Insulation and Heat Tracing
THERMAL INSULATION
• Conserve heat
• Protect personnel
• Maintain temperature for process control
• Preventing fluid freezing in cold climates
There are two basic types of thermal insulation:
• Mass Insulation
• Reflective Insulation
Calcium Silicate which is a compound of lime and silica with reinforcement fibers molded into pipe shapes, sizes, including elbows. It is used in applications with system
temperatures up to 1200° F. Even though the dust caused by working with Calcium
Mineral-Fiber Insulation which is available in both blankets and shapes. It is made from rock and slag fibers which have been bonded together. It is used in applications with system temperatures to 1500° F.
Flange connections typically have removable sections or a flexible blanket assembly
placed over the joint which permit easy future removal. Nameplates, code plates,
pipe plugs and blind nipples should be left exposed or have a small removable
section of insulation placed over them.
Removable insulation covers should be:
• One piece construction wherever possible
• Fabricated in multiple sections when a one piece cover exceeds 60 pounds total
weight
• Constructed with edges that butt tightly together to minimize heat loss and
provide a cover of neat finished appearance
• Resistant to water, oil, and steam
• Constructed to prevent the entry of fluids or moisture into the internal insulating
material
• Constructed to fit snugly around the contours of the component being insulated,
including valves, flanges, straight pipe, and fittings
• Constructed with no sharp edges or protrusions on the outer surface
• Vendor furnished and installed attachment devices
• Welded attachments installed to secure the insulation
• Stainless steel, copper coated steel, or aluminum steel wire
• Stainless steel or aluminum bands
Prior to the installation of the insulation jacketing, the installed insulation must be
verified to be complete and properly installed. Joints provided for thermal expansion
or contraction must be filled with insulating mastic material or mineral fiber batting.
The jacketing on both piping and equipment insulation should be fastened with
bands wherever possible. When bands cannot be used due to the piping or
equipment configuration, the jacketing may be secured with sheet metal screws.
Jacketing joints and openings must be sealed with a caulking material when the
insulation system contains a moisture or vapor barrier and the system is installed
outdoors. Removable insulation jacketing must overlap adjacent pipe by an amount
equal to the insulation overlap.
Four typical heat trace systems include:
• Electrical Heat Trace
• Bare Steam Trace
• Heat Transfer Cemented Steam Trace
• Hot Water
Insulation is defined as any material that resists the transfer of heat energy. The
purpose of thermal insulation is therefore either to keep heat confined in the
mechanical system or to keep it excluded from the system by preventing or resisting
heat transfer.
purpose of thermal insulation is therefore either to keep heat confined in the
mechanical system or to keep it excluded from the system by preventing or resisting
heat transfer.
The four functions of insulation for hot piping and equipment are:
• Conserve heat
• Protect personnel
• Maintain temperature for process control
• Preventing fluid freezing in cold climates
There are two basic types of thermal insulation:
• Mass Insulation
• Reflective Insulation
Mass insulation is made up of small pockets or spaces that trap air or gases that are
separated by solid structures. The voids provide resistance to the heat transfer process.
separated by solid structures. The voids provide resistance to the heat transfer process.
Mass type insulation includes:
Calcium Silicate which is a compound of lime and silica with reinforcement fibers molded into pipe shapes, sizes, including elbows. It is used in applications with system
temperatures up to 1200° F. Even though the dust caused by working with Calcium
Silicate may be a safety concern, the insulation material is more rigid and more durable than other insulating materials.
Mineral-Fiber Insulation which is available in both blankets and shapes. It is made from rock and slag fibers which have been bonded together. It is used in applications with system temperatures to 1500° F.
Glass Type insulation is available in several forms including glass wool, fiber board,
and felted glass fibers. Some forms of glass type insulation are designed for
temperature services up to 1000° F.
and felted glass fibers. Some forms of glass type insulation are designed for
temperature services up to 1000° F.
Reflective insulation materials include Aluminum or Stainless Steel sheets or foil
used for the construction of reflective blankets. The temperature limits for the
aluminum materials are approximately 1000° F. The stainless steel materials are
adequate for temperature ranges up to 1500° F.
used for the construction of reflective blankets. The temperature limits for the
aluminum materials are approximately 1000° F. The stainless steel materials are
adequate for temperature ranges up to 1500° F.
The inner layer of insulation is normally installed as the insulating material and the
outer metal cover is installed to protect the insulation from damage. Insulating
outer metal cover is installed to protect the insulation from damage. Insulating
jackets or protective covers are usually aluminum or stainless steel sheeting.
Personnel protection insulation is normally provided on hot piping that is not required
to be insulated for design requirements but which can be reached by a person
standing on the ground or the nearest platform. Normally personnel protection
insulation is provided on uninsulated piping with operating temperatures above
140° F and within 7 feet of the ground or 3 feet from the platform edges or ladders.
to be insulated for design requirements but which can be reached by a person
standing on the ground or the nearest platform. Normally personnel protection
insulation is provided on uninsulated piping with operating temperatures above
140° F and within 7 feet of the ground or 3 feet from the platform edges or ladders.
Flange connections typically have removable sections or a flexible blanket assembly
placed over the joint which permit easy future removal. Nameplates, code plates,
pipe plugs and blind nipples should be left exposed or have a small removable
section of insulation placed over them.
Removable insulation covers should be:
• One piece construction wherever possible
• Fabricated in multiple sections when a one piece cover exceeds 60 pounds total
weight
• Constructed with edges that butt tightly together to minimize heat loss and
provide a cover of neat finished appearance
• Resistant to water, oil, and steam
• Constructed to prevent the entry of fluids or moisture into the internal insulating
material
• Constructed to fit snugly around the contours of the component being insulated,
including valves, flanges, straight pipe, and fittings
• Constructed with no sharp edges or protrusions on the outer surface
Equipment Insulation
Equipment insulation blocks, boards, or blankets are normally attached to the equipment surface with joints staggered and the edges tightly butted and sealed with insulation cement, except in those cases where expansion or contraction joints are provided.
Equipment insulation blocks, boards, or blankets are normally attached to the equipment surface with joints staggered and the edges tightly butted and sealed with insulation cement, except in those cases where expansion or contraction joints are provided.
Insulation is normally attached by one of the following methods:
• Vendor furnished and installed attachment devices
• Welded attachments installed to secure the insulation
• Stainless steel, copper coated steel, or aluminum steel wire
• Stainless steel or aluminum bands
Insulation Jacketing and Surface Finish
Prior to the installation of the insulation jacketing, the installed insulation must be
verified to be complete and properly installed. Joints provided for thermal expansion
or contraction must be filled with insulating mastic material or mineral fiber batting.
The jacketing on both piping and equipment insulation should be fastened with
bands wherever possible. When bands cannot be used due to the piping or
equipment configuration, the jacketing may be secured with sheet metal screws.
Jacketing joints and openings must be sealed with a caulking material when the
insulation system contains a moisture or vapor barrier and the system is installed
outdoors. Removable insulation jacketing must overlap adjacent pipe by an amount
equal to the insulation overlap.
HEAT TRACING
Four typical heat trace systems include:
• Electrical Heat Trace
• Bare Steam Trace
• Heat Transfer Cemented Steam Trace
• Hot Water
Electrical heat trace systems are installed by simply wrapping electrical trace around
piping and equipment to provide mild winterization protection. Some high
temperature piping systems require the use of a layer of insulation between the pipe
and heat trace to avoid damage to the heat trace.
Bare Heat Transfer Cemented Steam Trace and Hot Water Trace systems are
applied by placing and banding tubing along the piping runs and looping the tubing
around equipment and valves. The function of the steam trace is to maintain the
process fluids at temperature levels that provide proper flow characteristics.
piping and equipment to provide mild winterization protection. Some high
temperature piping systems require the use of a layer of insulation between the pipe
and heat trace to avoid damage to the heat trace.
Bare Heat Transfer Cemented Steam Trace and Hot Water Trace systems are
applied by placing and banding tubing along the piping runs and looping the tubing
around equipment and valves. The function of the steam trace is to maintain the
process fluids at temperature levels that provide proper flow characteristics.
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