THIS STANDARD IS: STD NO : 2-64-04

Updated INDEX : 6.0

DESIGN STANDARD DATE : 25 JAN 2001
OWNER : 9814
PAGE : 1 OF 12

SUBJECT : INSULATION THICKNESS CALCULATION

PURPOSE : To provide a method for determining insulation thickness and heat flow
for safe operation of heated surfaces.

REMARKS: This Standard to be effective immediately.

NOTES: 1. See Page 2 for Versions.

DESIGN PRODUCT ENGINEER

REVIEWED BY: H. SCHORTMAN NON-PRESSURE PARTS ENGINEERING - 9814
MANAGER
APPROVED FOR CONTENT: D. PALMER NON-PRESSURE PARTS ENGINEERING - 9814
PROGRAM MANAGER
APPROVED FOR PUBLICATION: T. MISKELL STANDARDS ENGINEERING - 8126

This document contains proprietary data and shall not be

reproduced or disclosed without permission of ALSTOM Power Inc.
SUBJECT: Insulation Thickness Calculation STD NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 2 OF 12
______________________________________________________________________________________________________

UNITS: n ENGLISH; o METRIC; o BOTH; o NONE

PRODUCT LINES: CHECK THE PRODUCT LINES THAT THE STANDARD IS APPLICABLE TO

n ALL; o A = CONTROLLED CIRC. BOILERS o H = HEAT RECOVERY STEAM GENERATORS

o B = SUPERCRITICAL BOILERS o P = BOWL MILLS (PULVERIZERS)
o C = VU40 AND VU60 BOILERS o R = CHEMICAL RECOVERY BOILERS
o E = FLUIDIZED BED BOILERS (CFB) o S = SERVICES (AFTER MARKET USE)
o F = NATURAL CIRC. BOILERS (UTILITY)

Versions

Ver. 3 – Standard reviewed and revalidated.

Ver. 4 – Updated Standard format; text not

changed; name change to ALSTOM Power Inc.;
new graphs.
SUBJECT: Insulation Thickness Calculation
______________________________________________________________________________________________________
1.0 Heat Transmission
1.1 Heat is transmitted through insulation
by conduction and dissipated from the surface to
the surrounding air by radiation and convection.
1.2 The rate at which heat is dissipated
from a surface is dependent on (1) cold face
temperature, (2) ambient air temperature, (3)
ambient air velocity, (4) type of surface, and (5)
position of surface. The factors governing Items 4
and 5 are described in Paragraph 1.2.2 and
1.2.3.
1.2.1 When the cold face temperature,
ambient air temperature and air velocity are
known, the rate at which heat is dissipated to the
surroundings can be determined from Charts 1
and 2. Likewise, if the heat dissipating rate,
ambient air temperature and air velocity are
known, the cold face temperature can be
determined. An example is given in Paragraph
2.1.
1.2.2 Charts 1 and 2 differ only
because the emissivity of a surface greatly affects
heat dissipated by radiation.
Chart I was constructed for
vertical surfaces with an emissivity factor of 0.95
which applies to surfaces such as brick, cement,
black iron, etc.
Chart II was constructed for
vertical surfaces with an emissivity factor of 0.20
which applies to brighter surfaces such as
aluminum.
1.2.3 Horizontal surfaces, such as
floors or roofs, radiate heat with the same rate as
vertical surfaces but the heat dissipated by
convection varies considerably. Charts 1 and 2,
with the following modification, may also be used
for the purpose of estimating heat dissipated from
horizontal surfaces.
STD. NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 3 OF 12
For Chart 1 the heat dissipating
rate should be increased approximately 10% for
surfaces facing upward, such as a roof and
decreased approximately 18% for surfaces facing
downward, such as floors.
For Chart 2 the corresponding
percentages should be 20% and 38%,
respectively. When these surfaces are subject to
air velocities of 1 mph or greater, the position of
the surface may be neglected.
1.2.4 The rate at which heat is
dissipated from a surface will not be significantly
affected by applying paint unless the paint
applied is aluminum. For any surface coated with
aluminum paint, Chart 2 applies. For estimating
purposes, the values obtained should be
increased by 10% for still air and 5% for moving
air. An example is given in Paragraph 2.3.
1.3 When the heat dissipating rate or the
cold face temperature has been determined from
Chart 1 or 2 to meet specifications, the
equipotential heat flow curves are used to
determine the thickness of insulating material
required to satisfy these conditions. These Charts
are based on heat transfer by conduction through
insulation under steady state conditions and are
based on ALSTOM Power specifications for
insulating materials. Examples are given in
Paragraph 2.1, 2.2 and 2.3.
1.3.1 A curve for the thermal
conductivity of each insulating material appears
on the appropriate Chart. The “k” factor can be
obtained for various mean temperatures from the
curves.
SUBJECT: Insulation Thickness Calculation STD. NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 4 OF 12
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1.3.2 The equipotential heat flow
charts have been constructed based on an
ambient air temperature of 800 F. The
temperature differential between the ambient air
and the cold face temperature will be affected by
raising or lowering the ambient air temperature
and this in turn will affect the heat flow. However,
this variation in heat flow is so insignificant that it
may be neglected for the normal range of
ambient air temperatures.
Step (a): Determine the heat flow from Chart 1.
Locate the cold face temperature of 1170 F on the
abscissa and at the point of intersection with the
900 F ambient air curve read the heat flow (at the
left) of 72 Btu/ft2 hr. on the 1.5 mph ambient air
velocity ordinate.
Note 1: If the heat flow were know, the reverse
operation would determine the cold face
temperature.

1.3.3 The equipotential heat flow Note 2: Chart 2 is used in the same manner as
curves may be used to determine the required described above for bright surfaces such as
insulation thickness of other brands of insulation aluminum casings.
provided the following conditions are satisfied:
Step (b): With a heat flow of 72 Btu/ft2 hr.
a. The required thickness shall be determine the insulation required from Chart 3.
determined from the ratio of the thermal The vertical height between the abscissa and the
conductivities “k’s” at the same mean intersection of the 7000 F ordinate with the 72
temperature. Btu/ft2 hr. curve gives a thickness of 3.65”. The
nearest thickness available commercially is 4”.
b. The required thickness of Therefore, 4” of insulation should be used.
insulation shall be determined by the ratio of the
thermal conductivity (k) of the similar material to 2.2 Given Conditions
the thermal conductivity (k) of the ALSTOM Power
specification multiplied by the thickness indicated Hot face temperature 9000 F
by Charts 3, 4 and 4A. Cold face temperature 1170 F
Ambient air temperature 900 F
1.4 Unless otherwise specified, ALSTOM Ambient air velocity 1.5 mph
Power will provide insulation to limit the heat Wall surface 12 gauge
dissipation rate to a maximum of 80 Btu/FT2 hr. Insulating material Mineral Fiber Batts or
for a still ambient air temperature of 800 F. Blankets (7500 F
maximum by the
2.0 Determine the insulation thickness required Customer) Calcium
for the following problems. Silicate (asbestos free)
Blocks
2.1 Given Conditions

Hot face temperature 7000 F

Cold face temperature 1170 F
Ambient air temperature 900 F
Ambient air velocity 1.5 mph
Wall surface 12 gauge steel
casing
Insulating material Mineral Fiber Batts or
Blankets
SUBJECT: Insulation Thickness Calculation STD. NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 5 OF 12
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Step (a): Determine the heat flow from Chart 1.
Proceed in the same manner as Step (a),
Paragraph 2.1. Heat flow = 72 Btu/ft2 hr.
Step (b): With a heat flow of 72 Btu/ft2 hr.,
determine the insulation required from Chart 3.
Step (a): Determine the heat flow from Chart 2.
Locate the cold face temperature of 1200 F on the
abscissa and at the point of intersection with the
800 F ambient air curve, read heat flow (at the
left) of 60 Btu/ft2 hr. on 1mph ambient air velocity
ordinate.

A commercial thickness of mineral fiber
batts or blankets should be selected that will give
an interface temperature at or slightly below the
maximum interface temperature of 7500 F set by
the Customer. The vertical height or numerical
difference between the abscissa and the
intersection of the 7200 F ordinate with the 72
Btu/ft2 hr. curve gives a thickness of 4” which can
be obtained commercially.
Step (c): With a heat flow of 72 Btu/ft2 hr.,
determine the balance of the insulation required
from Chart 4A.
The vertical height or numerical
difference between the intersection of the 7200 F
ordinate with the 72 Btu/ft2 hr. curve and the
intersection of the 9000 F ordinate with the 72
Btu/ft2 hr. curve gives a thickness of 2” which can
be obtained commercially.
Since aluminum paint has been applied to
the surface, as estimation of the heat dissipating
rate may be obtained by increasing the rate
determined from Chart 2 by 5%. The new value
63 Btu/ft2 hr., (60 Btu/ft2 hr. + 5%) is used to
determine the thickness of insulation required.
(See Paragraph 1.2.4)
Step (b): With a heat flow of 63 Btu/ft2 hr.
determine the insulation thickness required from
Chart 3.
Draw a new equipotential curve for 63
Btu/ft2 hr. on Chart 3 as indicated by the dashed
line. The vertical height between the abscissa
and the intersection of 6700 F ordinate with the
63 Btu/ft2 hr. curve gives a thickness of 3.89”.
The nearest thickness available commercially is
4”. Therefore, 4” of insulation should be used.

The insulation required to meet the

specifications stated in Paragraph 2.2 is 4”
mineral fiber batts or blankets and 2” calcium
silicate (asbestos free) block when the interface
temperature is 7200 F.

2.3 Given Conditions

Hot face temperature 6700 F

Cold face temperature 1200 F
Ambient air temperature 800 F
Ambient air velocity 1 mph
Wall surface 12 gauge
aluminum painted steel
casing
Insulating material Mineral Fiber Batts or
Blankets
SUBJECT: Insulation Thickness Calculation STD. NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 6 OF 12
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Chart 1

A M B IE N T A IR

50°F

HEAT FLO W
IN
2 60°F
B T U /F T H R

70°F
200

180 80°F

160
90°F
140

H E A T D IS S IP A T IO N F R O M V E R T IC A L
120
100° S U R F A C E S T IL L A N D A M B IE N T A IR
AT SURFACE.
100
S U R F A C E M A T E R IA L : B R IC K ,
80 110° CEM ENT, RO UGH STEEL.
E M IS S IV IT Y F A C T O R 0 .9 5
60
120°
40

A M B IE N T A IR V E L O C IT Y , M .P .H .

2 100 110 120 130 140 150 160 170 180 190 200
1
10 7 .5 5 2 .5 1 .5 0 C O L D F A C E T E M P E R A T U R E , °F
 SUBJECT: Insulation Thickness Calculation STD. NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 7 OF 12
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Chart 2

H E A T D I S S I P A T I O N F R O M V E R T IC A L S U R F A C E
S T I L L A N D A M B IE N T A IR A T S U R F A C E .
S U R F A C E M A T E R IA L : A L U M I N U M .
E M I S S I V I T Y F A C T O R 0 .2 0

HEAT FLO W A M B IE N T
IN A IR
2
B T U /F T H R

50°F

60°F
200

70°F
180

80°F
160

140 90°F

100°
120

100 110°

80 120°

60
40

A M B I E N T A I R V E L O C I T Y , M . P .H .
2 100 110 120 130 140 150 160 170 180 190 200
10 7 .5 5 2 .5 1 0 C O LD FA C E TEM P ER A TU R E , °F
SUBJECT: Insulation Thickness Calculation STD. NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 8 OF 12
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Chart 3 – Btu/ft2hr

50 60 70 80 90
6
E Q U IP O T E N T IA L H E A T F L O W C U R V E S
M IN E R A L F IB E R B A T T S 100
5 .5 S T A N D A R D 3 2 -6 5 , IN D E X 6 .4 .2
B O N D E D M IN E R A L F IB E R B L A N K E T S 110
5 S T A N D A R D 1 8 -6 8 , IN D E X 6 .3 .3
8 0 ° F A M B IE N T A IR T E M P E R A T U R E
120
S T A N D A R D T H IC K N E S S 1 /2 " T O 4 "
4 .5 130
IN 1 /2 " IN C R E M E N T S

4 140
150
INCHES INSULATION

3 .5 160

170
3
200
2 .5

1 .5

0 .5

0
100 200 300 400 500 600 700 800 900 1000
H O T F A C E D T E M P E R A T U R E , °F
SUBJECT: Insulation Thickness Calculation STD. NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 9 OF 12
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Chart 3 (Cont.) – Thermal Conductivity Curve

0 .9

0 .8

0 .7

0 .6
THERMAL CONDUCTIVITY

B.T.U.IN./FT HR°F
2

0 .5
"k"

0 .4

0 .3

0 .2

0 .1
0 200 400 600 800
H O T F A C E D T E M P E R A T U R E , °F
SUBJECT: Insulation Thickness Calculation STD. NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 10 OF 12
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Chart 4 - Btu/ft2hr

50 60 70 80 90 100 110
6 120

E Q U IP O T E N T IA L H E A T F L O W C U R V E S
5 .5 130
C A L C IU M S IL IC A T E B L O C K
T H E R M A L IN S U L A T IO N
5 S T A N D A R D 3 2 -6 5 , IN D E X 6 .4 .2 140
8 0 ° F A M B IE N T A IR T E M P E R A T U R E 150
S T A N D A R D T H IC K N E S S 1 /2 " T O 6 "
4 .5
IN 1 /2 " IN C R E M E N T S 160

4 170
INCHES INSULATION

3 .5 200

2 .5

1 .5

0 .5

0
100 200 300 400 500 600 700 800 900 1000 1100 1200
H O T FA C E D T EM P ER AT U R E , °F
 SUBJECT: Insulation Thickness Calculation STD. NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 11 OF 12
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Chart 4A

50
60
12

E Q U IP O T E N T IA L H E A T F L O W C U R V E S
C A L C IU M S IL IC A T E B L O C K
11 T H E R M A L IN S U L A T IO N
S T A N D A R D 3 2 -6 5 , IN D E X 6 .4 .2
8 0 ° F A M B IE N T A IR T E M P E R A T U R E
S T A N D A R D T H IC K N E S S 6 " T O 1 2 " 70
10 IN 1 /2 " IN C R E M E N T S

9 80
INCHES INSULATION

8
90

100
7

110

6 120

4
500 600 700 800 900 1000 1100 1200
H O T FA C E D TE M P E R A TU R E , °F
 SUBJECT: Insulation Thickness Calculation STD. NO. : 2-64-04
INDEX : 6.0
DATE : 25 JAN 2001
OWNER : 9814
PAGE : 12 OF 12
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Charts 4 and 4A (Cont.) – Thermal Conductivity Curve

0 .7

0 .6
THERMAL CONDUCTIVITY

B.T.U.IN./FT HR°F
2
"k"

0 .5

0 .4

0 .3
0 100 200 300 400 500 600 700 800 900 1000
M EA N TE M P E R A TU R E °F