Lloyd
Lloyd
Lloyd
SUGAR SECTOR
Services Rendered
Thermal Insulation for Industrial / Commercial Applications Refractory & Ceramic Fibre Lining Acoustic Insulation / Enclosures Pre-Engineered Buildings / Structures Turnkey Cold Storage Construction with PUF Sandwich Panels Specialised Cold Storages Construction (CA / Ripening)
MATERIAL DETAILS : Rockloyd Resin Bonded Rockwool Mattresses For operating temp. up to 100-120 Kg/M3 conforming to IS :8183 1993, 400 C BS : 3958 Part-3, ASTM : C 592-80 Rockloyd Resin Bonded Rockwool Mattresses 150 Temperature above 400 C Kg/M3, conforming to IS :8183 1993, BS : 3958 Part-3, ASTM : C 592-80 Rockloyd Rockwool Preformed Pipe Sections 144 Kg/M3 conforming to IS:9842, BS : 3958 Part-4, ASTM:C 547-95, up to 350 mm NB pipe dia Up to 650 C
SUSTAINABILITY
Energy Conservation Energy conservation is defined largely as cost-effective ways to reduce energy consumption through existing and improved technologies as well as through sound energy use practices. Energy efficiency technologies and practices can therefore play a significant role in reducing the threat of global climate change.
The judicious and effective use of energy to maximize profits (minimize costs) and enhance competitive positions
SUSTAINABILITY
One of the easiest and most effective energy efficient technologies available today is Thermal Insulation. Overall benefits from insulation are numerous, including thermal performance, personal comfort, sound control, condensation control, fire protection, provided to retard flow of heat or cold from environment to inside of building and vice-versa and personnel protection.
SUSTAINABILITY
SUSTAINABILITY Insulation is a product or service, which stands up very well on its own offering clear and straightforward energy efficiency and economic advantages and can go much further!
EXSISTING ENERGY CONSUMPTION
I N S U L A T I O N
JOB CREATION
REDUCED ILLNESS
$$ INVESTMENT
$$ SAVINGS
CO2 REDUCTION
ECONOMIC IMPACT
THERMAL INSULATIONS
THERMAL INSULATION DELIVERS THE FOLLOWING BENEFITS Reduce heat loss or heat gain to achieve energy conservation. Offer better process control by maintaining process temperature. Protect the environment through the reduction of Co2, NOx, & Greenhouse gases. Increase operating efficiency of heating / ventilation / cooling, steam, process & Power system. Control system temp. for personnel & equipment protection. Prevent corrosion by keeping the exposed surface of a refrigerated system above dew point. Provides fire protection to equipment. Absorbs vibration.
5 10 15 20
38 76 125 165
Ambient considered : 38 C Shape of Surface : Spherical Properly designed insulation can restrict the above values down to 10 - 15 kcal / M
SUSTAINABILITY
Surface Heat Transfer or film Coefficient
Ambient Temp (Ta)
Surface1 Emissivity = e
Wind Speed =V
Insulation
Heat
IS BS : ASTM :
8183 1993
TECHNICAL SPECIFICATIONS
1
2 3 4
Standard Densities
Application Temperatures Standard Thickness* Standard Size
* Other thickness from 20 to 100mm insteps of 5mm can also be made available.
BS
3958 Part-4
C 547-95
ASTM :
TECHNICAL SPECIFICATIONS
1 2 3 4 5 6 Standard Densities Application Temperatures Standard Thickness* Diameter Range** Standard Length Facings (if specified) 144, 150 & 160 Kg/m3 -1000C to +8000C 25, 40, 50, 65, 75mm 12.5mm to 350mm Nominal Bore 0.5, 0.75, 1.0 mtrs. Kraft Paper, Scrim Cloth, Canvas or Aluminium Foil
*Other thickness from 20 to 100mm insteps of 5mm can also be made available. ** Outer diameter of pipe to be specified.
ROCKLOYD SLAB
SPECIFICATION CONFORMANCE
IS : 8183 1993
BS
3958 Part-5
C 612
ASTM :
IMO for A-15, A-30 & A-60 Class Fire Barrier Insulation.**
*The only product to carry this certification in India.
ROCKLOYD SLAB
TECHNICAL SPECIFICATIONS
1 Standard Densities 48, 64, 96,144 Kg/m3
2 3
4
*Can be made available with increments in thickness of 5mm against special orders.
23
24
25
26
SUPERCERA ROPE
TWISTED / BRAIDED ROPE, CLOTH Insulation material for small dia / embedded pipes, DG Set exhaust pipeline, Packing material between expansion and contraction joints, Furnace curtains, Replacement of asbestos cloth and tape, Pipe hanger insulation, Cable & wire insulation, Fuel line insulation, Impulse Line Insulation.
SUPERCERA ROPE Supercera Twisted Rope is a 3 ply rope manufactured from supercera long fibres having 15-20% organic binder. Supercera Braided Rope in addition is braided with SS 304/310 wire netting. Size 6 to 40mm dia, 10/25M coils Density 300 kg/m3
SUPERCERA CLOTH / TAPE Supercera made from 15-20% organic coated supercera long fibres :
Cloth size : 3 x 300 / 1000mm x 10M Tape size : 3 x 50 / 25mm x 10M
SUPERCERA PADS Supercera blankets of density 128 kg/m3 and thickness 50 & 75mm encased in Supercera Cloth and stitched with SS Wire to form pads. Special hooks are stitched to the surface and corners for the purpose of positioning & tieing. USES : Steam Turbine Insulation, Fire Walls for Isolation AVAILABILITY : Width : 610mm; Length Max. : 7 mtr.
SUSTAINABILITY
Thickness Calculation based on ASTM C 680
Upgraded & latest method to calculate thickness of insulation Calculates effect of windage & emissivity for each pipeline Slightly more thickness Reduced heat loss
SUSTAINABILITY
ILLUSTRATION OT AT ST Cladding Wind Velocity Pipe OD Insulation Calculation Procedure : : : : : : : : 450 deg.C 40 deg.C 60 deg.C Aluminium ( 0.2 Emissivity) 0, 0.5, 1 8,10, 12 ROCKWOOL MATTRESSES 150 KG/M3 DENSITY ASTMC-680 & IS-14164
SUSTAINABILITY
WINDAGE = 0
COMPARATIVE OF THICKNESS
As per IS-14164 Dia (mm) 8 10 Thickness (mm) 175 185 Heat Loss (Kcal/m2hr.) 105 105 As per ASTMC-680 Thickness (mm) 210 220 Heat Loss (Kcal/m2hr.) 85 85
12
190
105
230
85
SUSTAINABILITY
WINDAGE = 0.5
COMPARATIVE OF THICKNESS `
Dia (mm)
As per IS-14164
Thickness (mm) Heat Loss (Kcal/m2hr.)
As per ASTMC-680
Thickness Heat Loss (mm) (Kcal/m2hr.)
8
10 12
135
140 145
143
143 143
165
175 180
119
119 119
SUSTAINABILITY
WINDAGE = 1
COMPARATIVE OF THICKNESS As per IS-14164 Dia (mm) 8 10 Thickness (mm) 115 120 Heat Loss (Kcal/m2hr.) 174 174 As per ASTMC-680 Thickness Heat Loss (mm) (Kcal/m2hr.) 140 150 143 143
12
125
174
155
143
SUSTAINABILITY
Windage
Thickness reduces with wind impact.
Emissivity
Thickness reduces with dull surface.
Thermal Insulation
From this, we can see that insulation is a major tool in improving energy availability
Reduces fuel consumption, and hence overall cost of operation Reduces capacity requirements for heating/cooling systems (e.g., boilers/ refrigeration units, etc)
Ceramic Fibre has a lower K value at elevated temps. as compared to Rockwool, Calcium Silicate & Perlite. Ceramic Fibre will reduce heat losses maximum An initial layer will bring down Interface temp. Subsequent layers with Rockwool Overall reduction in heat loss & ST
450 deg.C 40 deg.C 60 deg.C Aluminium 0 10, 12, 14 5 mtr. RW, Cal. Sil., CF+RW, Perlite
RW
185
95
Cal. Sil.
200
95
60
CF+RW
160
56
53
Perlite
215
96
60
RW
190
96
60
Cal. Sil.
205
96
60
CF+RW
165
62
54
Perlite
220
96
60
RW
195
97
60
Cal. Sil.
210
97
60
CF+RW
170
65
54
Perlite
225
96
60
RW
240
94
Cal. Sil.
250
95
55
CF+RW
235
62
49
Perlite
225
96
60
RW
275
95
Cal. Sil.
290
96
55
CF+RW Perlite
250 295
61 96
49 60
Rockwool is Techno-Economic and available as Water Repellent Grade. Calcium Silicate is expensive and hygroscopic. Ceramic Fibre is Soft Refractory Fibre and thermally most stable. Expanded Perlite is Water Repellent, higher K value & costly.
Supercera Pads
Supercera blankets of density 128 kg/m3 and thickness 50 & 75mm encased in Supercera Cloth and stitched with SS Wire to form pads. Special hooks are stitched to the surface and corners for the purpose of positioning & tieing. USES : Steam Turbine Insulation, Fire Walls for Isolation, Valves & Flange Insulation
1.
2.
3. 4. 5.
Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease.
Providing and fixing MS flat ring of size 25x3mm over pipes having diameter more than 150mm NB at every 1150mm distance having L shaped lugs with a packing of ceramic paper duly riveted and tightening it over the surface with nut and bolt. Providing and fixing the recommended insulation thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G.
2.
3.
5.
6.
7.
Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface. Providing and applying 4mm thickness APP modified membrane helically over the insulation with AL. paint coating. Providing and applying Aluminum sheet as cladding over the MS flat ring already provided at 1150 distance duly screwed with self tapping screw at 150mm distance at the sheet joints making an overlap of minimum 30mm. Sealing all the joints with mastic MAS-94. Providing and applying 22G AL band at every 450mm c/c over the cladding to secure it firmly to its place.
1.
Cleaning the surface thoroughly to ensure that the surface is free of all dust, rust and grease. Providing and fixing MS flat ring of size 25x3mm, over pipe having diameter more than 100mm, at every 1150 mm distance having L shaped lugs with a packing of ceramic paper, duly riveted and tightening it over the surface with nut and bolt. Providing and fixing the recommended insulation thickness of Rockloyd Resin Bonded Rockwool mattress of suitable density stitched with one side GI wire netting of size 20mm X 24G .
2.
3.
Butting the joints and stitching the mattress properly with GI wire of 20G to secure it firmly to the surface Providing and applying 25mm thick cement sand plaster over the insulation material .
5.
6.
Providing and applying bitumen primer over the cement sand plaster.
Providing and applying 4mm thickness APP modified membrane helically over the insulation with AL. paint coating.
7.
8.
9.
INSULATION
insulation material used for Chimney Insulation is Rockloyd Resin Bonded Rockwool Slab 100 kg/m3 in thickness of 50mm having K-value of 0.052 W/mK at 100 deg.C mean temperature conforming to IS : 81831993. Following ancilliary materials are also used for Chimney Insulation :Pins
& Studs of 10G in 75mm length. Speed washers 63mm dia or square.
Metal GI GI
INSULATION OF FLANGES
Sprayed Lloydwool fibre : Non corrosive, non combustible, non toxic & asbestos free fibres.
Fibre Dia : 4-5 mirocns
Sulphur Content : Less than 0.6% Max. Service Temp. : 750 C Density : 200 250 kg/m3 Thickness : 260-310 mm K-Value : 0.039 Kcal/m. hr.0C at 50 C (Mean Temp.)
SUSTAINABILITY
Thermal Insulation Survey
Thermal
insulation survey is a service oriented towards bringing existing shortcomings and unrealised opportunities of saving energy through extensive field data collection and possible up gradation of insulation materials for achieving higher plant efficiency.
SUSTAINABILITY
Annual heat loss in terms of money are then worked out. A new upgraded insulation system is then designed An economic analysis is then carried out to study the viability of the proposed system. The investment on proposed system and simple payback are then worked out.
SUSTAINABILITY
Cost of Fuel
SUSTAINABILITY
SUSTAINABILITY
The
data collected during plant survey are then analysed systematically and calculations are performed on present value to arrive at the quantity of energy and financial losses.
SUSTAINABILITY
SUSTAINABILITY
: Economic Thickness
H+I I H
MC Insulation Thickness
SUSTAINABILITY
SELECTION OF INSULATION MATERIAL:
THE MATERIALS USED FOR INSULATION SHALL CONFORM TO THE RELEVANT INDIAN STANDARDS WHEREEVER THEY EXSIST. INSULATION MATERIAL USED SHOULD BE SUITABLE FOR USE AT THE OPERATING TEMPERATURE AS STATED BY THE PURCHASER. HAND MADE MATERIALS FROM LOOSE WOOL ARE NOT PERMITTED DUE TO POOR CONSISTENCY. ALL INSULATION MATERIAL SHALL HAVE A PROVEN SERVICE RECORD OF SATISFACTORY PERFORMANCE UNDER INDIAN CONDITIONS IN SIMILAR PROCESS PLANT
SUSTAINABILITY
OTHER IMPORTANT ASPECTS Water repellents Corrosion resistant
we recommended to insulate the un-insulate valve with 150 mm cf pad insulation of 128 kg/m3 density. application procedure was also recommended to enhance the life of insulation After re-insulation the following were the findings :1. 2. 3. 4. 5. 6. 7. 8. 9. Average Ambient Temp. Average Surface Temp. Total area insulated Designed Heat Loss Cost of Energy Total Savings Insulation Thickness Total cost of insulation Average pay back period 40 C 60 C 1 m2 98 Kcal/m2 hr. Rs.500 /million Kcal Rs. 31064 /year 150 mm CF Pad 128 kg/m3 density. Approx. Rs. 20,000 /8 Months
So proper insulation with a little bit investment accrues lot of savings with a defined shorter pay back period.
50mm insulation compared with an un-insulated pipe = 255 80 (Consider 1 m length ) = 175 Kcal/hr. No of operating hr. in year Total Heat loss Consider Boiler Efficiency Cost of fuel (Coal) Calorific of Coal Yearly fuel saving Yearly fuel saving = 8760 Hr. = 8760 x 175 = 1533000 Kcal/hr. = 80 % = Rs. 3500 / Ton = 3200 Kcal / Kg = 1533000 / ( 3200 x 0.80 ) = 598 Kg/ Year
1. 2. 3. 4. 5. 6. 7. 8. 9.
Average Ambient Temp. Average Surface Temp. Total area insulated Designed Heat Loss Cost of Energy Total Savings Insulation Thickness Total cost of insulation Average pay back period
40 C 60 C 400 m2 98 Kcal/m2 hr. Rs.500 /million Kcal Rs. 695789 /year 255 mm RW Rs. 786840/14 Months
So proper insulation with a little bit investment accrues lot of savings with a defined shorter pay back period.
We had carried out Thermal Insulation audit of pipe lines. The data recorded are as follows:
1. 2. 3. 4. 5. 6. 7. 8. 9. Average Ambient Temp. Average Surface Temp. Average Operating Temp. Total area insulated Heat Loss Total Heat Loss Cost of Heat Loss Running Hr. Average cost of Heat Loss - 37 C - 77 C - 507 C - 10 m2 - 388 Kcal/m2 hr. - 7080 Kcal/hr. - Rs. 664 /million Kcal. - 8760 / Yr. - Rs.41183 / year
IS : 14164 - 2008
For pipelines operating above 5000C combination of Ceramic Fibre & Rockwool can be used for reducing heat loss, taking advantage of lower K-value of Ceramic Fibre at higher temperature.
Increasing the supply of energy is in one way of dealing with energy shortage in our country. A second way is to improve energy efficiency by using Firesafe Fire Barrier Thermal Insulation Products
THINK INSULATION
SAVE ENERGY
PROTECT ENVIORNMENT
THANK YOU !!