or W/(mK). The thermal conductivity depends on the temperature, the apparent density andthe structure of the insulation and is made up ofthe following parts: Thermal conduction of the dormant air in  spaces between the bres Thermal radiation  Thermal conduction through the bres  Convection  The fundamental dependencies of these heat transporters upon temperature and apparent density in the case of mineral wool, are claried in the graphs below. The individual parts cannot be recorded using measurement techniques and together form the thermal conductivity of an insulation material.

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Fundamental dependency of the thermal conductivity upon the apparent density at a certain temperature

Thermal conductivity

1. Conduction through the dormant air - 2. Thermal radiation- 3. Conduction of the pipe - 4. Convection 5.Thermal conductivity of the insulation

Apparent density

Fundamental dependency of the thermal conductivity upon the temperature for a certain apparent density

Thermal conductivity

1. Conduction through the dormant air - 2. Thermal radiation- 3. Conduction of the pipe - 4. Convection 5.Thermal conductivity of the insulation

Temperature

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2.2  Product properties & test methods

2.2.2 Thermal conductivity
Thermal conductivities for technical insulation can be measured according to thetest methods below. The core consists of a hot pipe with a length of 3 metres. The thermal conductivity is calculated at the mean temperature between the hot and cold side and expressed at the mean temperature. Themain difference is that the hot pipe apparatus test method includes the seams within the insulation. This explains why the measured values will be higher than the guarded hot plate apparatus test. A distinction is drawn between the denition of thermal conductivity. Laboratory thermal conductivity   Thermal conductivity is measured under laboratory conditions with the guarded hot plate apparatus or hot pipe apparatus test method. Nominal (or declared) thermal conductivity  Thermal conductivity specied by the manu facturer, allowing for production related variations in quality and possible ageing, for example caused by gas exchange in closed cell insulation materials. Practical thermal conductivity  Declared thermal conductivity including the inuence of joints, design uncertainties, temperature differences, convection, changes indensity, moisture absorption and ageing. These effects are taken into consideration using supplementary factors. Operational thermal conductivity  Practical thermal conductivity, whereby the supplementary values for insulation related bridges, such as bearing and support structures are included in the value.

Guarded hot plate apparatus test method

The thermal conductivity of at products, slabs and wired mats can be measured with the guarded hot plate apparatus according to EN12667 or ASTM C177.

The core components of the apparatus usually consist of two cold-surface units and a guarded hot-surface unit. The insulation material to be measured is sandwiched between these units. Thethermal conductivity is calculated at the mean temperature between the hot and the cold side and expressed at the hot face temperature.

Hot pipe apparatus test method

The thermal conductivity of pipe sections and exible mats can be measured with the hot pipe apparatus according to EN ISO 8497 or ASTM C335.

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2.2.3 Maximum service temperature

The temperature at which an insulation material is used should be within the temperature range specied for the material, in order to provide satisfactory long-term service under conditions ofuse. This temperature is dened as maximum service temperature. The following factors should be considered when selecting insulation materials to be used at elevated operating temperatures. Ability to withstand loads and vibrations  Loss of compression strength after heating  Linear shrinkage are heating  Change in thickness after heating and loading  Internal self-heating (exothermic reaction or   punking) phenomena Type of nishing of the insulation  Support structures for the insulation  Support structures for the cladding 

ASTM C411
ASTM C411 is the standard test method for hot-surface performance of high-temperature thermal insulation. This standard covers the determination of the performance of mats, slabs and pipe sections when exposed to simulated hot-surface application conditions. Mats and slabs are tested with the heating plate or pipe apparatus. The heating plate or pipe is uniformly heated to the declared maximum service temperature. Products are exposed to one sided heating. ASTM C411 places no specic demands on the product performance after heating. Only the following results must be reported. Extent of cracking, other visible changes  Any evidence of aming, glowing, smouldering,  smoking, etc. Decrease in thickness, warpage, delamination  Sagging pipe (pipe insulation) 

Important note The maximum service temperature of insulation materials can be tested in accordance with the test methods: EN 14706 and -7 (replaces AGI Q 132), ASTM C411 or BS2972. Each test standard has a different ttest method and its own criteria. ASTM C411 and BS2972 can be used to determine the maximum operating temperature at which an insulation material can be used, without its insulating capacity deteriorating. EN 14706 and -7 are used to classify insulation materials according to their behaviour at high temperatures based upon time-load exposure. Due to the effect of load during testing, the measure maximum service temperature in accordance with EN 14706 and -7 is lower than the other standards and therefore tends to reect a more practical temperature limit for design performance.

BS 2972
This standard species test methods for the various properties of inorganic thermal insulation materials. Section six heat stability of this standard is designed to determine the performance of insulation materials when exposed to heating for 24 hours in an oven or furnace at the designed temperature. BS 2972 places no specic demands on the product performance after heating. Only the following results must be reported: A   verage percentage change of length, width, thickness and volume of specimens; P   ercentage change of mass of the specimens before and after the test C   hange in compression strength of the specimens before and after the test.

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2.2  Product properties & test methods

2.2.3 Maximum service temperature
According to BS 3958 standard specication for thermal insulation materials, the insulation material shall maintain its general form and shall not suffer visible deterioration of brous structure when heated to the maximum service temperature.

EN14706 (replaces AGI Q132)

The maximum service temperature replaces the term classication temperature, which was still the customary term in the AGI G 132 of 1996. It is recorded in the laboratory under steady conditions, and takes into account the delivery form. The maximum service temperature for at products is determined according to the EN 14706 standard and is determined according to the EN 14707 for pipe sections. During the test, the sample insulation material is loaded with 500 Pa pressure, which is equal to a load of approximately 0,5 kN/m. The sample is then heated on one side at a heating rate of 5 K/min, until the target maximum service temperature is reached. The temperature is then maintained for 72 hours, before the insulation is allowed to cool down naturally to the ambient temperature. The deformation of the insulation is measured throughout the entire procedure. The deformation is not permitted to exceed 5 % throughout the entire testing process.

116

Application of maximum service temperature

The practical application of the test methods varies per country and plant owner. In case of special conditions, where the insulation is permanently exposed to high dynamic loads and temperatures (e.g. Power Plants), which cannot be included within the measurements, a considered insulation selection is required. This can be done based on expert judgement or by using the reduction factors (fa) as dened in the German Standard AGI Q101 Insulation works on power plant components. The calculated service temperature (Obere Anwendungstemperatur) isgenerally below the maximum service

temperature (Anwendungsgrenz temperatur). When selecting a suitable insulation material in terms of the maximum service temperature, the external inuences affecting the insulation system must be considered, for example: S   tatic loads (e.g. cladding) D   ynamic loads (e.g. oscillations) T  ype of construction (with or without a spacer). The table shown on the following page, showing general reduction ratios fa for determining the working temperature, is taken from AGI Q101. Inthis respect, the maximum service temperature should be multiplied by fa.

Reduction ratio (fa) for determining the working temperature

Reduction ration (fa) Maximum service temperature With spacer and Without spacer and With spacer and support construction support construction support construction +air space 1.0 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.8 0.9 0.8 0.9 0.9 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.9 0.9 0.8 0.9 0.9 0.9 0.9 0.9 0.8

400 oC Pipes DN 500 580 oC 710 oC 400 oC Pipes DN 500 Flue gas ducts, hot air ducts, steel chimneys, vessels, gas turbine ducts Boiler walls Within range of boiler roof Dead spaces 580 oC 710 oC 400 oC 580 oC 710 oC

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2.2 P  roduct properties & test methods

2.2.4 Water leachable chloride content
The corrosion resistance of steel is increased by the addition of alloying elements such as chromium, nickel and molybdenum. Since this alloying results in a so-called austenitic (facecentred cubic) atomic structure, these types of steel are also called austenitic steels. Despite their generally high resistance to corrosion, these steels tend to exhibit stress corrosion under certain conditions. Three boundary conditions must all be fullled in order for stress corrosion cracking to occur: The material must be susceptible to stress   corrosion. Tensile stresses must be present in the   component (for example, as a result of thermal elongations). There must be a specic attacking agent.   These specic attacking agents include, for example, chloride ions. An insulation material with an extremely low quantity of water-leachable chlorides must therefore be used to insulate objects made from austenitic stainless steel. For this application, only those insulation materials that are manufactured with a low water leachable chloride content may be used. The classication criteria will depend on the used standard. In general, a distinction can be made between American ASTM standards and European EN standards.

ASTM C871
Chemical analysis of thermal insulation materials for leachable chloride. This standard covers the laboratory procedures for the determination of the mentioned ions which accelerate stress corrosion of stainless steel. If the results of the chemical analysis for the leachable ions chloride, sodium and silicate fall in the acceptable area of the graph in ASTM C795 and also pass ASTM C692, the insulation material should not cause stress corrosion cracking.

ASTM C692
Evaluating the Inuence of Thermal Insulations on External Stress Corrosion Cracking Tendency of Austenitic Stainless Steel. This standard covers the procedures for the laboratory evaluation of thermal insulation materials that may actively contribute to external stress corrosion cracking (ESCC) of austenitic stainless steel due to soluble chlorides within the insulation. This corrosion test consists of using specimens of insulation to conduct distilled or deionized water by wicking or dripping to an outside surface, through the insulation, to a hot inner surface of stressed stainless steel for a period of 28 days. If leachable chlorides are present, they will concentrate on the hot surface by evaporation. At the conclusion of the 28-day test period, the stainless steel coupons are removed, cleaned and inspected for stress corrosion cracks. To pass the test no cracks may be found on the surface of the coupons.

AS-Quality (AGI Q135 EN 13468)

The following acceptance criteria apply for insulation materials of AS-Quality. The average of six test samples must exhibit a water leachable chloride content of 10 mg/kg. The maximum value of individual measurements must not exceed 12 mg/kg.

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ASTM C795
Thermal Insulation for Use in Contact with Austenitic Stainless Steel. This specication covers non-metallic thermal insulation for use in contact with austenitic stainless steel piping and equipment. In addition to meeting the requirements of this standard, the insulation materials must pass the preproduction test requirements of ASTM C692, for stress corrosion effects on austenitic stainless steel, and the conrming quality control, chemical requirements when tested according to ASTM C871. ASTM C795 shows the results of ASTM C871 in a graph to illustrate a range ofacceptable chloride concentrations in conjunction with sodium plus silicate concen trations (see graph illustration below).
ASTM C 795 acceptability of insulation material on the basis of the plot points of the Cl- and the Na+ an SiO32analyses 10.000

2.2.5 Water repellency

The thermal conductivity and therefore the insulating capacity of mineral wool insulation materials are considerably impaired by the penetration of moisture into the material. Wet insulation material can also contribute to corrosion. Therefore, insulation materials must be protected against moisture during storage, construction and after being tted. To protect the material against the ingress of moisture, mineral wool insulation materials are offered with a hydrophobic treatment. Hydrophobic treatment makes it difcult for water to penetrate into the insulation and repels water affecting the insulation from the outside. During the mineral wool manufacturing process, hydrophobic oil, which surrounds each bre like a protective lm, is added. This provides effective protection against moisture penetration across the entire insulation thickness. Hydrophobic treatment does not affect the water vapour diffusion transmission. The effectiveness of the hydrophobic treatment is temporary and depends on the level of moisture. It decreases when exposed to high temperatures. The primary objective of the hydrophobic treatment is to protect the insulation from short bursts of rainfall during installation, for example. In principle, even mineral wool insulation that has been hydrophobically treated must be protected against the ingress of moisture during transport, storage and application. The water repellency of mineral wool insulation can be tested in accordance with several standards.
10.000 100.000

Water-leachable content Chloride (Cl-) (ppm)

1.000

Unacceptable analysis

100 Acceptable analysis 10

Rockwool mineral wool

1 100 1.000 1 10

Water-leachable content Sodium and Silicate (Na+ an SiO32-) (ppm)

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2.2  Product properties & test methods

2.2.5 Water repellency EN 1609 & EN 13472 Partial immersion
Tested in accordance with two mineral wool standards, i.e. the EN 1609 standard for slabs and the DIN EN 13472 standard for pipe insulating products. The maximum permissible water absorption in these testing procedures must not exceed 1 kg/m. ProRox insulation products are hydrophobically treated and therefore fulll these requirements.

BS 2972 Section 12 Partial Immersion

This part of standard covers the determination of the amount of water absorption by mineral bre insulation. The test sample is immersed vertically with one 150 mm* 25 mm side 6 mm below the surface of tap water for 48 hours. After the immersion period the sample must be drained for 5 minutes. The water absorption is calculated using the weight difference before and after testing and is expressed in kilograms per square metre.

BS 2972 Section 12 Total Immersion

This part of the standard covers the determination of the amount of water absorption by mineral bre insulation. The test sample is immersed completely in tap water for two hours with the upper surface approximately 25 mm below the surface of the tap water. After the immersion period, the sample must be drained for 5 minutes. The water absorption is calculated using the weight difference before and after testing and the increase is expressed in kg of water per m.  Note: British Petroleum places specic demands on the water repellency of mineral wool products. In accordance with the BP172 standard, the samples are heated for 24 hours at 250 C. Thewater repellency is tested afterwards in accordance with BS 2972 Section 12 Partial Immersion. Special water repellent grade (WRG) products are available on request.

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ASTM C1104 / 1104M

Determining the Water Vapor Sorption of Unfaced Mineral Fibre Insulation This standard covers the determination of the amount of water vapor sorbed by mineral bre insulation exposed to a high-humidity atmosphere. The test samples are rst dried in an oven and then transferred to an environmental chamber maintained at 49 C and 95 % relative humidity for 96 hours. The water vapor sorption is calculated using the weight difference before and after testing and is expressed in weight percentage or volume percentage.

2.2.6 Water vapour transmission

With installations constructed outdoors, the possibility of moisture penetrating the insulation system or being built in can never be ruled out. Therefore, it is important that insulation exhibits a high degree of water vapour permeability, which allows the water to escape from the installation once it has been started up started through diffusion or evaporation processes. This will prevent a negative impact on the insulation properties.

2.2.7 Air ow resistance

The resistance that an insulation material offers against the ow of air is referred to as air ow resistance. It depends on the apparent density, the bre dimensions, the bre orientation and the proportion of non-brous elements. It determines the level of convection in the insulation and its acoustic-technical properties. The air ow resistance is expressed in terms of Pa s/m and describes the relationship between the pressure difference and ow rate in an insulation material of one metre thickness.

Caution with regard to paint shops When using hydrophobically treated insulation materials in spraying plants, also ensure that the hydrophobic oil does not have any negative impact e.g. by means of paint wetting impairment substances such as silicon oils on the coating process. ProRox insulation products are hydrophobically treated without silicon oils or silicon resins and therefore also full the guidelines of the automotive industry, such as VW-Test 3.10.7. They may be used in paint shops.

One of the factors that inuences convection in an insulation material is its ow resistance. This is important when insulation materials adjoin air spaces, such as nned walls in boilers, and there are no airtight roofs or intermediate layers (foils).

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2.2 P  roduct properties & test methods

2.2.9 Density
When such thermal insulation materials are constructed vertically, the longitudinal ow resistance should therefore measure at least 50kPa s/m in accordance with EN 29053.

Fibre structure
The (vertical, horizontal,..) orientation of the bres inuences the longitudinal air ow resistance, compressive strength, and thermal conductivity. Generally, the more vertical bres, the better the compressive strength and the higher the thermal conductivity will be.

2.2.8 Compression resistance

The resistance that an insulation system offers to external mechanical loads (wind loads, people, cladding loads) is inuenced by factors including the pressure resistance of the insulation. The compressive stress of mineral wool is preferably specied at 10 % compression. The compressive strength is the ratio of the strength under a predetermined compression to the loaded surface of the test sample, as identied during a compression test in accordance with EN 826.

Non-brous particles
Non-brous particles or shot content in mineral wool products have a negative inuence on the thermal conductivity. For example, a mineral wool product with a density of 100 kg/m3 and 15 % shot content, {(tested in accordance with ASTM C 612 on a meshed netting (150 mm, 100 mesh)}, would have the same thermal conductivity as a mineral wool product with a density of 140 kg/m3 and 40 % shot content. ProRox products have a very low shot content. Due to the unique production process, ProRox products achieve excellent thermal conductivity, even at low densities.

2.2.9 Density
The density of mineral wool products is the amount of bres per cubic metre. Special care should be taken when comparing only the densities of insulation products. Density inuences several product properties. It is however not a product property itself. A common assumption is that the higher the density, the more the compression resistance, maximum service temperature and thermal conductivity will improve. This is only correct to a certain extent. Afew examples:

Insulation selection
Every mineral wool insulation product has specic characteristics. Insulation should therefore be based on the actual product performance, not on the density.

Binder content
During the manufacture of mineral wool products, a so called binder is added to glue/form the bres into the desired shape. The binder content positively inuences the compression strength, but due to its organic compounds has a negative effect on the maximum service temperature and re resistance.

2.3  Bases for thermal calculations

The following section outlines a number of theoretical bases for heat transfer and basic approaches to thermo-technical calculations. Detailed calculation processes are outlined in the VDI 2055, and the EN12241 standards, as well as in various international standards, such as ASTM C 680 and BS 5970. The calculation bases are similar in all the standards. In Europe, the VDI 2055 is the most widely used and accepted calculation basis. The calculation of multiple-layer insulation constructions is to some extent quite complex, as iterative calculation processes need to be carried

Thermal conductivity
For high temperatures it is often better to use high density (less radiation) mineral wool insulation. Attemperatures below 150 C, the conduction throughout the bres will be more dominant, so using a lower density product is preferable.

122

out. The procedures outlined below are therefore only suitable to obtain an approximate calculation of insulation constructions. The thermo-technical engineering program Rockassist offered by ROCKWOOL Technical Insulation can be used for detailed calculations.

owing through. The unit is expressed in W/m for surfaces or in W/m for pipes, for example. In the eld of insulation technology, the heat ow density refers to the surface of the insulation system. Thermal conductivity The heat-insulating effect of insulation materials is described in terms of the thermal conductivity . is specied in the physical unit of W(m K). It indicates the quantity of heat Q& that, in t amount of time and ata temperature difference of T, ows across the thickness s through the surface

Heat transfer
During a thermal transfer, thermal energy is transported as a result of a temperature drop. Thermal transfers can occur through conduction, convection or radiation. Thermal conduction is the transport of heat   from one molecule to another, as a result of a drop in temperature. In solid substances, the average distance between the individual molecules remains the same. In liquids and gases however, the distance changes. In the case of convection, the thermal transfer   takes place in liquids and gases through ow processes. A distinction is drawn between free convection, in which the movement occurs as a result of variations in density, and forced convection, in which the ow is generated by external inuences such as the wind and by blowers. Thermal transfer through radiation takes place   as a result of the exchange of electromagnetic radiation between two body surfaces, which have different temperatures and are separated by radiation permeable media, such as air.

Q l J m J W = = = A t T m2 s K m s K mK

The unit of the thermal conductivity is expressed in terms of J/(m s K) or W/(m K). Thermal conductance The coefcient of thermal conductance indicates, for a given layer, the heat ow density owing vertically between the surfaces over an area of 1 m at a temperature difference of 1 K. The unit used to express the coefcients of thermal conductance is W/(m K).

Thermal conductivity = Applied insulation thickness s

W 2 m K

Terms
Heat quantity Q The heat quantity is the thermal energy that is supplied to or dissipates from a body. The unit used to designate the heat quantity is J. Heat ow Q` The heat ow Q` is the heat quantity owing in a body or being transferred between two bodies per time unit. The unit used to designate the heat ow is W (1W = 1J/s). Heat ow density q The heat ow density q is the heat ow being applied to the unit of the surface that the heat is

Thermal resistance R The thermal resistance R is the reciprocal of the coefcients of thermal resistance. The unit used to express the thermal resistance is (m K)/W.

Applied insulation thickness Thermal conductivity

2 s m K W

for walls

d ln a di (mK ) RPipe = for pipe insulation 2 W

Surface coefcient of heat transfer The surface coefcient of heat transfer gives the heat ow density circulating at the surface of a body in a medium or vice versa, when the
123

2.3 Bases for thermal calculations

temperature difference between the body and theliquid or gaseous medium amounts to 1 K. Theunit used to express surface coefcients of heat transfer is W/(mK). Heat transfer resistance 1/ The heat transfer resistance 1/ is the reci procal of the surface coefcients of heat transfer. The unit used to express the heat transfer resistance is (mK)/W. Coefcient of thermal transmittance k The coefcient of thermal transmittance k indicates the heat ow density q circulating through a body, when there is a temperature difference of 1 K between the two media, which are separated by the body. The coefcient of thermal transmittance includes the thermal resistance and heat transfer components. Theunit used to express coefcients of thermal transmittance is W/(m K). Thermal transmission resistance 1/k The thermal transmission resistance is the reciprocal of the coefcients of thermal transmittance. The unit used to express thermal transmission resistance is (mK)/W. 1 = Heat transfer + Heat transfer + Heat transfer resistanceinside resistanceinside resistanceoutside k

Calculation bases
The heat ow density through a at wall constructed of multiple layers is calculated asfollows:

q = k ( M L ) s 1 1 s1 s2 1 = + + + ... + n + k i 1 2 n a q= ( M L ) s 1 s1 s2 1 + + + .... + n + n a i 1 2 W m2

The following symbols are used in this calculation: q Heat ow density W/m M Temperature of the medium in C L Ambient temperature in C i Surface coefcient of heat transfer inside W/(m K) a Surface coefcient of heat transfer outside W/(m K) s1sn Thickness of the individual layers of insulation m 1n Thermal conductivity of the W/(m K) individual insulation layers k Coefcient of thermal transmittance W/(m K) With multiple-layer hollow cylinder (pipe insulation), the heat ow density is calculated as follows:

1 1 1 = +R + k w i w a

m2 K for a wall W mK W

qR = k R ( M L )

1 1 1 = +R + kR di i R da a
for pipe insulation

d d d ln a ln 2 ln 3 dn d1 d2 1 1 1 mK + .... + + = + + 2 n da a k R di i 2 1 2 2 W

qR =

( M L ) 1 1 1 2 n + .... + + + + 2 2 2 n da a di i 2 1 d ln 2 d d ln 3 d d ln a d

W m

124

The following symbols are used in this calculation: qR Heat ow density per m pipe W/m M Temperature of the medium in C L Ambient temperature in C d1 External diameter of pipe m da External diameter of insulated pipe m i Surface coefcient of heat transfer inside W/(m K) a Surface coefcient of heat transfer outside W/(m K) 1n Thermal conductivity of the individual insulation layers W/(m K) k Coefcient of thermal transmittance W/(m K) s1sn Thickness of the individual layers ofinsulation m Hint When performing thermo-technical calcula tions in insulation technology, the internal heat transfer does not generally need to be considered. This simplication is based on the assumption that the medium is the same temperature as the interior of the pipe. The following terms may therefore be omitted from the calculations shown above:

The surface temperatures O can be calculated as follows:

O =

kW a

( M - L)+ L C

for walls

O =

( M - L) + L C 1 s1 s2 sn 1 a + + + .... + + n a i 1 2 kR for pipe insulation ( M - L)+ L C  da a products

O =

O =

( M - L) + L d2 d3 da ln ln ln d1 d2 dn 1 1 C + + + .... + + da a di i 2 1 2 2 2 n da a

Hint The internal heat transfer can once again be  disregarded (see hint above).

1 r  emove from the denominator in the equation i for the wall 1 r  emove from the denominator in the di i equation for pipe insulation

The characteristic of emitting heat from a surface (e.g. the external sheet cladding) into the surrounding medium, which is usually air, is described by means of the external surface coefcient of heat transfer a. The surface coefcient of heat transfer is made up of the rate of convection and radiation. a = k + r The following symbols used in this calculation: k the rate of convection r the rate of radiation The rate of convection consists only of free convection (air movement due solely to variations in density as a result of temperature), forced convection (blowers, wind) or of a mixture of free and forced convection. Theconvection also depends on the geometry of the building component.
125

The rate of radiation depends on factors such as the material of the cladding (emission ratio ), the surface temperature and the orientation of the object in relation to other components. The calculation procedures are explained in the VDI 2055 and DIN EN 12241 standards. A detailed description will not be given at this point. Use the following procedure to obtain an approximate estimate of the external surface coefcients of heat transfer a. It applies in respect of the following boundary conditions: Applicable only for free convection   = O L 60K   m = 0,5 ( O L ) 40 C  da 0,5m 

The values for A and B have been compiled for a number of materials and surfaces in the table shown below.
Surface Aluminium, rolled Aluminium, oxidised Galvanised sheet, bright Galvanised sheet, tarnished Austenitic steel Alu-Zinc sheet Non-metallic surface A 2,5 3,1 4,0 5,3 3,2 3,4 8,5 B 2,7 3,3 4,2 5,5 3,4 3,6 8,7

Supplementary values Thermal bridges

In addition to the insulation thickness, the total heat loss from insulated objects depends on thermal bridges, which have a negative impact on the insulation system. A distinction is drawn between thermal bridges caused by the insulation and thermal bridges caused by the installation. Thermal bridges caused by the insulation system include support constructions and spacers, whereas thermal bridges caused by the installation include pipe hangings and supports, anges and brackets. Allowances are made for these thermal bridges in the form of supplementary factors that are multiplied by the surface coefcients of heat transfer. Table 3 of the VDI 2055 includes relevant supple men tary values for thermal bridges caused by the insulation. The thermo-technical engineering calculation program "Rockassist" can be used to calculate heat losses from objects whilst allowing for thermal bridges. Please visit the rockwool-rti.com website for consulting the Rockassist program on line.

The following applies for horizontal pipes:

a = A + 0,05

W 2 m K

The following applies for vertical pipes and walls:

a =B+ 0,09

W 2 m K

O is the surface temperature of the cladding L is the ambient temperature

126

ProRox
Industrial insulation

Tables

3. Tables
Table of contents
3.1
3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10 3.1.11 3.1.12 3.1.13 3.1.14

Units, conversion factors and tables

Symbols, denitions and units Mathematical symbols SI pre-xes Greek alphabet SI units SI derived units with special names Compound units derived from SI-units Temperature scales and conversions Conversion degrees Celcius and Fahrenheit Imperial (Anglo-Saxon) units Conversion of energy and heat scales Conversion power scales Conversion of pressure scales Conversion of SI-units into Imperial units, pre-SI units and technical scales

130
130 131 132 132 133 133 135 136 136 137 140 140 141 141

3.2  Product properties insulation and cladding materials

3.2.1 3.2.2 Insulation materials Cladding materials

142
142 142

3.3
3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8 3.3.9 3.3.10 3.3.11 3.3.12 3.3.13

Usage tables
Construction materials Fluids which are commonly used in process industry Gases which are commonly used in process industry Conversion factors in relation to the heat of combustion Specic enthalpy super heated steam in kJ/kg Density super heated steam Dew point table Climate data Guidelines average velocities in pipe work Pipe diameter Equivalent pipe length for anges & valves Minimum radius ProRox slabs Fire curve: ISO and hydrocarbon

145
145 145 146 147 148 149 150 151 158 158 160 161 162

129

3. Tables
3.1  Units, conversion factors and tables
3.1.1  Symbols, denitions and units
Symbol Denition Unit

A b C12 c cp d f H h k k' l m . m n P Q . Q q R R s t T U w

Area Length Radiation coefcient Specic heat capacity Specic heat capacity at constant pressure Diameter Correction factor Height Enthalpy Heat transfer coefcient Total heat transfer coefcient Length Mass Massow Operation time Pressure Heat energy Heat ow Heat ow density Thermal resistance Specic heat capacity Insulation thickness Time Temperature (Kelvin) Circumference Wind speed Total heat transfer coefcient (incl. cold bridges)

m2 m W/(m2 K4) J/(kg K) J/(kg K) m m J/kg W/(m2 K), W/K, W/(m K) W/(m2 K), W/K, W/(m K) m kg kg/s, kg/h a Pa J W W/m2 oder W/m m2 K/W, m K/W, K/W J/(kg K) m h or s K m m/s W/(m2 K)

130

Symbol

Denition

Unit

(also t)

Linear expansion coefcient Thermal conductance Thermal conductivity Emissivity Yield, efciency Temperature Water vapour resistance factor Water vapour resistance Density Relative humidity Air ow resistance

K-1 W/(m2 K) W/(m2 K) C kg/m3 Pa s/m2

3.1.2 Mathematical symbols

Mathematical symbols

= < << +

equal to less than less than or equal to much less than plus innite pi 3.14159 approximately greater than equal to or greater than much greater than Difference Sum Logarithm base e Logarithm base 10

> >>

ln log

131

3.1 Symbols & units

3.1.3 SI pre-xes
Decimal parts and multiples of units are conveyed by means of prexes and corresponding symbols. Several prexes cannot be compounded.
Name Symbol Conversion factor

Atto Femto Piko Nano Mikro Milli Centi Deci Deca Hecto Kilo Mega Giga Tera Peta Exa

A F P n m c d da h k M G T P E

10-18 10-15 10-12 10-9 10-6 10-3 10-2 10-1 101 102 103 106 109 1012 1015 1018

3.1.4 Greek alphabet

Greek alphabet

Alpha Beta Gamma Delta Epsilon Zeta

Eta Theta Iota Kappa Lambda Mu

Nu Xi Omicron Pi Rho Sigma

Tau Ypsilon Phi Chi Psi Omega

132

3.1.5 SI units
The International System of Units, also referred toas SI (Abbreviation for French: Systme International dunits), embodies the modern metric system and is the most widely used units system for physical units. The system was originally established in response to demands from the eld of science and research, however it is now the prevalent units system for the economic, technological and trade industries. In the European Union (EU) and the majority of other states, the use of the SI units system in ofcial and business transactions is prescribed by law; however there are many national exceptions to this rule.

SI Base units
The SI units system is composed of seven base units. In order to use the base units for applications involving different scales, certain prexes such as Kilo or Milli are used. These are also used in conjunction with derived units and, tosome extent, with units from other systems.

Basic unit

Symbol

Quantity

Unit

Length Mass Time Electric current Thermodynamic temperature Amount of substance Luminous intensity

l m t I T n J

Metre Kilogramme Second Ampere Kelvin Mol Candela

m kg s A K mol cd

3.1.6  SI derived units with special names

In addition to the base units, the International System of Units also includes derived units, which are made up of one or more of these base units by means of multipli cation or division. The clearly dened product of powers of the base units are not referred to as a dimension of the physical size as such, but rather the system is formally structured in that way. It is possible for example to express areas in terms of metres square (m) or speeds in metres per second (m/s).

Some of these compounded units are assigned names and symbols, which can even be combined once again with all of the base units and derived units. The SI unit force for example, the Newton (1 N = 1 kg m/s), lends itself to express the unit energy, the Joule (1 J = 1 kg m/s), which is equal to the equation Newtons multiplied by metres. The following 22 derived units have their own name and unit symbol.

133

3.1 Symbols & units

3.1.6  SI derived units with special names
Name Symbol Quantity Unit Expression in terms of original SI Units m = 360 m 2p m2 m2 1 s kg m s2 kg N = s2 m m2 kg m2 =Ws=Nm s2 kg m2 m J =N = =VA s s s3 W J kg m2 = = s3 A A C A s kg m2 =Vs s2 A V kg m2 = s3 A2 A 1 s3 A2 = kg m2 kg m2 Wb = s2 A2 A C A2 s4 = kg m2 V kg Wb = m2 s2 A 0C = 273,15 K 1C = 274,15 K cd sr cd sr lm = m2 m2 1 s J kg J kg mol s

Plain angle Solid angle Frequency Force, weight Pressure, stress Energy, work, heat Power, radiant ux Voltage, electrical potential difference Electric charge or e lectricux Magnetic ux Electrical resistance Electrical conductance Inductance Electrical capacitance Magnetic eld Celsius-temperature Luminous ux Illuminance Radioactivity (decays per unit time) Absorbed dose (of ionising radiation) Equivalent dose (of ionising radiation) Catalytic activity

a, b, ...
f F p E, W P U Q

Radian Steradian Hertz Newton Pascal Joule Watt Volt Coulomb Weber Ohm Siemens Henry Farad Tesla degrees Celsius Lumen Lux Becquerel Gray Sievert Katal

rad sr Hz N Pa J W V C Wb

R G L C B

S H F T C lm lx Bq Gy Sv kat

(or t)
E A D H z

134

3.1.7 Compound units derived from SI-Units

Name Quantity Symbol Denition (Units)

Volume

Litre Minute hour Day Year Tonnes Grammes Bar

l, L min h d yr t g bar

1 l = 1 dm3 = 1L 1 min = 60 s 1 h = 60 min = 3600 s 1 d = 24 h = 1440 min 1 year = 365 d = 8760 h 1 t = 1.000 kg 1 g = 0,001 kg 1 bar = 105 Pa = 105 N/m2

Time

Mass Pressure

135

3.1 Symbols & units

3.1.8 Temperature scales and conversions
Temperature scale Unit Kelvin Kelvin Celsius Fahrenheit ( TK ) ( TC ) ( TF ) K C F TC TK - 273 TF 9/5 TK - 459 TF 9/5 * TC + 32 Conversion formulas Celsius TK 273 + TC Fahrenheit TK 255 +5/9*TF TC 5/9 * (TF - 32)

3.1.9  Conversion degrees Celcius and Fahrenheit

The white columns show the temperature in degrees Celsius and the grey columns show the temperature values in degrees Fahrenheit. If you
C F C F C

need to convert a temperature from Celsius to Fahrenheit, use the value shown in the grey column. If you need to convert a temperature fromFahrenheit to Celsius, use the value shown in the white column.
F C F C F

-200 -190 -180 -170 -160 -150 -140 -130 -120 -110 -100 -90 -80 -70 -60 -50 -40 -30 -20

-328 -310 -292 -274 -256 -238 -220 -202 -184 -166 -148 -130 -112 -94 -76 -58 -40 -22 -4

-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170

14 32 50 68 86 104 122 140 158 176 194 212 230 248 266 284 302 320 338

180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360

356 374 392 410 428 446 464 482 500 518 536 554 572 590 608 626 644 662 680

370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550

698 716 734 752 770 788 806 824 842 860 878 896 914 932 950 968 986 1004 1022

560 570 580 590 600 610 620 630 640 650 660 670 680 690 700 710 720 730 740

1040 1058 1076 1094 1112 1130 1148 1166 1184 1202 1220 1238 1256 1274 1292 1310 1328 1346 1364

136

3.1.10 Imperial (Anglo-Saxon) units

The Anglo-Saxon units (also referred to as Anglo-American meausrement systems) are derived from old English systems and were also used in other Commonwealth states prior to the

implementation of the metric system. Nowadays, they are only still used in the USA and to some extent in Great Britain and in some of the Commonwealth states.

Imperial unit, conversion to SI-Units:

Length, distance
Imperial Units Symbol Conversion to SI-Units

1 inch 1 foot 1 yard 1 mile 1 nautical mile

in. ft. yd. mi. nmi.

2,539998 cm (UK) 2,540005 cm (USA) 30,48 cm 91,44 cm 1,609 km 1,853 km

Area measurements
Imperial Units Symbol Conversion to SI-Units

1 square inch 1 square foot 1 square yard

(sq.in.) (sq.ft.) (sq.yd.)

6,45 cm2 929,03 cm2 0,836 m2

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3.1 Symbols & units

3.1.10 Imperial units
Overview Imperial units and conversion to SI-Units:

Standard measures of volume

Imperial Units Symbol SI-Units

1 cubic inch 1 cubic foot 1 cubic yard

(cu.in.) (cu.ft.) (cu.yd.)

16,39 cm3 28,32 dm3 0,7646 m3

Specic measures of volume

Imperial Units Symbol SI-Units

1 gallon 1 barrel

(gal.) (bbl.)

4,546 dm3 (UK) 3,787 dm3 (USA) 163,7 dm3 (UK) 119,2 dm3 (USA) 158,8 dm3 (USA, oil)

Measures of weight and mass

Imperial Units Symbol SI-Units

1 gallon 1 barrel

(gal.) (bbl.)

28,35 g 0,4536 kg

Density
Imperial Units SI-Units

1 lb/cu.in. (= 1lb/in3) 1 lb/cu.ft. (= 1 lb/ft )

3

2,766*104 kg/m3 16,02 kg/m3

138

Overview Imperial units and conversion to SI-Units:

Force, weight
Imperial Units SI-Units

Speed
Imperial Units SI-Units

1 lbf (lb. Force)

4,448 N

1 Knot intern. (kn.) 1 inch/second

0,514 m/s 1,852 km/h 0,0254 m/s 0,0914 km/h 0,03048 m/s 1,0973 km/h 0,9144 m/s 3,294 km/h 0,01524 m/s 0,055 km/h 0,447 m/s 1,609 km/h

Energy, work, heat

Imperial Units SI-Units

1 foot/second (ft./s.) 1 yard/second (yd./s.) 1 yard/minute (yd./min.) 1 mile per hour (m.p.h.)

1 BTU

1055,06 J

Power, capacity
Imperial Units SI-Units

1 BTU/sec 1 BTU/h 1 hp

1055,06 W 0,293 W 745,7 W

Pressure, stress
Imperial Units SI-Units

1 lbg/sq in. 1 lbg/sq ft

6894,7 N/m2 47,88 N/m2

139

3.1 Symbols & units

3.1.11 Conversion of energy and heat scales
Unit Joule (J) Kilojoule (kJ) Megajoule (MJ) Kilowatt hours (kWh) Kilocalorie (Kcal) British Thermal Unit (BTU)

Joule (J) Kilojoule (kJ) Megajoule (MJ) Kilowatt hours (kWh) Kilocalorie (Kcal) British Thermal Unit (BTU) 1000 106 3,6 * 106 4187 1055

0,001

10-6 0,001

2,78 * 10-7 2,7810 * 10-4 0,278

2,39 * 10-4 0,239 238,8 859,8

9,479 * 10-4 0,948 948 3412,3 3,873

1000 3600 4,187 1,055 3,6 4,19 * 10-3 1,055 * 10-3

1,2 * 10-3 2,933 * 10-4 0,252

3.1.12 Conversion of power scales

Unit Watt (W) Kilowatt (kW) Kilocalorie per second (kcal/s) Horsepower (HP) British Thermal British Thermal Unit per second Unit per hour (BTU/s) (BTU/h)

Watt (W) Kilowatt (kW) Kilocalorie per second (kcal/s) Horse power (HP) British Thermal Unit per second (BTU/s) British Thermal Unit per hour (BTU/h) 1000

0,001

2,39 * 10-4 0,239

1,36 * 10-3 1,36

0,948 * 10-3 0,948

3415,2 * 10-3 3415,2

4186,8

4,187

5,692

3,968

1,429 *103

735,5

0,736

0,176

0,698

2551,9

1055,06

1,06

0,252

1,433

3600

0,293

2,93 * 10-4

7,000 * 10-5

3,981 * 10-4

2,777 * 10-3

140

3.1.13 Conversion of pressure scales

Unit Pascal (Pa) Bar atm lb/sq ft lb/sq in.

Pascal (Pa) Bar atm lb/sq ft. lb/sq in. 10

5

10-5

9,869 * 10-6 0,987

0,201 2088,5 2116,2

1,450 * 10-4 13,50 14,70 6,944 * 10-3

101325 47,88 6894,8

1,013 4,788 * 10-4 0,0689 4,723 * 10-4 0,0680

144,00

3.1.14 Conversion of SI-Units into Imperial units, pre-SI units and technical scales
Symbol Quantity SI-Unit Technical scales Imperials units

Q Q

Heat, energy Energy, heat ux

J W/m2

kcal = 4186,8 J kcal W = 1,163 m2 m2 h

1 BTU = 1055,06 J

1 BTU W = 3,1546 (sq.ft.hr.) m

1 BTU W = 1,7307 (ft.hr.F) (m K)

Thermal conductivity

W/(m K)

kcal W = 1,163 (m K) m2 h

1 BTU in W = 0,1442 (sq.ft.hr.F) (m K) 1 BTU W = 20,7688 (in.hr.F) (m K)

R Cp C

Heat resistivity coefcient m2 K/W (R-value) Heat transfer coefcient W/(m2 K) specic heat capacity Radiant coefcient kJ/(kg K) W/(m2 K4)

1 m h

K = 0,86 m kcal

K W

1 sq.ft.hr.F K = 0,1761 m2 BTU W 1 BTU W = 5,6783 (sq.ft.hr.F) (m2 K) 1 BTU kJ = 4,1868 (lb. F) (kg K) 1 BTU kJ = 33,1156 (m2 K4) (sq.ft.hr.R4)

kcal W = 1,163 (m h K) (m2 K) kcal kJ = 4,1868 (kg K) kg K kcal = (m2 h K4) 1,63 W (m2 K4)

141

3. Tables
3.2  Product properties insulation and cladding materials
3.2.1 Insulation materials
The characteristic properties of the individual ProRox products are described in Chapter 4. For special applications, such as high-temperature insulation systems, cold insulation products or an additional spacer, it may be necessary to use ProRox products in connection with other insulation products. These may include, for example: CMS Calcium-Magnesium-Silicate bres for  high-temperature insulations Cellular glass as a spacer or as a support In any case, it is important that the product properties and processing instructions are taken into consideration during the application of these products. Further product information can be found in the various standards and regulations, such as DIN 4140, CINI, VDI 2055 and various other AGI Guidelines for example.

3.2.2 Cladding materials

3.2.2.1  Application selector for claddings
Maximum surface (cladding) temperature Cladding material Fire hazardous environment + Corrosive environment < 50 C < 60 C >60 C

Aluminum Alu-zinc steel Galvanised steel Stainless steel Aluminised steel Painted steel or aluminum Glass-bre reinforced polyester (e.g. Rocktight) Mastics Foils

+ + +

+ -

+ + + +

90C 80C

- not recommendable + suitable in general The selection of material should be geared to each installation and/or environment.

142

3.2.2.2 Product properties and standards

Cladding material Density (kg/m3) Linear expansion coefcient 10-6 K-1 Emissivity Type of material Standard(s)

Aluminium, bright

2700

23,8

0,05

Aluminium, oxydised Galvanised steel, bright Galvanised steel, oxidised Stainless steel Alu-zinc steel, bright Alu-zinc steel, oxidised Aluminised steel Painted steel Glass bre reinforced polyester (e.g. Rocktight)

2700 7800 - 7900 7800 - 7900 7700 - 8100 7800 - 7900 -

23,8 11,0 11,0 16,0 11,0 -

0,13 0,26

Al Mg2 Mn 0,8 EN AW 5049 Al MG 3 EN AW 5745 AL 99,5 EN AW 1050

DIN EN 485-2 CINI 3.1.01 DIN EN 12258-1 DIN EN 13195-1

DX 51 D 0,44 0,15 0,16 0,18 0,90 DX 51 D 1.4301, 1.451, 14571

CINI 3.1.03, DIN EN 10327 CINI 3.1.05, EDIN EN 10028-7, EN 10088-3

CINI 3.1.02, DIN EN 10327 see data sheet of the manufacturer see data sheet ofthemanufacturer orCINI3.2.11

0,90

3.2.2.3 Thickness metal cladding in accordance with CINI

Sheet thickness in mm External diameter insulation (mm)

Aluminium (CINI 3.1.01)

Aluminised steel (CINI 3.1.02)

Alu-zinc steel (CINI 3.1.03)

Galvanised steel (CINI 3.1.04)

Stainless steel (CINI 3.1.05)

< 140 130 - 300 > 300

0,6 0,8 1,0

0,56 0,8 0,8

0,5 0,8 0,8

0,5 0,8 0,8

0,5 0,8 0,8

143

3.2  Product properties insulation and cladding materials

3.2.2 Cladding materials
3.2.2.4 Thickness metal cladding in accordance with DIN 4140
Minimum sheet thickness Overlap

External diameter insulation (mm)

Galvanised, Aluminised, Alu-zinc and painted steel

Stainless steel E DIN EN 10028-7 and DIN EN 10088-3

Aluminium

Longitudinal joint

Circumferential joint

up to 400 400 to 800 800 to 1200 1200 to 2000 2000 to 6000 > 6000
a

0,5 0,6 0,7 0,8 1,0 1,0

0,5 0,5 0,6 0,6 0,8 0,8

0,6 0,8 0,8 1,0 1,0 1,2

30 40 50 50

Smaller sheet thicknesses are also possible in consultation with the customer. With regard to pipes, the circumferential joint overlap can be omitted if the circumferential joints are joined by swage and counter swage. In the case of cladding with a large surface area and high wind loads, structural verications may be required. In that instance, only those binding agents permitted by the building authorities may be used. The DIN 1055-4 applies in respect of the loading assumptions.
b

3.2.2.5 Thickness of metal cladding in accordance with BS 5970

Protected mild steel Flat Proled mm mm 1,2 1,0 1,6 1,0 0,8 0,6 0,8 0,8 Aluminium Flat mm 1,6 1,2 1,6 1,2 0,9 0,7 Proled mm 0,9 0,9 Stainless steel Flat mm 1,0 0,8 1,0 0,8 0,6 0,5 Proled mm 0,6 0,5 -

Type of area

Large at areas over exible insulation Smaller at areas over exible insulation, or large areas over preformed slabs (including large curved surfaces) Removable insulated manhole and door covers Flange and valve boxes Pipes with an insulated diameter of more than 450 mm Pipes with an insulated diameter of 150 mm to 450 mm Pipes with an insulated diameter of less than 150 mm a For at surfaces, large curved areas and pipes with an insulated diameter of 450 mm or more For pipes with an insulated diameter of less than 450 mm

As metal on adjacent pipe

Recommended thickness for reinforcing plates and where foot trafc is likely
1,6 1,0 0,3 0,4 1,6 1,2 0,3 0,4 1,0 0,8 0,3 0,4 -

Recommended thickness where no mechanical damage is likely

For pipes with an insulated diameter of less than 1000 mm For pipes with an insulated diameter of more than 1000 mm

144

a For insulation diameters of 150 mm or less, the thickness of reeded aluminium should be not less than 0,25 mm. For insulation diameters in excess of 150 mm, it should be 0,4 mm or greater.

3. Tables
3.3 Usage tables
3.3.1 Construction materials
Material Density kg/m Thermal conductivity Specic heat capacity W/(mK) at 20 C kJ/(kg K) Linear expansion coefcient 10-6 K-1

Aluminum Concrete Bitumen (Solid) Bronze, red brass Cast iron Wrought (cast) iron Copper Wet soil Dry soil Stainless steel Iron

2700 2400 1050 8200 7100 - 7300 7800 8960 1600 - 2000 1400 - 1600 7700 - 8100 7850

221 2,1 0,17 61 42 - 63 67 393 1,2 - 3,0 0,4 - 0,6 10 - 46 46 - 52

0,92 0,92 - 1,09 1,72 - 1,93 0,37 0,54 0,46 0,40 2,0 0,84 0,50 0,48

23,8 11,0 - 12,0 200,0 17,5 10,4 11,7 16,5 16,0 11,0

3.3.2  Fluids which are commonly used in process industry

Group Material Density kg/m3 Specic heat capacity kJ/(kg K) at 20 C 4,19 2,34 2,495 3,77 3,94 1,97 2,02 1,93 1,88 1,72 2,20

General Alcohols

Water Ethanol Methanol Beer

1000 714 792 1030 1030 920 620 - 780 830 850 980 790

Food

Milk Olive oil Petrol Diesel

Fuels

Fuel oil (HEL) Fuel oil (HS) Petroleum

145

3.3 Usage tables

3.3.2  Fluids which are commonly used in process industry
Group Material Density kg/m3 Specic heat capacity kJ/(kg K) at 20 C 1,67 3,64 1,72 1,06 4,74 1,73 1,16 1,72 2,09 - 2,3

Oils

Silicone oil Machine oil Hydrochloric acid (10%) Hydrochloric acid (30%) Nitric acid (10 %)

940 910 1070 1150 1050 1500 1070 1400 1840 609 1524 879 1336 867 1100 - 1500

Acids

Nitric acid (<90%) Sulfuric acid (10%) Sulfuric acid (50%) Sulfuric acid (100%)

Bases

Ammonia (30%) Sodium hydroxide (50%) Benzol

Various

Dichlormethane Toluene Bitumen (uid)

3.3.3 Gases which are commonly used in process industry

Gas Density at 1 bar kg/m3 1,070 0,710 2,950 1,240 1,150 1,780 1,150 1,190 0,660 1,850 1,310 1,150 0,820 Specic heat capacity kJ/(kg K) at 20 C

Acetylene Ammonia Chlorine Ethane Ethylene Carbon dioxide Carbon monoxide Air Methane Propane Oxygen Nitrogen Hydrogen
146

1,687 2,093 0,477 1,754 1,553 0,846 1,038 1,007 2,227 1,671 0,913 1,038 14,34

3.3.4 Conversion factors in relation to the heat of combustion

Fuel Heat of combustion TJ/Gg Conversion factor tCO2 / TJ Conversion factor kgCO2/kg fuel 3,1 28,3 3,1 3,1 3,2 2,9 3,2 2,7 1,2 3,0 2,7

Oil Liquied gas Petrol Kerosene Diesel Ethane Petroleum cokes Black coal Brown coal Gas cokes Gas

42,3 44,2 44,3 43,8 43,0 46,4 32,5 28,2 11,9 28,2 48,0

73,3 64,1 69,2 71,8 74,0 61,6 97,5 94,5 101,1 107,0 56,1

147

3.3 Usage tables

3.3.5 Specic enthalpy super heated steam in kJ/kg
Steam temperature in C Pressure in bar 150 200 250 300 350 400 450 500 600 700 800

1 5 10 20 30 40 50 60 70 80 90 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

2776,1

2874,8 2854,9 2827,4

2973,9 2960,1 2941,9 2901,6 2854,8

3073,9 3063,7 3050,6 3022,7 2922,6 2959,7 2923,5 2883,2 2837,6 2784,6

3175,3 3167,4 3157,3 3136,6 3114,8 3091,8 3067,7 3042,2 3015,1 2986,3 2955,5 2922,2 2691,3

3278,0 3271,7 3263,8 3247,5 3230,7 3213,4 3195,5 3177,0 3157,9 3138,0 3117,5 3096,1 2974,7 2816,9 2578,1 2150,7 1988,3 1930,8 1897,3 1874,1 1843,0 1822,8 1808,7 1798,4 1790,9

3382,3 3377,2 3370,7 3357,5 3344,1 3330,4 3316,3 3301,9 3287,3 3272,2 3256,9 3241,1 3156,6 3060,8 2950,6 2822,3 2672,9 2513,2 2377,7 2284,7 2180,0 2123,6 2087,9 2063,2 2045,1

3488,2 3483,9 3478,6 3467,7 3456,6 3445,4 3433,9 3422,3 3410,5 3398,5 3386,4 3374,0 3309,3 3239,4 3164,2 3083,5 2997,3 2906,7 2814,2 2724,2 2571,9 2466,9 2397,7 2350,3 2316,2

3705,0 3701,9 3698,1 3690,2 3682,3 3674,3 3666,2 3658,1 3649,8 3641,5 3633,2 3624,7 3581,5 3536,7 3490,4 3443,1 3394,7 3345,8 3296,6 3247,7 3152,3 3063,8 2985,4 2918,7 2863,4

3928,8 3926,5 3923,6 3917,6 3911,7 3905,7 3899,7 3893,6 3887,5 3881,4 3875,2 3869,0 3837,6 3805,5 3773,0 3740,1 3706,9 3673,8 3640,7 3607,8 3543,5 3481,9 3424,2 3371,1 3323,1

4159,7 4157,8 4155,5 4150,9 4146,3 4141,7 4137,0 4132,3 4127,6 4122,9 4118,2 4113,5 4089,6 4065,4 4041,1 4016,7 3992,2 3967,8 3943,6 3919,5 3872,3 3826,7 3783,3 3742,4 3704,3

148

3.3.6 Density super heated steam

Steam temperature in C Pressure in bar 150 200 250 300 350 400 450 500 600 700 800

1 5 10 20 30 40 50 60 70 80 90 100 150 200 250 300 350 400 450 500 600 700 800 900 1000

0,5164

0,4604 2,3537 4,8566

0,4156 2,1083 4,2984 8,9757 14,172

0,379 1,9137 3,8771 7,9713 12,326 17,000 22,073 27,662 33,944 41,226

0,3483 1,7540 3,5402 7,2169 11,047 15,052 19,255 23,687 28,384 33,394 38,776 44,611 87,191

0,3223 1,6200 3,2617 6,6142 10,065 13,623 17,299 21,102 25,045 29,143 33,411 37,867 63,889 100,54 166,63 358,05 474,89 523,67 554,78 577,99 612,45 638,30 659,27 677,05 692,58

0,2999 1,5056 3,0263 6,1153 9,2708 12,497 15,798 19,179 22,646 26,202 29,855 33,611 51,200 78,732 109,09 148,45 201,63 270,91 343,37 402,28 479,87 528,62 563,69 591,14 613,80

0,2805 1,4066 1,8241 5,6926 8,6076 11,571 14,586 17,653 20,776 23,957 27,198 30,503 48,077 67,711 89,904 115,26 144,43 177,97 215,87 256,95 338,44 405,76 456,99 496,53 528,21

0,2483 1,2437 2,4932 5,0101 7,5512 10,117 12,709 15,326 17,970 20,642 23,341 26,068 40,154 55,039 70,794 87,481 105,15 123,81 143,44 163,99 207,20 251,73 295,45 336,53 373,93

0,2227 1,1149 2,2331 4,4794 6,7390 9,0121 11,299 13,599 15,914 18,242 20,584 22,941 34,943 47,319 60,080 73,234 86,779 100,71 115,01 129,64 159,77 190,65 221,74 252,48 282,36

0,2019 1,0105 2,0228 4,0531 6,0908 8,1360 10,189 12,249 14,316 16,391 18,474 20,564 31,124 41,871 52,803 63,919 75,214 86,682 98,312 110,09 134,02 158,30 182,72 207,03 231,03

149

3.3 Usage tables

3.3.7 Dew point table

Maximum Air water temperature content in g/m3

Maximum cooling of air temperature (to avoid condensation) at a humidity of

30 % 35 % 40 % 45 % 50 % 55 % 60 % 65 % 70 % 75 % 80 % 85 % 90 % 95 % 11,1 11,5 12,0 12,3 12,9 13,4 13,9 14,3 14,7 15,1 15,6 16,0 16,5 16,9 17,4 17,8 18,1 18,4 18,6 18,9 19,2 19,5 20,2 20,9 21,6 22,3 23,0 23,7 24,5 25,2 26,0 26,8 9,8 10,1 10,4 10,8 11,3 11,7 12,2 12,6 13,0 13,4 13,8 14,2 14,6 15,1 15,5 15,7 15,9 16,1 16,4 16,6 16,9 17,1 17,7 18,4 19,0 19,7 20,2 20,9 21,6 22,2 22,9 23,6 8,6 8,9 9,1 9,6 9,9 10,3 10,7 11,0 11,4 11,8 12,2 12,6 13,0 13,4 13,6 13,8 14,0 14,2 14,4 14,7 14,9 15,1 15,7 16,1 16,7 17,3 17,8 18,4 19,0 19,5 20,1 20,7 7,5 7,8 8,0 8,3 8,7 9,0 9,3 9,7 10,1 10,4 10,8 11,2 11,6 11,7 11,9 12,1 12,3 12,5 12,6 12,8 13,0 13,2 13,7 14,2 14,7 15,2 15,6 16,1 16,6 17,1 17,7 18,2 6,6 6,8 7,0 7,3 7,6 7,9 8,1 8,5 8,9 9,2 9,6 10,0 10,1 10,3 10,4 10,6 10,7 10,9 11,1 11,2 11,4 11,6 12,0 12,4 12,8 13,8 13,7 14,1 14,5 15,0 15,4 15,8 5,7 5,9 6,0 6,4 6,6 6,8 7,1 7,4 7,7 8,1 8,4 9,6 8,8 8,9 9,0 9,2 9,3 9,5 9,6 9,7 9,9 10,1 10,4 10,8 11,2 11,6 11,8 12,2 12,6 13,0 13,3 13,7 4,9 5,1 5,2 5,4 5,7 5,9 6,0 6,4 6,7 7,0 7,3 7,4 7,5 7,6 7,8 7,9 8,0 8,1 8,2 8,4 8,5 8,6 9,0 9,3 9,6 9,9 10,2 10,5 10,8 11,1 11,4 11,7 4,2 4,3 4,5 4,6 4,8 5,0 5,1 5,4 5,8 6,1 6,2 6,3 6,4 6,5 6,6 6,7 6,8 6,9 7,0 7,1 7,2 7,3 7,6 7,9 8,1 8,4 8,6 8,9 9,1 9,4 9,6 9,9 3,5 3,6 3,7 3,8 3,9 4,1 4,2 4,6 4,9 5,1 5,1 5,2 5,3 5,4 5,5 5,6 5,6 5,7 5,8 5,9 6,0 6,1 6,3 6,5 6,8 7,0 7,1 7,3 7,6 7,9 8,0 8,2 2,8 2,9 2,9 3,1 3,2 3,3 3,5 3,8 4,0 4,1 4,2 4,2 4,3 4,3 4,4 4,5 4,6 4,7 4,7 4,8 4,9 5,0 5,1 5,3 5,5 5,7 5,8 5,9 6,1 6,2 6,4 6,6 2,2 2,3 2,3 2,5 2,5 2,6 2,7 3,0 3,1 3,2 3,2 3,3 3,3 3,4 3,5 3,5 3,6 3,6 3,7 3,7 3,8 3,8 4,0 4,1 4,3 4,4 4,5 4,6 4,7 4,8 4,9 5,0 1,6 1,7 1,7 1,8 1,8 1,9 1,9 2,2 2,3 2,3 2,3 2,4 2,4 2,5 2,5 2,5 2,6 2,6 2,7 2,7 2,8 2,8 2,9 3,0 3,1 3,2 3,2 3,3 3,4 3,4 3,5 3,6 1,1 1,1 1,1 1,2 1,2 1,2 1,3 1,5 1,5 1,5 1,5 1,6 1,6 1,6 1,7 1,7 1,7 1,7 1,8 1,8 1,8 1,8 1,9 2,0 2,1 2,1 2,1 2,1 2,1 2,1 2,2 2,2 0,6 0,6 0,6 0,6 0,6 0,6 0,7 0,7 0,7 0,7 0,8 0,8 0,8 0,8 0,8 0,8 0,8 0,8 0,8 0,9 0,9 0,9 0,9 0,9 0,9 0,9 0,9 0,9 0,9 0,9 0,9 0,9

-30 -25 -20 -15 -10 -5 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 35 40 45 50 55 60 65 70 75 80

0,35 0,55 0,90 1,40 2,17 3,27 4,8 5,6 6,4 7,3 8,3 9,4 10,7 12,1 13,6 15,4 17,3 19,4 21,8 24,4 27,2 30,3 39,4 50,7 64,5 82,3 104,4 130,2 161,3 188,2 242,0 283,4

150

3.3.8 Climate data

3.3.8.1 Average year temperature and humidity
Europe Temperature (C) Humidity (%)

Athens Berne Geneva Amsterdam Innsbruck London Madrid Moscow Paris Rome Salzburg Warsaw Vienna Zurich

17.6 8.6 9.2 9,8 8.4 9.9 13.4 3.6 10.3 15.4 8.2 7.3 9.8 8.2

66 83 79 67 79 77 72 82 77 -

Africa

Annual Temperature (C) 17 21 26 20 17 26 16 17 28 19

Min. Temperature (C) 12 16 24 12 12 25 11 12 11 15

Max. Temperature (C) 25 27 28 28 22 28 20 21 27 21

Algeria, Skikda Egypt, Cairo Kenya, Mombasa Libya Morocco, Rabat Nigeria, Port Harcourt South Africa, Johannesburg South Africa, Cape Town Tunisia, Tunis Zimbadwe, Harare

151

3.3 Usage tables

3.3.8.1 Average year temperature and humidity
Artics Annual Temperature (C) -26 -19 Min. Temperature (C) -37 -35 Max. Temperature (C) -5 -1

Antarctica, Ellisworth Arctic

Asia

Annual Temperature (C) 12 13 25 27 12 16 27 25 28 27 15 27 12 22 28

Min. Temperature (C) 2 6 18 23 -3 4 23 14 24 23 8 22 -2 16 21

Max. Temperature (C) 25 25 29 31 26 28 30 32 32 31 27 32 25 29 30

Afghanistan, Kabul Azerbijan, baku Bangladesh Brunei China, Beijing China, Shanghai India, Mumbai India, Dehli India, Indonesia, Jakarta Japan, Tokio Malaysia, Kuala Lumpur South Korea, Seoul Taiwan, Taipei Thailand, Bangkok

152

Middle East

Annual Temperature (C) 25 19 17 27 22 16 17 26 20 28 27 26 16 27 29

Min. Temperature (C) 13 1 17 8 7 7 12 12 21 17 14 6 18 26

Max. Temperature (C) 26 31 34 34 23 25 37 26 35 35 36 26 35 32

Bahrain Gaza Strip Iran, Tehran Iran, Bandar-E-Abbas Iraq, Baghdad Israel, Jerusalem Jordan, Ammam Kuwait, Kuwait City Lebanon, Beiroet Oman, Muscat Qatar, Doha Saudi Arabia, Riyadh Syria, Damascus United Arab Emirates, Dubai Yemen, Aden

North America

Annual Temperature (C) 22 -4 24 12 14 20

Min. Temperature (C) 17 -8 18 1 10 11

Max. Temperature (C) 27 19 30 25 21 29

Bermuda Canada, Quebec Mexico, Baja California USA, New York USA, San Francisco USA, Houston

Oceania

Annual Temperature (C) 14 16 12

Min. Temperature (C) 5 7 5

Max. Temperature (C) 26 27 23

Australia, Melbourne Australia, Adelaide New Zealand, Nelson

153

3.3 Usage tables

3.3.8.1 Average year temperature and humidity
South America Annual Temperature (C) 16 25 13 10 25 27 12 27 23 27 Min. Temperature (C) 10 22 12 10 24 22 3 22 18 22 Max. Temperature (C) 23 28 13 11 26 32 20 33 27 31

Argentina, Buenos Aires Brazil, Rio de Janero Colombia, Bogota Ecuador, Tulcan French Guiana Guyana Peru, curzco Suriname, Paramaribo Venezuela, Caracas Venezuela, Barcelona

The Netherlands

Temperature (C) 9,8 9,4 9,9 9,6 9,9 9,3 9,0 9,2 9,8 10 9,8 9,6 9,8 10,4

Humidity (%) 84 81 83 84 81 83 86 85 82 84 82 81 82 82

Amsterdam (Schiphol) Arnhem (Deelen) Den Haag Den Helder Eindhoven Enschede Groningen Leeuwarden Maastricht Rotterdam s Hertogenbosch Soesterberg Utrecht (De Bilt) Vlissingen

154

Belgium

Temperature (C) 9,6 9,2 5,7 9,7 9,0 8,6 5,7 8,2 9,5 9,0 9,4 7,5 7,4 6,8 8,7

Humidity (%) 81 -

Antwerpen Beauvechain Botrange Brussel Chivres Dourbes Elsenborn Florennes Gent Kleine Brogel Koksijde Libramont Spa St-Hubert Virton

France

Min. Temperature (C)

Max. Temperature (C)

Humidity (%)

Ajaccio Bourges Bordeaux Dijon La Rochelle Lille Lyon Nice Paris Perpignan Rennes Strasbourg

10 0,8 8,5 6,4 9,5 6,5 7,5 12 8,6 11 7,6 6,1

20,1 15,8 18,1 15,1 16,5 14,1 16,4 19,2 15,5 19,8 16 14,8

77 -

155

3.3 Usage tables

3.3.8  Climate data
Germany Temperature (C) Humidity (%)

Berlin Braunschweig Bremerhaven Dresden Essen Erfurt Frankfurt/M. Frankfurt a.O. Giessen Grlitz Halle Hamburg Magdeburg Mannheim Munich Nuremberg Plauen Regensburg Rostock Stuttgart Trier

9.1 8.6 8.8 9.3 9.5 8.0 10.1 8.2 9.0 8.3 9.1 8.4 9.1 10.2 8.1 8.5 7.2 8.1 7.8 8.6 9.1

77 74 82 76 76 80 -

156

3.3.8.2 Wind speed

Beaufort scale Wind speed (m/s) Denition

0 1 2 3 4 5 6 7 8 9 10 11 12

0 - 0,2 0,3 - 1,5 1,6 - 3,3 3,4 - 5,4 5,5 - 7,9 8,0 - 10,7 10,8 - 13,8 13,9 - 17,1 17,2 - 20,7 20,8 - 24,4 24,5 - 28,4 28,5 - 32,6 >32,7

Calm Light air Light breeze Gentle breeze Moderate breeze Fresh breeze Strong breeze Moderate gale (strong wind) Fresh gale (strong wind) Strong gale (strong wind) Whole gale / storm Violent storm Hurricane

Generally speaking, the wind speed is also dependent on the height and location (inland, coastal). In order to calculate the insulation thickness, the following wind speeds are generally used:

 I nside: 0,5 m/s Outside in protected conditions: 1 m/s  Outside: 5 m/s  Outside in windy conditions  (e.g. near to coast): 10 m/s

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3.3 Usage tables

3.3.9 Guidelines average velocities in pipe work
Type of uid / piping Velocity (m/s)

Steam piping

Saturated steam LP(low-pressure) steam MP(medium-pressure) steam HP(high-pressure) steam

20 - 35 30 40 60 2 -3 1 1,5 0,5 2 0,5

(Hot) water supply

Feed Return

Oil

Low viscosity High viscosity

District heating Central heating (non residential buildings)

Average Main feed stock

3.3.10 Pipe diameter

Many different standards exist in relation to pipe sizes, the distribution of which varies according to the sector of industry and geographical area. The denotation of the pipe size generally comprises two numbers; one, which indicates the external diameter or nominal diameter, and a further number that indicates the wall thickness. In North America and Great Britain, high pressure pipe systems are generally classied by means of the Nominal Pipe Size (NPS) System in Inches. The pipe sizes are documented in a series of standards. In the USA, these standards include API 5L, ANSI/ ASME B36.10M and in Great Britain BS 1600 and BS 1387. As a rule, the pipe wall thickness is the xed variable and the internal diameter is permitted to vary In Europe, the same internal diameter and wall  strengths as used in the Nominal Pipe Size system are used for high-pressure pipe systems, however they are conveyed in a metric nominal diameter instead in inches as given in the NPS system. For nominal pipe sizes above 14, the nominal diameter (DN) size corresponds
158

to the NPS size multiplied by 25 (not 25.4). These pipes are documented in the EN10255 standard (formerly DIN 2448 and BS 1387) and in the ISO 65 standard and are often denoted as DIN- or ISO-pipes. In order to ensure a joint-free laying of theinsulation, it is important that you know the actual external diameter of the pipe, as there are an immense number of pipe dimensions. The following table provides a general overview of common pipe diameters with a comparison between the inches and DN size.

Nominal Pipe Size (NPS in inch) 1/8 1/4 3/8 1/2 3/4 1 1 1 2 2 3 3 4 4 5 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36

Nominal diameter (DN/Metric) DN 6 DN 8 DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 90 DN 100 DN 115 DN 125 DN 150 DN 200 DN 250 DN 300 DN 350 DN 400 DN 450 DN 500 DN 550 DN 600 DN 650 DN 700 DN 750 DN 800 DN 850 DN 900

Outer diameter (mm)

10,3 13,7 17,1 21,3 26,7 33,4 42,2 48,3 60,3 73,0 88,9 101,6 114,3 127,0 141,3 168,3 219,1 273,1 323,9 355,6 406,4 457,2 508,0 558,8 609,6 660,4 711,2 762,0 812,8 863,6 914,0

159

3.3 Usage tables

3.3.11 Equivalent pipe length for anges & valves
Reference values for plant related thermal bridges (table A14 - VDI 2055)

Item no. 50-100

Temperature range in C 150-300 Equivalent length in m 400-500

1 1.1 1.1.1

Flanges for pressure stages PN25 to PN100 Uninsulated for pipes In buildings 20C DN 50 DN 100 DN 150 DN 200 DN 300 3-5 4-7 4-9 5 - 11 6 - 16 7 - 11 9 - 14 11 - 18 13 - 24 16 - 32 22 - 31 25 - 32 0,7 - 1,0 0,1 - 1,0 0,8 - 1,1 0,8 - 1,3 0,8 - 1,4 1,0 - 1,4 1,1 - 1,3 5 - 11 7 - 16 7 - 17 10 - 26 12 - 37 9 - 16 13 - 23 14 - 29 18 - 38 21 - 54 28 - 53 31 - 52 0,7 - 1,0 0,8 - 1,2 0,8 - 1,3 0,9 - 1,4 1,0 - 1,6 1,1 - 1,6 1,1 - 1,6 9 - 15 13 - 16 17 - 30 20 - 37 25 - 57 12 - 19 18 - 28 22 - 37 27 - 46 32 - 69 44 - 68 48 - 69 1,0 - 1,1 1,1 - 1,4 1,3 - 1,6 1,3 - 1,7 1,4 - 1,9 1,6 - 1,9 1,6 - 1,8

1.1.2

In the open air 0C DN 50 DN 100 DN 150 DN 200 DN 300 DN 400 DN 500

1.2

Insulated in buildings 20C and in the open air 0C for pipes DN 50 DN 100 DN 150 DN 200 DN 300 DN 400 DN 500

2 2.1 2.1.1

Fittings for pressure stages PN 25 to PN 100 Uninsulated for pipes In buildings 20C DN 50 DN 100 DN 150 DN 200 DN 300 DN 400 9 - 15 15 - 21 16 - 28 21 - 35 29 - 51 36 - 60 16 - 29 24 - 46 26 - 63 37 - 82 50 - 116 59 - 136 27 - 39 42 - 63 58 - 90 73 - 108 106 - 177 126 - 206

DN 500
160

46 - 76

75 - 170

158 - 267

Item no. 50-100

Temperature range in C 150-300 Equivalent length in m 400-500

2.1.2

In the open air 0C / Only for pressure stage PN 25 DN 50 DN 100 DN 150 DN 200 DN 300 DN 400 DN 500 22 - 24 33 - 36 39 - 42 51 - 56 59 - 75 84 - 88 108 - 114 27 - 34 42 - 52 50 - 68 68 - 87 90 - 125 106 - 147 134 - 182 35 - 39 56 - 61 77 - 83 98 - 101 140 - 160 165 - 190 205 - 238

2.2 2.2.1

Insulated for pipes In buildings 20C and in the open air 0C for pipes DN 50 DN 100 DN 150 DN 200 DN 300 DN 400 DN 500 4-5 4-5 4-5 5-7 5-9 6-9 7 - 11 5-6 5-6 5-6 5-9 6 - 12 7 - 12 8 - 15 supplementary value Z* 0,15 0,25 6-7 6-7 6-7 7 - 10 7 - 13 8 - 15 9 - 19

3 3.1 3.2

Pipe suspensions In buildings In the open air

* The ranges given cover the effect of the temperature and of the pressure stages. Flanges and ttings for higher pressure stages give higher values so overlappings in the given temperature ranges are possible.

3.3.12 Minimum radius ProRox slabs

Minimal radius ProRox slabs Product insulation thickness (mm)

40 ProRox SL 920 ProRox SL 930 ProRox SL 950 500 500 500

50 700 700 700

60 900 1000 1000

70 1100 1200 1200

80 1300 1500 1400

100 1800 1900 -

120 2000 2400 -

161

3.3 Usage tables

3.3.13 Fire curve: ISO and hydrocarbon
ISO re curve 1400 1200

Temperature (C)

1000 800 600 400 200 0 0 50 100 150 200 250 300 350 Time (min.)

Hydrocarbon re curve 1400 1200

Temperature (C)

1000 800 600 400 200 0 0 50 100 150 200 250 300 350 Time (min.)

162

Notes

163

Notes

164

ProRox
Industrial insulation

Products

4. Products
Through the ProRox range, ROCKWOOL Technical Insulation offers a wide assortment of high quality stone wool insulation products for sustainable insulation of industrial and power generation plants. Each of them is developed with a specic eld of application (e.g. pipework, boilers, vessels, columns and storage tanks) inmind.

ROCKWOOL Technical Insulation products and solutions for industry

ProRox pre-formed Pipe Sections: ProRox Pipe Sections are supplied, split and hinged for easy snap-on assembly and are suitable for thermal and acoustic insulation of industrial pipework. ProRox Pipe Sections are available in a wide range of diameters and thicknesses. The use of ProRox Pipe Sections ensures optimal insulation.

ProRox Wired Mats: ProRox Wired Mats are lightly bonded rock wool mat stitched on galvanised wired mesh with galvanised wire. Wired mats are available in a wide range of densities and thicknesses up to 120 mm. Stainless steel wired mesh and wire are available upon request. Wired mats are suitable for thermal and acoustic insulation of industrial pipework, boiler walls, furnaces and industrial smoke exhaust ducts. The use of ProRox Wired Mats provides both exibility and quality of insulation.

ProRox pre-formed Slabs: ProRox Slabs are available in a wide range of densities and well suited to thermal and acoustic insulation of at surfaces.

1. Firesafe 2. Acoustical 3. Thermal 4. Durable 5. Sustainable

Storage tanks

Columns

Pipework

Vessels

167

4. Products
The main characteristic of ProRox products is their excellent thermal insulation capacity. Next to this, they of course also comply with the most stringent requirements on re resistance and acoustic insulation. Below you will get an overview of the most important ProRox products which are internationally available. More information can be found on our website www.rockwool-rti.com

Product Group

New name

Description

Pipe Sections

ProRox PS 960 ProRox PS 970

Pipe section Heavy duty pipe section Load bearing mats Wired mats Heavy duty wired mats Flexible slab Semi-rigid slab Rigid slab High temperature slab Heavy duty slab Compression resistant slab Loose ll Granulated loose ll Watertight insulation cladding

Load bearings Mats Wired Mats

ProRox MA 520 ALU ProRox WM 950 ProRox WM 960

Slabs

ProRox SL 920 ProRox SL 930 ProRox SL 950 ProRox SL 970 ProRox SL 980 ProRox SL 580

Loose Fill

ProRox LF 970 ProRox GR 903

Insulation protection

ProRox Rocktight

168

ProRox PS 960
Applications
ProRox PS 960 is a pre-formed stone wool pipe section. Thesections are supplied split and hinged for easy snap-on assembly, and are suitable for the thermal and acoustic insulation ofindustrial pipe work.

Pipe section

Advantages E   xcellent t provides optimal performance E   asy to handle and to install W   ide range of diameters and insulation thicknesses S   uitable for use over stainless steel F   or temperatures up to 350C, a support construction is not generally necessary

ProRox PS 970
Applications
ProRox PS 970 is a pre-formed high density stonewool pipe section. The sections are suppliedsplit and hinged for easy snap-on assembly, and are especially suitable for the thermal and acoustic insulation of industrial pipework which is exposed to high temperature and light (e.g. vibrations) mechanical loads.

Heavy duty pipe section

Advantages Suitable for heavy duty applications which  are exposed to high temperatures and light mechanical loads Excellent t provides optimal performance  Easy to handle and to install  Wide range of diameters and insulation  thicknesses Suitable for use over stainless steel  For temperatures up to 350C, a support  construction is not generally necessary

For more detailed information such as: product performance, certication and standards, see our website: www.rockwool-rti.com

169

4. Products
ProRox WM 950
Applications
ProRox WM 950 is a lightly bonded stone wool matstitchedon galvanised wire mesh using galvanised wire.The wired mat is suitable for thermal and acoustic insulation of industrial applications reaching high temperatures, such asindustrial pipe work, boiler walls, furnaces andsmoke ducts.

Wired mat

Advantages Suitable for high temperature application Flexible application Available in a wide range of thicknesses Suitable for use over stainless steel

Variants available on request: P  roRox WM 950 wired mats can be supplied with stainless steel mesh, stainless steel stitching wire and aluminium foil to special order. Please contact ROCKWOOL Technical Insulation for more information.

For more detailed information such as: product performance, certication and standards, see our website: www.rockwool-rti.com

170

ProRox WM 960
Applications
ProRox WM 960 is a lightly bonded heavy stone wool mat stitched on galvanised wired mesh with galvanised wire. Thewired mat is especially suitable for industrial installations such as high-pressure steam pipes, reactors, furnaces, etc. where high demands are made on the temperature resistance of the insulation.

Wired mat

Advantages Suitable for heavy duty applications which  are exposed to high temperatures and light mechanical loads Resistant to high temperatures  Flexible application  Available in a wide range off thicknesses  Suitable for use over stainless steel 

Variants available on request: ProRox WM 960 wired mats can be supplied with stainless steel mesh, stainless steel stitching wire and aluminium foil to  special order. Please contact ROCKWOOL Technical Insulation for more information.

171

4. Products
ProRox MA 520 ALU
Applications
ProRox MA 520 ALU is a stone wool insulation mat bonded onto breglass reinforced aluminium foil. The insulation mat is suitable for the thermal and acoustic insulation of especially vessels, ducts, and equipment up to intermediate temperatures.

Load bearing mat

Advantages Optimal insulation performance Flexible application No support construction needed Suitable for use over stainless steel

For more detailed information such as: product performance, certication and standards, see our website: www.rockwool-rti.com

172

ProRox SL 920
Applications
ProRox SL 920 is a strong but exible stone wool board for the thermal insulation of horizontal and vertical walls.

Flexible slab

Advantages Flexible application Available in a wide range off thicknesses

ProRox SL 930
Applications
ProRox SL 930 is a rigid board for the thermal and acoustic insulation of horizontal and vertical walls where a stable insulation product is required. Forexample, tank walls or acoustic panels.

Semi-rigid slab

Advantages Available in a wide range of thicknesses  Semi-rigid product combined with  aluminium foil or breglass coating provides a smart, smooth surface nish

173

4. Products
ProRox SL 950
Applications
ProRox SL 950 is a strong, rigid slab, specially developed for the thermal and acoustic insulation of boilers, columns and vessels up to intermediate temperatures.

Rigid slab

Advantages Suitable up to intermediate temperatures  Retains shape  Available in a wide range of thicknesses 

ProRox SL 970
Applications
ProRox SL970 is a strong and rigid stone wool slab, for the thermal and acoustic insulation of constructions where higher temperatures and light mechanical loads (e.g. vibrations) occur. Typical examples are ovens, furnaces and exhaustducts.

High temperature slab

Advantages Suitable for high temperature application Retains shape Available in a wide range of thicknesses

For more detailed information such as: product performance, certication and standards, see our website: www.rockwool-rti.com

174

ProRox SL 980
Applications
ProRox SL 980 is a strong and rigid stone wool slab, for the thermal and acoustic insulation of constructions where higher demands are made on the temperature resistance and mechanical loads of the insulation.

Heavy duty slab

Advantages Suitable for heavy duty applications which  are exposed to high temperatures and light mechanical loads Retains shape Available in a wide range of thicknesses 

ProRox SL 580
Applications
ProRox SL 580 is a pressure resistant stone wool slab with high resistance to mechanical loads. The compression resistant slab is developed for the thermal insulation of tank roofs subjected to pedestrian trafc, and the thermal and acoustic insulation of constructions subjected to a mechanical load.

Compression resistant slab

Advantages Resistant to foot trafc Available in a wide range of thicknesses

175

4. Products
ProRox LF 970
Applications
ProRox LF 970 is lightly bonded, impregnated stone wool. This product is especially suitable for thermal and acoustic insulation of voids, joints and irregularly formed constructions.

Loose ll

Advantages Ease of use Flexible application

ProRox GR 903
Applications
ProRox GR 903 is a stone wool granulate with noadditives. The granulate is especially suitable for the thermal insulation of cold boxes and air separation plants.

Granulated loose ll

Advantages Complies with the most stringent requirements for the insulation of cold boxes Chemically inert to steel Easy to remove for inspection purposes

For more detailed information such as: product performance, certication and standards, see our website: www.rockwool-rti.com

176

ProRox Rocktight ProRox Rocktight, the watertight cladding

Achieving the best insulation system for your application is not easy. Besides the right choice and implementation of the insulation, the insulation protection system also plays an important role. Specic uses call for specic solutions. Certain processes require a fully watertight and closed nish. Strong and easy to clean, with great durability and chemical resistance. An insulation protection that results in a high amount of operational safety, low maintenance costs and limited energy costs. ROCKWOOL Technical Insulation, together with FiberTec Europe, has therefore developed an innovative protection system for ROCKWOOL ProRox insulation: ProRox Rocktight.

Watertight insulation cladding

ProRox Rocktight: for a durable insulation protection

ProRox Rocktight is a berglass reinforced polyester mat positioned between two sheets of lm. The material contains resins, berglass and special llers and is ready to use. Unprocessed it is soft and malleable. In this state, ProRox Rocktight can be cut or trimmed into any shape which makes it easy to apply to the insulation. Thepolyester subsequently cures under the inuence of ultraviolet (UV) light. After curing, ProRox Rocktight is absolutely watertight and is able to give optimal mechanical protection.

The advantages The ProRox Rocktight system has important advantages that enhances the quality of your work. G  reat durability: Rocktight forms a seamless connection that offers a watertight protection to the ROCKWOOL insulation. It minimizes the damaging effects of the weather (wind, rain, seawater, etc.) or general wear and tear. It is chemical- resistant and withstands mechanical stresses (i.e. can be walked upon). Easy to clean: ProRox Rocktight can with stand spray-cleaning. Cleaning with water is possible without damaging the insulation. L  ow start-up costs: processing and installation takes place on location. This makes investments for the pre-fabrication of the insulation protection unnecessary. F  lexible use: cold and hot insulation, underground and above ground cables and pipes, on and offshore. ProRox Rocktight molds itself to every technical application.

177

ProRox Rocktight: strong and easy to install.

Reinforced polyester mat positioned between two sheets of lm.

ProRox Rocktight can be cut or trimmed into any shape.

The polyester cures ultraviolet (UV) light.

Optimal mechanical protection and absolutely watertight.

178

Contents
1. System solutions
1.1 Planning and preparation 1.2 Insulation of piping 1.3 Insulation of vessels 1.4 Insulation of columns 1.5 Insulation of storage tanks 1.6 Insulation of boilers 1.7 Insulation of ue gas ducts 1.8 Cold boxes

7
11 23 49 55 61 69 77 84

2. Theory
2.1 Norms & Standards 2.2 Product properties & test methods 2.3 Bases for thermal calculations

87
90 110 122

3. Tables
3.1 Units, conversion factors and tables 3.2 Product properties insulation and cladding materials 3.3 Usage tables

127
130 142 145

4. Products
ProRox PS 960 ProRox PS 970 ProRox WM 950 ProRox WM 960 ProRox MA 520 ALU ProRox SL 920 ProRox SL 930 ProRox SL 950 ProRox SL 970 ProRox SL 980 ProRox SL 580 ProRox LF 970 ProRox GR 903 ProRox Rocktight

167
169 169 170 171 172 173 173 174 174 175 175 176 176 177

 ROCKWOOL Technical Insulation, an independent or-

All explanations correspond to our current range of knowledge and are therefore up-to-date. The examples of use outlined in this document serve only to provide a better description and do not take special circumstances of specic cases into account. ROCKWOOL Technical Insulation places great value upon continuous develop ment of products, to the extent that we too continuously work to improve our products without prior notice. We therefore recommend that you use the most recent edition of our publications, as our wealth of experience and knowledge is always growing. Should you require related information for your specic application or have any technical queries, please contact our sales department or visit our website www.rockwool-rti.com

ganisation of the international ROCKWOOL Group, is the world wide market leader in technical insulation. With our two product lines, ProRox and SeaRox, we cover the whole industrial market and marine & offshore industry, providing a full range of products and systems for the thermal and resafe insulation of technical applications. Besides sustainable products we offer reliable expert advice, from documentation to delivery and after sales service. Throughout the whole chain from specier, through dealer to contractor and installer we aim to add value. We dont just sell products, we supply solutions. Its this total approach that makes us the ideal choice for professionalism, innovation and trust.

ROCKWOOL Technical Insulation

Delfstoffenweg 2 6045 JH Roermond The Netherlands Tel. +31 (0) 475 35 36 18 Fax +31 (0) 475 35 36 01 E-mail: [email protected] www.rockwool-rti.com ROCKWOOL Technical Insulation is part of ROCKWOOL International A/S
ROCKWOOL Technical Insulation, ROCKWOOL, SeaRox and ProRox are registered trademarks of ROCKWOOL International. ROCKWOOL Technical Insulation reserves the right to change the information in this brochure without prior notice.

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RTI/09.12/2.3K/gen. edit./English Intern. 410

ROCKWOOL Technical Insulation, excellence in technical insulation solutions