Owner MB POWER (Madhya Pardesh) Unit 1 & 2 (2 x 600 MW )

EPC Lanco Infratech Limited

FO Contractor Moser Baer Engineering & Constructions Limited
Title Design Calculation - INSULATION THICKNESS
Doc No LITL - 020 - MEV-213 - R - 41807 REV-0 DATE 03.08.2011
O-1107-MBFO-CL-09 REV-1 DATE 14.10.2011
CALCULATIONS FOR INSULATION THICKNESS

HFO LINES HFO LINE BOILER STEAM AT 3.5 STEAM AT 13 CONDENSATE CONDENSATE HFO STORAGE
FROM STORAGE HEATER RETURN TO KG/SQCM(g) KG/SQCM(g) FROM 3.5 FROM 13 & DRAIN OIL
UNLOADING TANK TO OUTLET TO STORAGE KG/SQCM(g) KG/SQCM(g) TANK
BASIC DATA
AREA TO LINE BOILER TANK STEAM STEAM
STORAGE HEATER
TANK INLET
Ambient temperature (min) 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 6.5 deg C
Ambient temperature (max) 42.2 42.2 42.2 42.2 42.2 42.2 42.2 42.2 42.2 deg C
Maximum cladding temperature 60 60 60 60 60 60 60 60 60 deg C
Fluid temperature 45 60 120 120 147.2 360 147.2 360 45 deg C
Mean temperature 43.6 51.1 81.1 81.1 94.7 201.1 94.7 201.1 43.6 deg C
Value of K from IS:8183 for LRB of 81-120 0.43 0.43 0.52 0.52 0.62 0.73 0.52 0.73 0.43 mW/cm*degC
kg/cum density
Value of K from IS:8183 for LRB of 81-120 0.037 0.037 0.045 0.045 0.053 0.063 0.045 0.063 0.037 kcal/m*degC
kg/cum density
Insulating material Light resin bonded mineral wool as per IS:8183
Density 120 kg/cum
Cladding material Aluminum sheets of 24 gauge thickness
Factor f for aluminum surface
Heat loss per unit area of shell surface
q= kcal/hr*m2
th-tm / {d/2k*ln (d1/d) + 1/ f(d/d1)}
where
th deg C Temp of hot surface
tm deg C Ambient temp (min) for worst case
f 4.89 Kcal/hr*m2 Factor for aluminum surface from IS: 7413
d m Outer dia of pipe
Insulation thickness m Insulation thickness
d1 m OD of insulated pipe
k kcal/m deg C Thermal conductivity at mean temp

Temp rise over ambient temp

t= (q*d) / (d1*f)
where
q kcal/hr*m2 Heat loss per unit area
d m Outer dia of pipe
d1 m OD of insulated pipe

Caldding temperature at min ambient, tc tmin+t

(min)=
Caldding temperature at max ambient, tc tmax+t
(max)=
Insulation thickness for HFO LINES FROM UNLOADING AREA TO HFO STORAGE TANK & DRAIN OIL LINES
Pipe size Thermal Pipe OD Thickness of Mean dia OD th-tm d / 2k ln(d1/d) (d/d1) 1/f(d/d1) {d/2k*ln (d1/d) + Heat loss Temp rise Cladding Cladding
Conductivity insulation 1/ f(d/d1)} temp at temp at
minimum maximum
ambient temp ambient temp

k d d1 q t tc (min) tc (max)
NB m m m m deg C kcal / hr*m2 deg C deg C deg C
15 0.037 0.022 0.025 0.047 0.072 38.5 0.297 1.186 0.306 0.669 1.022 37.67 1.68 8.18 43.88
25 0.037 0.034 0.025 0.059 0.084 38.5 0.460 0.904 0.405 0.505 0.921 41.80 2.47 8.97 44.67
50 0.037 0.06 0.025 0.085 0.11 38.5 0.811 0.606 0.545 0.375 0.867 44.42 3.54 10.04 45.74
80 0.037 0.089 0.025 0.114 0.139 38.5 1.203 0.446 0.640 0.319 0.856 44.98 4.21 10.71 46.41
100 0.037 0.115 0.025 0.14 0.165 38.5 1.555 0.361 0.697 0.293 0.855 45.04 4.59 11.09 46.79
150 0.037 0.165 0.025 0.19 0.215 38.5 2.231 0.265 0.767 0.266 0.857 44.93 5.04 11.54 47.24

Insulation thickness for HFO LINES FROM STORAGE TANK TOLINE HEATER INLET
Pipe size Thermal Pipe OD d Thickness of Mean dia OD th-tm d/2k ln(d1/d) (d/d1) 1/f(d/d1) {d/2k*ln (d1/d) + Heat loss Temp rise Cladding Cladding
Conductivity insulation d1 1/ f(d/d1)} temp at temp at
minimum maximum
ambient temp ambient temp

NB m m m m deg C q t tc (min) tc (max)

15 0.037 0.022 0.025 0.047 0.072 53.5 0.297 1.186 0.306 0.669 1.022 52.35 2.34 8.84 44.54
25 0.037 0.034 0.025 0.059 0.084 53.5 0.460 0.904 0.405 0.505 0.921 58.09 3.44 9.94 45.64
50 0.037 0.06 0.025 0.085 0.11 53.5 0.811 0.606 0.545 0.375 0.867 61.73 4.92 11.42 47.12
80 0.037 0.089 0.025 0.114 0.139 53.5 1.203 0.446 0.640 0.319 0.856 62.51 5.85 12.35 48.05
100 0.037 0.115 0.025 0.14 0.165 53.5 1.555 0.361 0.697 0.293 0.855 62.59 6.38 12.88 48.58
150 0.037 0.165 0.025 0.19 0.215 53.5 2.231 0.265 0.767 0.266 0.857 62.43 7.00 13.50 49.20

Insulation thickness for HFO LINES FROM LINE HEATER TO BOILER

Pipe size Thermal Pipe OD d Thickness of Mean dia OD th-tm d/2k ln(d1/d) (d/d1) 1/f(d/d1) {d/2k*ln (d1/d) + Heat loss Temp rise Cladding Cladding
Conductivity insulation d1 1/ f(d/d1)} temp at temp at
minimum maximum
ambient temp ambient temp

NB m m m m deg C q t tc (min) tc (max)

15 0.045 0.022 0.025 0.047 0.072 113.5 0.246 1.186 0.306 0.669 0.961 118.12 5.28 11.78 47.48
25 0.045 0.034 0.025 0.059 0.084 113.5 0.380 0.904 0.405 0.505 0.849 133.68 7.91 14.41 50.11
50 0.045 0.06 0.025 0.085 0.11 113.5 0.671 0.606 0.545 0.375 0.782 145.23 11.58 18.08 53.78
80 0.045 0.089 0.025 0.114 0.139 113.5 0.995 0.446 0.640 0.319 0.763 148.75 13.92 20.42 56.12
100 0.045 0.115 0.030 0.145 0.175 113.5 1.286 0.420 0.657 0.311 0.851 133.37 12.81 19.31 55.01
150 0.045 0.165 0.030 0.195 0.225 113.5 1.845 0.310 0.733 0.279 0.851 133.37 14.30 20.80 56.50

Insulation thickness for HFO LINES FROM BOILER RETURN TO STORAGE TANK
Pipe size Thermal Pipe OD d Thickness of Mean dia OD th-tm d/2k ln(d1/d) (d/d1) 1/f(d/d1) {d/2k*ln (d1/d) + Heat loss Temp rise Cladding Cladding
Conductivity insulation d1 1/ f(d/d1)} temp at temp at
minimum maximum
ambient temp ambient temp

NB m m m m deg C q t tc (min) tc (max)

15 0.045 0.022 0.025 0.047 0.072 113.5 0.246 1.186 0.306 0.669 0.961 118.12 5.28 11.78 47.48
25 0.045 0.034 0.025 0.059 0.084 113.5 0.380 0.904 0.405 0.505 0.849 133.68 7.91 14.41 50.11
50 0.045 0.06 0.025 0.085 0.11 113.5 0.671 0.606 0.545 0.375 0.782 145.23 11.58 18.08 53.78
80 0.045 0.089 0.025 0.114 0.139 113.5 0.995 0.446 0.640 0.319 0.763 148.75 13.92 20.42 56.12
100 0.045 0.115 0.030 0.145 0.175 113.5 1.286 0.420 0.657 0.311 0.851 133.37 12.81 19.31 55.01
150 0.045 0.165 0.030 0.195 0.225 113.5 1.845 0.310 0.733 0.279 0.851 133.37 14.30 20.80 56.50
Insulation thickness for STEAM LINES OF 3.5 KG/SQCM(g) & CONDENSATE LINES
Pipe size Thermal Pipe OD d Thickness of Mean dia OD th-tm d/2k ln(d1/d) (d/d1) 1/f(d/d1) {d/2k*ln (d1/d) + Heat loss Temp rise Cladding Cladding
Conductivity insulation d1 1/ f(d/d1)} temp at temp at
minimum maximum
ambient temp ambient temp

NB m m m m deg C q t tc (min) tc (max)

15 0.053 0.022 0.025 0.047 0.072 140.7 0.206 1.186 0.306 0.669 0.914 153.96 6.88 13.38 49.08
25 0.053 0.034 0.025 0.059 0.084 140.7 0.319 0.904 0.405 0.505 0.794 177.29 10.49 16.99 52.69
50 0.053 0.06 0.040 0.1 0.14 140.7 0.563 0.847 0.429 0.477 0.954 147.50 9.24 15.74 51.44
80 0.053 0.089 0.040 0.129 0.169 140.7 0.835 0.641 0.527 0.388 0.924 152.35 11.73 18.23 53.93
100 0.053 0.115 0.040 0.155 0.195 140.7 1.078 0.528 0.590 0.347 0.916 153.57 13.24 19.74 55.44
150 0.053 0.165 0.040 0.205 0.245 140.7 1.547 0.395 0.673 0.304 0.915 153.72 15.14 21.64 57.34

Insulation thickness for STEAM LINES OF 13.0 KG/SQCM(g) & CONDENSATE LINES
Pipe size Thermal Pipe OD d Thickness of Mean dia OD th-tm d/2k ln(d1/d) (d/d1) 1/f(d/d1) {d/2k*ln (d1/d) + Heat loss Temp rise Cladding Cladding
Conductivity insulation d1 1/ f(d/d1)} temp at temp at
minimum maximum
ambient temp ambient temp

NB m m m m deg C q t tc (min) tc (max)

15 0.063 0.022 0.040 0.062 0.102 353.5 0.175 1.534 0.216 0.948 1.217 290.49 9.16 15.66 51.36
25 0.063 0.034 0.040 0.074 0.114 353.5 0.271 1.210 0.298 0.686 1.013 348.87 15.21 21.71 57.41
50 0.063 0.06 0.060 0.12 0.18 353.5 0.478 1.099 0.333 0.613 1.138 310.50 15.13 21.63 57.33
80 0.063 0.089 0.100 0.189 0.289 353.5 0.709 1.178 0.308 0.664 1.499 235.84 10.62 17.12 52.82
100 0.063 0.115 0.100 0.215 0.315 353.5 0.916 1.008 0.365 0.560 1.483 238.36 12.72 19.22 54.92
150 0.063 0.165 0.100 0.265 0.365 353.5 1.314 0.794 0.452 0.452 1.496 236.34 15.62 22.12 57.82

Insulation thickness for HFO STORAGE & DRAIN OIL TANK

TANK DIA Thermal TANK OD Thickness of Mean dia OD th-tm d/2k ln(d1/d) (d/d1) 1/f(d/d1) {d/2k*ln (d1/d) + Heat loss Temp rise Cladding Cladding
Conductivity d insulation d1 1/ f(d/d1)} temp at temp at
minimum maximum
ambient temp ambient temp

m m m m m deg C q t tc (min) tc (max)

16 0.037 16.02 0.040 16.06 16.1 38.5 216.604 0.005 0.995 0.206 1.284 29.97 4.36 10.86 46.56
1.8 0.037 1.812 0.040 1.852 1.892 38.5 24.500 0.043 0.958 0.214 1.272 30.27 4.24 10.74 46.44