insulation binder.pdf

Owner

Torrent Power Generation Limited

Consultant

TCE CONSULTING ENGINEERS LIMITED MUMBAI

B 2007/02/26 I.B.KIM S.H.SEO SECOND ISSUE

A 2006/12/05 I.B.KIM S.H.SEO FIRST ISSUE Index Rev.

Datum Data

bearb. Coord.

gepruft Checked

Anderungshinweis / Details of Revision

Sub-Contractor

Sub-Contractor document No.

T05099-PIP-L020 Urspaung-Nr./Original No. Ursprung/ Original

Urspr-PKZ-Nr. Orig.-PC

Projekt/project

1100 MW SUGEN CCPP PKZ/PC

IND696 Datum Data Name

MaBstaB Scale A4

UA/DCC Type XW01

gezeich. Drawn

2006/12/05 I.B.KIM bearb, Coord.

2006/12/05 J.H.NAM Gepruft Checked

2006/12/05 S.H.SEO

Infalrskennzeichen Contents Code

UHA

Abtlg Dept. E932

Benennung/Title

Design Report for Thermal Insulation Piping

Zahl-Nr.

Reg.No. 208020

SIEMENSSIEMENSSIEMENSSIEMENS Dienstst./Det

E932

UNID

440099145 Index/Rev.

B

Version

IND696-XW01-H-208020 Ang-VR./Offer-Var. Var./Opt. Blatt-Nr./Page-No.

1/19 Erstellt mit / designed with: Intergraph

Ersatz fur Supersedes

Cop

yrig

ht (

C)

Sie

men

s 20

01

N/A

10.5.73.36 / 2007.02.25 20:47 / H112413

Copyright by DOOSAN Heavy Industries and Construction. Co.,Ltd. All Rights Reserved.

SPEC. NO. IND696-XW01-H-208020 Rev.B

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PIPING INSULATION AND LAGGING SPECIFICATION OUTLINE

1.0 General

1.1 Work Included 1.2 Application 1.3 Code and Standards

2.0 Design Condition

2.1 Design Criteria 2.2 Design Data

3.0 Design of Thermal Insulation 3.1 Insulation Materials 3.2 Metal Jacketing 3.3 Seams in Metal Jackets 3.4 Special Provisions

3.4.1 Pipe Bends and Fittings 3.4.2 Flanges and Valves 3.4.3 Piping Products Subject to Inservice Inspection

3.5 Spacers and Supports

4.0 Insulating Materials 4.1 Mineral Fiber Blankets

4.1.1 General Requirements 4.1.2 Chemical Properties of the Insulating Materials

4.2 Jacketing Materials 4.2.1 Aluminum Sheet 4.2.2 Stainless Steel 4.2.3 Bolting Materials

5.0 Mineral Fiber Insulation Thickness

6.0 Attachments Piping Insulation & cladding Detail Drawing

Drawing no. Title INS-01 Vertical Piping Jacking INS-02 Vertical Piping Insulation INS-03 Horizontal Piping Insulation INS-04 Reducer & Inservice Inspection Insulation INS-05 Tee & Elbow Insulation INS-06 Cut-out & Thermowell Insulation INS-07 Flange Insulation INS-08 Valve Insulation INS-09 Support Ring Detail INS-10 Tee & Elbow Insulation ( 2 and Smaller )

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1.0 General

1.1 Work Included

The work included in this specification consists of the insulation design for piping and accessories materials to install the insulation. This specification defines the design criteria, material requirements and installation requirements for the insulation.

1.2 Application

The insulation will be installed on the piping systems for three(3) units of HRSG. The piping systems to be insulated will be installed on outdoor.

1.3 Codes and Standards

The insulating materials shall be provided and installed in accordance with the requirements of this specification and the related following standards;

- American Society for Testing and Materials (ASTM)

2.0 Design Condition

2.1 Design Criteria

- Ambient Temperature : 30.0 C - Surface Temperature : Max. 60.0 C - Wind Velocity : still air(0 m/s) - Allowable Heat Loss : Max. 150 W/m2

2.2 Design Data

See section 5.0(Mineral Wool blankets insulation thickness) of this specification.

3.0 Design of Thermal Insulation

3.1 Insulation Materials

PIPE : Bonded mineral wool( IS 8183) shall be used DN250 and above pipe, for DN200 and below Pipe shall be used calcium silicate pipe cover( IS 8154).

Valves & Equipments : - Bonded mineral wools board, quilted on one side with galvanized Wire mesh, in thickness from 30mm to 75mm, shall be used.

- Calcium silicate board

Insulation thickness shall be as follows ; - Up to 75mm : single-ply - 75mm to 150mm : two-ply

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- Over 150mm : three-ply or more Abutting joints in multi-layer materials shall be staggered on all sides. All circular and longitudinal seams of the insulation is arranged on the underside of the tubes. All circular and longitudinal joints shall be stitched with galvanized binding wire, minimum diameter of 1.00mm. A minimum of 15 stitches per meter run of insulation shall be provided.

3.2 Metal Jacketing

The blankets shall be enclosed in metal jacketing. Aluminium sheet shall be used outdoor. The jacket thickness shall be selected according to the outside diameter of the insulated plant item according to the following table;

3.3 Seams in Metal Jackets

The longitudinal seams of overlapping metal jacket segments shall be joined with stainless steel self-tapping screws(at least 5 screws per meter). Circumferential seams shall be designed with flanges and an overlap of at least 50mm or at least 30 mm in case of parts with DN 80 and smaller, to allow the insulation to accommodate thermal expansions and piping displacements without damage or deterioration.

Longitudinal joints in metal courses shall be arranged so as to prevent ingress of moisture into the insulation.

Metal jackets for outdoor plant items shall be splashproof. For this purpose, circumferential seams shall be sealed with a 20mm wide, elastic, heat-resistant band of sealing material. (Heat and cool proof -60C and +180C silicone rubber or Terostat strip). The aerostat strip shall be trimmed neatly after installation. Adequate provisions shall be made to allow condensation to drain from piping shutdown periods. Overlapping direction of metal jacket segments shall consider the line slope. Inclusion of sliding joints shall safeguard the thermal insulation in the event of pipe expansions.

3.4 Special Provisions

3.4.1 Pipe Bends and Fittings

Metal jacketing for pipe bends and fittings shall be constructed from segments, joined by means of flanges and mating flanges and held together with screws. Insulating blankets shall also be used for pipe bends. Extreme care shall be taken in cutting the blankets to size in order to achieve a perfect fit with tight joints.

Thermal insulation of loose wool fiber shall be acceptable for small pipe bends only,

Outside Diameter of Thermal Insulation

Aluminium Jacket Thickness

< 150 mm 0.711 mm 150 mm to 450 mm 0.914 mm

450mm 1.219 mm

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but a packing density of approx, 100kg/m3 shall be guaranteed.

3.4.2 Flanges and Valves

Flanges and valves shall be insulated with removable caps. These caps shall be constructed in two or more parts for valves up to DN125 and for flanges so that components are completely exposed to view once the caps have been removed.

Bodies of welding-end valves larger than DN125 shall be provided with permanent insulation and only the upper parts of these valves shall be fitted with removable caps constructed in two or more parts to enable the yoke assemblies and internals of such valves to be dismantled without difficulty (i.e. the yoke assembly is not insulated).

Valve bodies and flanges of flanged valves of all nominal diameters shall be insulated with removable caps.

Multi-part caps shall be manufactured to manageable dimensions and weights and equipped with self-locking toggle catches riveted directly onto the cap parts.

The blanket inlay shall be stitched carefully and fastened with lacing hooks riveted to the metal jacket. The wire mesh shall face the piping.

If he connected piping has insulation of 60mm thick or more, the insulating pads in the caps may be up to 20mm thinner, but not less than 50mm thick. If piping insulation is less than 60mm thick, the insulation pads in the caps shall be the same thickness as the insulation on the piping.

The caps shall be pulled over the abutting thermal insulation for a sufficient distance (not less than the thickness of the insulating layer).

All openings shall be provided with rosettes.

3.4.3 Piping Products Subject to Inservice Inspection

In superheated HP-steam lines (LBA10, DN 250) and which are subject to recurrent tests ( for example where appropriate : hot and cold reheat LBB, LBC, HP Bypass LBF, extraction steam LBQ) the position of the welding seams shall be marked on the sheet metal cover of the insulation and arrangement shall be made to facilitate simple examination and inspection of the welded seams. For this purpose the standard insulation is interrupted for approx. 500mm on both sides of welding seam and shall be made in form of easily detachable insulation.

3.5 Spacers and Supports

Spacer shall be required for all pipes of DN 200 and more or on all parts with insulation thicknesses of 60mm or more. The spacers shall be fastened at maximum intervals of 950mm in horizontal to secure the insulation evenly all round and ensure a close fit with the spherical shape of the metal jacket.

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Upright vessel and vertical piping shall be provided with cam supported clamping rings at intervals of max. 3.5m to prevent the insulation from bunching. The insulation may also be stayed on the pipe supports, in which case the metal jackets shall be supported on S-hooks and furnished with sufficient spider joints at appropriate intervals.

4.0 Insulating Materials

4.1 Mineral Fiber Blankets

4.1.1 General requirements

Plant items and vessels shall be insulated with long-fiber mineral or rock blankets, quilted on 0.5mm thick galvanized wire mesh.

The insulating material shall be completely free from impurities and metallic particles and shall not react in any way with the plant item to be insulated. No asbestos is allowed.

It shall demonstrate the following properties ; Chemically inert, no trace of sulphur, free from water soluble alkaline constituents, rot-proof, resistant to hot water and steam, even if alkaline, and absolutely non- flammable .

A packing density of : for rock wool blankets

- Temp < 400:::: 100kg/m3 - Temp400:::: 150kg/m3

for preformed section(Calcium Silicate) 250 kg/m3

shall be guaranteed for the finished insulation without jacketing.

Assurance shall be given that the coefficients of thermal conductivity given below for the insulating material are not exceeded at the part in question (tolerance range of +/- 5%) in accordance with VDI 2055.

Coefficients of thermal conductivity(Insulation Material Including Spacers) Mean temperature tm (C) 50 100 150 200 250 300 Thermal conductivity (W/mk) 0.045 0.053 0.064 0.076 0.090 0.107

4.1.2 Chemical Properties of the Insulating Materials

The insulating fiber shall satisfy the following conditions ; There shall be no traces of sulphur or sulphides. The insulating fiber shall be insoluble in acids and caustic solutions(with the exception of hydrofluoric acid).

Water-soluble constituents shall not exceed the following concentrations ; - Chlorides 0.0006 % (6ppm) - Sulphates 0.02 % - Sodium 0.25 %

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- Potassium 0.02 %

The analysis shall be performed by boiling 1g of insulating fiber in 100ml of water.

Data for the aqueous extract ; - PH value at 20C lower than 10.5, higher than 8.5 - Conductivity at 20C lower than 250 u S/cm.

4.2 Jacketing Materials

4.2.1 Aluminum Sheet

Aluminum sheet with vapor barrier( ASTM B 209 A3003-H14)

4.2.2 Stainless Steel

Stainless steel (ASTM Grade 304)

4.2.3 Bolting Materials

Aluminum sheets shall be held together by means of stainless steel self-tapping Screws(dimension 4.2 x 13mm) and inner/outer retaining rings on the spacers shall be secured by means of galvanized bolts of size M8 or larger.

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5.0 Insulation Thickness

Design Criteria Ambient Air Temperature : 30C

Surface Temperature : 60C (140F) Wind Velocity : still air (0.0 m/s)

5.1 Calcium Silicate Pipe Cover Insulation Thickness - Calcium Silicate Pipe Cover Insulation Thickness(mm) - Density : 240 kg/

Temp(Oc)

NPS(inch) 61 |

99

100 |

149

150 |

199

200 |

249

250 |

299

300 |

349

350 |

399

400 |

449

450 |

499

500 |

549

550 |

575 DN15 (1/2) 30 30 40 50 65 75 90 90 100 115 130 DN20 (3/4) 30 40 40 50 65 75 90 100 115 130 130 DN25 (1) 30 40 40 50 65 90 90 100 115 130 140

DN40 (1-1/2) 30 40 50 65 75 90 100 115 130 140 150 DN50 (2) 30 40 50 65 75 90 100 115 130 150 175

DN65 (2.5) 30 40 50 65 75 90 100 130 140 150 175 DN80 (3) 30 40 50 65 90 100 115 130 140 175 180

DN100 (4) 40 50 50 75 90 100 115 140 150 180 190

DN150 (6) 40 50 65 75 90 115 130 150 175 190 200

DN200 (8) 40 50 65 75 100 115 140 150 180 200 215

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5.2 Bonded Mineral Wool Insulation Thickness - Mineral Fiber Blanket Insulation Thickness(mm) - Density : 150 kg/(Temp.400), 100 kg/(Temp.

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