Lining and Insulation

1.
1 Introduction :
• Heat flows from a body at higher temperature to a body at lower
temperature.
• However for efficient performance of boiler heat has to be conserved and
heat loss has to be minimized.
• Thermal Insulation is a method to minimize Heat loss and bring down
the temperature to safe limit to serve the purpose of heat conservation
and personnel protection.
2.0 Categories:
Thermal Insulation materials are of two basic categories,
• i)Refractory materials.
• ii)Insulation materials.
Refractory Materials:
• Refractories are used in those areas where the steel material and
tubes or panels are directly exposed to flames or gas at elevated
temperatures and also where cooling by incoming steam is not
possible.
• It is highly conductive, almost equivalent to metal.
• It acts like a gas seal between outer surface and tubes.
• It can withstand high temperature of around 1400-1600°c.
• It has high density of about 2000 Kg/m³and high strength in the
order of 175 Kg/cm².
• For refractory and insulating material, its powdered form is used as
mortar or binding material.
• Since Portland cement can withstand only low temperature
applications; in boiler, we use Castable cement for binding
• When we raise it to 900°c, then only these refractories become a
fully hardened rock (chemical reaction or ceramic bonding takes
place at 900°c).
Insulation:
• It has low density of about 100 - 148 Kg/m³ and low strength.
• It is made up of Fibres or Powdered Material.
• It can withstand temperature up to 700°c.
Insulation Bricks:
• Insulation bricks is an intermediate between Refractory and insulation.
• It has density around 1000 Kg/m³ and strength about 10 Kg/cm².

Types of Insulation:
i) Fibrous Insulation
ii) Rigid Insulation
iii) Reflective Insulation
iv) Acoustic Insulation

Fibrous Insulation:
Fibrous insulations are materials made from minerals that are available
in nature. These materials are also called as Mineral Wool and are
further classified into four types.
Rigid Insulation:
Calcium silicate:
 It can be manufactured in laboratory.
 Its density is of about 250 kg / m³.
 It is a good insulation material but its cost is higher than rock wool, lesser than
ceramic.
 It is used in Pipeline Insulation in Boiler.
 It can be made into two half sections which gives good finish and aesthetic look of
the finished pipe insulation.
 Calcium Silicate is Hygroscopic i.e. absorbs moisture from atmosphere.
 So calcium silicate and wool material should be provided with Anti‐hydrant gels to
repel moisture.
Acoustic Insulation:
 It is used to reduce the noise. (Ex. Avoid the noise of fan due to
vibration).
Reflective Insulation
 Reflective insulation is used in small scale application.
 Polished surfaces are used as insulating material.
 It is costlier and maintenance of polished surfaces in large scale is

difficult.
 It is used in Thermo flasks.

Cladding:
• Cladding is used for good aesthetics and to protect insulation from
damage, rain and other external hindrances.
• Cladding in boiler is done using metal sheet of galvanised type or
Aluminium sheets.
• Aluminium sheet with non-corrosive coating is used for cladding. Also

Galvanised sheet with black bituminous coating is used in cladding. But
aluminium sheet is 2 to 3 times costlier than Galvanised sheet.
 Shiny finish gives less radiation loss (for aluminium) and dull finish is
more prone to radiation.
 In low temperature applications ( in sub-zero levels), water droplets will

be produced due to conduction of atmospheric moisture and travel
towards low temperature side. This conduction will be done by the air
gaps in the insulation provided.so a vapour barrier has to be provided
like foil or finishing cements, etc.
 Aluminium sheets of thickness less than 1 mm is used in boiler for

cladding so that it can be easily cut into required size. Usually NTPC
prefers 0.91mm .
 Before cladding, each layer of insulation should be provided with sealant

material at joints to prevent penetration of water inside.

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1.

• It can withstand temperature up to 700°c.

• Insulation bricks is an intermediate between Refractory and insulation.

• It has density around 1000 Kg/m³ and strength about 10 Kg/cm².

ii) Rigid Insulation

iii) Reflective Insulation

iv) Acoustic Insulation

 Polished surfaces are used as insulating material.

 It is costlier and maintenance of polished surfaces in large scale is

 It is used in Thermo flasks.

damage, rain and other external hindrances.

• Cladding in boiler is done using metal sheet of galvanised type or

• Aluminium sheet with non-corrosive coating is used for cladding. Also

 In low temperature applications ( in sub-zero levels), water droplets will

 Aluminium sheets of thickness less than 1 mm is used in boiler for

 Before cladding, each layer of insulation should be provided with sealant

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