THERMAL INSULATION

EFFICIENT THERMAL INSULATION IS ESSENTIAL WITH HIGH OPERATING TEMP & INCREASED ENERGY COST PRODUCTION, DISTRIBUTION, & USE OF STEAM REQUIRE THERMAL INSULATION FOR ENSURING PROCESS REQUIREMENT STEAM GENERATED AT BOILER MUST BE DELIVERED TO THE POINT OF USE AT CURRECT TEMP & PRESSURE

OBJECTIVE OF THE ENERGY AUDIT OF THERMAL INSULATION

ENERGY CONSERVATION RESOURCE OPTIMISATION HIGH AVAILABILITY HIGH REILIABILITY OPTIMUM COST EFFECTIVE MAINTENACE PLANNING & SCHEDULING

TYPES AND FORMS OF INSULATION MATERIAL

S.NO. INSULATION TYPE DENSITY (kg/m) 150 80-250 10-150 20-250 APPROXIMATE LIMITING TEMP.( C) 450 600 550 850

1. 2. 3. 4.

Cellular glass Asbestos Glass fibre Rockwool and Slagwool

Cellular Fibrous Fibrous Fibrous

5.
6. 7. 8. 9. 10. 11. 12. 13.

Calcium silicate
Magnesia Diatomaceous Silica Aluminosilicate Aluminosilicate Aluminium Stainless steel Vermiculite

Granular
Granular Granular Fibrous Fibrous Granular Reflective Reflective Granular

200-260
200 250-500 50-150 50-250 500-800 10-30 300-600 50-500

850
300 1000 1000 1200 1200 500 800 1100

Determination of the Economic thickness of Insulation Material

cost

: : : : : : : : :
INSULATION THICKNESS

I : Cost of Insulation I + H : Total Cost

H : Cost of Heat Loss M : Economic Thickness

The determination of economic thickness requires the attention to the following factors. I. II. III. IV. V. VI. VII. VIII. Cost of fuel Annual hours of operation Heat content of fuel Boiler efficiency Operating surface temperature Pipe diameter/thickness of surface Estimated cost of insulation. Average exposure ambient still air temperature.

HEAT LOSS CALCULATIONS

S = [10 + (Ts Ta)/20] (Ts Ta) S = SURFACE HEAT LOSS IN K.Cal/hr M2 Ts = HOT SURFACE TEMP, C Ta = AMBIENT TEMP, C

EXAMPLE : HEAT LOSS CALCULATION

STEAM PIPE 100 MM DIA BARE UPTO 100 METERS

LENGTH STEM SUPPLY AT 10KG/Cm2 , INSULATION THICKNESS 65 MM BOILER EFFICIENCY 80%, FUEL OIL COST - $300/TONNE INSULATED SURFAC TEMP - 65C; BARE SURFACE 170 C AMBIENT TEMP 25 C

HEAT LOSS CALCULATIONS

HEAT LOSS THROUGH BARE SURFACE:S = [10 + (170 25)/20] x (170 -25) = 2500 K Cal/hrm2
HEAT LOSS THROUGH INSULATED SURFACE:S = [10 + (65 25)/20] x (65 - 25) = 480 K Cal/hrm2

FUEL SAVINGS CALCULATIONS

PIPE SURFACE AREA = 3.14 X .1X100 = 31. 4m2
REDUCED HEAT LOSS = 2500 480 = 2020 KCal/hrm2 TOTAL HEAT LOSS = 2020X31.4X8400 = 532795200 K Cal/yr CALORIFIC VALUE OF FUEL OIL 10300 K. Cal/kg BOILER EFF 80%, DENSITY OF FUEL 0.97 kg/L FUEL PRICE - $ 300/kl. YRLY OILSASVINGS (532795200)/(10300)X(0.8)X(0.97) -- 66659 LITRES OR 66.659 KL MONETARY SAVINGS = 66.659X300 = $19997

HEAT LOSS CALCULATIONS BASED ON STEFEN BOLTZMANS EQUATION/EXPRESSION

HR = A(Ts4 Ta4) Watt

= E MISSIVITY OF SURFACE A = AREA OF HOT ZONE Ts = SURFACE TEMP, k Ta = AMBIENT TEMP, k Hc = CA (Ts Ta) Watt C = COEFICIENT OF CONVECTION
= 0.6 (OXIDISED Al SURFACE) C = 5 (NATURAL WIND FLOW VELOCITY 0.5 1.0 m/s)

CONVECTIVE HEAT TRANSFER

HEAT TRANSFER TAKES PLACE BY TWO MECHANISMS - BY DIRECT CONDUCTION THROUGH THE FLUID - BY THE MOTION OF THE FLUID ITSELF CONVECTIVE HEAT FLOW IS DETERMINED BY SURFACE TEMP, SURROUNDING TEMP & SPEED OF THE FLUID MOTION CONVECTIVE HEAT TRANSFER BETWEEN DECK SURFACE & THE SURROUNDING AIR CAN BE OBTAINED BY USING LANGMUIRS EQUATION. QC = 1.947 (Ts Ta)5/4 (V+0.35)/0.35, w/m2 Ts = SURFACE TEMP OF THE DECK, C Ta = AMBIENT AIR TEMP, C V = WIND VELOCITY, m/s

GUIDELINE FOR THE INSULATION SCHEME

Temperature 25 mm Less than 100C 100 150C 150 200C 200 250C 25 mm 25 mm 25 mm 25 mm Pipe Diameter 50 mm 25 mm 25 mm 40 mm 50 mm 75 mm 100 mm 50 mm 50 mm 50 mm 50 mm 50 mm 65 mm 50 mm 65 mm Flat 150 mm Surfa ces 65 mm 65 mm 75 mm 75 mm 50 mm 75 mm 90 mm 90 mm

250 - 300C

25 mm

50 mm

50 mm 75 mm

90 mm

100 mm

Thermal insulation can be justified by balancing the cost of different heat losses or heat savings against the cost of insulation.

EVALUATION OF OPTIMUM INSULATION THICKNESS

PIPE DIA = 100 mm, PROCESS TEMP = 200C, AMB. TEMP = 40C TEMP. AT INSULATED SURFACE = 55C , BOILER EFF = 88% COAL COST = Rs 1.9/kg, CV OF COAL = 3770 K Cal/kg K OF ROCKWOOL = 0.036, PLANT OPTG HRS = 7920 (24X330) DEPRICIATION OF INS = 20%; INTEREST ON INS COST = 15% COST OF USEFUL HEAT = Rs 1.9/(3770X0.88) = Rs 0.0005727/ K Cal ASSUMING INS THICKNESS = T = 25 mm, GIVEN PIPE DIA (D) = 100 mm AREA IN m2/m LENGTH OF PIPE = 3.14 (D+2T) = 3.14 [(100 + 2X25)/1000] = 0.471 HEAT LOSS, K. Cal/m2hr = KT/INS. THICKNESS,

= 0.036 (200-55)/0.025=208.80
HEAT LOSS COST = (208.8)(7920)(0.471)(0.0005727) = 446.07 (Rs/m)

IS 14164 : 1994 (-80C TO 700C )

ACCEPTABLE SKIN TEMP FOR STEAM PIPE
LINES/BOILERDRUMS/BOILER SURFACE 15 C WITH WIND VELOCITY OF IM/S

+ AMB

MOST NEGLECTED AREAS ARE FLANGES/ VALVES/TEES etc MIN, DENSITY OF ROCKWOOL MATTRESS 128 kg/M3 FOR SURFACE TEMP>400 C & 100 kg/M3 FOR <400 C
AL SHEET OF 18/20/22 SWG MAY BE USED FOR CLADDING.

ROCKWOOL MATTRESS:
ROCKWOOL IS A PRECISELY ENGINEERED RESIN BONDED FIBROUS INSULATION TO OFFER MAXIMUM RESISTANCE TO HEAT PASSAGE. FIBRES ARE SPUN FROM SELECTED ROCKS, MELTED AT 1600C AND BLENDED TO A CAREFULLY ADJUSTED CHEMICAL COMPOSITION. ITS CENTRIFUGALLY SPUN FIBRES HAVE A DIAMETER 1/20TH THAT OF HUMAN HAIR WHICH ARE FELTED USING STATE OF THE ART TECHNOLOGY INTO BONDED AND CURED MATTRESS TO OPTIMUM DENSITY AND RESILIENCE.

WHY RESIN BOND & MACHINE STITCH:LIKE ALL SCIENTIFICALLY PROCESSED FIBROUS INSULANTS IS COMPOSED OF FIBRES WHICH ARE LAID IN THE OPTIMUM CONFIGURATION TO OFFER MAXIMUM RESISTANCE TO HEAT FLOW. TO RETAIN THESE EXCEPTIONAL PROPERTIES UP TO THE POINT OF END-USE, FIBRES ARE INTERLOCKED BY LIGHTLY BONDING THEM TOGETHER USING A THERMOSETTING BINDER. SUBSEQUENTLY, MATTS ARE FACTORY STITCHED TO SPECIFIED WIRE MESH USING A CONTINUOUS STITCHING MACHINE TO PERMIT A READY-TO-USE CONFIGURATION.

SALIENT FEATURES OF INSULANT

HIGHER THERMAL PERFORMANCE, AS IT IS MADE OUT OF
ROCKWOOL AND NOT SLAGWOOL. ELIMINATES SETTING AND SAGGING. LONGER LIFE, PERMITTING REUSE AFTER REMOVAL DURING MAINTENANCE. ENVIRONMENT FRIENTLY, AS THERE IS NO CHICKEN FEAT HERING (WHICH NORMALL POLLUTES THE ENVIRONMENT). IT IS ECO FRIENDLY TO PERSONNEL DUE TO THE CHEMISTRY OF FIBRES. UNCONTAMINATED, AS MANUFACTURING IS TOTALLY A DRY PROCESS. APPLICATION FRIENDLY, AS IT PERMITS VERY FAST INSTALLATION.

TECHNICAL SPECIFICATIONS
STANDARD DENSITIES
: 100, 120 AND 150Kg/m APPLICATION TEMPERATURES : -100 C +800 C STANDARD THICKNESS * : 25, 40, 50, 65, 75mm STANDARD SIZE : 1520 X 1220 mm * OTHER THICKNESS FROM 20 TO 100 mm INSTEPS OF 5 mm CAN ALSO BE MADE AVAILABLE

CORROSION - PROTECTION
ROCKWOOL FIBRES, IN THE FIRST PLACE, ARE DEVOID OF IMPURITIES LIKE HALIDES (CHLORIDES & FLUORIDES) AND SULPHIDES WHICH ARE COMMONLY FOUND IN OTHER MATERIALS SUCH AS CALCIIUM SILICATE. THIS IS DUE TO THE FACT THAT FIBRES ARE MANUFACTURED BY A DRY MANUFACTUING PROCESS AND ITS FAINT ALKLINITY ACTUALLY FIGHT A AGAINST CORROSIVE REACTIONS. IT MEETS VARIOUS CRITICAL SPECIFICATIONS INCLUDING ASTM C-795 REQUIREMENTS WHERE SPECIFIED. THIS FEATURE IS RESPONSIBLE FOR ITS EXCLUSIVE SELECTION FOR CRITICAL APPLICATIONS SUCH AS NUCLEAR POWER PLANTS.

INSULATION CONDITION PREDICTION

Plant visit & discussion

Collection of Techno-commercial information. Field study by using most sophisticated Thermovision instrument (camera) Model NEC-TH-5104 Identification of Hot zones/spots Calculation of Heat Loss Estimation of annual financial savings

THERMOGRAPHY
Advantage of Thermography:
Non-contact type of temperature meausrement Portability Effective observation & inspection Easy interpretation through colour images Quick report generation

EXECUTIVE AUDIT SUMMARY STAGE I (2X210MW)

UNIT -I UNIT - II TOTAL

Present Heat Loss (Kcal/hr)

Heat Loss Saving Potential after Insulation upgradation (Kcal/hr) Saving Potential in Rupees

794279

613012

1407291

608401

523338

1131740

21,73,008

18,65,617

40,38,625

FINDNGS: Unit#1: Boiler Side

Kcal/hr Bare Only 63243 % 11 Area m2 33 % 9

Damaged/Inadequate
No Cladding

504416
4520

88
1

337
1

91
0

FINDNGS: Unit#1: Turbine Side

Kcal/hr % Area m2 49 97 11 %

Bare Only Damaged/Inadequate No Cladding

127125 90812 4162

57 41 2

31 62 7

FINDNGS: Unit#2: Boiler Side

Kcal/hr Bare Only Damaged/Inadequate No Cladding 65334 483280 7202 % 12 87 1 Area m2 33 335 6 % 9 90 2

FINDNGS: Unit#2: Turbine Side

Kcal/hr % Area m2 %

Bare Only
Damaged/Inadequate No Cladding

31362
21819 4015

55
38 7

11
26 7

25
59 15

UNIT-WISE OBSERVATIONS & RECOMMENDATIONS UNIT # 1 BOILER SIDE: The following areas are having temperature more than 200 C. . The insulation of these areas to be upgraded at the earliest.
S. N O. Area Identified Side Present Insulation Condition Total Area (m2) Refer Thermal Observed Saving ` Image No. Surface (Kcal/hr Temp ) (C) 330 305 3146 Image No. 01 955

1. 2.

54 Meter Level MS ERV Body 3. RH Start-up vent valve Body2 nos. 4. CRH S/V body 5. HRH S/V body 6. 52 Meter Level 7. CRH S/V neck 8. 31 Meter Level 9. Rightside peephole 10. 28 Meter Level

Left

Bare

0.471 0.160

Righ Bare t Left Left Bare Bare

0.251 0.251

256 215

1035 729

Left

Bare

0.118 0.480

306 205

652 Image No. 02 1333 Image No.22

Left- Inadequate Pl

ENERGY AUDIT : FINANCIAL SAVINGS

UNIT # 1
Total present surface heat loss = 794279 kcal/hr Total reduction of heat loss by insulation upgradation = 608401 kcal/hr Average C.V. of coal = 3750 kcal/kg Average Boiler efficiency = 0.7835 So, equivalent reduction of coal consumption = 608401 / (3750 x 0.78) = 207.07 Kg/hr Equivalent annual reduction of coal assuming 330 days of plant operation = 207.07 x 24 x 330 Kg = 1640 MT Annual monetary saving @ Rs. 1325/- per MT = 1640 x 1325 = Rs. 21,73,008/-

ENERGY AUDIT : FINANCIAL SAVINGS

UNIT # 2
Total present surface heat loss = 613012 kcal/hr Total reduction of heat loss by insulation upgradation = 523338kcal/hr Average C.V. of coal = 3750 kcal/kg Average Boiler efficiency = 0.785 So, equivalent reduction of coal consumption = 608401 / (3750 x 0.785) = 177.78 Kg/hr Equivalent annual reduction of coal assuming 330 days of plant operation = 177.78 x 24 x 330 Kg = 1408 MT Annual monetary saving @ Rs. 1325/- per MT = 1408 x 1325 = Rs. 18,65,617/-