Insulation Systems
405
Example. For a 4-in. pipe operating at 700°F in an 85°F
ambient temperature with aluminum jacketing over the
insulation, determine the thickness of calcium silicate
that will keep the surface temperature below 140°F.
Since this is a pipe, the equivalent thickness must first
be calculated and then converted to actual thickness.
STEP 1. Determine k at tm = (700 + 140)/2 = 420°F. k =
0.49 from Table 15-1 or appendix Figure 15-A1 for calcium
silicate.
STEP 2. Determine Rs from Table 15-4 for aluminum.
ts – ta = 140 – 85 = 55. So Rs = 0.85.
STEP 3. Calculate Eq tk:
700 – 140
Eq tk = (0.49)(0.85) —————
140 – 85
= 4.24 in.
STEP 4. Determine the actual thickness from Table 15-
2. The effect of 4.24 in. on a 4-in. pipe can be accomplished
by using 3 in. of insulation.
Note: Thickness recommendations are always
increased to the next 1-in. increment. If a surface tem-
perature calculation happens to fall precisely on an even
increment (such as 3 in.), it is advisable to be conserva-
tive and increase to the next increment (such as 3-1/2
in.). This reduces the criticality of the Rs number used.
In the preceding example, it would not be unreasonable
to recommend 3-1/2 in. of insulation since it was found
to be so close to 3 in.
To illustrate the effect of surface type, consider he
same example with a mastic coating.
Example. From Table 15-4, Rs = 0.50, so
700 – 140
Eq tk = (0.49)(0.50) —————
140 – 85
= 2.49 in.
This corresponds to an actual thickness require-
ment on a 4-in. pipe of 2 in. This compares with 3 in.
required for an aluminum-jacketed system. It is of inter-
est to note that even though the aluminum system has
a higher surface temperature, the actual heat loss is less
because of the higher surface resistance value.
Graphical Method
The calculations illustrated above can also be car-
ried out using graphs which set the heat loss through
the insulation equal to the heat loss off the surface, fol-
lowing the discussion in Section 15.4.2.
Figure 15-4 will be used for several different cal-
culations. The following example gives the four-step
procedure for achieving the desired surface temperature
for personnel protection. The accompanying diagram
outlines this procedure.
Example. We follow the procedure of the first example,
again using aluminum jacketing.
STEP 1. Determine ts – ta, 140 – 85 = 55°F.
STEP 2. In the diagram, proceed vertically from (a)
of ∆t = 55 to the curve for aluminum jacketing (b).
STEP 2a. Although not required, read the heat loss
Q = 65 Btu/hr ft2) (c).
STEP 3. Proceed to the right to (d), the appropriate
curve for th – ts = 700 – 140 = 560°F. Interpolate between
lines as necessary.
STEP 4. Proceed down to read the required insulation
resistance Rt = 8.6 at (e). Since R = tk/k or Eq tk/k,
tk or Eq tk = RIk
700 + 140
tm = ——————— = 420°F
2
k = 0.49 from appendix Figure 15-A1 and
tk or Eq tk = (8.6) (0.49) = 4.21 in.
which compares well with the 4.24 in. from the earlier
calculation.
The conversion of Eq tk to actual thickness re-
quired for pipe insulation is done in the same manner,
using Figure 15-3.
A better understanding of the procedure involved
in utilizing this quick graphical method will be obtained
406 Energy Management Handbook
after working through the remainder of the calculations
in this section.
15.4.4 Condensation Control
On cold systems, either piping or equipment, in-
sulation must be employed to prevent moisture in the
warmer surrounding air from condensing on the colder
surfaces. The insulation must be of sufficient thickness
Figure 15-4. Heat Loss and Surface Temperature Graphical Method. (From Ref. 16.)
to keep the insulation surface temperature above the
dew point of the surrounding air. Essentially, the cal-
culation procedures are identical to those for personnel
protection except that the dew point temperature is
substituted for the desired surface temperature. (Note:
The surface temperature should be kept 1 or 2° above
the dew point to prevent condensation at that tempera-
ture.)
Dew Point Determination
The condensation (saturation) temperature, or dew
point, is dependent on the ambient dry-bulb and wet-
bulb temperatures. With these two values and the use of
a psychrometric chart, the dew point can be determined.
However, for most applications, the relative humidity is
more readily attainable, so the dew point is determined
using dry-bulb temperature and relative humidity rather
than wet-bulb. Table 15-5 is used to find the proper
dew-point temperature.
Calculation
This equation is identical to the previous surface-
temperature problem except that the surface tempera-
ture ts now takes on the value of the dew point of the
ambient air. Also, th now represents the cold operating
temperature.
t –t
tk or Eq tk = kR s h s
ts – ta
Insulation Systems 407

Example. For a 6-in.-diameter chilled-water line op- Eq tk = 0.23 0.54 35 – 85

erating at 35°F in an ambient of 90°F and 85% RH,
determine the thickness of fiberglass pipe insulation
with a composite kraft paper jacket required to prevent
condensation.
STEP 1. Determine the dew point (DP) using either
a psychrometric chart or Table 15-5. DP at 90°F and 85%
RH = 85°F. (In Step 5, the thickness is rounded up, which
yields a higher temp.)
STEP 2. Determine k at tm = (35 + 85)/2 = 60°F. k
at 60°F = 0.23, from Table 15-1 or appendix Figure 15-
A2.
STEP 3. Determine Rs from Table 15-4. ∆t here is
(ta, – ts) rater than (ts – ta), ta – ts = 90 – 85 = 5°F, Rs =
0.54.
STEP 4. Calculate Eq tk.
85 – 90
= 1.24 in.
STEP 5. Determine the actual thickness from Fig-
ure 15-2 for 6-in. pipe, 1.24 in. Eq tk. The actual thickness
is 1.5 in.
Graphical Method
The graphical procedures are as described in
Section 15.4.3. As the applications become colder, it is
apparent that the required insulation thicknesses will
become larger, with RI values toward the right side of
Figure 15-4. It is suggested that the graphical procedure
not be used when the resulting RI values must be de-
termined from a very flat portion of the (th – ts) curve
(anytime the numbers are to the far right of Figure 15-4).
It is difficult to read the graph with sufficient accuracy,
particularly in light of the simplicity of the mathematical
calculation.

Table 15-5. Dew Point Temperature.

Dry-
Bulb Percent Relative Humidity
Temp.
(°F) 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

5 – 35 – 30 – 25 – 21 – 17 – 14 – 12 – 10 – 8 – 6 – 5 – 4 – 2 – 1 1 2 3 4 5
10 – 31 – 25 – 20 – 16 – 13 – 10 – 7 – 5 – 3 – 2 0 2 3 4 5 7 8 9 10
15 – 28 – 21 – 16 – 12 – 8 – 5 – 3 – 1 1 3 5 6 8 9 10 12 13 14 15
20 – 24 – 16 – 8 – 4 – 2 2 4 6 8 10 11 13 14 15 16 18 19 20
25 – 20 – 15 – 8 – 4 0 3 6 8 10 12 15 16 18 19 20 21 23 24 25
30 – 15 – 9 – 3 2 5 8 11 13 15 17 20 22 23 24 25 27 28 29 30
35 – 12 – 5 1 5 9 12 15 18 20 22 24 26 27 28 30 32 33 34 35
40 – 7 0 5 9 14 16 19 22 24 26 28 29 31 33 35 36 38 39 40
45 – 4 3 9 13 17 20 23 25 28 30 32 34 36 38 39 41 43 44 45
50 – 1 7 13 17 21 24 27 30 32 34 37 39 41 42 44 45 47 49 50
55 3 11 16 21 25 28 32 34 37 39 41 43 45 47 49 50 52 53 55
60 6 14 20 25 29 32 35 39 42 44 46 48 50 52 54 55 57 59 60
65 10 18 24 28 33 38 40 43 46 49 51 53 55 57 59 60 62 63 65
70 13 21 28 33 37 41 45 48 50 53 55 57 60 62 64 65 67 68 70
75 17 25 32 37 42 46 49 52 55 57 60 62 64 66 69 70 72 74 75
80 20 29 35 41 46 50 54 57 60 62 65 67 69 72 74 75 77 78 80
85 23 32 40 45 50 54 58 61 64 67 69 72 74 76 78 80 82 83 85
90 27 36 44 49 54 58 62 66 69 72 74 77 79 81 83 85 87 89 90
95 30 40 48 54 59 63 67 70 73 76 79 82 84 86 88 90 91 93 95
100 34 44 52 58 63 68 71 75 78 81 84 86 88 91 92 94 96 98 100
105 38 48 56 62 67 72 76 79 82 85 88 90 93 95 97 99 101 103 105
110 41 52 60 66 71 77 80 84 87 90 92 95 98 100 102 104 106 108 110
115 45 56 64 70 75 80 84 88 91 94 97 100 102 105 107 109 111 113 115
120 48 60 68 74 79 85 88 92 96 99 102 105 107 109 112 114 116 118 120
125 52 63 72 78 84 89 93 97 100 104 107 109 111 114 117 119 121 123 125
408 Energy Management Handbook

Thickness Chart for Fiberglass Pipe Insulation
Table 15-6 gives the thickness requirements for fi-
berglass pipe insulation with a white, all-purpose jacket
in still air. The calculations are based on the lowest tem-
perature in each temperature range. Three temperature/
humidity conditions are depicted.
STEP 2. Determine Rs for aluminum from Table
15-4. ts – ta = 140 – 0 = 60°F, so Rs = 0.85.
STEP 3. Calculate RI = 4/0.53 = 7.5.
STEP 4. Calculate

15.4.5 Process Control 850 – 80

QF = —————— = 92 Btu/hr • ft2
Included under this heading will be all the cal- 7.5 + 0.85
culations other than those for surface temperature and
economics. It is often necessary to calculate the heat flow STEP 5. Calculate the surface temperature ts, as
through a given insulation thickness, or conversely, to follows:
calculate the thickness required to achieve a certain heat
Rs × QF = ts – ta
flow rate. The final situation to be addressed deals with
(Rs × QF) + ta = ts
temperature drop in both stagnant and flowing systems.
ts = (0.85 × 92) + 80
Heat Flow for a Specified Thickness = 158°F
Calculation Equations. Again, the basic equation
for a single insulation material is STEP 6. Calculate tm to check assumption and to
check the k value used.
th – ta
QF = ———— t m = 850 – 80
2
RI + Rs
= 504°F
Example. For an 850°F boiler operating indoors in an
80°F ambient temperature insulated with 4 in. of cal-
Since k at 504°F = k at 495°F (assumed) = 0.53, the as-
cium silicate covered with 0.016 in. aluminum jacketing,
sumption is okay. A check on Rs can also be made based
determine the heat loss per square foot of boiler surface
on the calculated surface temperature.
and the surface temperature.
STEP 7. If the assumption is not okay, recalculate
STEP 1. Find k for calcium silicate at tm. Assume
using a new k value based on the new tm.
that ts = 140°F. Then tm = (850 + 140)/2 = 495°F, k at
The QF used above is for flat surfaces. In determin-
495°F = 0.53, from Table 15-1 or appendix Figure 15-
ing heat flow from a pipe, the same equations are used
A1.
Table 15-6. Fiberglass Pipe Insulation: Minimum Thickness to Prevent Condensationa.

80°F and 90% RH 80°F and 70% RH 80°F and 50% RH

Operating Pipe
Temperature Pipe Size Thickness Pipe Size Thickness Pipe Size Thickness
(°F) (in.) (in.) (in.) (in.) (in.) (in.)
0-34 Up to 1 2 Up to 8 1 Up to 8 1/2
1-1/4 to 2 2-1/2 9-30 1-1/2 9-30 1
2-1/2 to 8 3
9-30 3-1/2
35-49 Up to 1-1/2 1-1/2 Up to 4 1/2 Up to 30 1/2
2-8 2 412-30
9-30 3
50-70 Up to 3 1-1/2 Up to 30 1/2 Up to 30 1/2
3-1/2 to 20 2
21 -30 2-1/2
Source: Courtesy of Johns-Manville, Ref. 16.
aBased on still air and AP Jacket.