100, Insulation Selection, Hot Systems
100, Insulation Selection, Hot Systems
100, Insulation Selection, Hot Systems
Systems
Abstract
This section covers the selection of insulating materials for hot lines, tanks, and
major equipment. It discusses the properties and uses of different types of insula-
tion. Flexible removable covers are described, and the Company’s specifications and
standard drawings for insulating hot systems are listed.
Section 300 gives calculation methods and insulation selection charts, which will
help you choose the most economical thickness for a given insulation system.
Ceramic fiber insulating refractory is covered in Part 2 of this manual.
Refer to the Pipeline Manual for information on insulated pipelines.
Contents Page
110 Introduction
This section covers the selection of suitable insulating materials for hot lines and
major equipment. It outlines the operating conditions where insulation is required
and types of insulation material commonly used.
Tanks
Tank insulation is usually a matter of economics. We insulate to:
• Maintain crude oil or product in a viscous state above its pour point to main-
tain its flowability.
• Reduce or eliminate the need for tank heaters, cooling coils, etc., to reduce
operating costs.
• Stabilize operations, e.g., maintain a more constant temperature in a fluid being
fed to a process.
• Reduce evaporation losses.
• Reduce fire hazard where justified by minimizing heat absorption from possible
adjoining fires.
• Equipment and piping that are refractory lined. Use metal cages for personnel
protection.
• Cooling water lines.
• Water side of coolers and condensers.
• Steam traps.
• Bellows expansion joints.
• Nameplates, code data plates, etc.
• Bearing housings of pumps.
• Seals pots, vent chambers, and drip pots should be insulated only if steam
traced.
A word of caution about heat conservation and operating stability: regardless of the
amount of insulation installed on low pressure vapor or gas lines, the heat loss may
still be excessive due to heat loss through pipe support steel. In such cases, consider
using insulated pipe hangers or low conductivity material between the line and the
supports.
121 Materials
Figure 100-1 gives the important properties for the most frequently used insulating
materials. These materials are briefly described next.
Calcium Silicate. For plant applications, physical strength and durability in addi-
tion to thermal conductivity are important factors in selecting insulation. For this
reason, calcium silicate rigid, pre-formed block insulation is preferred for lines and
major equipment up to 1200°F in refinery service, particularly in areas subject to
mechanical damage and for vessels insulated for fire protection.
Perlite. Goodtemp (manufactured by Howred Corporation) is made of expanded
perlite and sodium silicate reinforced with fibers. This product has properties and
appears similar to calcium silicate. Perlite can be used for insulating piping, vessels,
etc., up to 1200°F and is an acceptable alternative to calcium silicate.
Mineral Wool. Mineral wool insulation is also used up to 1200°F. Mineral wool has
lower heat conductivity than calcium silicate for temperatures below 600°F.
However, even with metal weatherjacketing, mineral wool is subject to mechanical
damage due to its low compressive strength and lack of resiliency, which can lead to
increased heat loss and/or increased maintenance. For example, mineral wool
should not be used to insulate piping such as pipe racks — even above ground —
that workers are likely to walk on.
The Pascagoula Residuum Conversion Project used mineral wool insulation for
most vessels 8 feet in diameter and larger except for top and bottom heads on
vertical vessels and certain areas where fire or mechanical strength dictated the
use of calcium silicate. Smaller horizontal vessels had calcium silicate insulation.
Fig. 100-1 Typical Material Properties for Frequently Used Insulation Materials (1 of 2)
Piping Insulation
Material
K Factor Maximum
Generic Commercial (Btu-In/ Compressive Density Usage
Type Brands hr-ft2-°F) Strength (psi) (lb/ft3) Temp. (°F)
Calcium Calsilite (preferred)(2) ASTM C335 100 10-13 1200
Silicate(1) Johns Manville 0.47 at 400°F
0.50 at 600°F
0.54 at 800°F
ASTM C177
0.45 at 400°F(3)
Mineral Partek - Paroc 1200 0.30 at 200°F 1.3 @ 10% 10-12 1200
Wool(4) 0.35 at 300°F deformation
0.40 at 400°F
0.46 at 500°F
0.53 at 600°F
0.60 at 700°F
Perlite(5) Calsilite/Sproul Corp 0.50 at 300°F 80 at 5% 12-14 1200
Sproul WR1200 0.60 at 500°F deformation
0.71 at 700°F
Cellular Pittsburgh Corning - Foamglas 0.42 at 200°F 100 8.5 800
Glass(6) (-290°F to 250°F) 0.49 at 300°F
0.59 at 400°F
0.70 at 500°F
0.85 at 600°F
1.03 at 700°F
Fiberglass Owens/Corning - ASJ-SSL-11 0.27 at 200°F No effective 5-6 450
Fiberglass 0.35 at 300°F compressive
Certainteed - ASJ-APT-Snap on(7) 0.45 at 400°F strength
Schuller - APT-APJ-Micro Loc 0.55 at 500°F
Knauf - ASJ-SSL-Knauf
Pipe Insulation
Ceramic A.P. Green - Inswool HP 0.90 at 1000°F No effective 4-8 2300
Fiber(7),(8) Carborundum - Fiberfrax 1.70 at 1500°F compressive
Thermal Ceramics - Kaowool 2.30 at 1800°F strength
Thermal Ceramics - Cerablanket
Soluble Carborundum - Insulfrax 1800 0.85 at 1000°F No effective 8 1800
Amorphous (preferred) 1.35 at 1500°F compressive
Wool Thermal Ceramics - SF607 1.70 at 1800°F strength 6
Calcium American Thermal Products - 0.60 at 175°F 83 min 40-42 800
Carbonate(9) Gilsulate 500 0.65 at 300°F
Fig. 100-1 Typical Material Properties for Frequently Used Insulation Materials (2 of 2)
Tank Insulation
Material
K Factor Maximum
Generic Commercial (Btu-In/ Compressive Density Usage
Type Brands hr-ft2-°F) Strength (psi) (lb/ft3) Temp. (°F)
Fiberglass(10) Owens/Corning - Insul-Quick 0.25 at 100°F 0.5 @ 10% 3 450
(Block) Schuller - Precipitator Spin Glass 0.30 at 200°F deformation
Certaineed - 850 Board 0.35 at 300°F
0.48 at 400°F
Mineral(10) Partek - Industrial Board 1240 0.30 at 200°F 1.3 @ 10% 8 1200
Wool 0.36 at 300°F deformation
(Block) 0.45 at 400°F
0.50 at 500°F
0.59 at 600°F
0.68 at 700°F
Polyurethane(11) Celotex - Thermax 0.15 at 75°F 25 2 300
(FoamBoard) or Polymer Building Systems - (Isocyanu-
Modified Poly- PBS/800 rate cured)
urethane RMAX-TSX 2000
Dow-Trymer
Cellular Glass Pittsburgh Corning - Foamglas Properties
are the same
as shown
for piping
insulation
(1) High compressive strength—good for resistance to physical abuse. Does not burn. Absorbs moisture, which can raise the K factor.
(2) Manufactured at the Brunswick, GA plant only.
(3) Independent laboratory testing results from State of California Department of Consumer Affairs, Bureau of Home Furnishings and
Thermal Insulation.
(4) Not strong—not good for physical abuse. Uses a binder which burns out, making it more friable. Better K factor than calcium silicate.
(5) Use this material for insulating stainless steel.
(6) Will crack near 500°F due to differences in thermal expansion between ID and OD if installed in a single layer. A system is available for
use to 900°F (Pittsburgh-Corning Stratafab).
(7) 6 lb/ft3 density
(8) Very high temperature usage. Often used as refractory material.
(9) Not to be confused with Gilsonite, which is no longer available.
(10) Other densities available. K factor and compressive strength varies with density. Consult manufacturer for more information.
(11) Should be double-laminated with aluminum foil.
Bids for the Richmond Lube Oil Project indicated a considerable cost advantage for
mineral wool compared to calcium silicate piping insulation. The mineral wool
insulation system used in high traffic areas was high density 12-pound mineral wool
with 0.020-inch or 0.024-inch weather jacket.
Fiberglass. Fiberglass is widely used as industrial insulation, particularly for build-
ings; however, it is easily damaged, for the same reasons as for mineral wool, and
has a Chevron-imposed temperature limit of 450°F due to binder burnout.
Note that preinsulated copper tubing with fiberglass insulation and a PVC jacket has
been used for steam tracing systems on several large projects recently with signifi-
cant cost savings over conventional insulation. This product, called Dekeron from
Eaton Control Systems, has a 400°F maximum temperature limit.
Refractory Ceramic Fiber (RCF). For very high temperature above 1100°F and up
to 2300°F, RCF insulation is used. Very few refinery services except furnaces
require insulation in this temperature range.
Polyurethane. We no longer recommend the use of spray or poured-in-place poly-
urethane foam insulation (PUF) for the reasons discussed in Section 130.
PUF has been used to insulate cross-country and submarine pipelines [6, 7]. Straight
sections of pipe are shop-insulated by securing the pipe in a cylindrical mold and
pouring in the PUF. Bends are hand-insulated with calcium silicate and hand-poured
PUF. Drawbacks include difficult application and the tendency of the foam to creep
at high temperatures and under the weight of the pipe.
Polyisocyanurate Rigid Foam. Dow manufactures a polyisocyanurate rigid foam
(Trymer) which is not laminated and can be formed to fit pipes, tanks, etc. This
polyisocyanurate is often used for cold insulation and can also be used up to 300°F
(same as isocyanurate-cured urethanes). More information on this material is given
in Section 131.
Cellular Glass Block (Foamglas). Foamglas is a silica-based, closed-cell glass
manufactured by Pittsburgh Corning. Its use has been restricted primarily to cold
insulation because of high cost. Foamglas has a thermal efficiency similar to
calcium silicate and can be used to 350°F without concern for thermal cracks
(Stratafab system). Pittsburgh Corning markets a special system for up to 900°F.
However, we have no experience with it to date (1988).
The blocks are impermeable to moisture. However, moisture penetration at block
edges and nozzles can occur. Because Foamglas is rigid and impermeable to water,
care must be taken to keep water away from the hot metal surface. If the water
vaporizes, the expanding steam can damage the insulation. The insulation system on
a warm tank failed when water leaked in and was vaporized at the surface of the
tank, resulting in disintegration of the brittle foamglas, destroying the insulation.
Foamglas has also been used for insulating buried lines because of its low K factor
and high compressive strength. Again, moisture penetration at seams and joints is a
concern in preventing corrosion.
Calcium Carbonate. Gilsulate 500 (American Thermal Products, Inc.) is used as
insulation for underground pipes and tanks up to roughly 800°F. Gilsulate 500 is a
granular blend of inert inorganic particles composed primarily of calcium carbonate.
Gilsulate 500 is hydrophobic and has good load bearing capabilities. It competes
with Foamglas for underground applications because it is easier and cheaper to
install, less likely to allow water penetration, and eliminates several design prob-
lems associated with Foamglas such as thrust blocks and double layer joint overlap.
Insulating Cement. Small valves, turbines, pumps, and other equipment with
complex shapes are normally insulated with thermal insulating cement sealed with a
coating of mastic.
Specific Applications
Equipment Within 25 Feet of Furnaces and Reactor Structures. Use fire-
resistant weather jackets of stainless steel, galvanized steel, or coated steel. In some
cases, piping in these areas will also have steel weather jackets for fire resistance.
Equipment Insulated for Relief Load Reduction and Critical Vessels Such as
Reactors, Other Expensive Vessels, or Vessels With Large Liquid Volumes. Use
fire-resistant steel weather jacket.
Surfaces With Complex Shapes. These usually have a mastic weathercoat if a fire-
resistant jacket is not required. Mastic weathercoat should only be applied over
calcium silicate or perlite insulation, or over insulating cement.
High-maintenance Areas. Heavier gage weatherjacketing, in addition to rigid insu-
lation, should be used in areas that may get walked on during either shutdowns or
normal operations.
Offshore Applications. Use Type 304 stainless steel weatherjacketing. Coated
aluminum can be used in areas not subject to mechanical damage. Coated aluminum
is an attractive choice because it is only half the cost of stainless. One major draw-
back is that the coating may be damaged, and bare aluminum does corrode in
marine environments.
Steel weatherjacketing coated with a baked vinyl organosol is also available. This
product (one trade name is “Steel Jack”) costs about 40% more than aluminum
weatherjacketing.
Stainless steel (Type 304) is used for weatherjacketing in corrosive environments
too severe for bare aluminum or coated steel. This is the case offshore where we
recommend stainless steel weatherjacketing on the basis of favorable experience at
locations such as Ninian.
• PUF can cause corrosion. PUF will hold moisture because it is not 100% closed
cell. The water reacts with constituents in the foam and forms acids. Even with
epoxy primer, the presence of acids means a constant threat of
corrosion.
A preformed, double-laminated (with aluminum foil) polyurethane board insulation
is available. This product is satisfactory for many plant applications such as tanks.
Polyisocyanurate Rigid Foam (Trymer), manufactured by Dow Chemical
Company, can be formed to fit pipes, tanks, spheres, etc. The Company has experi-
enced cost savings with this system instead of the fiberglass semi-rigid board
because the Trymer sheets come in bigger sizes (4 by 8 feet as opposed to 2 by
4 feet for the fiberglass semi-rigid sheets). The benefits of the larger, stiffer sheets
include 1) shorter erection time, 2) less manpower required, and 3) less banding
needed. This material is good for roof installations because it has high compressive
strength and no edges to be caught and blown off by high winds. The polyisocyanu-
rate also has a lower K factor per inch of thickness than do other insulation
materials.
Bakersfield has written a good specification [1] for the use of this product on tanks
cooler than 225°F.
at almost all locations except coastal regions, where coated aluminum or coated
steel must be used.
Aluminum sheets should have a moisture barrier backing and must not be used over
calcium silicate unless the sheets are backed.
Corrugated sheets with 2½-inch corrugations are recommended for shells. The
corrugations are vertical and accommodate expansion and contractions. They should
be seamed along the vertical edges with sheet metal screws to prevent
slipping.
Roofs. An effective roof weathercoating system is very important. Wet insulation
can cause very high external corrosion rates on tank roofs. It can also cause “cool
spots” on the tank roof which cause high internal corrosion rates.
In the past an elastomeric coating, such as tar paper, was placed over Roof Deck
insulation on fixed roofs and covered with a layer of small rocks to provide slip
resistance, strength, and UV protection. This system has been prone to cracking and
separation around the circumference and protrusions, allowing entry of water. Often,
failure can occur in one to two years for the tar and gravel built-up systems. We no
longer recommend tar paper.
Two effective insulation and weatherjacketing systems for hot storage tank roofs are
recommended: the Thermacon Roof Insulation System and the Owens Corning
Roof-Deck/Belzona Membrane System. Although these specialized systems cost
more than the conventional built-up systems, they provide truly effective weather
barriers [14].
Thermacon's Roof Insulation System uses a weather-tight metal roofing system
which can move independently of the tank. This reduces the potential of damage
due to high winds or temperature variations. The roof system is available as a radial
design which may be installed on any shape roof over many suitable insulation
materials including mineral wool, fiberglass, calcium silicate or perlite.
The design Thermacon uses is proprietary and details are not included in
Company specification of drawings for hot storage tank insulation. Specification
IRM-MS-3865 lists the Thermacon system as acceptable for Company use. Please
contact Materials Engineering, CRTC, for more information on this system.
The Owens Corning Roof Deck/Belzona Membrane system has been used on eight
tanks in Richmond Refinery. A hot sulfur tank (T-3141) has had this system in
service the longest, for about two years as of Spring, 1990. The system exhibits no
significant visual deterioration and appears to be adhering well to penetrations
through the insulation and weather barrier. This system has replaced the tar and
gravel system in Specification IRM-MS-3865 and Drawing GD-N99995, Detail 7.
The Belzona Membrane is an acrylic ester copolymer with pigments for UV resis-
tance. It is reinforced with a fabric and has a total thickness of 16 mils. It is applied
over the Roof-Deck board insulation. This insulation has a “prefelted primed” side
that will accept the membrane without wicking. Several high density board (block)
insulations are acceptable beneath the Roof-Deck insulation, which is usually one
inch thick.
The main disadvantage to both systems is a tendency not always to seal effectively
around penetrations. Care must be taken and enforced during installation to use
proper design, procedures and materials for sealing around penetrations. These are
outlined in IRM-MS-3865. Overall Company experience with both systems has
been favorable.
Another tank roof insulation jacket system, called Tufseam, has been used success-
fully at El Segundo Refinery.
151 Background
It may be economically feasible to insulate hot flanges, valves, vessel manways, and
heat exchanger covers. Removable insulation covers are a safe way to insulate this
equipment, though they are expensive. The major advantage of covers is that they
are reusable from one shutdown to the next. In fact, crafts such as pipe fitters and
instrument mechanics can often re-install them. Insulation crafts may or may not be
required, depending upon the plant situation.
The Company Specification IRM-MS-4197 was developed as a result of the many
cover improvements made during construction of the Pascagoula Residuum Conver-
sion Project (PRCP) and the Richmond Lube Oil Project (RLOP). These two major
projects purchased over 20,000 covers at an expenditure of several million dollars.
Insulation cover materials and design vary substantially. This section presents
specific information on how removable covers should be made. The following
contractors were used to supply flexible insulation covers for RLOP and PRCP:
Insulation Technology, Inc.
5645 West Howard Street
Niles, Illinois 60648
(312) 647-1500
Energy Control Systems
Route 4
P.O. Box 380B
Gonzalez, Louisiana 70737
(514) 644-8435
• Use insulation covers designed for safe leakage. Refer to the Specification
IRM-MS-4197 for the design and manufacture of leak-safe, removable insula-
tion covers.
• Apply insulation when the flange is cold (after hydrotest and before startup) to
minimize startup stresses. Insulation may be temporarily removed after startup
to allow inspection for leaks.
A practical problem in the plants is the mixing of B7 and B16 studs, especially
during plant shutdowns when a great deal of bolting and unbolting is being done. If
a location cannot guarantee that these studs will be totally segregated, then another
option is to leave flanges over 750°F uninsulated and use a weathercover over them
to protect against wind and rain.
Bolt-up. Bolt-up procedures should follow Bolting-Up Practice found in Section
600 of the Piping Manual.
Spray Shields. Insulation covers for hydrocarbon service over 400°F should have a
spray shield installed between the cover and the flange being insulated. A spray
shield is a preformed sheet metal cover wrapped around the flange. The spray shield
should have a gap or a funnel at the bottom to provide a channel for safe leakage
through the insulation.
The spray shield and leakage port keep the insulation cover from becoming soaked
with hydrocarbon in the event of a leak. Insulation covers soaked with hydrocarbon
are poor insulators and can cause fires by auto-ignition.
Removal of Covers
Caution should be used when removing the cover from a hot flange to avoid the
possibility of being sprayed with hot material.
161 K Factor
The K factor relates to the efficiency of the insulating material. A low K value is a
better insulator, and a high K value a poorer insulator. The K factor for a material
should be measured by either ASTM C-177 (Guarded Hot Plate Test) or ASTM C-335
(Guarded Hot Pipe Test) and certified by an independent testing laboratory. K values do
not vary much within a generic class. If test results showed otherwise, we would
suspect that the test, not the insulation, is faulty because these tests are manipulated
easily.
Over the lifetime of an insulation, mechanical or thermal abuse will lower the effi-
ciency of the insulation, though the K factor will remain close to the original value.
Expect a 10% variance during normal use.
164 Flammability
Calcium silicate, perlite, and Foamglas have no organic components and will not
burn, but binders used in mineral wool and fiberglass will burn and could cause a
fire hazard. Hence, mineral wool and fiberglass insulation must meet ASTM E-84,
“Surface Burning Characteristics of Building Materials,” with a flame spread index
(FSI) of 25 or less, a fuel contribution of 50 or less, and a smoke development of 50
or less. Calcium silicate should have a rating of 0/0/0.
Fire-resistant urethane foams which have a flame spread index of 25 or less as
tested per ASTM E-84 are sometimes specified for new construction to provide
some fire resistance. However, polyurethane foams are organic and can burn. So-
called “self-extinguishing” polyurethane foams meeting ASTM D-1692 are avail-
able but are not recommended for new construction. This is because large-scale tests
have shown that some D-1692 foams will significantly feed a fire; hence, the E-84
test criteria are recommended instead.