Insulation Book

How to save energy and money
Guide Book 6
INSULATION
STRATEGY
ENERGY
EFFICIENCY
EARNINGS
STRATEGY
RG
MI
E
RA
3E
Netherlands Ministery of Economic Affairs
EUROPEAN COMMISSION
LS
AND
EN
TSI
Technical Services International
HOW TO SAVE
ENERGY AND MONEY
IN INSULATION
This booklet is part of the 3E strategy series. It provides advice on practical
ways of improving energy efficiency in industrial insulation applications.
Prepared for the European Commission DGXVII by:
The Energy Research Institute
Department of Mechanical Engineering
University of Cape Town
Rondebosch 7700
Cape Town
South Africa
Neither the European Commission, nor any person acting on behalf of the
commission, nor NOVEM, AEAT, ERI, nor any of the information sources is
responsible for the use of the information contained in this publication
The views and judgements given in this publication do not necessarily
represent the views of the European Commission
This project is funded by the European Commission and co-funded by the
Dutch Ministry of Economics, the South African Department of Minerals and
Energy and Technology Services International (ESKOM), with the Chief
contractor being AEAT.
HOW TO SAVE
ENERGY AND MONEY
IN INSULATION
HOW TO SAVE
ENERGY AND MONEY
IN INSULATION
Other titles in the 3E strategy series:
HOW TO SAVE ENERGY AND MONEY: THE 3E STRATEGY
HOW TO SAVE ENERGY AND MONEY IN ELECTRICITY USE
HOW TO SAVE ENERGY AND MONEY IN BOILERS AND FURNACES
HOW TO SAVE ENERGY AND MONEY IN COMPRESSED AIR
SYSTEMS
HOW TO SAVE ENERGY AND MONEY IN REFRIGERATION
HOW TO SAVE ENERGY AND MONEY IN STEAM SYSTEMS
Copies of these guides may be obtained from:
Rondebosch 7700
Cape Town
South Africa
Tel No: (+27 21) 650 3892
Fax No: (+27 21) 686 4838
Email: 3E@eng.uct.ac.za
Website: http://www.3e.uct.ac.za
ACKNOWLEDGEMENTS
The Energy Research Institute would like to acknowledge the following for
their contribution in the production of this guide:
.
.
.
.
.
Energy Technology Support Unit (ETSU), UK, for permission to use information
from the Energy Efficiency Best Practice series of handbooks.
Energy Conservation Branch, Department of Energy, Mines and Resources,
Canada, for permission to use information from the Energy Management
series of manuals.
TLV co, Ltd, for permission to use figures from their set of handbooks on steam.
Wilma Walden of Studio.com for graphic design work (Walden@grm.co.za).
Doug Geddes of South African Breweries for the cover colour photography.
Guide Book Essentials:

QUICK `CHECK-LIST' FOR SAVING
ENERGY AND MONEY IN INSULATION SYSTEMS
This list is a selected summary of energy and cost savings opportunities outline in the text. Many more are
detailed in the body of the booklet. These points are intended to be a quick `checklist'.
ADDING NEW INSULATION (Chapter 4)
1. Insulate non-insulated pipe.
2. Insulate non-insulated vessels.
ADDING EXTRA INSULATION (Chapters 2 and 4)
1. Repair insulation damage.
3. Add insulation to reach recommended thickness.
4. Upgrade existing insulation levels.
5. Review economic thickness requirement.
6. Limited budget upgrade.
Table of Contents
1. INTRODUCTION..................................................................................................................................................................................... 1
2. FUNDAMENTALS..................................................................................................................................................................................... 2
2.1 Terms and definitions...................................................................................................................................................................... 2
2.2 Selection of Insulation Material ................................................................................................................................................. 2
2.2.1 A Note on Asbestos ............................................................................................................................................................ 3
2.3 Heat Transfer ....................................................................................................................................................................................... 4
2.4 Heat Flow ............................................................................................................................................................................................... 4
FIGURE 1: TYPICAL INSULATED PIPE................................................................................................................................. 5
2.5 Protecting and Sealing the Insulation ..................................................................................................................................... 6
2.5.1 Protective Coverings and Finishes.................................................................................................................................. 6
2.5.2 Vapour Barriers ........................................................................................................................................................................ 6
2.6 Temperature Ranges........................................................................................................................................................................ 6
2.6.1 Low Temperature Thermal Insulation ......................................................................................................................... 6
2.6.2 Intermediate Temperature Thermal Insulation........................................................................................................ 7
2.6.3 High Temperature Thermal Insulation......................................................................................................................... 7
2.7 Insulation Thickness.......................................................................................................................................................................... 7
2.7.1 Selection Procedures............................................................................................................................................................. 7
2.7.2 Recommended Insulation Thickness............................................................................................................................. 7
2.7.3 Limited Budget Insulation Thickness ............................................................................................................................. 8
2.7.4 Economic Insulation Thickness......................................................................................................................................... 8
FIGURE 2: DETERMINATION OF ECONOMIC THICKNESS OF INSULATION...................................... 9
FIGURE 3: HEAT LOSS FROM FLAT SURFACE ............................................................................................................ 10
FIGURE 4: COST OF ENERGY LOSS AT VARIOUS INSULATION THICKNESSES................................ 11
FIGURE 5: INSULATION COST AT VARIOUS THICKNESSES ............................................................................ 11
2.8 Energy Management.......................................................................................................................................................................... 12
2.8.1 Energy Audits ............................................................................................................................................................................ 12
2.8.2 Energy Management Opportunities .............................................................................................................................. 12
3 MATERIALS SYSTEMS............................................................................................................................................................................. 13
3.1 Insulation Forms and Materials.................................................................................................................................................. 13
3.1.1 Types and Forms of Insulation ..................................................................................................................................... 13
3.1.2 Major Insulation Materials................................................................................................................................................ 13
3.2 Insulation Systems .............................................................................................................................................................................

3.2.1 Protective Coverings and Finishes..............................................................................................................................
3.2.2 Properties of Protective Coverings............................................................................................................................
3.2.3 Accessories .............................................................................................................................................................................
3.2.4 Securements ..........................................................................................................................................................................
3.2.5 Insulation Reinforcement for Cement and Mastics...........................................................................................
3.2.6 Water Flashing......................................................................................................................................................................
3.2.7 Stiffening...................................................................................................................................................................................
3.2.8 Supports...................................................................................................................................................................................
3.2.9 Sealing and Caulking ..........................................................................................................................................................
3.2.10 Expansion and Contraction Compensation..........................................................................................................
3.3 Common Applications....................................................................................................................................................................
3.3.1 Multiple Layer Construction..........................................................................................................................................
3.3.2 Pipe Insulation for Interior Applications..................................................................................................................
FIGURE 6: FIELD AND FACTORY-APPLIED NON-METAL JACKETING ......................................................
3.3.3 Metal Jacketing ......................................................................................................................................................................
3.3.4 Flexible Elastomeric Pipe Covering............................................................................................................................
3.3.5 Fittings Insulation..................................................................................................................................................................
3.3.6 PVC or Glass Fibre Fitting Insulation........................................................................................................................
FIGURE 7: FIELD APPLIED METAL JACKETING ............................................................................................................
FIGURE 8: FLEXIBLE ELASTOMERIC PIPE COVERING.............................................................................................
FIGURE 9: MITRED INSULATION ELBOW OVERSIZED APPLICATION .....................................................
FIGURE 10: PVC/GLASS FIBRE ELBOW INSULATION SYSTEM ........................................................................
3.3.7 Insulation of In-line Flanges or Couplings...............................................................................................................
3.3.8 Removable and Reusable Insulation..........................................................................................................................
3.3.9 Duct Insulation .....................................................................................................................................................................
FIGURE 11: PVC/GLASS FIBRE COUPLING OR IN-LINE FLANGE INSULATION SYSTEM..............
FIGURE 12: REMOVABLE AND REUSABLE INSULATION....................................................................................
FIGURE 13: FLEXIBLE FIBROUS BLANKET DUCT INSULATION RECTANGULAR/INDOORS ....
3.3.10 Field Applied Lining............................................................................................................................................................
3.3.11 Insulation of Tanks and Vessels ...................................................................................................................................
FIGURE 14: FIELD APPLIED LINING DUCTS, PLENUMS AND HOUSINGS..............................................
14
15
16
16
16
17
17
17
17
17
17
17
18
18
18
19
19
19
19
19
19
20
20
21
21
21
21
21
22
22
22
22
FIGURE 15: CURVED SURFACES RIGID BOARD INSULATION........................................................................ 22

3.3.12 Vessel and Tank Head Insulation ................................................................................................................................ 23
FIGURE 16: METAL HEAD INSULATION, SECUREMENT AND COVER FABRICATION ................. 23
4 ENERGY MANAGEMENT OPPORTUNITIES ......................................................................................................................... 24
4.1 Housekeeping Opportunities...................................................................................................................................................... 24
4.1.1 Housekeeping Worked Examples.................................................................................................................................. 24
4.2 Low Cost Opportunities............................................................................................................................................................... 25
4.2.1 Low Cost Worked Examples........................................................................................................................................... 25
4.3 Retrofit Opportunities.................................................................................................................................................................... 27
4.3.1 Retrofit Worked Examples ................................................................................................................................................ 27
APPENDICES...................................................................................................................................................................................................... 30
Worksheets ......................................................................................................................................................................................................... 30
Glossary .......................................................................................................................................................................................................... 40
Heat loss tables ................................................................................................................................................................................................. 47
Basic types of insulation selected properties.............................................................................................................................. 64
Protective coverings and finishes............................................................................................................................................................ 65
Vapour retarders.............................................................................................................................................................................................. 66
Energy Content of Some Fuels................................................................................................................................................................ 67
1. INTRODUCTION
Thermal insulation is the use of special materials to

retard the flow of heat energy. It prevents the loss
of heat, so saving on fuel and money, and
contributing to safety and comfort. Insulating
unlagged hot surfaces is one of the simplest and
most cost-effective ways of increasing energy
efficiency. Depending on the pipe's surface temperature, the payback time for insulating a section
of pipework is typically less than one year.
Refractory materials often need high resistance to

abrasion as elevated temperatures. This guide is
only about thermal insulation.
Insulation materials may come in boards, blocks,
bricks, sheets, pre-formed shapes, blankets or as
castable cements. The choice of materials depends
on cost, temperature, application, environment and
safety. The thickness of insulation should be
calculated so as to optimise the cost of the
insulation against the savings in energy. This guide
covers these topics and gives worked examples of
costs saved by insulation.
By improving energy efficiency, it is possible to

reduce the size of heating, cooling and ventilation
equipment and so reduce capital costs. Process
temperature control is made easier.
This guide uses metric units throughout but has

included some Imperial units, which are still used in
some South African plants.
Insulation may be divided roughly into three

temperature ranges. Cryogenic temperatures are
below 73oC. Thermal insulation is for temperatures from 730oC to 982oC. Refractory insulation is for temperatures above 982oC, as would be
found in cement kilns, steelworks and incinerators.
2. FUNDAMENTALS
2.1 TERMS AND

DEFINITIONS
an insulating material. The higher the R

values the better the insulation.
It should be noted that k, C, U, R can be equated as
follows.
t
l
l
R
k
C
U
Certain key terms used in this booklet are defined

below. A more extensive glossary of terms is
included in the appendices.
.
Conduction is the process, by which heat

flows from a hot body to a cooler body or
fluid, which is in stationary contact with it.
Convection is the process, by which heat
flows from a hot body to a gas or liquid,
which is in moving contact with it.
Radiation is the flow of heat from a hot
body without it being in contact with a fluid
or solid.
Thermal Conductivity (k) is a measure of
heat energy transmitted through a homogeneous material per unit thickness. A
material with a low thermal conductivity is
a good insulator. Expressed as W/(m oC)
or (Btu/h ft2 oF).
Thermal Conductance (C) is a measure of
the heat energy transmitted through a
homogeneous material of other than unit
thickness or through an assembly. Expressed as W/m2.oC) or [Btu/(ft2.hr.oF)].
Thermal Transmittance (U) is a measure
of the heat energy transmitted by a
material or assembly including the boundary air films. Expressed as W/(m2.K) or
[Btu/(h.ft2 oF)].
Thermal Resistance (RSI or R) indicates
the relative insulating value or resistance to
heat flow of material. Thermal Resistance is
the primary consideration in the choice of
Where, t material thickness (metres or inches)

.
2.2
Mean Temperature is the arithmetic

average of the hot and cold insulation
surface temperatures through which heat is
transmitted.
Emissivity is the ratio of heat energy
radiated from a surface compared to the
heat energy radiated from an ideal black
body at the same temperature.
Black Body is defined either as a body,
which absorbs all radiation falling upon it
and reflects or transmits none, or as a
radiator, which emits at any specific
temperature, the maximum possible
amount of thermal radiation.
SELECTION OF
INSULATION MATERIAL
The following is a list of important properties,

which must be considered in the selection of an
insulating material.
.
Thermal Resistance. The higher the value

of thermal resistance, the better the
insulating capability of the material.
Combustibility. This becomes significant as

it provides an indication of the insulating
material's contribution to a fire hazard.
Toxicity. Certain insulating materials are
combustible and release toxic fumes when
they burn. These must be avoided where
there is a danger of fire in a confined space.
See also the note on asbestos.
Shrinkage. Shrinkage or drying is significant
in high temperature applications. Shrinkage
can leave non-insulated gaps.
Resistance to Ultra Violet Radiation.
Where the insulating material is exposed
to sunlight in outdoor applications, its
ability to withstand ultraviolet radiation
without degradation is important. This
can be overcome by covering the insulating
material so that sunlight does not contact
the material.
Resistance to Fungal or Bacterial Growth.
This property is significant in food or
cosmetic processing areas.
Chemical Neutrality. The insulation
should be chemically neutral (pH 7) to
avoid any deterioration of metal contacting
it. This is particularly important in applications where the insulation could be subject
to intermittent wetting.
Coefficient of Expansion and Contraction. This property becomes important in
the design and location (spacing) of
expansion and contraction joints and in
multiple layer insulation applications.
Compressive Strength. Compressive
strength is significant where the insulating
material must support a load or withstand
mechanical abuse without crushing. When
cushioning or filling in space is needed, such
as in expansion/contraction joints, low
compressive strength materials would normally be specified.
Breaking Load. Breaking load is significant
in installations where the insulation is
applied over irregular or non-uniform

surfaces where the insulation must
bridge over a support discontinuity.
Capillarity. Where insulation material is in
contact with dangerous or flammable
liquids, or in areas where wash down
occurs, the resisting capability of the
material to wick-up (absorb) liquids by
capillary action becomes significant.
Appearance. Appearance is significant in
exposed areas and for purposes of identification.
Density. The density of an insulating
material affects many of its other properties, especially its thermal properties.
Some of these factors may not apply in all

insulation applications, however, each should be
considered, and ruled out if not applicable. Worksheet 1-1 has been developed as a checklist to
assist in establishing which properties are important
in a specific application.
Properly installed, mechanical insulation will have a
life equal to the life of the equipment or piping on
which it is installed. Mechanical insulation should
always be installed according to the manufacturer's
installation recommendations.
2.2.1 A NOTE ON ASBESTOS

Asbestos was much used in the past for thermal
insulation. However, because asbestos fibres when
inhaled can cause lung cancer, it is no longer used
for this purpose. Asbestos comes in many kinds, of
which the one most commonly used today is
chrysotile, one of the least dangerous types. It is
believed that there is a threshold below which
inhaled chrysotile fibres do no damage to human
health. Chrysotile is now used in cement building
materials, brake linings and certain other products
but not in thermal insulation.
Asbestos was used as an insulation material not so

much because its thermal conductivity is low (in
fact, at about 0.06 W/moC, it is higher than many
other materials) but because of its non-flammability. Old plants may still have asbestos insulation.
It is often safer to seal and leave it than to remove
it because the removal can release fibres into the
air. This is a matter that requires expert advice from
health and safety authorities.
2.3
insulation material is to retard heat flow. The

term thermal conductivity (k) is used to express the
quantity of heat, which will flow across a unit area
when a temperature difference of one degree
exists.
Thermal conductivity (k), is expressed as Watts per
metre per degree Celsius [W/(moC)] or [(Btu)/
(h.ft2 oF)]. Thermal Resistance can now be defined
as the opposition of the passage of heat through
the insulation and is expressed by the following
equation.
HEAT TRANSFER
Thermal Resistance
Heat is always transferred from a hot body to body

at a lower temperature, never the other way
round.
t
R [(m. oC)/W] or [(h.ft oF)/Btu]
k
Where t insulation thickness [metres or inches].
Heat is lost from hot bodies in three ways:

The higher the value of R, the better the insulation.
.
Conduction. Heat is transferred by contact

with another solid body or fluid without
movement.
Convection. Heat is transferred by contact
with a moving liquid or gas.
Radiation. Heat is transferred without
contact with another body or fluid. The
heat may be transmitted through a vacuum
or through air. The heat is transmitted as
electromagnetic radiation (such as infrared
radiation). Radiation becomes increasingly
important as temperature increases.
The heat flow through the insulation for a flat

surface may be calculated using the following
equation :
Heat flow in one hour
Where, DT Temperature difference across the

insulating material (oC)
A surface area (m2)
As an example, consider a 10m2 flat surface at a
temperature of 140oC. This surface has been
insulated with a 51 mm thick insulating material
having a thermal conductivity of 0.045 W/(m.oC).
The outer surface temperature of the insulation is
10oC. The thermal resistance can be determined as
follows.
For hot pipes and hot surfaces in factories, most

heat is lost by convection. The air in contact with
the hot surface heats up, moves off and is replaced
by cold air, which is heated up in turn
2.4
DT A
Wh
R
HEAT FLOW
t
k
0:051
0:045
1.133 m.oC/W
The term heat flow refers to the rate at which heat

moves from an area of higher temperature to an
area of lower temperature. The purpose of any
Now the heat flow in one hour through the

insulation can be determined.
Heat flow in one hour
For example, consider the heat loss from a 1 metre

length of 0.219 metre diameter pipe operating at
95oC. The 51 mm thick insulation has a thermal
conductivity of 0.037 W/(m.oC) and an outside
surface temperature of 25oC. This example is
shown in Figure 1. The heat flow through the
insulation can be determined as follows.
DT A
R
140
10 10
1:133
1147.4 Wh
r2
Heat flow through pipe insulation is somewhat

different since the inner and outer surfaces of the
insulation have different areas. This difference in
area must be taken into account in heat flow
calculations. As the heat from the pipe flows
outward through the insulation, the area of the
heat flow path becomes greater. This phenomenon
has the effect of increasing the value of the thermal
resistance.
0.1605m
r1
0:219
2
0.1095m
R
r2 ln
r2
r1
k
0:1605 In 0:1605
0:1095
0:037
To compensate for this effect an equivalent

thickness of insulation must be used. The
expression for the thermal resistance for piping
insulation can now be rewritten as follows.
R
0:219
0:051
0
0:1605 1:466
0:037
1.66 (m2 oC)/W

Heat Flow in one hour
equivalent thickness
[(m2.oC/W]
conductivity
r2 ln rr21
DT A
R
Where, r2 outside radius of insulation (m)
r1 inside radius of insulation (m)
95
25 1:008
Wh
1:66
70 1:008
1:66
42.51 Wh/metre of length of

the pipe
ln natural logarithm
It must be noted that A in the above equation is

the outside surface area of a 1-metre length of the
insulated pipe and is calculated as follows.
Where, D 3.14159
D outside diameter of insulation
(pipe outside diameter 2
insulation thickness)
Figure 1: Typical Insulated Pipe
(Source: Canadian Govn Pub)
l unit length (in this case 1 metre)
Therefore A 0:219 2 0:051 1
Additional details on protective coverings and

finishes may be found in the Material/Systems
section of this module.
( 0:321 : 1
3.14159 0.321
1.008 m2
2.5.2
A vapour retarder or vapour barrier is a material,

which retards the transmission of water vapour.
This is required for piping and equipment operating
at below ambient temperatures. Water vapour
from the air tends to diffuse into the insulation
where, because of the lower temperatures it
condenses and significantly reduces the effectiveness of the insulation. Moisture penetration may
also cause corrosion of metal surfaces.
2.5 PROTECTING AND

SEALING THE
INSULATION
2.5.1
VAPOUR BARRIERS
PROTECTIVE COVERINGS AND

FINISHES
The efficiency and service life of insulation is

directly dependent upon its protection from
moisture entry and mechanical and/or chemical
damage. Choices of jacketing and finish materials
are based upon the mechanical, chemical, thermal
and moisture conditions of the installation, as well
as cost and appearance.
Vapour barriers are applied on site and may consist

of semi-liquid mastic compositions and coating.
They may be sprayed, brushed or trowelled. The
manufacturer's specified thickness must be applied
in one or more continuous coatings. Suitable
reinforcement may be required as the vapour
barrier system must be adequate to resist cracking.
Protective coverings are divided into six functional

types.
.
2.6
Weather barriers, which protect the insulation from the effects of weather.
Vapour retarders, which are designed to
retard the passage of water vapour from
the atmosphere to the insulation.
Mechanical protection coverings, which
protect against mechanical damage from
personnel, equipment and machinery.
Low flame spread and corrosion resistant
coverings, which reduce the effect of flame
spread and corrosion.
Coverings and finishes are available to
enhance the aesthetic appearance of
insulated surfaces in highly visible areas.
Hygienic covers, which present smooth
surfaces to resist fungal and bacterial
growth.
TEMPERATURE RANGES
The temperature range within which the term

thermal insulation applies, is from 73oC
( 100oF) to 982oC (1800oF). All applications
below 73oC ( 100oF) are termed cryogenic
and those above 982oC (1800oF) are termed
refractory.
Thermal insulation is further divided into three
general application temperature ranges.
2.6.1
LOW TEMPERATURE THERMAL

INSULATION
Insulation used for low temperature applications is

subdivided into three general temperature ranges.
2.6.3
16oC (6OoF) through 0oC (32oF) cold

or chilled water.
-1 o C (31 o F) through 39 o C ( 39 o F)
refrigeration or glycol.
40oC ( 40oF) through
73oC
( 100oF) refrigeration or brine.
High temperature thermal insulation is used in the

temperature range of 3l5oC (600oF) to 870oC
(1600oF). As the refractory range of insulation is
approached, fewer materials and application methods are available. High temperature materials are
often a combination of other materials or of similar
materials manufactured using special binders.
Industrial power and process piping and equipment, commercial boilers, exhausts, furnaces and
incinerators fall within this application range.
The major problems on low temperature installations are moisture penetration and cost effectiveness. Ideally, the insulation material or system
should absorb no moisture and readily give up any
that enters. It should also resist water deterioration.
Vapour retarders are used extensively, but in
practice it is almost impossible to achieve a perfect
vapour retarder. The pressure of the vapour flow
from the warm outside surface is such that, even
with waterproof insulation, vapour may enter
through unsealed joints or cracks, condense, then
freeze, and cause damage. Vapour retarders must
have a perm rating well below 1. The colder the
equipment, the lower the desirable perm rating.
2.7
INSULATION THICKNESS
2.7.1
SELECTION PROCEDURES
Although insulating uninsulated areas means immediate returns in Rands saved, sometimes the
long-term potential Rand savings are forgotten.
Any facility that has not had its insulation upgraded
in the past ten years is likely to be under-insulated.
Since the cost of refrigeration is higher than the

cost of heating, more insulation is often justified in
low temperature applications where 4T is the
same. Extra thickness of insulation, even beyond
what would be economically dictated for cold line
application, are sometimes employed to keep the
warm surface temperature above the dew point.
2.6.2
HIGH TEMPERATURE THERMAL

INSULATION
Immediate savings can be realised from insulating

where no insulation exists. This includes piping,
tanks, vessels as well as valves and fittings. With
respect to valves and fittings, the insulation would
normally be specified to the standards and
thickness of the surrounding piping insulation
ducting or equipment.
INTERMEDIATE TEMPERATURE
THERMAL INSULATION
This temperature range, from 16oC (61oF) to

315oC (600oF) includes conditions encountered in
most industrial processes and in hot water and
steam systems found in commercial installations.
Selection of material in this range is based mainly
on thermal values but other factors such as
mechanical and chemical properties, availability of
forms, installation time and cost are also significant.
2.7.2
RECOMMENDED INSULATION
THICKNESS
Tables 1 and 2 have been included in the

Appendices and provide data, which is used to
perform energy savings, calculations. These tables
indicate the heat loss from bare steel pipe and
bare steel flat surfaces over the range of

temperatures normally encountered in most
facilities, and are based on an ambient air
temperature of 21.1oC.
cost of the insulation. This is necessary to establish

the economic thickness of the insulation.
One way of improving cost savings through
insulation is to upgrade to the insulation levels
shown in the recommended thickness tables
(Table 3). These should be used as guidelines.
For process applications, tables based on economics have been developed which provide a recommended insulation thickness for various insulating
materials and temperatures. Table 3 is a typical
table covering mineral fibre, calcium silicate, and
cellular glass insulation for pipes varying from NPS
1/2 to NPS 36 in diameter and process temperatures between 65oC and 566oC. These tables also
include flat surfaces. (NPS is Nominal Pipe Size
measured in inches).
In some cases these tables will not apply as plant or

building conditions may not be the same as those
used to determine the thickness charts. In these
cases, individual determinations of insulation thickness should be considered to insure a facility is
making its optimum investment in insulation.
2.7.3
It must be noted for a round tank or vessel with

diameter greater than 914 mm, the surface is
considered flat for purposes of heat loss calculations.
LIMITED BUDGET INSULATION

THICKNESS
Generally for hot mechanical systems, piping will be

the source of greatest heat loss. On a limited
budget, determine where the area of greatest
heat loss is and insulate it first. The first 25mm of
insulation will provide the greatest savings in energy
on a system but may not be the optimum
insulation level for maximising investment benefits.
This can also be an excellent approach to cost
reductions if insulation is to be paid out of an
annual maintenance or operating budget. Bear in
mind though, if only the minimum 25mm is applied,
the labour component may be the same as if a
greater thickness of insulation were used.
As an example of the use of these tables, consider

an NPS 6 steel pipe without insulation operating at
121oC in ambient conditions of 21.loC. Table 1
indicates this pipe will lose 700 Wh/linear metre of
heat every hour it is in operation. If the recommended thickness of 76 mm of mineral fibre
insulation as indicated in Table 3 were installed on
this pipe, the heat loss would be reduced to 37
Wh/lineal metre and the outer surface temperature
of the insulation would be 23oC.
Insulation manufacturers have prepared tables for
other materials since the thermal resistance varies
both with the material being used and the process
temperature. In the event that tables cannot be
obtained, heat loss from piping and flat surfaces
may be calculated using the equation in the
previous section of this module entitled Heat Flow,
and R values as selected from Table 4 in the
appendix.
2.7.4
ECONOMIC INSULATION
THICKNESS
Insulation can be considered a long-term investment with associated financial benefit, following a
relatively short initial payback. There are a number
of computer programs available to aid in selecting
the most economic insulation thickness. This is the
thickness, which provides the highest insulation
value for the lowest cost.
A series of calculations will have to be performed

and the energy savings compared to the installed
Economics is the primary concern in evaluating

investment alternatives. When applied to an
insulation system, economics can be used to
establish the following items.
Evaluation of two or more insulation
materials for lowest cost for a given
thermal performance.
Selection of the optimum insulation thickness for a given insulation type.
not manufactured in single layers of sufficient

thickness and/or to alleviate expansion and contraction movements. This results in higher total
labour costs than to install one layer equal to the
cumulative thickness. Figure 2 is a typical representation of installed costs for a multi-layer
application. The average slope of the curves
increases with the number of layers because labour
and material costs increase at a more rapid rate as
insulation thickness increases.
In either case economics is used to determine the

most cost effective solution for insulating. Beyond
the optimum economic thickness, additional insulation does not yield the maximum rate of return
on investment.
The cost of lost energy is directly related to the

rate of heat transfer through the insulation and the
Rand value of the energy. As also shown in Figure
2, the cost of lost energy decreases as insulation
thickness increases.
Material and often labour costs increase with

insulation thickness. Insulation must often be
applied in multiple layers because materials are
Consider a process application with a flat surface

holding a process fluid at 150oC. The ambient
temperature is 20oC.
Figure 2: Determination of Economic Thickness of Insulation (Source: Canadian Govn Pub)
Calculation of heat loss for 50, 75 and 100 mm of

glass mineral fibre insulation with a density of
24 kg/m3 can be performed to establish the heat
losses at the various insulation thicknesses.
Process temperature:
Ambient Temperature:
DT:
The surface area will remain constant for the

insulation since this is a flat surface.
Heat loss can now be evaluated for a typical 1 m2
area for each insulation thickness.
150oC
20oC
150 20 130oC
Heat loss in one hour
137.86 Wh
Heat loss (75 mm insulation)/m
130 1
in one hour
1:415
91.873 Wh
The thermal resistance (R) can be calculated for

the various insulation thicknesses using the equation
R
R50
0:050
0.943
0:053
R75
0:075
1.415
0:053
R100
0:100
1.887
0:053
DT A
R
Heat loss
130 1
(50 mm insulation) in one hour
0:943
From Table 5 thermal conductivity (k) at a mean

temperature of 93.3oC (closest value not exceeding 1300C) is 0.053 W/(m oC).
Heat loss (100 mm

insulation)/m in one hour
130 1
Wh
68:89
Using Table 2 it is established that the heat loss

from one square metre of the same surface with no
insulation would be approximately 2100 Wh/m2.
These figures can be plotted on a graph (Figure 3)
showing insulation thickness versus heat loss to
generate a heat loss curve.
Figure 3: Heat Loss from Flat Surface (Source: Canadian Govn Pub)
10
Figure 4: Cost of Energy Loss at Various Insulation Thicknesses (Source: Canadian Govn Pub)
Knowing the value of the heat energy, the cost of

lost heat at the various insulation thicknesses can
be established by the following equation.
The installed cost of the insulation for the various

thicknesses can now be established and a second
curve (Figure 5) can be produced.
Rand loss per unit area

Heat loss per unit area R per unit of heat
energy
Figures 4 and 5 may be superimposed and will

produce a curve generally of the shape of Figure 2.
If the dollar loss and insulation cost curves are
combined, and a new curve plotted, the insulation
thickness equivalent to the low point on the new
curve will be the economical insulation thickness.
Total Rand loss (Figure 4)

Total area R Loss/unit area hours/year
Figure 5: Insulation Cost at Various Thicknesses (Source: Canadian Govn Pub)
11
installed cost of the added material. The reduction

in energy consumption establishes the Rand
savings.
2.8 ENERGY MANAGEMENT

2.8.1
ENERGY AUDITS
With this information, simple payback calculations

can establish the financial viability of the opportunity.
An energy audit involves the identification of areas

throughout a facility where energy may be wasted
because of non-existent or inadequate insulation.
2.8.2
The audit may be applied to the facility as a whole,

or may be concentrated on specific pieces of
process equipment or piping systems.
2.8.1.1
Energy Management Opportunities can be divided

into three categories.
WALK THROUGH AUDIT
The initial action is a Walk Through Audit, which is

a tour through the facility looking for obvious signs
of energy waste. The walk through audit is generally
more meaningful if it is conducted by an individual
who, though not associated with the facility
operation, is familiar with both the subject of
process insulation and the concept of energy
management.
Typical items which could be noticed during a walk

through audit would include missing or damaged
insulation, hot or cold surfaces, wet insulation,
deteriorating insulating coverings or protective
finishes, missing or damaged vapour retarders, gaps
in insulation at expansion/contraction joints, excessive heat radiating from insulated surfaces and
other similar items.
2.8.1.2
ENERGY MANAGEMENT
OPPORTUNITIES
Housekeeping, refers to an energy management action that is repeated on a

regular basis and never less than once a
year. Examples include repairing damaged
insulation coverings, finishes and insulation.
Low Cost, refers to an energy management action that is done once, and for
which the cost is not considered great.
Examples of low cost items could be the
insulation of valves and fittings and the
replacement of coverings and finishes.
Retrofit, refer to an energy management
action that is done once, and for which
the cost is significant. Examples of retrofit
items could be the insulation of piping,
ductwork, vessels, tanks, and equipment,
upgrading insulation to the recommended
thickness, and upgrading protective coverings on outdoor tanks and vessels.
It must be noted that the Rand division between

low cost and retrofit is normally a function of the
size, type and financial policy of the organisation.
DIAGNOSTIC AUDIT
Once items have been identified in the walk

through audit, a diagnostic audit is required to
determine the existing energy loss, the reduction in
energy loss which would result if new or additional
insulation or covering were installed and the
Energy management is dealt with in more detail in

Section 4.
12
3 MATERIALS SYSTEMS
3.1 INSULATION FORMS AND

MATERIALS
material, or combined with a binder and

fibres to make a rigid insulation.
Insulation is produced in a variety of forms suitable
for specific functions and applications. The combined form and type of insulation determines the
proper method of insulation. The forms most
widely used follow,
3.1.1 TYPES AND FORMS OF

INSULATION
Insulation materials are addressed in the following
text according to their generic types and forms.
Type indicates composition and internal structure,
while form implies overall shape or application.
Types are normally subdivided into the following

three groups.
.
Fibrous Insulation is composed of small

diameter fibres, which finely divide the air
space. The fibres may be parallel or
perpendicular to the surface being insulated and they may be separated or
bonded together. Glass, rock wool, slag
wool and alumina silica fibres are used.
Glass fibre and mineral wool (rock and
slag) are the most widely used insulation of
this type.
Cellular Insulation is composed of small
individual cells separated from each other.
The cellular material may be glass or
foamed plastic such as polystyrene (closed
cell), polyurethane and elastomeric.
Granular Insulation is composed of
small nodules, which contain voids or
hollow spaces. It is not considered a true
cellular material since gas can be transferred between the individual spaces. This
type may be produced as a loose pourable
3.1.2
Rigid boards, blocks, sheets and preformed shapes (i.e. pipe covering, curved
segments, lagging). Cellular and granular
insulation are produced in these forms.
Flexible sheets and pre-formed shapes.
Cellular and fibrous insulation are produced in these forms.
Flexible blankets. Fibrous insulation is
produced in flexible blankets.
Cements (insulating and finishing). Produced from fibrous and granular insulation
and cement.
MAJOR INSULATION
MATERIALS
The following is a general inventory of the

characteristics and properties of major insulation
materials used in Industrial, Commercial and
Institutional installations.
.
13
Calcium Silicate is a granular insulation

made of lime and silica reinforced with
organic arid inorganic fibres and moulded
into rigid forms. The temperature range
covered is from 38oC (100oF) to 982oC
(1800oF). Flexural strength is good. Cal-
cium Silicate is water absorbent, however,

it can be dried out without deterioration.
The material is non-combustible and used
primarily on hot piping and surfaces.
Jacketing is generally field applied.
Cellular Elastomeric insulation is composed principally of natural or synthetic
elastomers, or both, processed to form a
flexible, semi-rigid or rigid foam with a
predominantly closed-cell structure. Upper
temperature limit is 104oC (221oF).
Cellular Glass is fabricated into boards,
pipe covering and other shapes. Service
temperatures range from -40oC (-40oF) to
482oC (900oF). This material has a low
thermal conductivity at low temperatures,
low abrasion resistance, good resistance to
substrate corrosion, and good sound
absorption characteristics in fibre and
cellular form.
Fibrous Glass products are manufactured
in a variety of forms including flexible
blankets, rigid and semi-rigid boards and
pipe coverings. Service temperatures range
from -73oC (~110oF) to 538oC (1000oF)
depending on structure and binder. Glass
fibres are bonded together with heat
resisting binders. Conductivity of fibrous
glass products is low. Cutting characteristics
are good. The resilience of glass fibre is
high while the impact resistance is low.
Installation costs are low. There are good
sound absorption characteristics with glass
fibre insulation.
Foamed Plastic insulation is predominantly
closed cellular rigid materials. Thermal
conductivity may deteriorate (i.e. increase)
with time due to ageing because of air
diffusing into the cells. Foamed plastics are
lightweight with excellent cutting characteristics. The materials themselves are
combustible, but can be produced selfextinguishing. They are available in pre-
formed shapes and boards. Foamed plastics

are generally used in lower and intermediate temperature ranges.
Insulating and Finishing Cements are a
mixture of various insulating fibres and
binders with water and cement, to form a
soft plastic mass for application on irregular
surfaces. Installation costs are high, and
insulation values are only fair. Cements
may be applied to high temperature
surfaces. Finishing cements are one-coat
cements used in the lower to intermediate
temperature range.
Mineral Fibre or Mineral Wool is produced by bonding rock and slag fibres
together with a heat resistant binder. The
upper service temperature limit can reach
982oC (1800oF). The material is noncombustible. Mineral fibre is available in
both rigid pre-formed shapes for piping and
vessels, and as a flexible blanket. It is used in
high and intermediate temperature ranges.
Refractory Fibre Insulation is mineral or
ceramic fibres, including alumina and silica,
bound with extremely high temperature
binders. They are manufactured in blanket
or rigid brick form. Thermal shock resistance and temperature limits are high. The
material is non-combustible.
Common insulation materials are summarised in

Table 6.
3.2
INSULATION SYSTEMS
As an owner contemplating the insulation of

equipment or mechanical systems, it is helpful to
think of an insulation system as having the following
three components.
.
.
14
Insulating material.
Protective covering or finish.
Accessories to secure, fasten. Stiffen, support, seal or caulk the insulation and its
protective covering or finish.
characteristics of each type.

Vapour retarders are available in three forms.
.
These components must be compatible for the

insulation system to function properly.
.
3.2.1
PROTECTIVE COVERINGS
AND FINISHES
As indicated in the section titled `Fundamentals',

the efficiency and service of insulation is directly
dependent upon its protection from moisture
entry and mechanical or chemical damage. Choices
of jacketing and finish materials are based upon the
mechanical, chemical, thermal and moisture conditions of the installation, as well as cost and
appearance.
3.2.1.3
Protective coverings are divided into six functional

types.
3.2.1.1
WEATHER BARRIERS
3.2.1.4
LOW FLAME SPREAD AND

CORROSION RESISTANT
COVERINGS
When selecting material for potential fire hazard

areas, the insulation material and the jacketing must
be considered as a composite unit. Most of the
available types of jacketing and mastic have low
(less than 25) flame spread rating. This information
can usually be obtained from manufacturer's data.
VAPOUR RETARDERS
Vapour retarders are designed to retard the

passage of moisture vapour from the atmosphere
to the surface of the insulation (Table 1). Joints and
overlaps must be sealed with a vapour tight
adhesive or sealer. Refer to Table 8 for detailed
information on types of vapour retarders plus
MECHANICAL ABUSE
COVERINGS
Metal jacketing provides the strongest protection

against mechanical damage from personnel, equipment, and machinery. The compressive strength of
the insulation material should also be considered
when assessing mechanical protection.
The basic function of the weather barrier is to

prevent the entry of water. If water is deposited
within the insulation, its insulation properties will be
significantly reduced. Applications consist of either
a jacket of metal or plastic, or a coating of weather
barrier mastic (Table 7). Jacketing must be overlapped sufficiently to repel water. The use of plastic
jacketing materials with low resistance to ultraviolet
rays should be avoided unless protective measures
are taken.
3.2.1.2
Rigid jacketing reinforced plastic, aluminium or stainless steel fabricated to the

exact dimensions and sealed vapour tight.
Membrane jacketing metal foils, laminated foils and treated or coated papers,
which are generally factory, applied to the
insulation material. Additional sealing beyond the factory seal may be necessary
depending on the installation temperature
and humidity conditions.
Mastic applications either emulsion or
solvent types which provide a seamless
coating but require time to dry.
Resistance to corrosion varies among the plastic

and metal jacketing materials. Of the metal jackets,
stainless steel is the most successful in resisting
corrosive atmospheres, spills or leaks. Mastics are
also generally resistant to corrosive atmospheres.
15
3.2.1.5
APPEARANCE COVERINGS
AND FINISHES
insulation), or if a significant amount of vibration

must be considered.
Various coatings, finishing cements, fitting covers

and jackets are chosen primarily for their appearance value in exposed areas. Typically for piping,
jacketed insulation is covered with a reinforcing
canvas and coated with mastic to give a smooth
even finish. When dry it can be painted or left as is
to give a white colour.
3.2.1.6
3.2.2.3
The covering must be suitable for the operating

temperature of the insulation surface.
3.2.2.4
3.2.3
PROPERTIES OF PROTECTIVE
COVERINGS
Certain properties of jacketing and mastic materials

that must he considered to meet the previously
listed functions follow.
COMPATIBILITY
.
Coverings must be compatible with the insulation

material over which they are applied, as well as
with elements in the environment such as industrial
chemicals, salt air and ultraviolet or infrared light.
3.2.2.2
ACCESSORIES
The term accessories is applied to devices or

materials serving one or more of the following
functions.
.
3.2.2.1
VAPOUR PERMEABILITY
Coverings should have low vapour permeability on

low temperature installations to prevent, or at least
retard the passage of moisture vapour into the
insulation. For high temperature applications a
vapour permeable covering should be used to
allow moisture to pass outwards.
HYGIENIC COVERINGS
Coatings and jackets must present a smooth

surface, which resists fungal or bacterial growth,
especially in food processing areas. High temperature steam or high-pressure water wash down
conditions require jackets with high mechanical
strength and temperature ratings (plastics or metals
are typically used).
3.2.2
TEMPERATURE RANGE
.
.
.
Securement of the insulation and/or jacketing.

Insulation reinforcement for cement or
mastic applications.
Stiffening around structures which may not
support the weight of high-density insulation.
Supports (pipe, vessel and insulation).
Sealing and caulking.
Water flashing.
Compensation for expansion/contraction
of piping and vessels.
Improper application of any of these accessories

could be a significant factor in the failure of
insulation systems.
RESISTANCE TO INTERNAL
AND EXTERNAL MOVEMENT
The ability of a covering to resist movement is an

important element to consider if there will be
thermal expansion and contraction of the insulation it covers (i.e. shrinkage of high temperature
3.2.4
16
SECUREMENTS
Insulation is not a structural material and must be

supported, secured, fastened or banded in place.
3.2.8
Securements must be compatible with insulation

and jacketing materials. Possible choices are listed
below.
.
.
.
.
.
.
Insulation at points of support is necessary to

minimise heat loss. Accessories, which may be used
at points of support, are as follows.
.
High-density insulation inserts to protect
insulation at points of support. Pipe
support saddles and shoes.
.
Metal shields used to protect insulation.
.
Wood blocks or dowels for load bearing.
Welded studs and pins.

Staples.
Clips.
Wire and metal straps.
Self-adhering laps on outer jackets.
Adhesives.
Ambient temperature and humidity conditions

affect the effectiveness of tapes and adhesives on
certain installations. Check the temperature range
and vapour permeability properties before choosing adhesives.
3.2.5
3.2.9
.
.
.
.
INSULATION REINFORCEMENT
FOR CEMENT AND MASTICS
3.2.10
Canvas.
Glass fibre fabric.
Expanded metal lath.
Metal mesh.
Wire netting (chicken wire).
WATER FLASHING
3.3 COMMON
APPLICATIONS
Flashing directs the flow of water away from the

insulation and may be constructed of metal or
plastic.
3.2.7
The following section deals with typical application

methods experienced in the insulation industry.
They should not be considered as the only
methods of applying insulation and its installation.
For example, different thickness and different
insulation may require radically different attach-
STIFFENING
Metal lath and wire netting can be applied on high

temperature surfaces before insulation is applied.
EXPANSION AND
CONTRACTION
COMPENSATION
Accessories used in the design of expansion and

contraction joints, include the following:
.
Manufactured overlapping or slip joints.
.
Bedding compounds and flexible sealers.
Compatibility of materials must be considered to

prevent corrosion.
3.2.6
SEALING AND CAULKING
A variety of sealers, caulking and tapes are available

for sealing vapour and weather barrier jackets,
joints and protrusions. These products are manufactured in a large range of temperature and
vapour permeability properties. Some are designed
specifically for use with one type of insulation or
manufacturer's product.
Whether factory or field applied, mechanical

strength can be added to insulation through the
application of any of the following items.
.
SUPPORTS
17
ment methods because of weight. Also, system

temperature plays a big part in deciding which
application method is most suitable. Insulation
contractors or manufacturers are usually willing to
recommend the most appropriate application
method.
method of application may be used where available

insulation thickness is less than that required, or for
retrofitting applications. Care should be taken with
pipe insulation to ensure that dimensional measures coincide with standard industry practice to
provide a proper fit for multiple layer construction.
Pipe covering is generally the dominant part of a

mechanical insulation system. This section describes a number of different pipe insulation
installation methods. Typical duct, vessel and tank
insulation systems are also shown.
3.3.1
3.3.2
PIPE INSULATION FOR

INTERIOR APPLICATIONS
A jacketing material is generally applied to mineral

fibre pipe insulation for the purpose of protection
or to act as a vapour retarder. The application is
suitable for hot or cold temperature conditions.
The type of jacketing used depends on the end use
conditions (Figure 6). Generally the jacket is a
laminate of kraft and foil with glass fibre scrim
reinforcement. Other materials may be used in
cases where greater protection or a different finish
is required.
MULTIPLE LAYER
CONSTRUCTION
Multiple layer construction is the use of more than

one layer of insulation rather than a single layer of
equivalent thickness. This application method
provides compensation for expansion and contraction where pipe or equipment temperatures
are high. Staggering of joints in multiple layer
construction reduces heat loss at the joints thus
creating a more thermally efficient installation. This
The jacketed product may be left exposed or

finished with a canvas and lagging material to
provide a smooth, neat and long lasting finish.
1. Pipe.
2. Insulation.
3. Longitudinal lap on factory-applied jacket (selfadhesive or secured with adhesive).
4. Longitudinal lap on factory-applied jacket secured
with staples (staples are coated with super-barrier
mastic on cold applications).
5. Circumferential butt strip. Self adhering or field
adhering.
6. Longitudinal lap on field-applied jacketing is
adhered with appropriate adhesive or sealer.
7. Butt joint overlap sealed (tape at overlap joints is
optional on cold applications).
8. Wire, tapes or hands securing insulation in place
before the jacket is applied.
Figure 6: Field and Factory-Applied Non-Metal Jacketing
18
3.3.3
METAL JACKETING
Metal jacketing is generally used to protect

insulation from physical damage (Figure 7). It is
particularly useful for outdoor applications. The
jacketing material may also be chosen to resist
chemical attack. For example, a highly corrosive
atmosphere may require the application of a
stainless steel jacketing system instead of the
standard aluminium material.
3.3.4
FLEXIBLE ELASTOMERIC PIPE

COVERING
Flexible elastomeric pipe covering is used on cold

temperature piping such as air-conditioning systems
(Figure 8). It is generally manufactured as a
continuous tube, which can be pushed over small
diameter piping during installation. Slitting before
installing is another option. Joints are sealed with
contact adhesive.
3.3.5
1.
2.
3.
4.
Pipe
Insulation.
Wire, tape or bands securing insulation in place.
Overlaps positioned to shed water (butt joint overlaps should be wide
enough to provide weatherproofing).
5. Rivets or screw at longitudinal laps for securement.
6. Metal bands at butt joint overlaps, and spaced between butt joints for
jacket securement.
Figure 7: Field Applied Metal Jacketing

FITTINGS INSULATION
Insulation of fittings on a job is an extremely

important part of the overall system (Figure 9). The
insulation of elbows is usually accomplished by
using mitred pipe insulation. Generally the same
material and size of insulation is used to make the
elbow insulation. Where a Victaulic type pipe fitting
is used insulation is either built up to a greater
thickness than the surrounding line pipe insulation,
or standard pipe covering is grooved out to fit
around the coupling. In some cases, pre-formed
fitting insulation is available to simplify the installation. The insulated fitting is then covered with cloth
or canvas and lagging material for protection and a
neat finish.
3.3.6
1. Pipe or tubing.
2. Insulation (to facilitate sweating of joints, insulation can be pulled back
temporarily on either side of the connection then released to extend over
the joint before sealing.)
3. Contact adhesive is applied to both surfaces of longitudinal and butt
joints.
PVC OR GLASS FIBRE FITTING

INSULATION
PVC fitting covers are generally used for hot or

cold commercial applications where a neat finish is
19
Figure 8: Flexible Elastomeric Pipe Covering

1. Pipe.
2. Pipe insulation (shown in A) with factory applied non-metal jacketing
(metal jacketing shown in B). Jacketing extends under the fitting
insulation and finish.
3. Mitered segments of pipe covering, cut to form a tight fit (adhesive
between miters on pre-fabricated applications or when required.)
4. Glass fiber fill insulation (optional used as a means of support when
the mitered elbow has not been prefabricated into two self supporting
halves.)
5. Wire or banding (unnecessary when prefabricated.)
6. Pre-formed metal elbow cover secured with sheet metal screws.
7. Finishing cement applied to smooth surface.
8. Fabric applied with adhesive on the surface of finishing or insulating
cement.
Figure 9: Mitred Insulation Elbow Oversized Application
sufficient and a final finishing method (i.e. canvas) is

not required (Figure 10). These fittings are easy to
install and come in different colours (white being
the most common) with either a dull or shiny

appearance. PVC jacketing may also be used to
protect piping insulation.
1.
2.
3.
4.
5.
6.
7.
Pipe.
Pipe insulation (shown with factory-applied jacket).
Collar of oversized pipe insulation.
Glass fiber insert wrapped around the elbow.
PVC fitting cover.
Reducing end cap.
Vapor retarder adhesive on all joints and overlaps (cold applications
only.)
8. Vapor retarder tape.
Figure 10: PVC/Glass Fibre Elbow Insulation System
20
3.3.7
INSULATION OF IN-LINE
FLANGES OR COUPLINGS
In-line flanges or couplings, are difficult to insulate

with standard sized products. In these cases blanket
wrap insulation is used to surround the coupling
and is finished with both canvas and lagging, or a
PVC fitting cover (Figure 11).
3.3.8
REMOVABLE AND REUSABLE

INSULATION
1.
2.
3.
4.
5.
Removable insulation may be used where valves

require constant maintenance. These are made of a
fabric cover with a contained insulation, and a
fastening system such as the one shown (Figure
12).
3.3.9
Pipe.
Pipe insulation (factory applied jacket).
Vapor retarder tape along longitudinal seam and around ends.
Glass fiber insert wrapped around the coupling.
PVC cover extending over the pipe insulation.
Figure 11: PVC/Glass Fibre Coupling or In-Line

Flange Insulation System
DUCT INSULATION
Ducts can be insulated with either a flexible blanket

type product or with a rigid board system (Figure
13). The rigid board system offers superior abuse
resistance, but may be more difficult to apply
because of the necessity of cutting and fitting
around connections and changes in direction.
Where a vapour retarder system is required for
cold or dual temperature ducting, care should be
taken to seal all joints with adhesive to maintain the
vapour retarder. Any punctures of the vapour
retarder facing should be vapour-sealed.
Rigid board insulation with factory applied jacketing
should have joints and edges sealed with an
adhesive backed vapour retarder tape. Blanket
wrap insulation may be available with a lap joint,
which can be sealed with a vapour retarder
adhesive.
1.
2.
3.
4.
5.
6.
7.
21
Valve.
Removable cover.
machine stitching.
Metal stitching at edges.
Quilting washer.
Lacing hooks and wire.
Adjacent insulation.
Figure 12: Removable and Reusable Insulation
1.
2.
3.
4.
Rectangular duct.
Blanket insulation (shown with factory-applied vapor retarder jacket).
Factory lap (sealed with adhesive and/or staples or vapor retarder tape).
Vapor retarder tape over tears and penetrations of the vapor retarder
jacket (optional in hot applications.)
5. Mechanical fasteners supporting insulation n the underside of ducts ovedr
24" wide (spaced 3" from the butt joint.)
1.
2.
3.
4.
5.
Figure 13: Flexible Fibrous Blanket Duct

Insulation Rectangular/Indoors
3.3.10
Housing or shaft.
Liner or fibrous board insulation.
Adhesive.
Mechanical fasteners.
Joint sealer.
Figure 14: Field Applied Lining Ducts,

Plenums and Housings
FIELD APPLIED LINING
When field applied (applied on site rather than in

the factory where the components were made) to
the inside surface of housings or shafts, insulation is
attached by means of adhesives and mechanical
fasteners, depending on the size of the housing and
the velocity of the air moving through it (Figure 14).
Transverse joints and exposed edges are taped or
coated with sealer to hold the insulation firmly in
place.
3.3.11
INSULATION OF TANKS AND

VESSELS
1. Vessel wall.
2. Insulation board, scored or beveled to fit the
curvature of the vessel surface.
3. Stainless steel bands and "S" clips as required
(see inset). An alternate method of securement
is impalement of
insulation on mechanical fasteners.
4. Bottom tier of insulation is cellular glass in areas where water absorption
and wicking may occur (optional).
5. Corrugated or smooth sheet metal sheathing.
6. Head flashing.
7. Caulking/flashing at fittings.
The choice of application method depends on the

conditions of the system. If welding pins onto an
existing tank or vessel (Figure 15) is dangerous then
the insulation can be secured by banding in place.
Either flexible batt or rigid board insulation may be
used to insulate tanks or vessels. The insulation
22
Figure 15: Curved Surfaces Rigid Board

Insulation (Source: Canadian Govn Pub)
1.
2.
3.
4.
5.
6.
Head insulation (rigid block is shown).

Floating ring of cable.
Head bands on 12" centers.
Shell insulation.
Head insulation supporting ring (not required for horizontal vessels).
1" joint between support ring and shell insulation packed with mineral
or glass fibre insulation.
7. Segments of flat sheet metal cut in wedge shapes, to overlap and
conform to the surface of the head insulation.
8. Band at base of head insulation cover.
9. Sheet metal screws on 3" centres along horizontal and vertical seams.
10. High density insulation for walkway.
11. Roofing materials or reinforced mastic.
12. Caulking and flashing as required.
13. Banding to secure rim angle.
14. Metal I-beams used to stiffen head structure.
Figure 16: Metal Head Insulation, Securement and Cover Fabrication (Source: Canadian Govn Pub)
3.3.12
manufacturer may recommend choice of type of

product. Rigid insulation such as calcium silicate will
have to be scored to conform to the curvature of
the tank. Mineral fibre insulation may be bent to
conform to the vessel shape.
VESSEL AND TANK HEAD

INSULATION
Vessel tops are a major source of heat loss. Thus,

the insulation of the tops of tanks and vessels
(Figure 16) is important to maintain temperature
within the process. Proper protection of the
insulation on the top of the tank or vessel is critical
to prevent heat loss in the system.
Where the tank or vessel comes in contact with

the ground, an insulation material that does not
wick or absorb moisture should be used around
the base of the tank. Cellular glass is typically used.
In addition to the insulation method shown, roofing

contractors normally insulate flat tank surfaces. The
nature of the insulation system is critical and should
be performed by qualified insulation contractors
only.
Weather protection of insulated outdoor tanks and

vessels is a key requirement. Sheet steel or
aluminium panels are fastened together with
vertical and horizontal laps sufficient to shed rain
water to protect the insulation.
23
4 ENERGY MANAGEMENT
OPPORTUNITIES
4.1.1
Energy Management Opportunities is a term that

represents the ways that energy can be used wisely
to save money. A number of typical Energy
Management Opportunities subdivided into
Housekeeping, Low Cost, and Retrofit categories
are outlined in this section with worked examples
to illustrate the potential energy savings. This is not
a complete listing of the opportunities available for
insulation. However, it is intended to provide ideas
for management, operating and maintenance
personnel to allow them to identify other
opportunities that are applicable to a particular
facility. Appropriate modules in this series should
be considered for Energy Management Opportunities existing within other types of equipment and
systems.
4.1.1.1
HOUSEKEEPING WORKED
EXAMPLES
REPAIR DAMAGED
INSULATION
During a walk through audit of a process facility it

was noted that the insulation on an NPS 4 pipeline
had been damaged and removed for a ten-metre
length. This pipeline was carrying high temperature
process fluid at 121oC and the ambient temperature was 18oC. The original insulation was 76 mm
thick mineral fibre.
A diagnostic audit was performed to establish the
heat loss from this section of pipe before and after
the damaged insulation had been removed to
establish the additional energy loss without insulation.
The following text briefly highlights several Energy

Management Opportunities and is followed by
worked examples or explanatory text for illustrative purposes.
From Table 1 the heat loss from NPS 4 pipe at

121oC is approximately 530 Wh/m.
From Table 3 the heat loss for the same piping with
76 mm of mineral fibre insulation is 28 Wh/m.
4.1 HOUSEKEEPING
OPPORTUNITIES
For a ten-metre length, the reduction in heat loss is

now calculated.
Implemented housekeeping opportunities are energy management actions that are done on a
regular basis and never less than once a year. The
following are typical Energy Management Opportunities in this category include:
1. Repair damaged insulation.
2. Repair damaged coverings and finishes.
3. Maintain safety requirements.
Heat loss reduction per hour 10 (530 28)

10 502
5020 Wh/h
If the pipe in question is in operation 8760 hours
per year the annual heat loss reduction can be
calculated.
24
Annual heat loss reduction

Hourly heat loss reduction operating hours
per year
4.1.1.2
5020 8760
Damage to the insulation cover and finish can

expose the insulation and leave it susceptible to
damage by water, sunlight and mechanical abuse.
Damage will reduce the effectiveness of insulation
and thus will increase the heat loss and its
associated cost.
43 975 200 Wh/yr or 43 975.2 kWh/yr.

If the process fluid is heated by electricity which
costs R0.20/kwh, the reduction in heat loss can be
equated to a Rand savings as follows.
4.1.1.3
Annual Rand savings

Annual reduction in heat loss energy unit
cost
REPAIR DAMAGED
INSULATION COVERS AND
FINISHES
MAINTAIN SAFETY
REQUIREMENTS
Pipes that are exposed to human contact should

be insulated such that the temperature of the
exposed surface does not exceed 70oC. Major
burn hazards exist at temperatures above this. A
review of Table 3 shows that the insulation surface
temperatures never approach this figure.
43 975 200 kWh=yr RO:20=kWh

1000
R8795.04/yr
The estimated cost to supply and install 10 metres
of 76mm glass fibre insulation was R4000.
4.2
R4000:00
Simple payback
R8795:04
0.45 years (5 months)
LOW COST
OPPORTUNITIES
Implemented low cost opportunities are energy

management actions that are done once and for
which the cost is not considered great. The
following are typical Energy Management Opportunities in this category include:
A further benefit of the insulation is the removal of

a potential employee burn hazard. Without
insulation, the pipe surface temperature would be
approximately 121oC. By adding the insulation the
outer surface of the insulation would be 23oC.
1. Insulate non-insulated pipe.

2. Insulate non-insulated vessels.
3. Add insulation to reach recommended thickness.
This is a housekeeping item even though there is a

cost involved for the replacement of the 10 metres
of insulation because it is considered as a part of
the normal housekeeping / maintenance program
in any facility.
4.2.1
To assist in performing the calculation Worksheet

1-2 has been developed and is completed for this
specific example.
4.2.1.1
25
LOW COST WORKED

EXAMPLES
INSULATE NON-INSULATED
PIPING
During a walk through audit of a facility it was

noted that an NPS 2 branch steam main 20 metres
long feeding a new unit heater had not been

insulated during the original installation. The steam
temperature was 121oC. It was decided to
investigate the potential energy and dollar savings
if this main was insulated with the recommended
thickness of cellular glass insulation. The main was
in operation 2880 hours per year.
insulated with the recommended insulation thickness of mineral fibre insulation.
From Table 3 it was established that the

recommended thickness of cellular glass insulation
for this application was 64 mm, and the heat loss if
this amount of insulation were installed would be
35 Wh/m From Table 1 the heat loss from this
same pipe with no insulation is 290 Wh/m.
10m2
Vessel surface area

ATop ASide ABottom
(2 1) [(2 1) (2 1) (1 1) (1 1)] (2 1)
262
From Table 3 the recommended insulation thickness for a flat surface at 177oC is 102 mm, and its
heat loss is 63 Wh/m2. Worksheet 1-3 is used to
calculate the annual loss due to the addition of
insulation as 551 880 kWh/yr.
Using Worksheet 1-2 the annual reduction in heat

loss due to the addition of insulation would be 14
688 00 Wh/yr or 14 688/yr or 52 876.8 MJ/yr.
On the basis that the vessel is heated with electric

immersion heaters, and the energy cost for
electricity is R0.20/kWh, the annual potential Rand
savings may be calculated.
Steam was produced in a boiler operating at 75 per

cent efficiency using Sasol gas at R53.00/GJ.
Rand savings
Annual savings 551 880 R0.20
52 876:8 53:00
1000 0:75
R110 376
R3736.62/yr
Estimated cost to supply and install 100 mm of

mineral fibre insulation on the top, side and bottom
of the tank is R30 000.
Estimated cost to supply and install the insulation is

R3000.
Simple payback
R3 000:00
R3 736:62
Simple payback
R30 000
R110 376
4.2.1.2
INSULATE NON-INSULATED
VESSELS
4.2.1.3
During a walk through audit of a facility it was

noted that a rectangular tank 2m long by 1 m wide
by 1 m deep, with a hinged lid was not insulated
even though the tank was maintained at 177oC for
8760 hours per year.
A diagnostic audit was performed to establish the
potential energy and cost savings if the vessel was
26
ADD INSULATION TO REACH

RECOMMENDED THICKNESS
During a walk through audit of a facility, it was

noted that a two-metre diameter vessel, with a
surface area of 25 m2 containing a liquid being
maintained at 65oC was insulated with 25 mm of
mineral fibre insulation. The vessel was in operation
8400 hours per year and was heated with
electricity at the cost of R0.20/kWh
Using Table 3 the recommended insulation thickness for this application was 51 mm with an
associated heat loss of 32 Wh/m2. A diagnostic
audit was performed to establish the energy and
cost savings if the insulation was increased in
thickness to the recommended 51 mm.
4.3 RETROFIT
OPPORTUNITIES
Implemented retrofit opportunities are energy
management actions, which are done once and
for which the cost is significant. Many of the
opportunities in this category will require detailed
analysis by specialists, and cannot be covered in this
module. The following are typical Energy Management Opportunities in the retrofit category:
Manufacturer's data for 25 mm of mineral fibre

insulation under these conditions indicated the
heat loss was 105 Wh/m2 of surface area of the
tank.
1. Upgrade existing insulation levels.

2. Review economic thickness requirement.
3. Limited budget upgrade.
Worksheet 1-3 is used twice. The first time to

calculate the reduction in heat loss from a bare
vessel to 25 mm of insulation and the second time
to calculate the reduction in heat loss between the
bare vessel and 51 mm of insulation.
4.3.1
The energy savings in adding 26 mm of insulation

and increasing the overall thickness to 51 mm can
be calculated.
4.3.1.1
Energy Savings
81 900 000 61 950 000
19 950 000 Wh/yr
or
19 950 kWh/yr
A review of Table 3 indicated that the heat loss for

this main based on the cellular glass insulation was
145 Wh/m. It was further noted that if the
insulation was changed to mineral fibre, the heat
loss would be reduced to 99 Wh/m. It should be
noted that the insulation thickness remained the
same.
Rand savings 19 950 R0.20

R3 990
Estimated cost to supply and install the additional
insulation is R30 000.
Simple payback
UPGRADE EXISTING
INSULATION LEVELS
During a walk through audit it was noted that an

NPS 6, steam header operating at 288oC for 8760
hours per year was insulated with cellular glass
insulation. The steam header was 100 metres long.
Savings with 51 mm Savings with 25 mm
RETROFIT WORKED EXAMPLES
Annual energy savings of mineral fibre insulation

can be calculated.
R30 000
R3 990
7.5 years
Annual energy savings

(Cellular glass loss mineral fibre loss) Length operating hours
per year
27
(147 100) 100 8760

41 172 000 Wh/yr
or 41 172 000 3.6
148 219 200 kJ/yr
or 148 219.2 MJ/yr
numerous steam branch mains were not insulated.

These steam mains varied in size from NPS 1 to
NPS 6. It was estimated that the equivalent length
would be equal to 350 m of NPS 4. The
temperature of the steam was 121oC and the
mains were in operation for an estimated 4400
hours per year. The steam was produced in a lowpressure boiler, which used synthetic gas as the fuel
and operated at 77 per cent efficiency. The cost of
gas at the facility was R58.00/GJ.
The steam was produced in a boiler operating at

76 per cent efficiency using synthetic at a cost of
R58.00/GJ.
Rand savings
148 219:2 R58:00

1000 0:76
A review of Table 3 indicated that the recommended mineral fibre insulation thickness for NPS
4 pipe at 121oC would be 76 mm. and that the
heat loss would be 28 Wh/m. Table 1 indicates
that the heat loss for bare steel pipe at 121oC is
530Wh/m.
R11 311.50/yr
The estimated cost to replace the cellular glass
insulation with glass fibre insulation was R100 000.
Simple payback
R100 000
R11 311:50
8.8 years
Using Worksheet 1-2 it was established that the

reduction in heat loss if the bare pipe were
insulated to the recommended thickness with glass
fibre insulation would be or 2 783 088 MJ/yr.
In this case the replacement is not justified based

on the payback. However, if the original insulation
had been less than the recommended thickness,
the heat loss and therefore the savings would have
been much greater. This would have to be
calculated using insulation manufacturers published
data.
4.3.1.2
Dollar savings
2 783 088 R58:00

1000 0:77
R209 635/yr
The cost to supply and install the 76mm insulation
on the uninsulated piping was R80 000
REVIEW ECONOMIC
INSULATION THICKNESS
Simple payback
R80 000
R209 635

As indicated in the `Fundamentals' section of this
module, in some instances, the economic insulation
thickness should be considered and compared to
recommended insulation thickness to establish
potential savings.
4.3.1.3
However, due to certain financial constraints,

management was not prepared to invest this
amount of money at this time.
Because of the budget limitations imposed by
management, a new set of calculations was
performed on the basis of using 25 mm of mineral
fibre insulation. The insulation manufacturer indicated that under these conditions the heat loss
would be 200 Wh/m for every hour of operation.
LIMITED BUDGET UPGRADE
During a walk through audit of a facility, which was

being considered for purchase, it was noted that
28
Using Worksheet 1-2 again the reduction in heat

loss if 25 mm of mineral fibre insulation is used is 1
829 520 MJ/yr
Rand savings
Even though the simple payback was not as good

as with the 25 mm as with the 76 mm of insulation,
management was prepared to invest R70 000 for
this limited budget upgrade.
1 829 520 R58:00

1 000 0:77
R137 808/yr
Estimated cost to supply and install the insulation is
R70 000
Simple payback
R70 000
R137 808
0.51 year (6 months).
29
APPENDICES
WORKSHEETS
WORKSHEET 1-1
Insulation Material Properties Selection Considerations
Company: _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Date: ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Location: ________________________________________________________________________________________________________________________________________________ By: ___________________________________________________________________________________________________________________________________________________________________
Insulation for: ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Important
Property
APPEARANCE (is insulation exposed?)
CHEMICAL NEUTRALITY (is insulation subject to intermittent wetting?)
BREAKING LOAD (Must insulation bridge discontinuities in its support?)
CAPILLARITY (is insulation in a wet area?)
COEFFICIENT OF EXPANSION AND CONTRACTION (is insulation layered
or are expansion joints required?)
COMBUSTIBILITY (is there a fire hazard in the area?)
COMPRESSIVE STRENGTH (must insulation support a load or be subject to
mechanical abuse?)
DENSITY
SHRINKAGE (is this a high temperature application?)
RESISTANCE TO ULTRAVIOLET RADIATION (is insulation exposed to
sunlight?)
RESISTANCE TO BACTERIAL OR FUNGAL GROWTH (is insulation used in
a food or cosmetic preparation area?)
30
Not
Important
WORKSHEET 1-2
Heat Loss From Piping
Company: ______________________________________________________________________________________________________________________________
Date: ___________________________________________________________________________________________________________________________________________________
Location: __________________________________________________________________________________________________________________________________
By: _______________________________________________________________________________________________________________________________________________________
Pipe diameter (NPS) _________________________________________________________________________________________
Pipe Length ________________________________________________________________________________________________________________ m
Pipe temperature _________________________________________________________________________________________ oC
Operating
Hours per year ______________________________________________________________________________________________________ h
Proposed
insulation type _______________________________________________________________________________________________________________
Proposed
Insulation thickness _________________________________________________________________________________ mm
Uninsulated
Insulated
Heat loss
Per metre _________________________________________________________________Wh/m.h (Table 1)
______________________________________________________________________________________________________Wh/m.h (Table 3)
Heat loss/h Heat loss/m.h length
Heat loss/m.h length
___________________________________________________________________________ _____________________________________________________
_____________________________________________________________________________ _______________________________________________________
_________________________________________________________________________________________________________________________________________________Wh/h
_________________________________________________________________________________________________________________________________________________Wh/h
Annual heat loss Heat loss h/yr
Heat loss/h h/yr
___________________________________________________________________________ _____________________________________________________
_____________________________________________________________________________ __________________________________________________________________________
____________________________________________________________________________________________________________________________________Wh/h (1)
__________________________________________________________________________________________________________________________________Wh/yr (2)
Reduction in heat loss due

to addition of insulation
(1) (2)
________________________________________________________________________________________________ ____________________________________________
_____________________________________________________________________________________________________________________________________Wh/yr
or ______________________________________________________________________________________Wh/yr 3.6 kJ/Wh
_____________________________________________________________________________________________________________________________________________kJ/yr
Annual Rand savings may now be calculated using cost per unit of heating medium. Ensure that units are
compatible.
31
WORKSHEET 1-2
Company: _____________________________________________ABC
_________________Co.
________________________________________________________________
Date: ___________________________________________________________________________________________________________________________________________________
Location: ________________________________________ANYTOWN
__________________________________________________________________________________________
Low cost worked example No. 1
By: ______________________________________________________________MBE
_________________________________________________________________________________________
Pipe diameter (NPS) ________________________________________________2_________________________________________
Pipe Length _________________________________________________________20

_______________________________________________________ m
Pipe temperature _________________________________________121

________________________________________________ oC
Operating
Hours per year _________________________________________2_______880
______________________________________________________ h
Proposed
insulation type ___________________________________cellular
__________________________glass
__________________________________________________
Proposed
Insulation thickness _________________________________34
________________________________________________ mm
Uninsulated
Insulated
Heat loss
Per metre ________________________________290
_________________________________Wh/m.h (Table 1)
_________________________________________________35
_____________________________________________________Wh/m.h (Table 3)
___________________________________290
________________________________________ __________________________20
___________________________
___________________________________35
__________________________________________ _________________________20
______________________________
______________________________________________________________________5_______800
____________________________________________________________________Wh/h
___________________________________________________________________________700
______________________________________________________________________Wh/h
Heat loss/h h/yr
__________________________________5________800
_________________________________ ________________________2________880
_____________________
_______________________________700
______________________________________________ ________________2_______880
___________________________________________________
___________________________________________16
____________704
________________000
___________________________________________________________Wh/yr (1)
_________________________________________________________2_______016
_________________000
_________________________________________________Wh/yr (2)

(1) (2)
______________________________16
____________704
________________000
______________________________________ _____2_______016
________________000
________________
_______________________________________________14
____________688
________________000
__________________________________________________________Wh/yr
or _______________________14
____________688
________________000
___________________________________Wh/yr 3.6 kJ/Wh
__________________________________52
____________876
________________800
_______________________________________________________________________________kJ/yr
compatible.
32
WORKSHEET 1-2
Company: _____________________________________________XYZ
__________________Co.
_______________________________________________________________
Date: ___________________________________________________________________________________________________________________________________________________
__________________________________________________________________________________________
Housekeeping worked example No. 1
By: ______________________________________________________________MBE
_________________________________________________________________________________________
Pipe Length _________________________________________________________10

_______________________________________________________ m
Pipe temperature __________________________________________________________121

_______________________________ oC
Operating
Hours per year _________________________________________8_______760
______________________________________________________ h
Proposed
insulation type ___________________________________mineral
____________________________fibre
________________________________________________
Proposed
________________________________________________ mm
Uninsulated
Insulated
Heat loss
Per metre ________________________________530
_________________________________Wh/m.h (Table 1)
_________________________________________________28
_____________________________________________________Wh/m.h (Table 3)
___________________________________530
________________________________________ __________________________10
___________________________
____________________________________28
_________________________________________ _________________________10
______________________________
______________________________________________________________________5_______300
____________________________________________________________________Wh/h
___________________________________________________________________________280
______________________________________________________________________Wh/h
Heat loss/h h/yr
__________________________________5________300
_________________________________ ________________________8________760
_____________________
_______________________________2800
______________________________________________ ____________________8_______760
_______________________________________________
___________________________________________46
____________428
________________000
_____________________________________________________________Wh/h (1)
_________________________________________________________2________452
________________800
_________________________________________________Wh/yr (2)

(1) (2)
______________________________46
____________428
________________000
______________________________________ _____2_______452
________________800
________________
_______________________________________________43
____________975
________________200
__________________________________________________________Wh/yr
or ______________________________________________________________________________________Wh/yr 3.6 kJ/Wh
_____________________________________________________________________________________________________________________________________________kJ/yr
compatible.
33
WORKSHEET 1-3
Company: ______________________________________________________________________________________________________________________________
Date: ___________________________________________________________________________________________________________________________________________________
Location: __________________________________________________________________________________________________________________________________
By: _______________________________________________________________________________________________________________________________________________________
Equipment ____________________________________________________________________________________________________________________________
Operating
Hours per year ______________________________________________________________________________________________________ h
Surface area __________________________________________________________________________________________________________ m2
Proposed Insulation
type __________________________________________________________________________________________________________________________________________________
Product temperature ____________________________________________________________________________ C
Proposed
Insulation thickness _________________________________________________________________________________ mm
Uninsulated
Insulated
Heat loss_________________________________________________________________________Wh/m2 (Table 1)
_________________________________________________________________________________________________________Wh/m2 (Table 3)
Total heat loss/h Surface area Heat loss
Surface area Heat loss
___________________________________________________________________________ _____________________________________________________
_____________________________________________________________________________ _______________________________________________________
_________________________________________________________________________________________________________________________________________________Wh/h
_________________________________________________________________________________________________________________________________________________Wh/h
Heat loss/h h/yr
___________________________________________________________________________ _____________________________________________________
_____________________________________________________________________________ __________________________________________________________________________
__________________________________________________________________________________________________________________________________Wh/yr (1)
__________________________________________________________________________________________________________________________________Wh/yr (2)

(1) (2)
________________________________________________________________________________________________ ____________________________________________
_____________________________________________________________________________________________________________________________________Wh/yr
or ______________________________________________________________________________________Wh/yr 3.6 kJ/Wh
_____________________________________________________________________________________________________________________________________________kJ/yr
compatible.
34
WORKSHEET 1-3
Company: _____________________________________________ABC
_________________Co.
________________________________________________________________
Date: ___________________________________________________________________________________________________________________________________________________
__________________________________________________________________________________________
By: ______________________________________________________________MBE
_________________________________________________________________________________________
Equipment ______________________________Heating
_____________________________tank
_________________No.
________________1________________________________
Operating
Hours per year _________________________________________8_______760
______________________________________________________ h
Surface area _________________________________________________10

_________________________________________________________ m2
Proposed Insulation
type __________________________________________________________________mineral
____________________________fibre
____________________________________________________
Product temperature __________________________________177

__________________________________________ oC
Proposed
________________________________________________ mm
Uninsulated
Insulated
Heat loss_______________________________________2_______800
___________________________Wh/m2 (Table 5)
_________________________________________________63
________________________________________________________Wh/m2 (Table 3)
___________________________________10
________________________________________ ______________________2_______800
________________________
____________________________________10
_________________________________________ _________________________63
______________________________
____________________________________________________________________28
____________000
_________________________________________________________________Wh/h
___________________________________________________________________________630
______________________________________________________________________Wh/h
Heat loss/h h/yr
__________________________28
___________000
______________________________________ ___________________8_______760
___________________________
_______________________________630
______________________________________________ ________________8_______760
___________________________________________________
____________________________________________________245
________________280
________________000
________________________________________________Wh/h (1)
_________________________________________________________5________518
________________800
_________________________________________________Wh/yr (2)

(1) (2)
_____________________________245
________________280
________________000
___________________________________ ________5_______518
________________800
_____________
_______________________________________________239
_________________761
________________200
_____________________________________________________Wh/yr
or _______________________239
________________761
________________200
___________________________________Wh/yr 3.6 kJ/W
__________________________________863
________________140
________________320
___________________________________________________________________________kJ/yr
compatible.
35
WORKSHEET 1-3
Company: _____________________________________________XYZ
__________________Co.
_______________________________________________________________
Date: ___________________________________________________________________________________________________________________________________________________
__________________________________________________________________________________________
Low cost worked example No.3
By: ______________________________________________________________MBE
_________________________________________________________________________________________
Equipment ______________________________Heating
_____________________________tank
_________________No.
________________2________________________________
Operating
hours per year ___________________________________________8_______400
______________________________________________________ h
Surface area __________________________________________________25

________________________________________________________ m2
Proposed Insulation
type __________________________________________________________________mineral
___________________________fibre
_____________________________________________________

__________________________________________ oC
Proposed
________________________________________________ mm
Uninsulated
Insulated
Heat loss_______________________________________504.7
__________________________________Wh/m2 (Table 5)
_________________________________________________32
________________________________________________________Wh/m2 (Table 3)
___________________________________25
________________________________________ ______________________504.7
_______________________________
____________________________________25
_________________________________________ _________________________32
______________________________
____________________________________________________________________12
____________617.5
_________________________________________________________________Wh/h
___________________________________________________________________________800
______________________________________________________________________Wh/h
Heat loss/h h/yr
__________________________12
___________617.5
______________________________________ ________________________8________400
_____________________
_______________________________800
______________________________________________ ________________8_______400
___________________________________________________
____________________________________________________105
________________987
________________000
________________________________________________Wh/h (1)
_________________________________________________________6________720
________________000
_________________________________________________Wh/yr (2)

(1) (2)
____________________________105
_________________987
________________000
___________________________________ ________6_______720
________________000
_____________
_______________________________________________99
____________300
________________000
__________________________________________________________Wh/yr
or _______________________99
____________300
________________000
___________________________________Wh/yr 3.6 kJ/Wh
__________________________________357
________________480
________________000
___________________________________________________________________________kJ/yr
compatible.
36
WORKSHEET 1-3
Company: _____________________________________________ABC
_________________Co.
________________________________________________________________
Date: ___________________________________________________________________________________________________________________________________________________
__________________________________________________________________________________________
Low cost worked example No. 3
By: ______________________________________________________________MBE
_________________________________________________________________________________________
Equipment ______________________________Holding
______________________________tank
_________________No.
________________2_______________________________
Operating
Hours per year _________________________________________8_______400
______________________________________________________ h
Surface area _________________________________________________25

_________________________________________________________ m2
Proposed Insulation
type __________________________________________________________________mineral
____________________________fibre
____________________________________________________

__________________________________________ oC
Proposed
________________________________________________ mm
Uninsulated
Insulated
Heat loss_______________________________________504.7
__________________________________Wh/m2 (Table 5)
_________________________________________________115
_________________________________________________Wh/mm2 (Table 3)
___________________________________25
________________________________________ ______________________504.7
_______________________________
____________________________________25
_________________________________________ _________________________115
______________________________
____________________________________________________________________12
____________617.5
_________________________________________________________________Wh/h
___________________________________________________________________________2_______875
_______________________________________________________________Wh/h
Heat loss/h h/yr
__________________________12
___________617.5
______________________________________ ________________________8________400
_____________________
_______________________________2_______875
_______________________________________ _______________________8________400
___________________________________________
____________________________________________________105
________________987
________________000
______________________________________________Wh/yr (1)
_________________________________________________________21
____________150
________________000
_____________________________________________Wh/yr (2)

(1) (2)
_____________________________105
________________987
________________000
___________________________________ _____21
____________150
________________000
___________
_______________________________________________81
____________837
________________000
__________________________________________________________Wh/yr
or _______________________81
____________837
________________000
___________________________________Wh/yr 3.6 kJ/Wh
__________________________________294
________________613
________________200
___________________________________________________________________________kJ/yr
compatible.
37
WORKSHEET 1-2 (Page 1 of 2)

Company: _____________________________________________ABC
_________________Co.
________________________________________________________________
Date: ___________________________________________________________________________________________________________________________________________________
__________________________________________________________________________________________
Retrofit worked example No. 3
By: ______________________________________________________________MBE
_________________________________________________________________________________________
Pipe diameter (NPS) _______________________________________4__________________________________________________
Pipe Length _____________________________________________________350

___________________________________________________________ m
Pipe temperature _________________________________________121

________________________________________________ oC
Operating
Hours per year ____________________________________4________400
__________________________________________________________ h
Proposed
____________________________fibre
________________________________________________
Proposed
________________________________________________ mm
Uninsulated
Insulated
Heat loss_______________________________________530
________________________________Wh/m.h (Table 1)
_________________________________________________28
_____________________________________________________Wh/m.h (Table 3)
___________________________________530
________________________________________ __________________________350
___________________________
___________________________________28
__________________________________________ _________________________350
______________________________
___________________________________________________________185
________________500
______________________________________________________________________Wh/h
___________________________________________________________________________9_______800
_______________________________________________________________Wh/h
Heat loss/h h/yr
__________________________185
________________500
_________________________________ _______________________4_______400
_______________________
_______________________________9_______800
_______________________________________ _______________________4_______400
____________________________________________
____________________________________________________816
________________200
________________000
________________________________________________Wh/h (1)
_________________________________________________________43
____________120
________________000
_____________________________________________Wh/yr (2)

(1) (2)
____________________________816
_________________200
________________000
___________________________________ _____43
____________120
________________000
___________
_______________________________________________773
________________080
_________________000
_____________________________________________________Wh/yr
or _______________________773
________________080
________________000
_______________________________Wh/yr 3.6 kJ/Wh
__________________________________2_______783
________________088
________________000
____________________________________________________________________kJ/yr
compatible.
38
WORKSHEET 1-2 (Page 2 of 2)

Company: _____________________________________________ABC
_________________Co.
________________________________________________________________
Date: ___________________________________________________________________________________________________________________________________________________
__________________________________________________________________________________________
Retrofit worked example No. 3
By: ______________________________________________________________MBE
_________________________________________________________________________________________
Pipe Length _________________________________________________________350

_______________________________________________________ m
Pipe temperature __________________________________________________________121

_______________________________ oC
Operating
Hours per year _________________________________________4_______400
______________________________________________________ h
Proposed
____________________________fibre
________________________________________________
Proposed
________________________________________________ mm
Uninsulated
Insulated
Heat loss
Per metre ________________________________530
_________________________________Wh/m.h (Table 1)
_________________________________________________200
_____________________________________________________Wh/m.h (Table 3)
___________________________________530
________________________________________ __________________________350
___________________________
____________________________________200
_________________________________________ _____________________________350
__________________________
______________________________________________________________________185
________________500
___________________________________________________________Wh/h
__________________________________________________________________70
____________000
___________________________________________________________________Wh/h
Heat loss/h h/yr
__________________________185
________________500
_________________________________ ____________________4_______400
__________________________
_______________________________70
____________000
__________________________________ ___________________________4________400
_______________________________________
___________________________________________816
________________200
________________000
_______________________________________________________Wh/yr (1)
_________________________________________________________308
________________000
________________000
_________________________________________Wh/yr (2)

(1) (2)
__________________________816
_______________200
________________000
_______________________________________ _308
________________000
________________000
___________
_______________________________________________508
_________________200
________________000
_____________________________________________________Wh/yr
or _______________________508
________________200
________________000
_______________________________Wh/yr 3.6 kJ/Wh
__________________________________1_______829
________________520
_________________000
___________________________________________________________________kJ/yr
compatible.
39
GLOSSARY
Ambient Temperature The temperature of the

medium, usually air, surrounding the
object under consideration.
Batt
the liquid being the surface tension.

Caulking Compound A soft, plastic material,
consisting of pigment and carrier, used
for sealing joints in buildings, and other
structures, where normal structural
movement may occur.
A piece of insulation, of the flexible type,

cut into easily handled sizes, square or
rectangular in shape, usually 609.6 mm
(24) or 1219 mm (48) long with a
vapour retarder on one side, and with, or
without, a container sheet on the other
side.
Cellular Elastomeric Flexible Thermal Insulation

Insulation composed principally of
natural or synthetic elastomers in expanded cellular form.
Blanket Insulation, of the flexible type, formed

into sheets or rolls, usually with a vapour
retarder on one side, and with, or without, a container sheet on the other side.
Cellular Glass Thermal Insulation Insulation

composed of glass processed by fusion
to form a homogeneous rigid mass of
closed cells.
Block Rigid or semi-rigid insulation formed into

sections, rectangular both in plan and
cross-section, usually 36 (914.4 mm) to
1219 mm (48) long, 152.4 mm (6) to
609.6 mm (24) wide, and 25.4 mm (1)
to 152.4 mm (6) thick.
Celsius The temperature measuring scale

(formerly Centigrade) in which the
freezing point of water is taken at 0o
and the vaporisation point at 100o.
Absolute zero on this scale is -273.15oC.
Chemically Foamed Plastic A cellular plastic
produced by gasses generated from
chemical interaction of constituents.
Calcium Silicate Insulation Insulation composed

principally of hydrous calcium silicate,
which usually incorporates fibres of
varying types to act as a binder.
Canvas A light, plain weave, coarse, cotton cloth
with hard twisted yarns, usually not more
than 271 grams per square metre.
Chlorinated Solvent An organic chemical liquid

characterised by a high chlorine content
and used in coating products to impart
non-flammability.
Capillarity That property of a material which

enables it to suck a liquid up into or
through itself, with the driving force of
Closed-Cell Foamed Plastic A cellular plastic in

which there is a predominance of noninterconnecting cells.
40
Coating A liquid, or semi-liquid, protective finish

suitable for thermal insulation or other
surfaces, usually applied by brush or
spray, in moderate thickness, less than
0.80 mm approx. [30 mils (0.030)].
contact: also called contact bond or dry

bond adhesive.
Corrosion Effect The wearing away' or destruction of a substrate caused by acid or
alkaline reactions between materials
contained in the insulation and substrate.
Coefficient of Expansion (Contraction) The

increase (decrease) in length of a
material one unit long, due to the
increase (decrease) of temperature by
one degree.
Coverage-Wet The property of a material which

measures the thickness of wet material
that must be applied to a given area to
obtain a specific thickness after it has
cured and dried.
Combustible Capable of uniting with air or

oxygen in a reaction initiated by heating
accompanied by the subsequent evolution of heat and light i.e. capable of
burning.
Cryogenic Pertaining to the extremely low

temperatures, such as the liquefaction
points of gaseous elements, usually
approaching absolute zero (-273.15oC).
Combustibility That property of a material which

measures its tendency to burn. It is
normally expressed in the arbitrary terms
of Flame Spread Index and Smoke
Density Index
Curing Agent An additive incorporated in a

coating or adhesive resulting in increased
chemical activity between the components, with an increase or decrease in the
rate of cure.
Compressive Strength Resistance to change in

dimension when acted on by a compacting force.
Curved Segmental Block A piece of rigid pipe

insulation, moulded or cut from a block
to fit the exact dimensions of a given size
of pipe.
Condensation The act of water vapour turning

into water upon contact with a surface at
a lower temperature than the dew point
of the vapour.
Density The mass per unit volume of a

substance.
Conductivity See Thermal Conductance.
Dewpoint The temperature at which the

quantity of water vapour in a material
would cause saturation, with resultant
condensation of the vapour into liquid
water by any further reduction of
temperature.
Contact Adhesive An adhesive which is

apparently dry to the touch and which
will adhere to itself instantaneously' upon
Diatomaceous Silica Insulation Insulation composed principally of diatomaceous earth

with, or without, heat-resistant inorganic
Conduction The transfer of energy within a

body, or between two bodies in physical
contact, from a higher temperature
region to a lower temperature region.
41
of 212o with 180 even divisions between

and corresponding divisions above and
below. Absolute zero on this scale is 459.67o.
binders and which usually incorporates

mineral fibres.
Dimensional Stability That property of insulation,
which enables it to hold its original size,
shape and dimensions.
Felt An insulation material composed of fibres,

which are interlocked and compacted
under pressure.
Drying Time (Adhesives) Time elapsed since

bonding and the time when no further
increase in bond strength is realised.
Fibreglass A composite material consisting of

glass fibres and a resin binder.
Drying Time (Finishes) Time elapsed after which

no further significant changes take place
in appearance or performance properties, due to drying.
Filler A relatively inert material added to a mastic

or coating to modify its strength, permeance, working properties, or other
qualities.
Ductility That property of a material which

enables it to undergo large deformations
without rupture.
Finishing Cement A mixture of fibres, bonding

clays, and water mixed to a plastic mass
on the job, and used on the surface of
insulation to provide a medium-hard to
hard, even finish.
Elastomer Material, which at room temperature

can be stretched repeatedly to at least
twice its original length and immediately
upon release of the stress, will return
with force to the approximate original
length.
Fire Resistance That property of a material that

enables it to resist decomposition or
deterioration when exposed to a fire.
Emittance The ratio of the total heat lost per unit

of time through the same unit area of a
perfect blackbody.
Fire Retardance That property of a material,

which delays the spread of fire, either
through or over itself.
Exposed Any surface, which will be visible in the

finished structure.
Flame Spread The rate, expressed in distance and

time, at which a material will propagate
flame on its surface. As this is a difficult
property to measure in time and distance, the measure is now by flame
spread index to enable the comparison
of materials by one of the following test
methods: CAN2- S102-M83 or ASTM
E84.
Facing A thin layer on the surface of an insulating

product, acting as either a vapour
retarder, weather barrier, protector from
damage or a decorative coating.
Fahrenheit The temperature scale of The British
System of units in which the freezing
point of water is assigned the value of
32o and the vaporisation point the value
Flammable That property of a material which

permits it to oxidise rapidly and release
42
heat of combustion when exposed to

flame or fire, and allows continuous
burning after the external ignition source
is removed.
Insulation A material of low thermal conductivity

used to reduce the passage of heat.
Insulation Coating A material, or materials, used
over insulation or over the weather
coating to provide the desired colour
or texture for decorative purposes.
Flashing A thin strip of metal inserted at the

junction of 2 materials to divert water in
a specific direction.
Insulation Cover The cover for a flange,

pipefitting, or valve, composed of the
specified thickness of insulating material,
and pre-formed into the proper shape
before application.
Flash Point The lowest temperature of a material

(at a fixed pressure) at which it gives off
vapour, which, when combined with air
near the surface, forms an ignitable
mixture.
Insulation System An application of insulation to

piping, ductwork or equipment that may
include the use of adhesives, mechanical
fastenings, coatings, reinforcing fabrics,
sealant and metal covering.
Flexibility That property of a material, which

allows it to be bent (flexed) without loss
of strength.
Flexural Strength That property of a material
which measures its resistance to bending
(flexing) usually expressed in kg/m (lbs/
in).
Jacket A covering placed around an insulation to

protect it from mechanical damage, and,
insofar as it is intrinsically able, from
weather, water, ultraviolet light, etc.
Freeze-Thaw Resistance The property of a

material which permits it to be alternately frozen and thawed through many
cycles without damage from rupture or
cracking.
Lag A long, narrow piece of rigid insulation,

rectangular in plan, trapezoidal in crosssection, moulded, or cut from a block of
the proper thickness.
Fuel Contribution Flammable by-products of fire

generated by, and emitted from, a
burning object.
Lagging An insulation layer, on a cylindrical

surface, composed of lags.
Laminated Foils A product made by bonding a
foil sheet to at least one other material
such as kraft paper.
Hanger A device such as a welded pin, stud or

adhesive secured fastener, which carries
the weight of the insulation or piping
system.
Lap Adhesive (Lap Cement) The adhesive

material used to seal the side and end
laps of insulation jackets.
Humidity A measure of the amount of water

vapour in the atmosphere.
Linear Shrinkage The property of a material that

indicates the proportional loss of dimen-
43
sions when exposed to high temperatures.
Pipe Insulation Thermal insulation suited for

application to cylindrical surfaces of pipe
and tubing.
Loose Fill Insulation Particulate material in

granular, nodular, fibrous, powdery, or
similar form designed to be installed dry
by pouring, blowing, or hand placement
between retaining surfaces or as a
covering layer.
Pre-formed Pipe Insulation Thermal insulation in

cylindrical, semi-cylindrical, or segmental
sections to fit pipes and tubing.
Pre-formed Thermal Insulation Block A rigid or
semi-rigid thermal insulating material,
either flat or segmental, for application
as received.
Mastic A relatively thick consistency protective

finish capable of application to thermal
insulation or other surfaces, usually by
spray or trowel, in thick coats greater
than 30 mils (0.80 mm approximately).
Primer The first application of a coating system

used to seal or condition the surface for
the proper bonding of subsequent layers
or coats.
Metal Lath A lattice type of material of various

gauges and sizes used to provide reinforcement for insulation.
PVC-Polyvinyl Chloride Plastic material moulded

into finished shapes such as fitting covers.
Mineral Fibre (Wool) A generic term for all nonmetallic inorganic fibres, which may be
natural, or may be manufactured from
such sources as rock, slag, or glass.
Reflective Insulation Thermal insulation depending for its efficiency in large part on the
reduction of radiant heat transfer across
spaces by use of one or more surfaces of
high reflectance and low emittance.
Mineral Fibre Blanket Insulation A blanket

thermal insulation composed of inorganic fibres, with, or without, added binders.
Reinforcing Membrane A loosely woven cloth

or fabric of glass or resilient fibres, placed
approximately in the centre of the
vapour retarder or weather barrier to
act as reinforcing to the mastic of the
barrier.
Mitred Insulation Insulation that has been cut in

bevelled sections so that when it is fitted
together, it follows the contour or curve
of the object being insulated.
Non-combustible A material that will not
contribute fuel or heat to a fire to which
it is exposed.
Scrim Woven screening type fabric used to

reinforce an insulation covering.
Tack The property of an adhesive that enables it
to form a bond of measurable strength
immediately after adhesive and adherent
are brought into contact under low
pressure.
Non-flammable That property of a material that

prevents it from oxidising rapidly and
releasing heat or combustion when
exposed to fire or flame.
44
Temperature Limits The upper and lower

temperatures at which a material will
experience no essential change in its
properties.
formed by the mating surfaces of jackets

and vapour retarders over insulation. A
good sealer will not shrink much. There
are several types of sealers, such as nonsetting, and heat resisting.
Thermal Insulation Material having air-filled or

gas-filled pockets, void spaces, or heatreflective surfaces, which, when properly
applied will retard the transfer of heat
with reasonable effectiveness under ordinary conditions.
Service Temperature Limits The temperature

range within which the applied coating
will provide satisfactory service.
Smoke Density (Smoke Developed) The Smoke
Density Factor is the amount of smoke
given off by the burning material compared to the amount of smoke given off
by the burning of a standard material.
Reinforcing Mesh Generic term for poultry

netting, chicken wire, etc., usually made
from pre-galvanised wire woven in 25.4
mm (1 inch) mesh size. Also available in
post-galvanised and rustless metal alloys.
Softening Point That temperature at which a

material will change its property from
firm or rigid to soft or malleable.
Relative Humidity The ratio of the actual

pressure of existing water vapour to
the maximum possible (saturation) pressure of water vapour in the atmosphere
at the same temperature, expressed as a
percentage. (See Dewpoint.)
Solvent Any substance, usually a liquid, which

dissolves another substance. Normally a
liquid organic compound used to make a
coating work more freely.
Resilient Capable of recoiling from pressure or

shock unchanged or undamaged.
Substrate A material upon the surface of which

an adhesive or coating is spread.
Sag Excessive flow in material after application to a

surface, resulting in curtaining or running.
Thermal Shock Resistance That property of a

material which enables it to maintain
shape and not distort, crack or shatter,
from a sudden temperature change.
Self-Ignition Temperature (Autogeneous Ignition)

The lowest temperature of a material
which will cause it to ignite without
another ignition source.
Thermoplastic Capable of being repeatedly

softened by an increase of temperature.
Note: Thermoplastic applies to those
materials whose change upon heating is
substantially physical.
Self-Extinguishing That property of a material

which enables it to stop ignition after
external ignition sources are removed.
Thermoset A plastic or other coating which,

when cured by the application of heat or
chemical means, changes to a substantially infusible and insoluble product.
Sealer A substance, composed of various

materials, used as a barrier to the passage
of water vapour or water into the joint
45
Toxicity The degree of hazard to health.
Viscosity The property of resistance to flow

exhibited within the body of a material.
Urethane Resins Resins made by the condensation of organic isocyanates with compounds or resins that contain hydroxol
groups. Note: Urethanes are a type of
isocyanates resins.
Water Absorption The increase in weight of a

material, expressed as a percentage of its
dry weight, after immersion in water for a
specified time.
Vapour Retarder A material, or materials, which

when installed on the high vapour
pressure side, retards the passage of the
moisture vapour to the lower vapour
pressure side.
Weather Barrier A material, which, when

installed on the outside of the insulation,
protects the insulation from weather
damage due to rain, snow, wind, atmospheric contamination, etc.
Vapour Migration (Permeability) That property

of a material, which measures the rate at
which water vapour will penetrate it, due
to vapour pressure differences between
its surfaces.
Weather Coating A material, or materials, which,

when installed on the outer surface of
thermal insulation, protects the insulation
from weather, such as rain, snow, sleet,
wind, solar radiation, and atmospheric
contamination.
Vapour Pressure The gas pressure exerted by

the water vapour present in the air.
Wire Netting Interwoven wires of metal used as

reinforcement for insulation.
Vermiculite Lightweight insulation material made

from the expansion of granules at high
temperatures.
Wicking The ability of a material to draw up

liquids by capillary action.
Victaulic A trade or patented name for a specific

type of coupling.
46
HEAT LOSS TABLES
47
48
49
50
51
HEAT LOSS TABLES
HEAT LOSS THROUGH PIPES WITH VARIOUS THICKNESSES OF INSULATION

TABLE 3
CELLULAR GLASS
PROCESS TEMPERATURE (oC)
NPS
66
121
177
232
288
343
399
0.5
Thickness
heat loss
surf. temp
25
12
24
38
25
26
51
37
28
64
49
28
76
61
29
89
72
30
102
86
31
Thickness
heat loss
surf. temp
25
16
24
51
28
25
64
41
27
76
55
28
89
68
29
102
83
30
102
102
32
1.5
Thickness
heat loss
surf. temp
38
17
23
64
31
24
76
46
26
102
58
27
102
77
29
102
98
31
102
121
33
Thickness
heat loss
surf. temp
38
14
22
64
35
25
76
51
27
102
64
27
102
86
29
102
110
32
114
128
32
Thickness
heat loss
surf. temp
38
25
24
76
39
24
89
60
26
102
79
26
102
106
31
114
127
32
127
148
33
Thickness
heat loss
surf. temp
51
25
23
76
46
25
102
64
26
102
92
28
102
123
31
114
147
32
127
170
33
Thickness
heat loss
surf. temp
51
34
23
89
54
24
102
82
27
102
118
29
114
147
31
140
165
31
152
193
33
Thickness
heat loss
surf. temp
64
36
23
86
65
25
98
99
27
98
142
31
123
163
31
135
196
32
159
217
33
10
Thickness
heat loss
surf. temp
64
42
23
102
70
24
102
116
28
102
167
31
140
179
31
140
229
33
178
239
32
52
TABLE 3 (CELLULAR GLASS Continued)

NPS
66
121
177
232
288
343
399
12
Thickness
heat loss
surf. temp
64
48
23
102
80
25
102
133
28
102
191
32
140
203
31
140
258
34
191
258
32
14
Thickness
heat loss
surf. temp
64
53
23
102
87
25
102
142
28
102
206
32
140
217
31
140
277
34
203
262
31
16
Thickness
heat loss
surf. temp
64
59
23
102
96
25
102
159
28
102
229
32
140
240
31
140
307
34
203
288
32
18
Thickness
heat loss
surf. temp
64
65
23
102
106
25
102
175
29
102
255
32
140
263
31
140
337
34
203
314
32
20
Thickness
heat loss
surf. temp
64
71
23
102
115
26
102
191
29
114
251
31
140
287
32
140
365
34
203
340
32
24
Thickness
heat loss
surf. temp
64
84
23
102
135
26
102
223
29
127
268
30
140
333
32
140
425
35
203
391
32
30
Thickness
heat loss
surf. temp
64
103
24
102
164
26
102
271
29
140
300
29
140
402
32
140
512
36
203
467
33
36
Thickness
heat loss
surf. temp
64
122
24
102
193
26
102
319
29
140
352
29
140
470
33
140
600
36
203
543
33
FLAT
Thickness
heat loss
surf. temp
64
41
406
102
63
25
102
101
28
140
107
28
140
145
31
191
136
31
216
148
32
Heat loss: Wh/m for pipe, Wh/m2 for flat surfaces

Based on 18oC ambient temperature
53

TABLE 3
CALCIUM SILICATE
NPS
66
121
177
232
288
343
399
454
510
566
0.5
Thickness
heat loss
surf. temp
25
8
22
38
15
24
51
23
24
64
32
26
76
41
26
89
52
27
102
63
28
102
81
30
114
96
31
140
110
31
Thickness
heat loss
surf. temp
25
11
23
25
20
24
51
29
26
64
39
27
89
47
26
102
59
27
102
76
29
114
92
30
127
110
31
140
130
32
1.5
Thickness
heat loss
surf. temp
25
13
23
51
21
23
64
32
25
76
43
26
102
52
26
102
70
28
102
90
30
140
99
29
140
123
31
152
146
32
Thickness
heat loss
surf. temp
38
12
22
51
24
24
76
23
24
89
45
25
102
59
26
102
78
28
102
101
31
140
110
29
152
132
31
152
162
33
Thickness
heat loss
surf. temp
38
15
22
64
27
23
89
37
24
102
52
25
102
72
27
114
90
28
114
117
31
152
128
30
165
148
31
178
177
32
Thickness
heat loss
surf. temp
38
18
22
76
28
23
102
40
23
102
61
26
102
85
28
127
98
30
140
121
29
152
146
31
178
167
31
191
198
32
Thickness
heat loss
surf. temp
51
20
22
76
37
23
102
52
24
102
78
26
114
100
28
127
125
29
140
153
31
165
174
31
191
200
32
203
237
33
Thickness
heat loss
surf. temp
51
25
22
86
40
23
98
62
24
98
93
27
123
112
27
123
149
29
135
182
32
172
196
31
196
225
32
208
266
33
10
Thickness
heat loss
surf. temp
51
31
22
89
48
23
102
74
25
102
111
27
127
130
28
140
163
29
140
212
32
191
217
31
216
249
32
229
295
33
54
TABLE 3
(CALCIUM SILICATE Continued)

NPS
66
121
177
232
288
343
399
454
510
566
12
Thickness
heat loss
surf. temp
64
45
23
102
72
24
102
116
27
102
163
30
127
184
30
140
256
32
178
227
31
203
252
31
216
288
32
241
317
33
14
Thickness
heat loss
surf. temp
64
49
23
102
78
24
102
125
27
102
176
30
127
197
31
140
233
32
178
242
31
203
252
31
229
296
32
241
338
33
16
Thickness
heat loss
surf. temp
76
48
22
102
87
24
102
138
28
102
196
31
140
203
29
191
228
30
203
255
31
229
295
32
254
325
32
254
358
33
18
Thickness
heat loss
surf. temp
76
53
23
102
95
24
102
153
28
102
216
31
140
223
30
165
249
31
191
278
31
216
308
31
229
353
32
254
387
33
20
Thickness
heat loss
surf. temp
76
58
23
102
104
25
102
167
28
102
236
31
140
242
30
165
270
31
191
300
31
216
333
32
241
366
32
254
418
33
24
Thickness
heat loss
surf. temp
76
68
23
102
122
25
102
195
28
102
276
31
140
282
31
165
312
31
191
346
31
216
382
32
241
420
32
254
478
34
30
Thickness
heat loss
surf. temp
76
83
23
102
148
25
102
237
28
102
336
31
140
339
31
178
354
31
203
393
31
229
435
32
254
479
32
254
566
34
36
Thickness
heat loss
surf. temp
64
114
23
102
174
25
102
280
28
102
394
32
165
345
29
191
390
30
203
457
31
229
504
32
254
554
33
254
655
34
FLAT
Thickness
heat loss
surf. temp
64
38
23
89
63
25
102
88
27
140
91
27
165
104
28
191
114
29
216
123
29
241
136
31
254
155
32
254
183
34

55

TABLE 3
MINERAL FIBRE
NPS
66
121
177
232
288
343
399
454
510
566
0.5
Thickness
heat loss
surf. temp
25
8
22
38
15
24
51
23
24
64
32
26
76
41
26
89
52
27
102
63
28
102
81
30
114
96
31
140
110
31
Thickness
heat loss
surf. temp
25
11
23
25
20
24
51
29
26
64
39
27
89
47
26
102
59
27
102
76
29
114
92
30
127
110
31
140
130
32
1.5
Thickness
heat loss
surf. temp
25
13
23
51
21
23
64
32
25
76
43
26
102
52
26
102
70
28
102
90
30
140
99
29
140
123
31
152
146
32
Thickness
heat loss
surf. temp
38
12
22
51
24
24
76
23
24
89
45
25
102
59
26
102
78
28
102
101
31
140
110
29
152
132
31
152
162
33
Thickness
heat loss
surf. temp
38
15
22
64
27
23
89
37
24
102
52
25
102
72
27
114
90
28
114
117
31
152
128
30
165
148
31
178
177
32
Thickness
heat loss
surf. temp
38
18
22
76
28
23
102
40
23
102
61
26
102
85
28
127
98
30
140
121
29
152
146
31
178
167
31
191
198
32
Thickness
heat loss
surf. temp
51
20
22
76
37
23
102
52
24
102
78
26
114
100
28
127
125
29
140
153
31
165
174
31
191
200
32
203
237
33
Thickness
heat loss
surf. temp
51
25
22
86
40
23
98
62
24
98
93
27
123
112
27
123
149
29
135
182
32
172
196
31
196
225
32
208
266
33
10
Thickness
heat loss
surf. temp
51
31
22
89
48
23
102
74
25
102
111
27
127
130
28
140
163
29
140
212
32
191
217
31
216
249
32
229
295
33
56
TABLE 3
(MINERAL FIBRE Continued)

NPS
66
121
177
232
288
343
399
454
510
566
12
Thickness
heat loss
surf. temp
51
35
22
89
55
23
102
84
25
102
126
28
127
148
28
140
185
30
140
239
33
191
243
31
216
279
32
241
318
33
14
Thickness
heat loss
surf. temp
51
38
22
89
59
23
102
90
25
102
136
28
127
259
28
140
198
30
165
227
31
191
261
32
229
286
32
241
338
33
16
Thickness
heat loss
surf. temp
64
36
22
89
65
23
102
101
26
102
151
28
140
164
28
178
219
31
203
237
30
229
273
31
254
313
32
254
358
33
18
Thickness
heat loss
surf. temp
64
39
22
89
72
23
102
111
26
102
166
28
140
180
28
140
240
31
178
260
31
203
298
31
229
340
32
254
388
33
20
Thickness
heat loss
surf. temp
64
43
22
89
79
24
102
121
26
102
182
28
140
196
28
140
262
31
178
281
31
203
322
32
229
368
32
254
419
33
24
Thickness
heat loss
surf. temp
64
51
22
102
83
23
102
141
26
102
212
28
140
228
28
152
284
30
191
308
30
203
371
32
229
422
33
254
479
34
30
Thickness
heat loss
surf. temp
64
62
22
102
101
23
102
172
26
102
258
29
140
275
29
165
319
29
191
368
31
216
422
32
254
462
32
254
568
34
36
Thickness
heat loss
surf. temp
64
74
22
102
118
23
102
203
26
102
304
29
140
322
29
178
350
29
203
406
30
229
467
31
254
535
32
254
657
34
FLAT
Thickness
heat loss
surf. temp
51
32
22
89
44
23
102
63
25
114
85
27
140
98
28
216
85
27
241
98
28
254
120
29
254
148
32
254
183
34

57
Thermal properties of typical building and insulation materials DESIGN VALUES

TABLE 4
MINERAL FIBRE
Description
Density
kg/m3
Conductivity
k
W/m.oC
4.8-32.0
4.8-32.0
4.8-32.0
4.8-32.0
4.8-32.0
4.8-32.0
Conductance
Resistance (R)
Specific
(C)
Heat
Per inch thickness For thick.oC)
W/m2.oC
kJ/(kg
(1/k) m.oC ness listed
(1/C)
m2.oC
INSULATING MATERIALS
Blanket and Batt
Mineral Fibre, fibrous form processed
from rock, slag, or glass
approx.
approx.
approx.
approx.
approx.
approx.
76.2-101.6 mm
88.9 mm
139.7-165.1 mm
152.4-177.8 mm
215.9-228.6 mm
304.8 mm
0.52
0.44
0.30
0.26
0.19
0.15
1.94
2.29
3.34
3.87
5.28
6.69
136
64-144
16.0
72.0
0.050
0.036
0.052
0.032
19.85
27.76
19.29
31.58
0.75
0.96
1.26
1.68
28.8
28.8-56.0
0.036
0.029
27.76
34.70
1.22
1.22
16.0
20.0
24.0
28.0
32.0
0.037
0.036
0.035
0.035
0.033
23.25
27.76
28.94
28.94
30.19
Board and Slabs

Cellular glass
Glass fibre, organic bonded
Expanded perlite, organic bonded
Expanded rubber (rigid)
Expanded polystyrene extruded
Cut cell surface
Smooth skin surface
Expanded polystyrene,
moulded beads
58
TABLE 4
Description
(MINERAL FIBRE Continued)

Density
kg/m3
Conductivity
k
W/m.oC
Cellular polyurethane (R-11 exp.)

0.023
24.0
(unfaced)
Foil-faced, glass fibre-reinforced cellular
0.020
32.0
Polyisocyanurate (R-11 exp.)
Nominal 12.70 mm
Nominal 25.40 mm
Nominal 50.80 mm
0.042
240
Mineral fibre with resin binder
Mineral fibreboard, wet felted
0.049
256-272
Core or roof insulation
0.050
288
Acoustical tile
0.0563
336
Acoustical tile
Mineral fibreboard,
0.060
368
wet moulded Acoustical tile
Wood or cane fibreboard
Acoustical tile 12.70 mm
Acoustical tile 19.05 mm

0.050
240
Interior finish (plank, tile)
Cement fibre slabs (shredded wood with
400-432 0.072-0.070
Portland cement binder)
Cement fibre slabs (shredded wood with
0.082
352
magnesia oxysulfide binder)
FIELD APPLIED
Polyurethane foam
Spray cellulosic fibre base
24.0-40.0 0.023-0.026
32.0-96.0 0.035-0.043
59
Conductance
(C)
W/m2.oC
Resistance (R)
Specific
Heat
Per inch
For thickkJ/(kg.oC)
thickness (1/k) ness listed
m.oC
(1/C)
m2.oC
43.38
1.59
1.58
0.79
0.39
49.97
23.94
0.63
1.27
2.53
0.92
20.40
19.85
18.74
0.80
16.52
0.59
4.54
3.01
19.85
0.22
0.33
1.30
1.34
13.88-13.12
12.15
1.30
43.38-36.50
23.11-28.94
0.71
Thermal conductivity (k) of industrial insulation DESIGN VALUES

W/m.oC
TABLE 5
Form
Material Composition
Accepted Typical
Max Density
Temp for (kg/m3)
Use, oC
Typical Conductivity k at Mean Temp oC

73.3 59.4 45.6 31.7 17.8 3.9 10.0 23.9 37.8 93.3 148.9 260.0 371.1 482.2
BLANKETS & FELTS

MINERAL FIBRE
(Rock, slag or glass)
Blanket, metal reinforced
650
540
Mineral fibre, glass

Blanket, flexible, fine-fibre
organic bonded
180
Blanket, flexible, textile-fibre

organic bonded
180
96-192
40.0-96.0
(
0.037 0.046 0.056 0.078

0.035 0.045 0.058 0.088
less
than
12.0
0.036 0.037 0.040 0.043 0.048 0.052 0.076
16.0
0.033 0.035 0.036 0.039 0.042 0.046 0.062
24.0
0.030 0.032 0.033 0.036 0.039 0.040 0.053
32.0
0.029 0.030 0.032 0.033 0.036 0.037 0.048
48.0
0.027 0.029 0.030 0.032 0.033 0.035 0.045
10.4
0.039 0.040 0.042 0.043 0.045 0.046 0.072 0.098
12.0
0.037 0.039 0.040 0.042 0.045 0.046 0.069 0.095
16.0
0.035 0.036 0.037 0.039 0.042 0.045 0.065 0.086
24.0
0.032 0.033 0.035 0.036 0.039 0.042 0.056 0.073
48.0
0.029 0.030 0.032 0.033 0.035 0.036 0.046 0.059
0.035 0.036 0.039 0.042 0.046 0.049 0.069
0.035 0.036 0.037 0.039 0.050 0.063
Felt, semi-rigid organic

bonded
200
Laminated & felted
450
650
48-128 0.023 0.024 0.026 0.027 0.039 0.030 0.032 0.033 0.035 0.050 0.079
48.0
0.050 0.065 0.0/86
120
VEGETABLE & ANIMAL

FIBRE
Hair Felt or Hair Felt plus
Jute
80
160
0.037 0.040 0.042 0.043
60
TABLE 5 (Thermal conductivity (k) of industrial insulation Continued)

Form
Accepted Typical
Max Density
Temp for (kg/m3)
Use, oC

73.3 59.4 45.6 31.7 17.8 3.9 10.0 23.9 37.8 93.3 148.9 260.0 371.1 482.2
BLOCKS, BOARDS & PIPE

INSULATION
ASBESTOS
Laminated asbestos paper
370
480
4-ply
150
176-208
0.078 0.082 0.098
6-ply
150
240-272
0.071 0.073 0.085
8-ply
150
288-320
0.068 0.071 0.082
MOULDED AMOSITE &

BINDER
820
240-288
0.046 0.053 0.060 0.075 0.089 0.104
85% MAGNESIA
320
176-192 192
0.050 0.055 0.060
CALCIUM SILICATE
650
176-240
0.055 0.059 0.063 0.075 0.089 0.104
980
192-240
0.091 0.107 0.137
CELLULAR GLASS
480
136
DIATOMACEOUS SILICA
870
336-352
0.092 0.098 0.104
1040
368-400
0.101 0.108 0.105
Organic bonded, block and

boards
200
48-160 0.023 0.024 0.026 0.027 0.029 0.032 0.035 0.036 0.037 0.048 0.058
Non-punking binder
540
48-160
Pipe insulation, slag or glass
180
48.0-64.0
0.058 0.065 0.072 0.086
Corrugated & laminated

asbestos Paper
0.039 0.040 0.042 0.043 0.045 0.046 0.048 0.050 0.052 0.060 0.071 0.101 0.148
MINERAL FIBRE
Glass,
0.037 0.045 0.055 0.075

0.029 0.032 0.033 0.035 0.042
Inorganic bonded-block
Pipe insulation slag or glass
260
48-160
540
160-240
0.048 0.055 0.065 0.079
980
240-384
0.046 0.053 0.060 0.075 0.089 0.107
540
160-240
0.048 0.055 0.065 0.079
0.029 0.035 0.036 0.037 0.048 0.058
61
TABLE 5E (Thermal conductivity (k) of industrial insulation Continued)

Form
Accepted Typical
Max Density
Temp for (kg/m3)
Use, oC

73.3 59.4 45.6 31.7 17.8 3.9 10.0 23.9 37.8 93.3 148.9 260.0 371.1 482.2
MINERAL FIBRE
Resin binder
240
0.033 0.035 0.036 0.037 0.040 0.042
RIGID POLYSTYRENE
Extruded, Refrigerant 12
exp. smooth skin surface
80
35.2
0.023 0.023 0.024 0.023 0.024 0.026 0.027 0.029
Extruded cut cell surface
80
28.8
0.024 0.026 0.027 0.029 0.030 0.033 0.035 0.036 0.039
Moulded beads
80
16.0
0.024 0.027 0.029 0.030 0.032 0.035 0.036 0.037 0.040
24.0
0.023 0.024 0.027 0.029 0.030 0.032 0.033 0.035 0.037
20.0
0.024 0.026 0.027 0.029 0.032 0.033 0.035 0.036 0.039
28.0
0.023 0.024 0.026 0.027 0.029 0.032 0.033 0.035 0.036
32.0
0.022 0.023 0.026 0.027 0.029 0.030 0.032 0.033 0.035
32.0
0.017 0.019 0.020 0.022
RIGID
POLYISOCYANDRATE
Cellular, foil-faced glass
fibre reinforced, Refrigerant
11 exp
120
POLYURETHANE
Refrigerant 11 exp
(unfaced)
100
RUBBER, Rigid Foamed
70
72
0.029 0.030 0.032 0.033
80
320
0.040 0.043 0.045 0.048
With colloidal clay binder
980
384-480
0.071 0.079 0.088 0.105 0.122
With hydraulic setting

binder
650
480-460
0.108 0.115 0.122 0.137
24.0-40.0 0.023 0.024 0.026 0.026 0.026 0.024 0.023 0.023 0.024
VEGETABLE & ANIMAL

FIBRE
Wool felt (pipe insulation)
INSULATING CEMENTS
MINERAL FIBRE
(Rock, slag or glass)
62
TABLE 5 (Thermal conductivity (k) of industrial insulation Continued)

Form
Accepted Typical
Max Density
Temp for (kg/m3)
Use, oC

73.3 59.4 45.6 31.7 17.8 3.9 10.0 23.9 37.8 93.3 148.9 260.0 371.1 482.2
LOOSE FILL
Cellulose insulation (milled
pulverised paper of wood
pulp)
Mineral fibre, slag, rock or
glass
Perlite (expanded)
Silica aerogel
Vermiculite (expanded)
40.0-48.0
0.037 0.039 0.042
32.0-80.0
48.0-80.0
122
0.027 0.030 0.033 0.036 0.037 0.040 0.045

0.032 0.035 0.036 0.039 0.040 0.043 0.045 0.048 0.050
112-131
0.019 0.020 0.022 0.022 0.023 0.024 0.026
64-96
0.056 0.058 0.060 0.063 0.065 0.068 0.071

0.049 0.050 0.056 0.058 0.060 0.063 0.066
63
Basic types of insulation selected properties

TABLE 6
TYPE
FORM
TEMPERATURE
RANGE
k-FACTOR *
NOTES
Calcium Silicate
Pipe Covering
Block Segments
Up to 982oC
(1800oF)
.066 at 150oC
.45 at 300oF
Good mechanical abuse

characteristics, non-combustible. Some are water
absorbent.
Cellular Glass
Pipe Covering
Block Segments
267oC to 482oC
( 450oF to 900oF)
.077 to 150oC
.53 at 300oF
Good strength, water and

vapour resistant, non-combustible. Poor abrasion resistance.
Glass Fibre
Pipe Covering
Board
to 455oC (850oF)
.035 at 24oC
.24 at 75oF
0.050 at 150oC
Blanket
to 510oC (950oF)
.35 at 300oF
varies see manuf. data
Properties variable. Good

handling and workability.
May be water absorbent.
Some are non-combustible.
Pipe Covering
to 870oC (1600oF)
.035 at 24oC
.24 at 75oF
.061 at 150oC
Mineral Fibre
Non-combustible, good
workability water absorbent.
.42 at 300oF
conductivity
varies with
density
Board
Ceramic Fibre
Blanket or Board
to 1760oC
(3200oF)
.30 at 93oC
(200oF)
Temperature ranges varies

with manufacturer, style
and type.
Cements
Hydraulic setting
cement
to 650oC
(1200oF)
1.75 at 315oC
(600oF)
High temperature mineral

wool
to 1040oC
(1900oF)
.69 at 315oC
(600oF)
Pointing and
finishing cement
to 760oC
(1400oF)
.55 at 93oC
(200oF)
One coat application

Insulating and finishing.
Slow drying, rough texture
filling and insulating. Used
over basic insulation
smooth finish, usually 3.175
mm (1/ 8") to 6.35 mm (1/ 4")
thick application.
(Mineral or
Vermiculite)
64
Protective coverings and finishes

TABLE 7
WEATHER BARRIERS
TYPE
COMPOSITION
FASTENERS
NOTES
JACKETS:
1. Films laminated to felts or

foil
Contact adhesives and/or

tape
Corrosion resistant bacteria

and mildew resistant
2. Stainless steel (various

alloys available with
factory-applied moisture
barrier)
Corrosion resistant bands,

screws or rivets
Excellent mechanical
strength, corrosion, mildew
and bacteria resistant
3. Galvanised Steel (coated

and with factory-applied
moisture barrier)

screws or rivets
Good mechanical strength
4. Aluminium alloys (usually

with factory-applied
moisture barrier)

screws or rivets
Good mechanical strength,

good workability
5. Polyvinyl Chloride (PVC)
Mechanical fasteners,
adhesive or matching tape
May require protection from

ultra-violet radiation.
6. High Impact Plastic (ABS)
ABS welding adhesive or

matching tape
Resists chemicals and

bacteria
7. Roofing felt
Bands or wire
Water base, a breather

mastic
1. Asphalt emulsion
Apply with reinforcing mesh
Solvent base, also a vapour

barrier
2. Asphalt cut-back
Tough, resilient film
3. Resin emulsion
4. Polyvinyl acetate
5. Acrylic
MASTICS:
Covering shall not be termed a weather barrier unless its joints and overlap are adequate to prevent the entry
of rainwater.
65
Vapour retarders
TABLE 8
TYPE
COMPOSITION
NOTES
JACKETS:
1. Foil Scrim Laminate
Seal joints. Mechanical strength is less than metal or plastic.

Generally for indoor applications.
2. Metal Jacketing
Seal joints. Mechanical strength is good.
3. Polyvinyl Chloride (PVC)
Seal with compatible adhesive and/or tape.
4. High Impact Plastic (ABS)
Seal with welding adhesive.
5. Film Laminate
Seal with contact adhesive and/or tape
1. Asphalt cut-back
Apply with reinforcing mesh. Combustible.
2. Resins advent type
Brush or spray application.
3. Elastomeric Polymer
Apply with reinforcing mesh. Combustible.
MASTICS:
66
Energy Content of Some Fuels

TABLE 9
Fuel
Energy content
blast furnace gas
3.1
MJ / cubic metre
coal: bituminous
25
MJ / kilogram
coke oven gas
17.3
gasworks gas
18
MJ / cubic metre
LPG (liquid)
27
MJ / litre
natural gas
33-42
oil
42
MJ / kilogram
paraffin
35
MJ / litre
SASOL gas: hydrogen rich
18
MJ / cubic metre
SASOL gas: methane rich
33-36
MJ / cubic metre
wood, air dried
17
67
MJ/cubic metre
MJ / cubic metre
MJ / kilogram
SOURCES OF
FURTHER
INFORMATION
For the latest news in energy efficiency technology:
Energy Management News is a free newsletter issued by the ERI, which contains information on the
latest developments in energy efficiency in Southern Africa and details of forthcoming energy
efficiency events.
Copies can be obtained from:
Rondebosch 7700
Cape Town
South Africa
Tel No: (+27 21) 650 3892
Fax No: (+27 21) 686 4838
Email: eri@eng.uct.ac.za
68

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How to save energy and money

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Guide Book Essentials:

3.2 Insulation Systems .............................................................................................................................................................................

FIGURE 15: CURVED SURFACES RIGID BOARD INSULATION........................................................................ 22

Thermal insulation is the use of special materials to

Refractory materials often need high resistance to

By improving energy efficiency, it is possible to

This guide uses metric units throughout but has

Insulation may be divided roughly into three

2.1 TERMS AND

an insulating material. The higher the R

Certain key terms used in this booklet are defined

Conduction is the process, by which heat

Where, t material thickness (metres or inches)

Mean Temperature is the arithmetic

The following is a list of important properties,

Thermal Resistance. The higher the value

Combustibility. This becomes significant as

applied over irregular or non-uniform

Some of these factors may not apply in all

2.2.1 A NOTE ON ASBESTOS

Asbestos was used as an insulation material not so

insulation material is to retard heat flow. The

Heat is always transferred from a hot body to body

Heat is lost from hot bodies in three ways:

Conduction. Heat is transferred by contact

The heat flow through the insulation for a flat

Where, DT Temperature difference across the

For hot pipes and hot surfaces in factories, most

The term heat flow refers to the rate at which heat

Now the heat flow in one hour through the

For example, consider the heat loss from a 1 metre

Heat flow through pipe insulation is somewhat

To compensate for this effect an equivalent

1.66 (m2 oC)/W

Where, r2 outside radius of insulation (m)

r1 inside radius of insulation (m)

42.51 Wh/metre of length of

It must be noted that A in the above equation is

l unit length (in this case 1 metre)

Therefore A  0:219 2 0:051 1

Additional details on protective coverings and

A vapour retarder or vapour barrier is a material,

2.5 PROTECTING AND

PROTECTIVE COVERINGS AND

The efficiency and service life of insulation is

Vapour barriers are applied on site and may consist

Protective coverings are divided into six functional

The temperature range within which the term

LOW TEMPERATURE THERMAL

Insulation used for low temperature applications is

16oC (6OoF) through 0oC (32oF) cold

High temperature thermal insulation is used in the

Since the cost of refrigeration is higher than the

HIGH TEMPERATURE THERMAL

Immediate savings can be realised from insulating

This temperature range, from 16oC (61oF) to

Tables 1 and 2 have been included in the

bare steel flat surfaces over the range of

cost of the insulation. This is necessary to establish

In some cases these tables will not apply as plant or

Therefore A 0:219 2 0:051 1