Upgraded & Prefab Insulation System: Recent Developments in Thermal Insulation System in Industry

UPGRADED & PREFAB INSULATION SYSTEM
RECENT DEVELOPMENTS IN THERMAL INSULATION SYSTEM IN INDUSTRY

Thermal Power Plants
 Thermal Power Plants being set up today are of 600
MW/660 MW /800MW Capacity and have very low
Gestation Period
 The Total surface area for Thermal Insulation are in

the order of 2 lakh Sqm (Approx.1600 MT) for a
typical 800 MW Unit and as the Thermal Insulation
is the last activity very little time is given to
complete the Installation
 The above pointers have necessitated Upgraded and

Pre-fab Technology to be brought in
Role of Thermal Insulation
 A provision made to retard heat flow from a hot
surface to a cold environment and from a warm
environment to a cold surface
 This simple ‘System’ in Industry has acquired
enormous importance in recent times for what it can
do if it is given a very little extra attention
 In Thermal Power Projects Thermal Insulation aids
in limiting the Temperature Drop in the main steam
line from Boiler Outlet to Turbine inlet
 Major tool for Energy Conservation
Hot Insulation Materials
manufactured on commercial scale..
• Rockwool / Mineral wool- by far the most widely manufactured worldwide
• Calcium Silicate- limited to countries where raw materials are available.
• Ceramic Fibre- its high refractoriness making it a material of choice for high temperatures
• Foam Glass-predominantly specified for low temperatures and load bearing applications
Fibrous Materials
• Raw materials like rocks, minerals and others used as
additives and correctives are available in plenty-
particularly in India
• They are made using dry processes- hence are free from
contaminants normally associated with process water.
• They are easily available in various usable forms:
– Blankets, Semi-rigid slabs, or preformed pipe
sections
– Moulded blocks and shapes
– Loose fill
– Encapsulated / laminated constructions
– Sprayable and cement type formulations
for trowel application
Commonly used Hot Insulation
Materials
• Mineral wool : our Rockloyd range
– Rockloyd Mattress
– Rockloyd Slab
– Rockloyd Pipe sections
- Conform to IS 8183, BS 3958 &ASTM-C-592/ C-612 IS 9842& C-547.
- Incombustible when tested as per IS 3144
- Concurrently approved as A-15, A-30 & A-60 Class fire barrier insulation under SOLAS,
Selection of Insulation Materials
0.14
Thermal Conductivity W/m°C
0.12
0.1
0.08
0.06
0.04
0.02
0
38 93 149 204 260 316 371
Mean Temperature °C
Rockwool Pipesections (ASTM C 547)

Perlite (ASTM C 610)
Calcium Silicate (ASTM C 533)
Insulation Materials for High
• Ceramic Fibre: Supercera range
– (RT grade up to 1260°C
– HT Grade up to 1430 °C )
Temperatures
– Supercera needled Blankets and fabrications such as:
• Folded modules
• Encased flexible sections
– Supercera Bulk Fibre
– Supercera rigid Boards / Vacuum formed blocks & Shapes
– Moist felt / Paper / Rope
Insulation Materials for High
• Ceramic Fibre: Supercera range
– Also used as Fire protection in
• Structural Steel applications
• Cable Trays
Temperatures
• Ship Bulkheads / deckheads
– Turbine Insulation
• Removable Type Pads
RECENT DEVELOPMENTS
Rockwool – Inhibited Grade

Thermal Insulation Materials
• Extra Low Thermal Conductivity Materials
– Microtherm
– Pyrogel / Cryogel
Micro porous insulation
Microporous insulation is based on nano-

structured sub-micron synthetic amorphous
silica („SAS“) and other environmentally safe
materials.
Long “chains” of SAS particles help to keep

solid heat conduction to a minimum.
Spaces in the structure smaller than the mean

free path of an air molecule eliminate most of
the gaseous heat convection.
Mineral oxide opacifiers effectively block infra

red radiation.
Microtherm
What are Aerogels?
Translucent silica aerogels are often called “frozen smoke”
 Nanoporous solid
 Aerogels refer both to a structural morphology and
a method to produce them (supercritical extraction
from gels)
 Open-cell structure with up to 99% open porosity
(our blanket is 93-95% open volume)
 Average pore diameters of 10 nm create unique
properties
 Reduced mean free path for gas molecules
 Reduced energy and mass transport
 Traditional silica aerogels are weak and brittle
TECHNICAL SPECIFICATIONS
S NO. MATERIAL
MICROPOROUS INSULATION
Pyrogenic Silica + Mineral opacifire reinforced with glass

1 Material
filament.
2 Density (Kg/M3) 220 to 350
3 Conformity ISO 8302 & ASTM C177 & 168
4 Stability 1000 Deg C
5 Passivity As per ASTM C871
6 Fire Resistance BS 476, DIN 4102, UL94V-0,
7 Compressive Strength 0.10 to 0.22 Mpa ASTM C165
8 Shrinkage < 3% 24hr. Full Soaking
9 Specific Heat Capacity (KJ/Kg.K) 0.92 to1.08
10 SIZE Custom Made
11 Thickness (mm) Standard = 3 to 10mm and 10 to 15mm on demand.
Thermal Conductivity (W/mK)
(as per Indian Standard) ISO 8302 & ASTM C177

Mean temp.
12
50 Deg.C. 0.021
200 Deg.C. 0.025
800 Deg. C 0.034
-170 Deg. C. 0.015
MICROPOROUS INSULATION ISSUES
• Low thermal conductivity at high temperatures

• Lower thickness
• Multiples of 12mm
• Needled blankets / pads
• Casted sections
• Imported
• Very expensive
Lowest k-Value
Mean Temperature (°F)
-300 -200 -100 0 100 200 300 400 500 600 700
120
0.8
Thermal Conductivity, k (Btu-in/hr-ft2-°F)

Thermal Conductivity, k (mW/m-K)
100 0.7
Expanded
Perlite 0.6
80
Mineral Wool 0.5
60 Calsil 0.4
0.3
40
0.2
20 Pyrogel
0.1
0 0
-200 -100 0 100 200 300 400
Mean Temperature (°C)
Insulation Finishes
The outer cover over insulation..

• Weather Barriers/ claddings- These all have one basic
function - to protect insulation from the known
hazards like external media, mechanical abuse etc.
• External coverings are what we get to seeing in a
completed plant or pipeline. Aesthetics becomes a
secondary, but significant role assigned to this
provision.
Insulation Finishes
Weather Barrier
• Installed on outer surface of thermal insulation, these protect the insulation from the weather (rain, snow, sleet, wind), solar radiation, or atmospheric contamination & mechanical
damage.
• They significantly contribute to protection of the insulant and play a vital role in the life of the system.
• Being the final exposed surface, its selection involves study and knowledge of all external and environmental factors the system is to encounter.
Metallic claddings
• As is well known, metallic sheeting fabricated into close conforming cover, with edge detailing to lap and seal effectively, is probably the most popular external cladding.
• However, Plastics, like High Density Poly ethylene (HDPE), PVC and special polymers are specified for niche applications / duties.
• Most popular metal cladding is based on Aluminium- in specific alloy grades for specific duties.
• When steels are specified, they are either of suitable grades of SS or of Carbon steels with a metallurgical protection like galvanizing, Aluminizing or a treatment consisting of a combination of Zinc and Aluminium.
Outer Cladding Systems for
Insulation
• Metallic Cladding Materials
– Aluminium or Galvanised Steel Bare or Colour
coated.
– Zincalume or Aluminised Steels
– Stainless Steel
• Other cladding systems
– Cementaceous plasters
– Liquid applied reinforced Coatings
– HDPE and PVC sheets / sleeves
Insulation Material Selection Chart
Metal Cladding- some important
issues..
• As can be easily appreciated, all metal cladding materials need careful selection from external corrosion point of view as a first consideration.
• However, another important aspect concerns corrosion from within- contributed by condensation of vapours from the insulation system on the inner surface.
• Since most insulants are faintly alkaline, such condensed water attacks the metal – particularly Aluminium and causes it to pit and fail as a barrier.
• All metal cladding, as a rule need protection on the inner surface- like a factory laminated Poly Surlyn treatment.
Cladding Materials
 Metal Claddings with Moisture Barrier
 PolySurlyn
Polyethylene
Surlyn
Polyethylene
Metal Corrosion
Pits
Cladding Specifications
CLADDING MATERIAL
& ACCESSORIES
TCE have specified
Aluminium Sheet with 3
mils thick Polysurlyn
coating for cladding for
4000 MW Ultra Mega
Power Project at
Mundra
27
Cladding Specifications
Alternatively :
3 mil thick
Polysurlyn coating
THERMAL INSULATION DESIGN
Design of insulation broadly covers the following :
1. Defining operating conditions i.e. operating temp.

2. Defining environment condition viz ambient temp. & windage

3. Type of surface – flat or pipe
4. Desired surface temp. usually 600C
5. Type of cladding or environment protective cover and its emissivity factor
6. Insulation material – thermal conductivity, density, form, thickness
7. Heat Loss over cladding – usually max. 150 Kcal/m2hr.
THERMAL INSULATION DESIGN
SPECIFICATIONS
TCE one of the leading Consultants for Thermal Power plants specify
the following Design Conditions and Material
Surface Temperature - 60 Deg C

Ambient Temperature - 30 Deg
Wind Velocity 0 m/s
Aluminium Finish 0.2 m/s
Insulation Material– for Temp upto 400 deg C- LRB Matts 100 Kgs/Cum
for Temp above 400 Deg LRB Matts 150
kgs/Cum
for Temp above 550 Deg 128 Kgs/Cum Ceramic
Fibre Blanket
Insulation Material Selection Chart
Super Heated Steam Pipelines operating
above 500OC
Insulation design
 Number of layers of insulation

 Multiple materials
 Interface temperature
SUPER HEATED STEAM LINES
CERAMIC FIBRE + ROCKWOOL INSULATION

FOR HIGH TEMP. LINES
SUPER HEATED STEAM LINES
CERAMIC FIBRE + ROCKWOOL INSULATION

FOR HIGH TEMP. LINES
SUPERCERA CERAMIC FIBRE PAD
INSULATION
Supercera Ceramic Fibre pad is a composite made of
Superspun Ceramic Fibre insulation material and High
Temperature Resistant High Silica Fabric or Fibre Glass
Fabric uniformly coated with the retardant silicon elastomer
on the top side.
USES : Steam Turbine Insulation, Fire Walls for Isolation,

Valve & Flange insulation cover
AVAILABILITY : Width : 610mm;
Length Max. : 7 mtr.
Tailor made shapes

NEW GENERATION REMOVABLE
INSULATION
PHYSICAL PROPERTIES OF SUPERCERA BLANKET
PHYSICAL RT RTZ HTZ
PROPERTIES
Melting Temp.(oC) 1760 1700 >1650
Specific Heat 1.07 1.07 1.07
(KJ/Kgk)
Fibre Diameter 2.8µ 2.8 µ 2.8 µ
(Mean)
Linear Shrinkage (%) 10000C 1.5 1.5 -
after 24 hrs. Firing / 11000C 2.2 2.2 -
Soaking 12000C 3.0 3.0 2.7
13000C - - 3.5
1400 0C - - 4.0
Max. Service Temp. (OC) 1260 1260 1425
K-Value at Mean Temp. W/mK
5000C 0.10
6000C 0.12
CHEMICAL COMPOSITION OF SUPERCERA BLANKET
GRADE Al2O3(%) SiO2 (%) ZrO2 (%) Max. Service

Temp.
RT 46-48 52-54 - 12600C
RTZ 41-43 50-54 4-6 12600C
HTZ 33-36 48-50 16-18 14250C

INSULATION
UNIQUE FEATURES
High Temperature stability and very good thermal shock resistance.
Very low heat storage
Very low thermal conductivity at very high mean temperature
Available in customized / tailor made shapes and sizes for Turbines, Valves,
flanges and pipes etc.
Outer surface is non-ignitable ‘Silica Fabric’ and thus can be directly mounted
on manifold surface.
Outer surface can be made water and oil proof for outdoor conditions
Snap on type insulation so almost NIL recurring expense during maintenance.
Belts, Toggles, Clips & hooks make mounting and demounting quick and easy.
Excellent physical and refractory properties to withstand up to 1000 0C
temperature.
INSULATION
APPLICATION & ADVANTAGES
Insulation of hot irregular surfaces
Piping, Valves, Flanges, Hot Seals, Welding curtains
Can be used as bellows & Baffles
Turbine Insulation, Exhaust Systems & Catalytic converters & heat exchangers etc.
Multilayer applications with staggered joints sealed with ceramic cloth or tape
Weld stress relieving of joints
Insulation of Boiler Rooms & Steam Station
Available in insulation thickness of 25, 50 & 75mm
ADVANTAGES OF SUPERCERA
CERAMIC FIBRE PAD
 Supercera Ceramic Fibre Pads can be used at
temps. up to 14250C.
 The lower K-value of Supercera Ceramic Fibre pads
results in lower heat loss into the atmosphere and
consequently cooler surface over insulation.
 Supercera Ceramic Fibre pad can be twisted. These
have high flexural strength.
 Supercera Ceramic Fibre pads can be easily
applied even departmentaly. Also this material
being reusable can be removed easily during
maintenance and can be reapplied thus resulting
into long term economy.
Supercera Ceramic fibre Removable Pads
for Turbine Insulation
TECHNICAL DATA SHEET
For Turbine Insulation with Removable & Reusable
Type Supercera Ceramic Fibre Pads
SI.
CHARACTERISTICS SPECIFIED VALUES
No.
PURPOSE / APPLICATION
A. This specification is for Fabric jacketed, Supercera ceramic fibre insulated,
flexible reusable pad for application on Turbine / Hot surfaces
Size (mm) 1000 x 610
Thickness (mm) 50, 75
Encase in Ceramic Fibre / Fibre Glass Cloth
B. CERAMIC FIBRE CLOTH
Colour White
Thickness (mm) 03
Density(Kg/m3) > 400
Organic Content (%) 15-20

SI.
No.
C. FIBRE GLASS CLOTH
Colour White
Thickness (Micron) 200
GSM 190 ± 5%
Oil & Water resistant
SI.
No.
D. CERAMIC FIBRE BLANKET
Colour White
Classification Temperature 1260°C
Density(Kg/m3) 12
Shot Content On 70 Mesh (%) < 30
Tensile Strength (kPa) > 40
Mean Fibre Dia (micron) 2-4
Linear Shrinkage (%)
3.50
at 1200°C for 24 Hours.
Thermal Conductivity (W/mK)
< 0.150
At Mean Temperature 500°C
Shock Resistance Excellent
SI.
No.
E. FIXING WITH
Stitching thread SS 504 wire
F. OTHER PROPERTIES
Fire Resistance Non - Combustible
Chemical Stability / Resistance

Good
of Corrosion
Shock Resistance Excellent
TURBINE INSULATION WITH
CERAMIC FIBRE PAD
APPLICATION SPECIFICATION
1. Cleaning the surface thoroughly with wire brush to ensure that the surface is free of all dust, rust and
grease.
2. Any contamination due to oil, grease shall be removed with a suitable solvent.
3. Providing and fixing MS flat ring of size 25x3mm on casing surface which is secured with either nuts and
bolts or welded on the pads already provided on the casing plate.
4. Additional frame work of M.S. strip is provided to impart adequate stand to the holding structure.
3 & 4 are optional, if pads are not adequately available.
5. The M.S. studs of thickness 6mm and height equivalent to the thickness of insulation (175mm) is fixed
on the MS flat ring holding structure.
6. Providing and fixing the recommended insulation thickness of hot face insulation quilt/pad of 75mm
thickness and cold face insulation quilt/pad of 100mm thickness (double layer of 50mm).
– The hot face insulation pad is made out of three layer of ceramic fibre blanket of thickness 25mm and density
128kg/m3 covered with ceramic cloth on all sides and joints stitched with 20SWG SS wire. Ceramic fibre tape 75mm
wide is applied on the edges of the pad so as to cover the cloth overlapping/stitching joints on all the sides. SS
washer are fixed on the corner and over the insulation pad Surface.
– The cold face insulation pad is made out of double / triple layers of 50mm each . Each 50mm pad is made out of two
layers of ceramic fibre blanket of thickness 25mm and density 128kg/m3 having 0.1mm aluminium foil inserted
between 2 layer of ceramic blankets, covered with MFMB glass cloth on all sides and joints stitched with 20SWG SS
wire. Glass fibre tape 50mm wide is applied on the edges of the pad so as to cover the cloth overlapping/stitching
joints on all the sides. SS washer are fixed on the corners and over the insulation pad Surface.
TURBINE INSULATION WITH
CERAMIC FIBRE PAD
APPLICATION SPECIFICATION
7. The insulation pads are held in the position with the help of SS clip washers provided after piercing of
these pads to the supporting cage work( already fabricated and fixed). SS wires are used to tie the pads.
The pads placing to have staggered joints.
8. Providing and applying 75mm ceramic tape at the pad overlapping joints.
9. The casing flange joints are provided with 18 SWG aluminium sheet fixed with MS cleats and filled with
insulation pads of same thickness.
10. Design Data for TURBINE insulation
Size of the insulation Pad = 1M x 0.61 M
Total insulation thickness= 200 to 250 mm
Ambient Temperature = 40 Deg.C
Operating Temperature = 565 Deg.C (max.)
Surface Temperature = 58 – 60 Deg.C
Wind Velocity = 0.25m/sec
Turbine Insulation
With Removable Type Ceramic Fibre Preformed
Pad
Turbine Insulation
With Removable Type Ceramic Fibre
Preformed Pad
Application Procedure
1. Surface Cleaning
2. Fixing frame work made out of MS angle for

holding the Heat shield by welding at
suitable position as per site condition.
3. Welding MS Flat on casing surface at

preinstalled plates
4. Covering Nuts Bolts with Aluminium Foil

Turbine Insulation
Preformed Pad
Application Procedure
5. Fixing SS Stud of required length with MS Flat
6. First layer CF Pad encased in CF Cloth and secure with
speed washer
7. Pad to Pad stitching with SS wire
8. Subsequent layers of CF pad encased in Glass Cloth in
staggered manner and securing with speed washer.
9. SS wire netting fixing after final layer
10. Wrapping Ceramic Tape of 75mm overlapping the
joints of Pads.
Turbine Insulation
Preformed Pad
Turbine Insulation
Preformed Pad
Fixing SS Stud of required length with MS Flat
SS Studs
25x3 MS Flat
Turbine Casing
Preinstalled Welding Points
Turbine Insulation
Preformed Pad
First layer Ceramic Pad
1st Layer Ceramic Fibre Pad
Speed Washer
Turbine Casing
Pad joints Stitched

with SS wire
Turbine Insulation
Preformed Pad
Subsequent Layer Ceramic Fibre Pad
1st Layer Ceramic Fibre Pad

Subsiquent Layer Ceramic Fibre Pad
Pad joints Stitched

with SS wire
Turbine Insulation
Preformed Pad
Turbine Insulation
Preformed Pad
SS wire netting fixing after final layer
SS Wire Mesh
Turbine Insulation
Preformed Pad
Securing Pad Joints with Ceramic Tape
75 mm Ceramic
Tape at PAD Joints
Insulation Thickness
i. Top - 175 to 225mm

ii. Bottom - 225 to 275mm
TURBINE INSULATION USING CERAMIC PADS
VALVES INSULATION USING CERAMIC
PADS
Removable type Teflon coated
Water Proof
PADS
Supercera Pad Application
Valve & Flange Insulation

SUPERCERA SPECIAL PRODUCTS
VALVE COVERS
QUICK INSULATION CONCEPT

Removable / Reusable Insulation Systems
PADS
BARE VALVE
AFTER 25MM
SUPERCERA CERAMIC
FIBRE PAD INSULATION
PADS
CAIRNS
BARMER

Recent applications

Recent applications

Recent applications
For Flexible, Removable & Reusable Type factory-
made, prefabricated Insulation Covers/Pads
A. Purpose/Application
This Engineering specification is for Fabric jacketed supercera ceramic Fibre insulated
flexible reusable covers/pad for application on pipes: pipe fittings, valves, flanges etc
vessels & equipments, tubes etc in hot services.
01 Dimension (mm) As per drawing/sketch provided by client

02 Thickness (mm) 25-100
1. Specification of Protective jacketed material
i Vest Cover Liner Fibre Glass Fabric
ii External Top Cover Polymer Coated Fibre Glass fabric Temp. resistance 300 Deg.
Fabric C, oil & water resistant
(for cold face)
iii External Bottom Cover High silica cloth for Temp Resistance up to 900 Deg C
fabric
(for hot face)
2. Specification of insulation Ceramic Fibre Blanket
Material (As per IS 15402)
i Classification Tempreature 12600C
ii Thickness 25 – 100mm
iii Bulk Density 128kg/m3
iv Shot content on 70 mesh %) <30
v Tensile strength (KPa) >40
vi Mean Fibre Dia (Micron) 2-4
vii Linear Shrinkage (%) At 1200 3.5
Deg. C for 24 Hrs
viii Thermal Conductivity (W/mK) 1000C 2000C 3000C 5000C
Max. 0.046 0.072 0.078 0.150
ix Chemical composition SiO2% 49-58
Al2O3% 41-48
ZrO2% 0-7
FeO3% <0.1
3 Hardware & Non Metal fastening
i) Buckle/Draw Stings Stainless steel, High Temp Braided Chord of fibre glass
ii) Stic Pins Stainless Steel Pins to prevent the insulation from
movement inside the cover
iii) Stitching Double sewn with Teflon coated Fibre glass wrapped
stainless thread.
iv) Belting High Temp Fabric same as used in hot face cover
4 Other Properties
i Fire Resistance Non-Combustible
(As per BS 476 Part-4)
ii Chemical Good
Stability/Resistance of
Corrosion/water
iv Shock Resistance Excellent
Fire Cover Insulation

Rating 30 mins. To 180 mins.
PADS
FIRE PROOFING OF VALVES

FIRE PROOFING & INSULATION

FIRE PROOFING & INSULATION
CABLE TRAYS
UPGRADED TG INSULATION
SPECIFICATIONS
SL. EXISTING PROPOSED
NO
.
1 Ceramic Fibre 128 Ceramic Fibre RTZ Grade, 128 kg/m3 Blankets.
kg/m3 Zirconia is a stabilizing component of long
expose to high temperature.
Only blankets, no edge cuttings material.
K-value is 0.10 W/mK at 500 deg.C mean
temperature.
2 Ceramic cloth facing on Ceramic cloth of speciality fabric and treated /
hot face and Glass cloth baked at factory for hot facing and stitched with
on Cold face SS wire at edges and provided with SS hooks at
the edges and body.
Glass cloth for cold face comprising of silicon /
polymer coating and outer face to be oil and
water resistance. The cold face pads to be
stitched with SS wire and provided with
industrial hooks at the edges and body. The
cold face pads will not absorb oil leakage
SPECIFICATIONS
NO
.
3 Other  Non-combustible
properties not  Excellent Chemical properties
mentioned  Excellent shock resistant
4 Application Placing of floating ring arrangement.
No method Welding of 6mm dia rods equivalent to insulation
provided thickness, placing hot face pad with joints overlapped and
held in position with speed washers and stitched with SS
wire through the hooks, placing of cold face pads in similar
fashion as above.
Final finish with glass cloth (oil & water resistant 190±5
gsm.) over the cold face pad tightly holding the pads.
Alternatively aluminium sheet cladding over a frame work.
The joints between pads to be applied with 75mm wide
tape. Proper application procedure will ensure snug fit
tightly held insulation and ensure no sagging over period
of time and heat losses.
SPECIFICATIONS
NO.
5 Performance Test procedure not PG Test with infra-red instruments and
there assurance of 60 deg.C surface
temperature
UPGRADED BOILER INSULATION SPECIFICATIONS
NO
.
1 Rockwool Insulation First layer 50mm (2x25mm) Ceramic Fibre
Mattress insulation 128 kg/m3 held with pins and stuck with
speed washers tightly over boiler surface with
joints overlapped and staggered
Ceramic fibre does not contain any phenol
formaldehyde resin hence no evaporation at
2300C, which otherwise makes the Rockwool first
layer loose after continuous exposure making
insulation loose over period of time. Ceramic
fibre keeps the insulation fitting tight over boiler
surface ensuring no sagging and increasing life of
insulation. Ceramic fibre has lower thermal
conductivity at 5000C mean temperature as
compared to Rockwool. First layer Ceramic Fibre
is already practiced in the Power Industry and now
part of NTPC project specification.
UPGRADED BOILER INSULATION
SPECIFICATIONS
NO.
2 Cladding corrugated Cladding with corrugated aluminium sheet
Aluminium sheet having 3 mil polysurlyn lamination on inner
side.
Polysurlyn lamination protects the sheet from
internal corrosion. Already practiced in the
industry (EIL, TCE, BHEL, PDIL)
3 Buckstay Cavity – no Filling cavity with 2 layers of Ceramic Blanket
procedure provided 128 kg/m3, 50mm held in position with
Ceramic Boards 25mm, 320 kg/m3 and
balance with Rockwool Mattress of 150 kg/m3.
Finally applying Aluminium sheet 20G as
cladding.
SUPERCERA BLANKET LINING
First layer Lining on Boiler
99
UPGRADED PIPING INSULATION
SPECIFICATIONS
NO
.
1 Rockwool Insulation  Rockwool insulation of 100 kg/m3 upto 400
Mattress for all deg.C.
temperatures  Rockwool insulation of 150 kg/m3 from 401 to
500 deg.C.
 First layer Ceramic Fibre Blanket 128 kg/m3,
50mm followed by Balance layer of Rockwool
Mattress 150 kg/m3 for above 500 deg.C.
 Ceramic blanket to be held with SS bands at
450mm C/C and 300mm C/C for pipe dia above
12”.
 Final layer of Rockwool Mattress to be tied with
aluminium band at 300mm C/C.
 Providing 22G aluminium sheet cladding with 3
mil thick polysurlyn lamination
 Providing aluminium bands over the cladding at
450 mm C/C.
UPGRADED VALVE & FLANGE
INSULATION SPECIFICATIONS
NO.
1 Rockwool insulation with Ceramic Fibre pad made with Ceramic
Aluminium sheet cladding Fibre blanket 128 kg/m3 and glass
once removed cannot be put cloth covering on all sides, tailor made
back to valve size.
These pads are removeable and re-
useable type
UPGRADING INSULATION OF
EXISTING PLANT
 Audit of plant services
 Recording of temperature data
 Submission of report with recommendation of
Thickness, Heat Loss, Cost of new insulation,
Reduced Heat loss and pay back
 Carrying out Re insulation
 Carrying out Performance Guarantee Test after
completion of work and commissioning of plant
THERMAL INSULATION AUDIT
THE
THENEED
NEED
Energy demand and consequently, consumption is ever increasing in every
Energy demand and consequently, consumption is ever increasing in every
conceivable industry.
conceivable industry.
Costs of non-renewable energy sources (Furnace Oil, LSHS, Coal etc.) have risen
Costs of non-renewable energy sources (Furnace Oil, LSHS, Coal etc.) have risen
by leaps and bounds, especially over the last decade and a half.
by leaps and bounds, especially over the last decade and a half.
Waste heat recovery systems, economizers etc. generally employed for energy
Waste heat recovery systems, economizers etc. generally employed for energy
conservation are capital intensive.
conservation are capital intensive.
Thermal insulation, when properly designed and applied, can reduce energy loss
Thermal insulation, when properly designed and applied, can reduce energy loss
(heat gain / loss), easily, to the extent of 90% or more.
(heat gain / loss), easily, to the extent of 90% or more.
Till a few years ago, insulation system was never ‘designed’. Insulation was applied
Till a few years ago, insulation system was never ‘designed’. Insulation was applied
only to “reduce surface temperature”.
only to “reduce surface temperature”.
Even when designed on a scientific basis, the design was based on ‘the then’ fuel
Even when designed on a scientific basis, the design was based on ‘the then’ fuel
costs.
costs.
Insulation material and application practices have improved upon yester year
Insulation material and application practices have improved upon yester year
standards.
standards.
Evidently, therefore, existing insulation systems, in almost every plant, are
Evidently, therefore, existing insulation systems, in almost every plant, are
ineffective.
ineffective.
In these days of depleting sources of fuel and prohibitive fuel costs, it is unwise not
In these days of depleting sources of fuel and prohibitive fuel costs, it is unwise not
to fully utilize the capability of insulation to save energy.
to fully utilize the capability of insulation to save energy.
The pressing need, therefore, is to assess the existing insulation systems, identify
The pressing need, therefore, is to assess the existing insulation systems, identify
the critical energy loss areas and upgrade the insulation systems of such areas on
the critical energy loss areas and upgrade the insulation systems of such areas on
priority basis.
priority basis.
THERMAL INSULATION AUDIT
PROCEDURE
 Surface
Surfacetemperature
temperatureover
overcladding
claddingofofpipeline
pipeline&&equipments
equipmentsare
are
recorded
recorded
 Measured
MeasuredAmbient
Ambienttemperature
temperature
 Site
Sitewind
windvelocity
velocityrecorded
recorded
 Insulation
Insulationthickness
thicknesschecked
checkedand
andrecorded
recorded
 Emissivity
EmissivityofofInsulation
InsulationCladding
Claddingsurface
surface
 Current
Currentoperating
operatingdata
datacollected
collectedand
andrecorded
recorded
 Design
Designdata
datarecorded
recorded
METHODOLOGY
The study is conducted in 3 stages:

I. Stage 1: Walk through audit to understand process energy
drivers, measurability and formulation of inspection plan
II. Stage 2: Detailed Insulation Audit
III. Stage 3: Off-site work for data analysis and report preparation
Thermal Imaging With Infrared Camera
UPGRADED INSULATION
PERFORMANCE TESTING
 Testing Performance of insulation over Piping and

Equipments with infra-red camera.
 Recording Surface Temperature over cladding which
should be 60 deg.C or below.
 During PG Test, actual parameters to be compared
with design parameters and interpolated.
 Submission of Manufacturer Test Report as well as
NABL approved laboratory Test Reports including K
value Test Certificates.
EFFICIENT INSULATION WORK
PROCEDURE FOR EXISTING PLANT
SERVICES
SUPPLY & APPLICATION SINGLE CONTRACT
ADVANTAGES
Proper estimation of material quantities by contractor including
management of increased quantities during execution.
Handling of situation with change / modification in specifications by
contractor amicably
Time management due to delays in mechanical / other related works
leading to delays in site releases
In typical shut down management & planning of materials & manpower
as per schedule and releases
EFFICIENT INSULATION WORK
PROCEDURE FOR EXISTING PLANT
SERVICES
SUPPLY & APPLICATION SINGLE CONTRACT
ADVANTAGES
Storagemanagement by contractor at site
Ensuring job quality with proper supervision
Thermal Performance Guarantee Test
Involvement of Established, Efficient & Experienced contractor
Any sort of contingency during execution

Quotation for labour contract usually for normal conditions & height.
Knowledge of materials, specifications & work

We, have In-house manufacturing units and therefore,
shall have full control on Quality and delivery schedule.
1.Rockwool : 60000 MTPA
2.Ceramic Fibre : 4500 MTPA
3.PUF / PIR : 17250 CUM PA
OTHERS
1.Aluminium Sheet
2.Ancillaries
3.Microporous Insulation
In case of any change in specifications /quantity / thickness
of insulation material during the course of execution of
work, the material can be organized in a very short notice,
meeting the revised specifications.
In-house Technical Services Dept. can assist in thickness

calculation.
In case of turnkey award on us and we having in-house
manufacturing unit shall bring material in a planned manner
at site progressively depending on the release of work front.
Thus less storage place at site is required / storage of
material for the long period is avoided + payment needs to
be released progressively by the client. Thus, less burden on
their financial resources.
In case of supply storage arrangement will be the client

account. Covered storage required for full quantity of
material.
We have the privilege of having associated with all major
industries for their Insulation requirement in India and thus
familiar with the local working conditions. We have our set
up in every nook and corner of all over India.
We have executed more than 20,000 projects during past 58

years all over India in ambient condition of -35 to 50 deg.C
(Leh to Barmer) and highly wet condition of North East &
Coastal areas.
Insulation being last activity in any Project all delays needs
to be compensated during Insulation work. Tight completion
schedule, - we work in two shifts – day & night. Have
enough manpower, Supervisor, Engineer, Quality engineer,
Safety Engineer, Qualified and Experienced Team. We have
work force of 2000+ company employees and additional
5000+ contractors / PRW work force to complete the site
execution work. We are better placed for Site Management
with reduced time period.
We can mobilize additional work force, Tool & Tackles,
Scaffolding, Safety Gadgets to meet the changed
completion target.
Since mobilized from early stages of project schedule will

be able to visualize the work progress and remain in contact
with client / consultant and do necessary material &
manpower planning and accordingly mobilization.
CREDENTIALS
LLOYD INSULATIONS STRENGTH
 60 Years+ old Design, Engineering, Contracting Company with
inhouse manufacturing
 ISO : 9001, 14001 & 18001 Certified Contracting & Manufacturing
Company.
 ESCO Company
 Highest order value Rs.1630 Million / Rs. 163 Cr.
 Highest insulation order Rs. 750 Million / Rs. 75 Cr.
 Highest Refractory order value Rs. 350 Million / Rs. 35 Cr.
 Highest PEB order Rs.406 Million / Rs. 40.60 Cr.
 Highest Panel work – Rs. 310 Million / Rs. 31 Cr.
 Highest Fire Proofing work – Rs.290 Million / Rs. 29 Cr.
 Highest Electric Heat Tracing work – Rs.270 Million / Rs.27 Cr.
 Highest PEB – Panel Cold Store work Rs. 280 Million / Rs. 28 Cr.
 Highest Acoustic Enclosure work – Rs.80 Million / Rs.8 Cr.
Power Plant Project References ….
Client : M/s. Powergen Infrastructures (L.L.C) (5x660MW, Adani Power Project,
Tiroda)
Tiroda)
Tiroda)
Tiroda)
Tiroda)
Tiroda)
Tiroda)
Tiroda)
Tiroda)
Tiroda)
Client : M/s. Siemens Limited, Haryana
(3x400MW CCPP Defence Project Daheja)
Client : M/s. Shandong Tieguin Electric Power Engg
(2x660MW & 3x660MW, APL Power Project Mundra)
Client : M/s. Shandong Tieguin Electric Power Engg
(2x660MW & 3x660MW, APL Power Project Mundra)
Client : M/s. Coastal Gujarat Power Limited, Mundra
Roofing &Cladding for coal handling system A/c. M/s. Adani Power Ltd.,
Mundra.
134
Double Skin Roofing & Cladding for Turbine Hall
A/c. M/s. JSW Energy Ltd., Ratnagiri Coastal Mega Power Project,
Jaigad
Roofing &Cladding for Power plant of M/s. Bechtel International
Inc., Dabhol Power Project, Dabhol.
Roofing &Cladding for National Thermal Power Corporation , Gandhar.
Roofing &Cladding for National Thermal Power Corporation,
Faridabad
Simhadri
Talcher
Thank you !

Upgraded & Prefab Insulation System: Recent Developments in Thermal Insulation System in Industry

Uploaded by

Copyright:

Available Formats

Upgraded & Prefab Insulation System: Recent Developments in Thermal Insulation System in Industry

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Upgraded & Prefab Insulation System: Recent Developments in Thermal Insulation System in Industry

Uploaded by

Copyright:

Available Formats

UPGRADED & PREFAB INSULATION SYSTEM

RECENT DEVELOPMENTS IN THERMAL INSULATION SYSTEM IN INDUSTRY

 The Total surface area for Thermal Insulation are in

 The above pointers have necessitated Upgraded and

Rockwool Pipesections (ASTM C 547)

Rockwool – Inhibited Grade

Microporous insulation is based on nano-

Long “chains” of SAS particles help to keep

Spaces in the structure smaller than the mean

Mineral oxide opacifiers effectively block infra

 Average pore diameters of 10 nm create unique

Pyrogenic Silica + Mineral opacifire reinforced with glass

9 Specific Heat Capacity (KJ/Kg.K) 0.92 to1.08

10 SIZE Custom Made

11 Thickness (mm) Standard = 3 to 10mm and 10 to 15mm on demand.

Thermal Conductivity (W/mK)

(as per Indian Standard) ISO 8302 & ASTM C177

• Low thermal conductivity at high temperatures

Thermal Conductivity, k (Btu-in/hr-ft2-°F)

The outer cover over insulation..

2. Defining environment condition viz ambient temp. & windage

Surface Temperature - 60 Deg C

 Number of layers of insulation

CERAMIC FIBRE + ROCKWOOL INSULATION

CERAMIC FIBRE + ROCKWOOL INSULATION

USES : Steam Turbine Insulation, Fire Walls for Isolation,

Tailor made shapes

GRADE Al2O3(%) SiO2 (%) ZrO2 (%) Max. Service

RTZ 41-43 50-54 4-6 12600C

HTZ 33-36 48-50 16-18 14250C

Stitching thread SS 504 wire

Fire Resistance Non - Combustible

Chemical Stability / Resistance

2. Fixing frame work made out of MS angle for

3. Welding MS Flat on casing surface at

4. Covering Nuts Bolts with Aluminium Foil

Fixing SS Stud of required length with MS Flat

First layer Ceramic Pad

1st Layer Ceramic Fibre Pad

Pad joints Stitched

Subsequent Layer Ceramic Fibre Pad

1st Layer Ceramic Fibre Pad

Pad joints Stitched

SS wire netting fixing after final layer

Securing Pad Joints with Ceramic Tape

i. Top - 175 to 225mm

Removable type Teflon coated

Valve & Flange Insulation

QUICK INSULATION CONCEPT

Valve & Flange Insulation

Valve & Flange Insulation

Valve & Flange Insulation

01 Dimension (mm) As per drawing/sketch provided by client

Fire Cover Insulation

FIRE PROOFING OF VALVES

FIRE PROOFING & INSULATION

FIRE PROOFING & INSULATION

First layer Lining on Boiler

The study is conducted in 3 stages: