Insulation of Piping, Installation Manual. Doc. P21020-WAR-DL-0304 - 01

Doc ID: P21020-WAR-DL-0304_01
Installation Manual
23.1 Insulation of piping
Document ID WDAAA116783f
Date of issue 12.09.2011
Status Approved
Classification Confidential
INSTRUCTIONS
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Doc ID: P21020-WAR-DL-0304_01
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Doc ID: P21020-WAR-DL-0304_01
Installation Manual
Table of Contents
23.1. Insulation of piping............................................................................................................................. 23.1-1

23.1.1. Before insulation............................................................................................................................ 23.1-1
23.1.2. Which pipes must be insulated?................................................................................................... 23.1-1
23.1.3. Insulation materials........................................................................................................................ 23.1-1
23.1.3.1. Thickness of insulation............................................................................................................ 23.1-1
23.1.3.2. Standard insulation channels.................................................................................................. 23.1-3
23.1.3.3. Elbows..................................................................................................................................... 23.1-3
23.1.3.4. Cover materials and equipment.............................................................................................. 23.1-3
23.1.4. Insulation of pipes.......................................................................................................................... 23.1-4
23.1.4.1. Pipes ≤ DN300........................................................................................................................ 23.1-4
23.1.4.2. Pipes > DN300........................................................................................................................ 23.1-4
23.1.4.3. Support rings.......................................................................................................................... 23.1-5
23.1.4.4. Cover joints............................................................................................................................. 23.1-6
23.1.4.5. Trace heated pipes................................................................................................................. 23.1-7
23.1.5. Insulation of elbows, tees and reducers........................................................................................ 23.1-7
23.1.6. Insulation of piping equipment and joints...................................................................................... 23.1-8
23.1.6.1. Insulation of flanges................................................................................................................ 23.1-8
23.1.6.2. Insulation of valves................................................................................................................ 23.1-11
23.1.6.3. Insulation of pipe supports.................................................................................................... 23.1-12
23.1.6.4. Insulation of bellows.............................................................................................................. 23.1-13
23.1.7. Insulation of exhaust gas pipes and bellows............................................................................... 23.1-15
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23.1.7.1. Insulation pillows (connection of turbocharger).................................................................... 23.1-15
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23.1.7.2. Insulation boxes.................................................................................................................... 23.1-16

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23.1.7.3. Vertical sections.................................................................................................................... 23.1-17

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23.1.7.4. Horizontal sections................................................................................................................ 23.1-17

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WDAAA116783f Confidential i
Doc ID: P21020-WAR-DL-0304_01
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Installation Manual 23.1. Insulation of piping
23.1. Insulation of piping
23.1.1 Before insulation

Before starting the insulation, ensure that the following work has been completed:
● All pipes have been assembled.
● Pressure, cleaning and other necessary tests have been made.
● The surface of pipelines to be insulated has been cleaned and dried.
● The pipes have been painted with a primer (where needed), at least at the welding joints.
● The trace heating system has been installed and properly tested.
23.1.2 Which pipes must be insulated?

Pipelines must be insulated to minimize the thermal losses and for personnel safety.
1 Pipelines that must be insulated to prevent thermal losses are:
● All trace heated pipelines
● Exhaust gas pipes
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● All pipelines including heat recovery

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● Pipelines between lube oil separator and diesel engine or system oil tank
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● Pipelines between nozzle temperature control unit and diesel engine.

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2 Pipelines that must be insulated for personnel safety are:

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● All pipes with surface temperature over 60 °C that are in places that can be accessed
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by the operator.
23.1.3 Insulation materials
23.1.3.1 Thickness of insulation

NOTE
Table 23.1-1 does not apply to insulation of pipes in units and modules where the
ambient temperature is below –10 °C.
WDAAA116783f Confidential 23.1-1

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23.1. Insulation of piping Installation Manual
Table Thickness of insulation

23.1-1
Insulation channel, density 100 kg/m3

Temperature of the contents (°C) and insulating
Pipe size
material thickness, mm
Pipe outside diameter,
DN 0–199 °C 200–450 °C
mm
10 17.2 30 40
15 21.3 30 40
20 26.9 30 40
25 33.7 30 50
32 42.4 50 50
40 48.3 50 50
50 60.3 50 50
65 76.1 50 80
80 88.9 50 80
100 114.3 80 80
125 139.7 80 80
150 168.3 80 80
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200 219.1 80 80
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250 273 80 80
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300 323.9 80 100

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Insulation carpets, density 80 kg/m3

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Temperature of the contents (°C) and insulating

Pipe size
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material thickness, mm
Pipe outside diameter,
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DN 0–199 °C 200–450 °C
mm
350 355.6 80 100
400 406.4 100 100
500 508 100 100
600 610 100 100
700 711 100 100
800 813 100 100
900 914 100 100
1000 1016 100 100
1100 1118 100 100
1200 1220 100 100
1300 1320 100 100
1400 1420 100 100
1500 1520 100 100
1600 1620 100 100
23.1-2 Confidential WDAAA116783f

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NOTE
Units and modules are calculated for surface temperature only, not considering
the clamps.
23.1.3.2 Standard insulation channels
Table Standard insulation channels

23.1-2
Insulation channels
Pipe diameter
No trace or electrical trace Ø12 steam trace
Inner diameter × PAROC™ channel Inner diameter × PAROC™ channel
Nominal Outer diameter
thickness type thickness type
DN15 21.3 22 × 30 PV-E 22-30 35 × 30 PV-E 35-30
DN20 26.9 28 × 30 PV-E 28-30 42 × 50 PV-E 42-50
DN25 33.7 35 × 30 PV-E 35-30 49 × 50 PV-E 49-50
DN32 42.4 42 × 50 PV-E 42-50 54 × 50 PV-E 54-50
DN40 48.3 49 × 50 PV-E 49-50 60 × 50 PV-E 60-50
DN50 60.3 60 × 50 PV-E 60-50
n 76 × 50 PV-E 76-50
DN65 76.1 76 × 50 PV-E 76-50 89 × 50 PV-E 89-50
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DN80 88.9 89 × 50 PV-E 89-50 102 × 50 PV-E 102-50

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DN100 114.3 114 × 80 PV-E 114-80 127 × 80 PV-E 127-80

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DN125 139.7 140 × 80 PV-E 140-80 159 × 80 PV-E 159-80

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DN150 168.3 169 × 80 PV-E 169-80 178 × 80 PV-E 178-80

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DN200 219.1 219 × 80 PV-E 219-80 230 × 80 PV-E 230-80

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DN250 273 273 × 80 PV-E 273-80 289 × 80 PV-E 289-80

DN300 323.9 324 × 80 PV-E 324-80 – –
23.1.3.3 Elbows
Insulate elbows by pressing the wool into the elbow. Use Insulation channels only at the ends
of the elbow.
The normal consumption of wool is about:
● 15 kg/100 elbow ≤ DN50
● 30 kg/100 elbow ≥ DN65.
23.1.3.4 Cover materials and equipment

Cover the insulation to protect it from water and dirt and also to provide a more pleasant look
and work finish. The material of the cover should be aluminium; in some cases galvanized
sheets are used. The normal width of these plates is 1 m and the thickness depends on the
size of the pipe. Use a thickness of 0.5 mm for pipes equal to and smaller than DN50. Use a
thickness of 0.7–0.8mm for pipes above DN50. Use a cover plate of at least 1.0 mm thickness
for exhaust gas pipes.

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Use blind rivets to keep the cover in place. The rivets are normally made of some alloyed
material. On straight pipes, there should be 7 pieces/meter, and for a bend, 8 pieces /meter
should be enough. A typical blind rivet size is 3.2 × 10 mm.
23.1.4 Insulation of pipes
23.1.4.1 Pipes ≤ DN300

● Insulate straight pipes less than or equal to DN300 with mineral wool groove. If the pipes
are trace heated, the channel must be one size bigger than the nominal diameter of the
pipe.
● Locate the groove so that the longitudinal joint faces downward (refer to Fig 23.1-1).
● Fasten the groove with 0.8 mm annealed and galvanized steel wire at a distance of 300
mm.
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Fig 23.1-1 Insulation of pipes ≤ DN300 GUID-9DF59F24-AFF8-46EE-B0C7-F5376C0E70E5 v1
23.1.4.2 Pipes > DN300

Insulate straight pipes larger than DN300 with mineral wool mat. Fasten the mat with wire
netting on the outside as shown in Fig 23.1-2. The insulation thickness is shown in Table
23.1-1.
Cover the insulation mat with galvanized steel sheet or with aluminium sheet. The thickness
of the sheet must be 0.7–0.8 mm for normal pipes and 1.0 mm for exhaust gas pipes. The
longitudinal and transversal joints of the sheet must have an overlap of min. 50 mm. Fasten
the sheet with self-tapping screws 3.5 × 13 or with pop rivets 3.2 × 10 at a distance of 200
mm.

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Fig 23.1-2 Insulation of pipes > DN300 GUID-8DCF8D98-AFE4-4FD3-A7E3-76CF8D886420 v1
23.1.4.3 Support rings

A supporting ring consists of:
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● a 3 mm thick plate ring spot welded onto the exhaust gas pipe (item 1 in Fig 23.1-3)
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● a 3 mm thick ring of 30 mm high flat bar iron spot welded onto the plate ring (item 2 in Fig
23.1-3).
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Fig 23.1-3 Supporting ring GUID-215816B2-B6A7-4CAA-BEED-7E4AA3752BE8 v1

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23.1.4.4 Cover joints
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Fig 23.1-4 Cover joints GUID-54C426C0-7ECA-4C98-9525-BB849860687E v1
Table Dimensions for beading type A (mm)

23.1-3
Outside diameter of insulation du a b c

150 < du < 300 3.5 8 2
< 600 5.5 10 3
< 800 7.5 12 4
Continued on next page

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Outside diameter of insulation du a b c

> 800 9.5 12 5
23.1.4.5 Trace heated pipes

Insulate trace heated pipes according to Fig 23.1-5. Pay attention to the following:
● Do not place any insulation material between the main pipe and the trace heating pipe or
cable.
● If a trace heating cable is used, make sure that the cable is not damaged during the
insulation work.
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Fig 23.1-5 Insulation of trace heated pipes

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GUID-88950103-AFCB-4702-8858-F145569284DB v1
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23.1.5 Insulation of elbows, tees and reducers

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Insulate elbows with separate insulation groove or with loose mineral wool. Fasten the loose
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mineral wool with wire netting on the outside (refer to Fig 23.1-2). The thickness of the
insulation and the covering material is the same as with straight pipes. Overlap the joints; make
the covering with 3-8 sections as shown in Fig 23.1-6.
Fig 23.1-6 Elbow cover GUID-4A308800-A35D-4E7D-9041-30D70205719E v1

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Fig 23.1-7 Branch connection cover GUID-6B444554-85D4-4F01-9C94-0A99AF9898B9 v1
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Fig 23.1-8 Cover joint type A or B GUID-0B6BF7E5-4994-4DC9-A959-1F3CD6CC5BAB v1
23.1.6 Insulation of piping equipment and joints
23.1.6.1 Insulation of flanges

Normally flanges are not insulated. However, insulate the flanges and valves if required for the
safety of personnel or to minimize thermal losses.

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Terminate the flange joint according to Fig 23.1-9 so that the bolts can be removed without
damaging the insulation.
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Fig 23.1-9 Termination of insulation at flange joint GUID-F58DAF5C-1924-449F-A992-0CEFCDDDBA53 v1
When flanges and valves are to be insulated, the cover must be removable (refer to Fig
23.1-10 and Fig 23.1-12).

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Fig 23.1-10 Insulation boxes for flanges GUID-E8930421-4286-45F0-A33C-1FA890B3DEEA v1
Table Dimensions for insulation boxes, flanges

23.1-4
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DN δ (mm) D (mm) L (mm)

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10–25 20 215 300

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32–50 20 285 305

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65–80 30 350 330

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100–150 30 470 380

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200 30 520 410

250–300 30 625 470
350–400 30 760 530
Exhaust gas pipes

DN δ (mm) D (mm) L (mm)
500–600 100 1210 630
700–800 100 1500 670
900–1000 100 1700 720
1100–1200 100 1930 720

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Fig 23.1-11 Protective collar of insulation box GUID-EDE7C2B9-D4F4-4488-BA66-01B12F3A41ED v1
23.1.6.2 Insulation of valves

Valves can be left without insulation if nothing else is specified. If the valves have to be
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insulated, use insulation boxes or blankets; see Fig 23.1-12 for examples.
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Fig 23.1-12 Insulation boxes/blankets for valves GUID-728B71A9-E24B-43A2-8090-CD0EE22FB32F v1
23.1.6.3 Insulation of pipe supports

Insulate pipe supports according to Fig 23.1-13.

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Fig 23.1-13 Insulation of pipe support GUID-D084AAEB-4AD1-4CC5-9FFD-32F366671FC7 v1
23.1.6.4 Insulation of bellows

Insulate steel bellows using insulation boxes as shown in Fig 23.1-15. The dimensions are
specified in Table 23.1-5.
NOTE
Do not insulate rubber bellows (Fig 23.1-14).

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Fig 23.1-14 Rubber bellows should not be insulated GUID-AE706E15-045B-462F-9C89-127018394763 v1
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Fig 23.1-15 Insulation of steel bellows GUID-AB22BB5F-A0B4-4E83-9321-04B8A9D3B54A v1

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Table Dimensions for insulation boxes, steel bellows

23.1-5
DN ~d D
15 83 105
20 90 115
25 96 125
32 145 150
40 150 160
50 163 175
65 180 195
80 190 210
100 277 277
125 302 302
150 330 330
200 382 385
Continued on next page

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DN ~d D
250 435 460
300 486 525
350 518 590
400 610 670
23.1.7 Insulation of exhaust gas pipes and bellows

Insulate exhaust gas pipes inside the power plant building. Likewise, insulate exhaust gas
pipes outside the building all way up to the first flange of stack pipe(s). The insulation is needed
in order to minimize thermal losses which can cause a temperature rise in the power plant
building. Insulate the exhaust gas bellow either with insulation pillows (see drawing
WDAAA194461) or with insulation boxes. The dimensions of the insulation pillow elements are
given for various types of flexible bellows in Table 23.1-6 and Table 23.1-7. The insulation
should be easily removable for maintenance work.
23.1.7.1 Insulation pillows (connection of turbocharger)

Mount the insulation pillows according to the following instructions and Fig 23.1-16.
Job Description n
1 Mount the insulation pillows on the bellow.
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2 Fasten the pillow with straps (3 pieces).

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Fig 23.1-16 Exhaust gas bellows insulated with insulation pillows GUID-73250101-3EF2-4D79-9869-5B0988535A5F
v1

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Table Dimensions for insulation pillows for bellows type 4V60B0020

23.1-6
DN Length Pcs / Bellow Breadth Thickness Bands / Pillow

200 1080 1 356 50 2
250 1250 1 376 50 2
300 1440 1 396 50 2
350 1600 1 390 50 2
400 1755 1 528 50 2
450 1930 1 528 50 2
500 2090 1 528 50 2
600 1210 2 528 50 2
700 1370 2 520 50 2
Table Dimensions for insulation pillows for bellows type 4V60B0133

23.1-7
DN Length Pcs / Bellow Breadth Thickness Bands / Pillow

600 1450 2 660 50 3
700 1370 2 n 660 50 3
800 1545 2 660 50 3
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900 1710 2 660 50 3

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1000 1860 2 660 50 3

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23.1.7.2 Insulation boxes

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It is also possible to insulate the exhaust gas bellows with insulation boxes, if needed (50 mm
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insulation only).
Fig 23.1-17 Insulation boxes for exhaust gas bellows GUID-5022F282-E535-4DA1-AA60-077606274CEF v1

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Table Dimensions for insulation boxes, exhaust gas bellows

23.1-8
DN S D L
500–600 100 1210 820
700–800 100 1500 820
900–1000 100 1700 820
1100–1200 100 1930 820
23.1.7.3 Vertical sections

The vibrations that occur in the exhaust gas piping system demand a proper and stable fixing
of the insulation material to the vertical sections of the pipe according to Fig 23.1-18.
This fixing is done by means of supporting rings attached to the vertical exhaust gas pipe. The
supporting rings prevent the insulation material from slipping down the pipe when it is
vibrating. On vertical pipes, the rings must be placed in between each insulation mat (pitch of
900 mm).
The supporting rings also function as fixing rings for the cover plate sheets. Longitudinal and
transversal joints of cover sheet must have an overlap of a minimum of 50 mm. The sheet is
fastened with pop rivets at a distance of 200 mm.
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Fig 23.1-18 Insulation of vertical sections in the exhaust gas piping GUID-CAD9B7F3-C07C-42A8-B3E3-
CDDB1ABE6826 v1
23.1.7.4 Horizontal sections

The insulation for the horizontal sections of the exhaust gas pipes is fastened and overlapped
in the same way as for the vertical sections, according to Fig 23.1-19.
The purpose of the supporting rings on horizontal pipes is to function as fixing rings for the
cover plate sheets.
The pitch between the supporting rings must be 900 mm on horizontal pipes.
Insulation boxes that cover flanges and bellows must be easy to remove. Note that they are
moveable along the surface of the pipe cover plate. The same types of locks as used on the
flexible bellow insulation box above turbo charger are recommended for easy removal of the
insulation.
The pipe must be equipped with extra supporting rings at the joints. These rings function as
fixing rings for the end of the cover sheet, as well as keeping the insulation mat in position.

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Flanges and bellows are insulated according to Fig 23.1-10, Fig 23.1-16 and Fig 23.1-17.
Fig 23.1-19 Insulation of horizontal sections in the exhaust gas piping GUID-BF10166B-8209-46CB-A49C-
A148E3867FA9 v1
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Doc ID: P21020-WAR-DL-0304_01
Wärtsilä is a global leader in complete lifecycle power solutions for the marine and energy markets. By
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emphasising technological innovation and total efficiency, Wärtsilä maximises the environmental and
economic performance of the vessels and power plants of its customers. Wärtsilä is listed on the
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NASDAQ OMX Helsinki, Finland.

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See also www.wartsila.com

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WÄRTSILÄ® is a registered trademark. © 2011 Wärtsilä Corporation.
Wärtsilä Services Main Office Vaasa, Finland

24hrs Phone +358 10 709 080
Switchboard +358 10 709 0000
Fax +358 10 709 1380
Find local offices at www.wartsila.com/addresses

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Date of issue 12.09.2011

23.1. Insulation of piping............................................................................................................................. 23.1-1

23.1.7.2. Insulation boxes.................................................................................................................... 23.1-16

23.1.7.3. Vertical sections.................................................................................................................... 23.1-17

23.1.7.4. Horizontal sections................................................................................................................ 23.1-17

Installation Manual 23.1. Insulation of piping

23.1. Insulation of piping

23.1.1 Before insulation

23.1.2 Which pipes must be insulated?

● All pipelines including heat recovery

● Pipelines between nozzle temperature control unit and diesel engine.

2 Pipelines that must be insulated for personnel safety are:

23.1.3 Insulation materials

23.1.3.1 Thickness of insulation

WDAAA116783f Confidential 23.1-1

23.1. Insulation of piping Installation Manual

Table Thickness of insulation

Insulation channel, density 100 kg/m3

300 323.9 80 100

Insulation carpets, density 80 kg/m3

Temperature of the contents (°C) and insulating

23.1-2 Confidential WDAAA116783f

Installation Manual 23.1. Insulation of piping

23.1.3.2 Standard insulation channels

Table Standard insulation channels

DN80 88.9 89 × 50 PV-E 89-50 102 × 50 PV-E 102-50

DN100 114.3 114 × 80 PV-E 114-80 127 × 80 PV-E 127-80

DN125 139.7 140 × 80 PV-E 140-80 159 × 80 PV-E 159-80

DN150 168.3 169 × 80 PV-E 169-80 178 × 80 PV-E 178-80

DN200 219.1 219 × 80 PV-E 219-80 230 × 80 PV-E 230-80

DN250 273 273 × 80 PV-E 273-80 289 × 80 PV-E 289-80

23.1.3.4 Cover materials and equipment

WDAAA116783f Confidential 23.1-3

23.1. Insulation of piping Installation Manual

23.1.4 Insulation of pipes

23.1.4.1 Pipes ≤ DN300

Fig 23.1-1 Insulation of pipes ≤ DN300 GUID-9DF59F24-AFF8-46EE-B0C7-F5376C0E70E5 v1

23.1.4.2 Pipes > DN300

23.1-4 Confidential WDAAA116783f

Installation Manual 23.1. Insulation of piping

Fig 23.1-2 Insulation of pipes > DN300 GUID-8DCF8D98-AFE4-4FD3-A7E3-76CF8D886420 v1

23.1.4.3 Support rings

Fig 23.1-3 Supporting ring GUID-215816B2-B6A7-4CAA-BEED-7E4AA3752BE8 v1

WDAAA116783f Confidential 23.1-5

23.1. Insulation of piping Installation Manual

23.1.4.4 Cover joints

Fig 23.1-4 Cover joints GUID-54C426C0-7ECA-4C98-9525-BB849860687E v1

Table Dimensions for beading type A (mm)

Outside diameter of insulation du a b c

23.1-6 Confidential WDAAA116783f

Installation Manual 23.1. Insulation of piping

Outside diameter of insulation du a b c

23.1.4.5 Trace heated pipes

Fig 23.1-5 Insulation of trace heated pipes

23.1.5 Insulation of elbows, tees and reducers

Fig 23.1-6 Elbow cover GUID-4A308800-A35D-4E7D-9041-30D70205719E v1

WDAAA116783f Confidential 23.1-7

23.1. Insulation of piping Installation Manual

Fig 23.1-7 Branch connection cover GUID-6B444554-85D4-4F01-9C94-0A99AF9898B9 v1

Fig 23.1-8 Cover joint type A or B GUID-0B6BF7E5-4994-4DC9-A959-1F3CD6CC5BAB v1

23.1.6 Insulation of piping equipment and joints