THERMAL INSULATION

•EFFICIENT THERMAL INSULATION IS ESSENTIAL

WITH HIGH OPERATING TEMP & INCREASED
ENERGY COST
•PRODUCTION, DISTRIBUTION, & USE OF STEAM
REQUIRE THERMAL INSULATION FOR ENSURING
PROCESS REQUIREMENT
•STEAM GENERATED AT BOILER MUST BE
DELIVERED TO THE POINT OF USE AT CURRECT
TEMP & PRESSURE
 OBJECTIVE OF THE ENERGY AUDIT OF
THERMAL INSULATION
• ENERGY CONSERVATION
• RESOURCE OPTIMISATION
• HIGH AVAILABILITY
• HIGH REILIABILITY
• OPTIMUM COST
• EFFECTIVE MAINTENACE PLANNING &
SCHEDULING
TYPES AND FORMS OF INSULATION MATERIAL
S.NO. INSULATION TYPE DENSITY APPROXIMATE
(kg/m³) LIMITING
TEMP.( °C)
1. Cellular glass Cellular 150 450
2. Asbestos Fibrous 80-250 600
3. Glass fibre Fibrous 10-150 550
4. Rockwool and Slagwool Fibrous 20-250 850
5. Calcium silicate Granular 200-260 850
6. Magnesia Granular 200 300
7. Diatomaceous Granular 250-500 1000
8. Silica Fibrous 50-150 1000
9. Aluminosilicate Fibrous 50-250 1200
10. Aluminosilicate Granular 500-800 1200
11. Aluminium Reflective 10-30 500

12. Stainless steel Reflective 300-600 800

13. Vermiculite Granular 50-500 1100
Determination of the Economic thickness of Insulation Material

cost :
I
:
:
H
:
:
:
:
M :
:
INSULATION THICKNESS
I : Cost of Insulation H : Cost of Heat Loss
I + H : Total Cost M : Economic Thickness
The determination of economic thickness
requires the attention to the following factors.

I. Cost of fuel
II. Annual hours of operation
III. Heat content of fuel
IV. Boiler efficiency
V. Operating surface temperature
VI. Pipe diameter/thickness of surface
VII. Estimated cost of insulation.
VIII. Average exposure ambient still air
temperature.
HEAT LOSS CALCULATIONS

S = [10 + (Ts – Ta)/20] (Ts – Ta)

S = SURFACE HEAT LOSS IN K.Cal/hr M2
Ts = HOT SURFACE TEMP, ° C
Ta = AMBIENT TEMP, ° C
EXAMPLE : HEAT LOSS CALCULATION
• STEAM PIPE 100 MM DIA BARE UPTO 100 METERS
LENGTH
• STEM SUPPLY AT 10KG/Cm2 , INSULATION
THICKNESS – 65 MM
• BOILER EFFICIENCY 80%, FUEL OIL COST - $300/-
TONNE
• INSULATED SURFAC TEMP - 65° C; BARE
SURFACE – 170 ° C
• AMBIENT TEMP – 25 ° C
HEAT LOSS CALCULATIONS
HEAT LOSS THROUGH BARE SURFACE:-
S = [10 + (170 – 25)/20] x (170 -25)
= 2500 K Cal/hrm2

HEAT LOSS THROUGH INSULATED

SURFACE:-
S = [10 + (65 – 25)/20] x (65 - 25)
= 480 K Cal/hrm2
 FUEL SAVINGS CALCULATIONS
• PIPE SURFACE AREA = 3.14 X .1X100 = 31. 4m2
• REDUCED HEAT LOSS = 2500 – 480 = 2020 KCal/hrm2
•TOTAL HEAT LOSS = 2020X31.4X8400 = 532795200 K
Cal/yr
• CALORIFIC VALUE OF FUEL OIL – 10300 K. Cal/kg
• BOILER EFF – 80%, DENSITY OF FUEL – 0.97 kg/L
FUEL PRICE - $ 300/kl.
YRLY OILSASVINGS – (532795200)/(10300)X(0.8)X(0.97)
-- 66659 LITRES OR 66.659 KL
MONETARY SAVINGS = 66.659X300 = $19997
HEAT LOSS CALCULATIONS BASED ON STEFEN
BOLTZMAN’S EQUATION/EXPRESSION

HR =∈ A(Ts4 – Ta4) Watt

∈ = E MISSIVITY OF SURFACE
A = AREA OF HOT ZONE
Ts = SURFACE TEMP, °k
Ta = AMBIENT TEMP, °k
Hc = CA (Ts – Ta) Watt
C = COEFICIENT OF CONVECTION
∈ = 0.6 (OXIDISED Al SURFACE)
C = 5 (NATURAL WIND FLOW VELOCITY 0.5 – 1.0 m/s)
 CONVECTIVE HEAT TRANSFER
•HEAT TRANSFER TAKES PLACE BY TWO MECHANISMS
- BY DIRECT CONDUCTION THROUGH THE FLUID
- BY THE MOTION OF THE FLUID ITSELF
•CONVECTIVE HEAT FLOW IS DETERMINED BY – SURFACE
TEMP, SURROUNDING TEMP & SPEED OF THE FLUID MOTION
•CONVECTIVE HEAT TRANSFER BETWEEN DECK SURFACE &
THE SURROUNDING AIR CAN BE OBTAINED BY USING
LANGMUIR’S EQUATION.
QC = 1.947 (Ts –Ta)5/4 √(V+0.35)/0.35, w/m2
Ts = SURFACE TEMP OF THE DECK, °C
Ta = AMBIENT AIR TEMP, °C
V = WIND VELOCITY, m/s
GUIDELINE FOR THE INSULATION SCHEME

Temperature Pipe Diameter Flat

25 mm 50 75 mm 100 150 mm Surfa
mm mm ces
Less than 25 mm 25 50 mm 50 65 mm 50
100°C mm mm mm
100 – 150°C 25 mm 25 50 mm 50 65 mm 75
mm mm mm
150 – 200°C 25 mm 40 50 mm 65 75 mm 90
mm mm mm
200 – 250°C 25 mm 50 50 mm 65 75 mm 90
mm mm mm
250 - 300°C 25 mm 50 50 mm 75 90 mm 100
mm mm mm
Thermal insulation can be justified by balancing the cost of
different heat losses or heat savings against the cost of insulation.
 EVALUATION OF OPTIMUM
INSULATION THICKNESS
• PIPE DIA = 100 mm, PROCESS TEMP = 200°C, AMB. TEMP = 40°C
TEMP. AT INSULATED SURFACE = 55°C , BOILER EFF = 88%
COAL COST = Rs 1.9/kg, CV OF COAL = 3770 K Cal/kg
K OF ROCKWOOL = 0.036, PLANT OPTG HRS = 7920 (24X330)
DEPRICIATION OF INS = 20%; INTEREST ON INS COST = 15%
COST OF USEFUL HEAT = Rs 1.9/(3770X0.88) = Rs 0.0005727/ K Cal
ASSUMING INS THICKNESS = T = 25 mm, GIVEN PIPE DIA (D) = 100 mm
AREA IN m2/m LENGTH OF PIPE = 3.14 (D+2T)
= 3.14 [(100 + 2X25)/1000] = 0.471
HEAT LOSS, K. Cal/m2hr = K∆T/INS. THICKNESS,
= 0.036 (200-55)/0.025=208.80
HEAT LOSS COST = (208.8)(7920)(0.471)(0.0005727)
= 446.07 (Rs/m)
IS 14164 : 1994 (-80°C TO 700°C )

ACCEPTABLE SKIN TEMP FOR STEAM PIPE

LINES/BOILERDRUMS/BOILER SURFACE → 15 °C + AMB
WITH WIND VELOCITY OF IM/S

MOST NEGLECTED AREAS ARE –

FLANGES/ VALVES/TEES etc
MIN, DENSITY OF ROCKWOOL MATTRESS – 128 kg/M3
FOR SURFACE TEMP>400 °C & 100 kg/M3 FOR <400 °C
AL SHEET OF 18/20/22 SWG MAY BE USED FOR CLADDING.
ROCKWOOL MATTRESS:
ROCKWOOL IS A PRECISELY ENGINEERED RESIN
BONDED FIBROUS INSULATION TO OFFER
MAXIMUM RESISTANCE TO HEAT PASSAGE. FIBRES
ARE SPUN FROM SELECTED ROCKS, MELTED AT
1600°C AND BLENDED TO A CAREFULLY ADJUSTED
CHEMICAL COMPOSITION. ITS CENTRIFUGALLY
SPUN FIBRES HAVE A DIAMETER 1/20TH THAT OF
HUMAN HAIR WHICH ARE FELTED USING STATE OF
THE ART TECHNOLOGY INTO BONDED AND CURED
MATTRESS TO OPTIMUM DENSITY AND RESILIENCE.
WHY RESIN BOND & MACHINE STITCH:-
LIKE ALL SCIENTIFICALLY PROCESSED FIBROUS
INSULANTS IS COMPOSED OF FIBRES WHICH
ARE LAID IN THE OPTIMUM CONFIGURATION TO
OFFER MAXIMUM RESISTANCE TO HEAT FLOW.
TO RETAIN THESE EXCEPTIONAL PROPERTIES
UP TO THE POINT OF END-USE, FIBRES ARE
INTERLOCKED BY LIGHTLY BONDING THEM
TOGETHER USING A THERMOSETTING BINDER.
SUBSEQUENTLY, MATTS ARE FACTORY
STITCHED TO SPECIFIED WIRE MESH USING A
CONTINUOUS STITCHING MACHINE TO PERMIT A
READY-TO-USE CONFIGURATION.
SALIENT FEATURES OF INSULANT
• HIGHER THERMAL PERFORMANCE, AS IT IS MADE OUT OF
ROCKWOOL AND NOT SLAGWOOL.
• ELIMINATES SETTING AND SAGGING.
•LONGER LIFE, PERMITTING REUSE AFTER REMOVAL DURING
MAINTENANCE.
•ENVIRONMENT FRIENTLY, AS THERE IS NO CHICKEN FEAT
HERING (WHICH NORMALL POLLUTES THE ENVIRONMENT). IT
IS ECO FRIENDLY TO PERSONNEL DUE TO THE CHEMISTRY OF
FIBRES.
•UNCONTAMINATED, AS MANUFACTURING IS TOTALLY A DRY
PROCESS.
•APPLICATION FRIENDLY, AS IT PERMITS VERY FAST
INSTALLATION.
TECHNICAL SPECIFICATIONS

• STANDARD DENSITIES : 100, 120 AND 150Kg/m³

• APPLICATION TEMPERATURES : -100 °C +800 °C
• STANDARD THICKNESS * : 25, 40, 50, 65, 75mm
• STANDARD SIZE : 1520 X 1220 mm
* OTHER THICKNESS FROM 20 TO 100 mm INSTEPS OF 5 mm CAN
ALSO BE MADE AVAILABLE
 CORROSION - PROTECTION

ROCKWOOL FIBRES, IN THE FIRST PLACE, ARE DEVOID OF

IMPURITIES LIKE HALIDES (CHLORIDES & FLUORIDES) AND
SULPHIDES WHICH ARE COMMONLY FOUND IN OTHER
MATERIALS SUCH AS CALCIIUM SILICATE. THIS IS DUE TO
THE FACT THAT FIBRES ARE MANUFACTURED BY A DRY
MANUFACTUING PROCESS AND ITS FAINT ALKLINITY
ACTUALLY FIGHT A AGAINST CORROSIVE REACTIONS. IT
MEETS VARIOUS CRITICAL SPECIFICATIONS INCLUDING
ASTM C-795 REQUIREMENTS WHERE SPECIFIED. THIS
FEATURE IS RESPONSIBLE FOR ITS EXCLUSIVE SELECTION
FOR CRITICAL APPLICATIONS SUCH AS NUCLEAR POWER
PLANTS.
 INSULATION CONDITION
PREDICTION
• Plant visit & discussion
• Collection of Techno-commercial information.
•Field study by using most sophisticated Thermovision
instrument (camera) Model NEC-TH-5104
• Identification of Hot zones/spots
• Calculation of Heat Loss
• Estimation of annual financial savings
 THERMOGRAPHY
Advantage of Thermography:

• Non-contact type of temperature meausrement

• Portability
• Effective observation & inspection
• Easy interpretation through colour images
• Quick report generation
 EXECUTIVE AUDIT SUMMARY
STAGE – I (2X210MW)
UNIT -I UNIT - II TOTAL

Present Heat Loss 794279 613012 1407291

(Kcal/hr)

Heat Loss Saving 608401 523338 1131740

Potential after
Insulation upgradation
(Kcal/hr)
Saving Potential in 21,73,008 18,65,617 40,38,625
Rupees
 FINDNGS: Unit#1: Boiler Side
Kcal/hr % Area %
m2
Bare Only 63243 11 33 9
Damaged/Inadequate 504416 88 337 91
No Cladding 4520 1 1 0

FINDNGS: Unit#1: Turbine Side

Kcal/hr % Area %
m2

Bare Only 127125 57 49 31

Damaged/Inadequate 90812 41 97 62
No Cladding 4162 2 11 7
 FINDNGS: Unit#2: Boiler Side

Kcal/hr % Area %
m2
Bare Only 65334 12 33 9
Damaged/Inadequate 483280 87 335 90
No Cladding 7202 1 6 2

FINDNGS: Unit#2: Turbine Side

Kcal/hr % Area %
m2
Bare Only 31362 55 11 25
Damaged/Inadequate 21819 38 26 59
No Cladding 4015 7 7 15
UNIT-WISE OBSERVATIONS & RECOMMENDATIONS
UNIT # 1 BOILER SIDE: The following areas are having temperature
more than 200 °C. .
The insulation of these areas to be upgraded at the earliest.
S. Refer Thermal
N Area Side Present Total Observed Saving ` Image No.
O. Identified Insulation Area Surface (Kcal/hr
Condition (m2) Temp )
(°C)
1. 54 Meter Level
2. MS ERV Left Bare 0.471 330 3146 Image No. 01
Body
3. RH Start-up Righ Bare 0.160 305 955
vent valve t
Body2 nos.
4. CRH S/V Left Bare 0.251 256 1035
body
5. HRH S/V Left Bare 0.251 215 729
body
6. 52 Meter Level
7. CRH S/V neck Left Bare 0.118 306 652 Image No. 02
8. 31 Meter Level
9. Rightside Left- Inadequate 0.480 205 1333 Image No.22
peephole Pl
10. 28 Meter Level
 ENERGY AUDIT : FINANCIAL SAVINGS
UNIT # 1

Total present surface heat loss = 794279 kcal/hr

Total reduction of heat loss by insulation upgradation = 608401 kcal/hr
Average C.V. of coal = 3750 kcal/kg
Average Boiler efficiency = 0.7835
So, equivalent reduction of coal consumption = 608401 / (3750 x 0.78)
= 207.07 Kg/hr
Equivalent annual reduction of coal assuming
330 days of plant operation = 207.07 x 24 x 330 Kg
= 1640 MT
Annual monetary saving @ Rs. 1325/- per MT = 1640 x 1325
= Rs. 21,73,008/-
 ENERGY AUDIT : FINANCIAL SAVINGS
UNIT # 2

Total present surface heat loss = 613012 kcal/hr

Total reduction of heat loss by insulation upgradation = 523338kcal/hr
Average C.V. of coal = 3750 kcal/kg
Average Boiler efficiency = 0.785
So, equivalent reduction of coal consumption = 608401 / (3750 x 0.785)
= 177.78 Kg/hr
Equivalent annual reduction of coal assuming
330 days of plant operation = 177.78 x 24 x 330 Kg
= 1408 MT
Annual monetary saving @ Rs. 1325/- per MT = 1408 x 1325
= Rs. 18,65,617/-