Insulation Design Guide

REAFFIRMATION WITH EDITORIAL REVISION
October 2010
Process Industry Practices

Insulation
PIP INEG1000
Insulation Design Guide
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major industrial
users, contractors, or standards organizations. By harmonizing these technical requirements
into a single set of Practices, administrative, application, and engineering costs to both the
purchaser and the manufacturer should be reduced. While this Practice is expected to
incorporate the majority of requirements of most users, individual applications may
involve requirements that will be appended to and take precedence over this Practice.
Determinations concerning fitness for purpose and particular matters or application of the
Practice to particular project or engineering situations should not be made solely on
information contained in these materials. The use of trade names from time to time should
not be viewed as an expression of preference but rather recognized as normal usage in the
trade. Other brands having the same specifications are equally correct and may be
substituted for those named. All Practices or guidelines are intended to be consistent with
applicable laws and regulations including OSHA requirements. To the extent these
Practices or guidelines should conflict with OSHA or other applicable laws or regulations,
such laws or regulations must be followed. Consult an appropriate professional before
applying or acting on any material contained in or suggested by the Practice.
This Practice is subject to revision at any time.
© Process Industry Practices (PIP), Construction Industry Institute, The University of Texas
at Austin, 3925 West Braker Lane (R4500), Austin, Texas 78759. PIP member companies
and subscribers may copy this Practice for their internal use. Changes or modifications of any
kind are not permitted within any PIP Practice without the express written authorization of
PIP. Authorized Users may attach addenda or overlays to clearly indicate modifications or
exceptions to specific sections of PIP Practices. Authorized Users may provide their clients,
suppliers and contractors with copies of the Practice solely for Authorized Users’ purposes.
These purposes include but are not limited to the procurement process (e.g., as attachments to
requests for quotation/ purchase orders or requests for proposals/contracts) and preparation
and issue of design engineering deliverables for use on a specific project by Authorized
User’s client. PIP’s copyright notices must be clearly indicated and unequivocally
incorporated in documents where an Authorized User desires to provide any third party with
copies of the Practice.
PRINTING HISTORY
December 1997 Issued October 2005 Complete Revision October 2010 Reaffirmation with Editorial Revision
April 1999 Complete Revision July 2007 Editorial Revision
Not printed with State funds

REAFFIRMATION WITH EDITORIAL REVISION
October 2010
Process Industry Practices

Function Team
PIP INEG1000
Insulation Design Guide
Table of Contents
1. Introduction................................. 2 8. Insulation Thickness ................ 16
1.1 Purpose ............................................. 2 8.1 General ............................................ 16
1.2 Scope ................................................. 2 8.2 3E Plus ............................................ 17
2. References .................................. 2 9. Type Codes ............................... 18
2.1 Process Industry Practices ................ 2 9.1General ............................................ 18
2.2 Industry Codes and Standards .......... 2 9.2Hot Insulation Types ........................ 18
2.3 Other References .............................. 3 9.3Cold Insulation Types ...................... 19
9.4Insulation Types for Traced and
3. Insulation Materials .................... 3 Energy Transfer Jacketed
3.1 Categories ......................................... 3 Systems ........................................... 20
3.2 Closed-Cell Insulations ...................... 3 9.5 AC – Acoustic Control Insulation ..... 21
3.3 Fibrous Insulations ............................. 4 9.6 FP – Fire-Protection Insulation ........ 21
3.4 Granular Insulations ........................... 5
Table 1: Insulation Materials Selection Table
3.5 Jacket Materials and Accessories ..... 5
(US Customary Units) .................. 22
3.6 Vapor Barriers .................................... 7
Table 1M: Insulation Materials Selection Table
4. Insulation System Design .......... 7 (SI Units) ...................................... 28
4.1 General .............................................. 7 Data Forms
4.2 Basic Design Criteria ......................... 8
4.3 Other Design Criteria ....................... 11 INEG1000-D1 – Documentation
Requirements Sheet
5. Corrosion under Insulation ..... 13 The following data forms shall be part of this Practice
only if indicated on the purchaser’s completed
6. Insulation Material Selection ... 14 Documentation Requirements Sheet.
6.1 General ............................................ 14
INEG1000-D2 – Hot Service Insulation
6.2 ASTM Considerations ...................... 14
Design Parameters
6.3 Insulation Materials Properties
Table ................................................ 15 INEG1000-D3 – Cold Service Insulation
Design Parameters
7. Extent of Insulation .................. 15
Process Industry Practices Page 1 of 33

PIP INEG1000 REAFFIRMATION WITH EDITORIAL REVISION
Insulation Design Guide October 2010
1. Introduction
1.1 Purpose
This Practice provides guidance for the design of insulation systems.
1.2 Scope
This Practice describes the types of insulation systems that are indicated by the
type code on the Piping and Instrumentation Diagrams (P&IDs), data sheets, and
other design documents. This Practice provides guidance on insulation design
criteria, insulation materials, extent of insulation, determination of insulation
thickness, and insulation material properties.
2. References
Applicable parts of the following Practices, industry codes and standards, and references
shall be considered an integral part of this Practice. The edition in effect on the date of
contract award shall be used, except as otherwise noted. Short titles will be used herein
where appropriate.
2.1 Process Industry Practices (PIP)

– PIP CTSE1000 – Application of External Coatings
– PIP INSC2000 – Installation of Cold Service Insulation Systems
– PIP INSH1000 – Hot Service Insulation Materials and Installation
Specification
– PIP INSR1000 – Installation of Flexible, Removable/Reusable Insulation
Covers for Hot Insulation Service
2.2 Industry Codes and Standards
American Petroleum Institute (API)

– API RP521 – Guide for Pressure-Relieving and Depressuring Systems
– API RP2001 – Fire Protection in Refineries
– API PUBL 2218 – Fireproofing Practices in Petroleum and
Petrochemical Processing Plants
American Society of Testing and Materials (ASTM)
– ASTM C240 – Standard Test Methods of Testing Cellular Glass
Insulation Block
– ASTM C533 – Standard Specification for Calcium Silicate Block and Pipe
Thermal Insulation
– ASTM C547 – Standard Specification for Mineral Fiber Pipe Insulation
– ASTM C552 – Standard Specification for Cellular Glass Thermal
Insulation
Page 2 of 33 Process Industry Practices

REAFFIRMATION WITH EDITORIAL REVISION PIP INEG1000
October 2010 Insulation Design Guide
– ASTM C591 – Standard Specification for Unfaced Preformed Rigid

Cellular Polyisocyanurate Thermal Insulation
– ASTM C610 – Standard Specification for Molded Expanded Perlite Block
and Pipe Thermal Insulation
– ASTM C680 – Standard Practice for Determination of Heat Gain or Loss
and the Surfaces Temperatures of Insulated Pipe and Equipment Systems
by the Use of a Computer Program
– ASTM C800 – Standard Specification for Glass Fiber Blanket Insulation
(Aircraft Type)
– ASTM C871 – Standard Test Methods for Chemical Analysis of Thermal
Insulation Materials for Leachable Chloride, Fluoride, Silicate, and
Sodium Ions
– ASTM C1055 – Heated System Surface Conditions That Produce Contact
Burn Injuries
– ASTM C1104 – Standard Test Method for Determining the Water Vapor
Sorption of Unfaced Mineral Fiber Insulation
– ASTM E96 – Standard Test Methods for Water Vapor Transmission of
Materials
NACE RP0198-2004 – The Control of Corrosion Under Thermal Insulation
and Fireproofing – A Systems Approach, NACE International
North American Insulation Manufacturers Association (NAIMA) – 3E Plus
2.3 Other References
Federal Energy Administration Report

– Economic Thickness for Industrial Insulation/ASM Metals Handbook,
“Corrosion” Volume 13, ASM International
National Oceanic and Atmospheric Administration (NOAA), U.S.
Department of Commerce – www.noaa.gov
3. Insulation Materials
3.1 Categories
Insulation materials fall into the following three major generic categories based
on the structure of the insulation material and each has properties that give it
unique performance characteristics:
a. Closed cell
b. Fibrous
c. Granular
3.2 Closed-Cell Insulations

3.2.1 Closed-cell insulations include:

a. Cellular glass
b. Various organic materials such as rigid polymer foams,
polyisocyanurate, polyurethane, and polystyrene
c. Elastomeric foams
3.2.2 The closed-cell structure of these materials provides a natural resistant to
absorption and permeation by external water and water vapor as well as
to absorption of leaking process chemicals. Closed-cell insulations are
frequently chosen for low-temperature applications in which control of
moisture penetration is important. ASTM E96 is a test method for water
vapor permeability that can be applied to all insulation materials.
ASTM C240 is a water absorption test method that is published for
cellular glass. Some insulation manufacturers test their materials using
both of these procedures and publish the results in their product
literature. For both test methods, the lower the value, the more resistant
the material is to absorption and permeability.
3.2.3 The upper-use temperature of the rigid polymers and elastomeric foams
is limited, and the manufacturer’s recommended maximum temperature
should be followed. Cellular glass is made from inorganic material that
gives a wider, usable temperature range and applicability in elevated
temperature service in which absorption resistance is needed.
3.2.4 In applications below ambient, most of these materials should be used
with a separate vapor barrier and with a weather-proof jacket. All outer-
layer joints should be sealed using the insulation manufacturer’s
recommended material in any application in which condensation could
occur on the insulated pipe or equipment. All the closed-cell materials
can be used for condensation control and cold conservation.
3.2.5 While the rigid foams and cellular glass have some strength, damage
resistance is not necessarily provided. The elastomeric foams are
resilient and should resist light physical abuse.
3.2.6 If exposed to ultraviolet (UV) light for extended periods of time, the
properties of most of the organic materials deteriorate. If using organic
closed-cell materials in an exterior application, a UV-protective finish
should be used.
3.3 Fibrous Insulations

3.3.1 Fibrous insulations include:
a. Fiberglass
b. Mineral fiber
c. Needled E glass
d. Ceramic fiber
3.3.2 The fundamental difference between the fibrous insulations is the raw
material from which they are made. Mineral fiber is made from volcanic

rock; fiberglass and E glass are made from inorganic glass fibers; and
ceramic fibers are made from inorganic ceramics.
3.3.3 Fibrous insulation is not resistant to moisture permeation and can absorb
water or chemicals if exposed to liquid or vapor. There is no permeation
minimum included in the ASTM standards for any of the fibrous
materials. For this reason, fibrous insulation is not used alone for low-
temperature applications in which condensation can occur. If used at an
elevated temperature, the organic binder that helps to hold the insulation
together is burned away causing a reduction in strength and an increase
in the ability to absorb moisture.
3.3.4 The fibrous insulations, depending on form, are somewhat flexible and
have little compressive strength. As a result, piping should not be
supported through fibrous insulation, and higher strength materials
should be considered in damage-prone areas.
3.3.5 The fibrous insulations do not burn but do absorb flammable chemicals
that can burn. In cases in which leaking flammables are likely, the
fibrous materials should not be used.
3.4 Granular Insulations

3.4.1 Granular insulations include perlite and calcium silicate because of
composition from a starting material that is granular in form.
3.4.2 Granular insulations have much higher density and compression strength
than most fibrous and closed-cell materials. Because of the higher
strength, the insulations can be used to support piping loads and to resist
damage.
3.4.3 Calcium silicate is highly absorbent and should not be used if direct
exposure to moisture or leaking chemicals is likely. At temperatures
below 500 F (260ºC), perlite resists moisture absorption and may be
used if corrosion under insulation is a concern; however, perlite is not
typically used in low-temperature applications. At temperatures above
500 F (260ºC), the organic binder that imparts the moisture resistance is
no longer effective, and moisture absorption is possible.
3.5 Jacket Materials and Accessories

3.5.1 The jacket is a key part of an insulation system. The primary function of
the jacket is to protect the insulation material from the elements,
especially water and external mechanical abuse.
3.5.2 Aluminum Jacketing
3.5.2.1 The most commonly used jacket material in chemical and
petrochemical plant applications is aluminum. The aluminum
materials are available in several thicknesses and finishes
depending on the application. The two major aluminum finishes
are stucco-embossed and smooth. Stucco-embossed aluminum
has a rough finish that is rolled into the sheet metal during

manufacture. The benefit of this finish is that minor surface

damage is less visible. Owners prefer the appearance of the
smooth jacket rather than stucco embossed because of
appearance and ease of cleaning.
3.5.2.2 Increasing the thickness and adding corrugations improves the
damage resistance of both materials. Corrugations increase the
bending strength perpendicular to the axis of the corrugations.
3.5.2.3 Corrugated jackets should not be used on horizontal surfaces if
the corrugations are oriented parallel to the horizontal axis,
because water can be held in the troughs formed by the
corrugations on the top surface. This water can run to the joints
in the jacket and enter the insulation.
3.5.2.4 Aluminum has excellent weathering characteristics if exposed to
normal industrial atmospheres. There are specific chemicals
such as caustics and chloride salts that can damage aluminum
and aluminum should not be used if directly exposed to these
chemicals. If chemical exposure is likely, a corrosion specialist
should be consulted to determine the appropriate jacket material.
Aluminum jacket can be obtained with a coating to provide
added chemical resistance, color-coding, or increased emissivity.
3.5.3 Other Jacket Materials
3.5.3.1 Other common jacket materials are stainless steel, zinc-
aluminum alloy-coated steel, and PVC.
3.5.3.2 Stainless Steel Jacketing
1. Stainless steel jacketing is used if fire resistance is needed.
Stainless steel has a much higher melting point than
aluminum and remains intact much longer during an external
fire than aluminum. The higher melting point allows the use
of smaller relief devices on insulated pressure equipment
and provides protection for both the equipment and
insulation.
2. Chemical resistance is also an important benefit of stainless
steel and can be used in areas where chemical fumes or
spills are a problem that aluminum cannot resist.
3. Stainless steel is stronger and heavier than aluminum, which
allows use in thinner sheets. The added strength improves
damage resistance in comparison to aluminum.
3.5.3.3 Zinc Aluminum Alloy-Coated Steel Jacketing
1. Zinc aluminum alloy-coated steel jacketing also is used if
mechanical strength or fire protection is needed.
2. Zinc aluminum alloy-coated jacketing should not be used on
stainless steel pipe and equipment because of the risk of zinc
embrittlement of the stainless steel in the event of a fire.

Zinc embrittlement occurs if the zinc coating melts and the

liquid zinc makes contact with austenitic stainless steel. The
liquid zinc penetrates the stainless steel and causes cracking.
Welds are especially vulnerable to this type of cracking.
3.5.3.4 Nonmetallic Jacketing
1. Nonmetallic jackets are also commonly used. White PVC is
used in outdoor applications or if cleanliness is important.
PVC is also available in a variety of colors if the jacket must
be color-coded, however, colored PVC should not be used
outdoors.
2. Complicated shapes can be handled by fabricating the jacket
in place using mastic and reinforcing fabric. This approach
is often used in combination with metal jacket in which the
metal is used for the straight sections, and the mastic is used
for the complicated shapes. Metal fittings should be used for
tees and elbows for PIP installations.
3.6 Vapor Barriers

3.6.1 Insulation systems that operate below the ambient dew point temperature
must be protected from the inward permeation of moisture. Water vapor
permeability is measured using ASTM test method E96, and the results
are reported in “perms.” Lower perm ratings represent better resistance
to moisture penetration. Closed-cell insulation materials have low perm
ratings, while fibrous and granular materials are generally not evaluated
for permeation. Because of the low perm rating, closed-cell materials are
used for low-temperature applications.
3.6.2 As an added measure of resistance against moisture penetration, an
additional vapor barrier is added to the outer surface of the insulation.
The vapor barrier can be sheet material or vapor barrier mastic that is
applied to the outside surface of the insulation. Nonsetting joint sealer is
used to seal the joints of single-layer insulation and the outer layer of
multilayer systems.
4. Insulation System Design
4.1 General
4.1.1 An insulation system consists of the insulation material, protective
covering if needed, and accessories used to secure the insulation in
place.
4.1.2 The insulation materials chosen depend upon the reasons that insulation
is being used. Many different criteria are important in the selection of an
insulation system. Not all the criteria mentioned in this Practice apply in
all cases. The criteria that apply to a project should be determined, and
priorities should be assigned to those criteria. In some cases, it may be
that only heat conservation or personnel protection are important. In

most projects, many criteria apply with some being much more
important than others. Because each project is unique, the criteria should
be assessed for each project, and selections should be made that are
appropriate to their unique circumstances. Design criteria that should be
considered in the selection of insulation materials are described in
Section 4.2 of this Practice.
4.2 Basic Design Criteria

4.2.1 The primary reason for using insulation should be established first.
Possible reasons are:
a. Heat conservation
b. Personnel protection
c. Process stability
d. Freeze protection
e. Condensation prevention
f. Cold conservation
The possible reasons are aligned with the PIP type codes that are used on
P&IDs to designate the insulation type.
4.2.2 Heat Conservation Insulation
4.2.2.1 Heat conservation (HC) insulation is applied to prevent the
escape of thermal energy from process equipment and piping.
An optimum thickness can be determined that balances the cost
of installing and maintaining the insulation system against the
value of the energy saved. This thickness is referred to as the
“economic thickness” and can also be defined as the insulation
thickness that yields the minimum total cost of owning
insulation.
4.2.2.2 Calculation of the economic thickness depends on many
variables and must be determined on a case-by-case basis. The
National Association of Insulation Manufacturers (NAIMA) has
published software (3E Plus) that can be used to calculate
economic thickness. 3E Plus uses heat transfer calculations that
are based on ASTM C680 and economic thickness calculations
based on the Federal Energy Administration Report, Economic
Thickness for Industrial Insulation. This method assumes that
the total cost of owning an insulation system is defined as the
sum of the cost of the insulation system materials plus the cost
of the energy lost minus any tax savings.
4.2.2.3 Energy loss is reduced for a given insulation material by
increasing the insulation thickness. Increasing the thickness
raises the cost of the insulation but lowers the cost of lost
energy. At the economic thickness, the cost of adding additional

insulation thickness exceeds the value of the additional energy

saved.
4.2.2.4 The calculations made to determine the economic thickness
require the input of project-specific data on process conditions,
ambient conditions, and economic data that is specific to the
project. To determine an accurate economic thickness, this data
must be obtained for each project. The software contains default
values for process, ambient, and economic variables. However,
the default values are subject to variation and can cause
inaccurate economic thickness calculations.
4.2.3 Personnel Protection Insulation
4.2.3.1 Personnel protection (PP) insulation is used to prevent contact
between personnel and hot operating surfaces. The maximum
allowable insulation system surface temperature is 140°F (60°C)
for metallic surfaces. Higher allowable surface temperatures
may be appropriate for non-metallic surfaces, as indicated in
ASTM C1055 Appendix for materials with lower thermal
inertia.
4.2.3.2 ASTM C1055 establishes a process for the determination of
acceptable surface operating conditions for heated systems.
ASTM C1055 also defines human burn hazards and presents
methods for use in the design and evaluation of heated systems
to prevent serious injury from contact with exposed surfaces.
The method establishes a safe surface contact temperature based
on an acceptable contact time and level of injury. A graph is
included in ASTM C1055 that establishes the temperature-time
relationship for burns of specific severity. For the purposes of
this Practice, the acceptable level of injury is reversible
epidermal injury as defined in ASTM C1055, and the PIP
adopted acceptable contact time is 2 seconds. Using the
ASTM C1055 graph and the injury and time parameters leads to
the PIP maximum allowable surface temperature of 140°F
(60°C). This temperature is used to calculate the personnel
protection thickness. The personnel protection thickness is
chosen so that the outside surface temperature of the insulation
system is no more than 140 F (60 C) for metallic surfaces under
the worst-case operating conditions of highest operating
temperature combined with the highest expected ambient
temperature.
4.2.3.3 Two very important variables in the calculation of outside
surface temperature are the emissivity of the jacket material and
the wind speed. As the wind speed increases, the surface
temperature falls significantly because of convective cooling.
The wind speed for indoor applications is low, resulting in
higher personnel protection thicknesses than for the same system
in an outdoor location. Choosing a jacket material with high

emissivity also reduces the surface temperature and is a method

that can be used to lower the personnel protection thickness for
indoor applications or for high temperature outdoor installations.
As the process temperature drops, increasing the emissivity
becomes less effective at lowering the surface temperature.
4.2.3.4 3E Plus or an equivalent program can be used to calculate the
personnel protection thickness.
4.2.4 Process Stability Insulation
Process stability (PS) insulation is used to maintain the process
temperature at a desired level. The amount of heat loss or heat gain
allowed for a process depends on the nature of the process. 3E Plus can
be used to calculate both heat loss and heat gain through insulation as a
function of insulation type and process conditions.
4.2.5 Prevention from Freezing Insulation
4.2.5.1 Prevention from freezing (PF) insulation is used to prevent water
or process fluid piping from freezing without using supplemental
heat input (either electric or steam). The system design requires
consideration of all potential heat leak paths, such as pipe
supports and terminations at enclosures. These heat leak paths
can result in localized ice formation and line plugging.
4.2.5.2 Insulation can be designed to prevent the contents of a pipe or
vessel from freezing when ambient temperatures fall below the
freeze point temperature of the insulated liquid. 3E Plus is not
used to calculate the required thickness but can be used to
calculate the heat loss rate (heat flux) from an uninsulated
surface as well as through a range of insulation thicknesses. The
important variables in making this calculation are ambient
temperature and wind speed. When the heat flux is known it can
be used to calculate the time required for the process fluid to
freeze. The volume of fluid, its heat capacity and heat of fusion
must all be known in order to calculate the amount of energy
that must be lost and the length of time required for freezing to
occur. Flow through the item to be insulated greatly complicates
the calculation. Local freezing could occur faster or slower as a
result of attachments to the insulated item. The insulation
thickness is selected to provide a specified period of time before
freezing occurs.
4.2.5.3 Caution should be exercised when calculating time to freeze
since slush can form before then and plug orifices and strainers.
This insulation approach should not be used where freezing
conditions over multiple days occur on a regular basis, or the
service is critical to process control or plant operation.

4.2.6 Cold Service Insulation

4.2.6.1 Cold service insulation (CC) is primarily intended to limit heat
gain by the process. The allowable heat gain must be determined
for each process. The required insulation thickness is determined
based on the local worst-case ambient conditions. In most cases,
the thickness should also be sufficient to keep the surface
temperature of the jacket material above the ambient dew point
temperature to prevent condensation on the jacket surface. 3E
Plus can be used to calculate heat gain, dew point, and surface
temperature.
4.2.6.2 The control of moisture penetration in low-temperature systems
is required to prevent condensation or the formation of ice inside
the insulation and on the surface of the insulated item. This
control is accomplished by designing an insulation system that
includes a closed-cell insulation material, a vapor barrier with a
low permeation rating as determined by ASTM E96, and an
appropriate jacket with moisture resistant caulking at all joints
and penetrations. Non-closed cell insulation does not resist
moisture penetration and is prone to moisture absorption if the
vapor barrier seal is broken. This insulation should not be used if
the operating temperature is below the highest expected ambient
dew point. In dual-temperature applications, fibrous material can
be used as an inner layer to compensate for thermal expansion,
but it should be covered by a closed-cell outer layer and vapor
barrier system to prevent condensation or ice formation on the
inner surface.
4.2.7 Condensation Prevention Insulation
Condensation prevention (CP) insulation is used only to prevent
condensation from occurring on the surface of piping and equipment that
is operating at or below the ambient dew point. The design of
condensation prevention systems is the same as cold service insulation.
Thickness is designed only to raise the surface temperature above the
project design ambient dew point. Condensation prevention is usually
important for housekeeping, safety and corrosion control. Closed-cell
insulation materials should be used in condensation control applications.
3E Plus can be used to determine the required thickness.
4.3 Other Design Criteria

4.3.1 Location of Facilities
The location of the items to be insulated determines the ambient
conditions that should be used in calculating the insulation thickness.
Location also plays an important role in the choice of accessories such
as the jacket type and the method of securement. In high wind areas,
band spacing should be reduced to keep the jacket in place. In corrosive
areas such as close to the seacoast or corrosive chemical fumes, it may

be necessary to select a jacket material that is resistant to the specific

corrosive condition. Equipment that is located inside a building is not
exposed to weather extremes or UV light and less durable jacket
materials, or in some cases no jacket material, can be suitable. Flame
spread and smoke developed properties may be important properties
depending on location of insulation (e.g. indoor or enclosed) and type of
facilities.
4.3.2 Strength and Durability
Physical strength and durability requirements can determine the choice
of both insulation and jacket materials. In some cases, pipe support loads
are carried by the insulation. In that case, a rigid insulation material is
used. Rigid insulation materials can be selected for surfaces that are
easily accessible by personnel working on or around the equipment.
Jacket materials that are more damage resistant, such as thick aluminum
or stainless steel, can be used in conjunction with the rigid insulation to
produce a very damage-resistant system.
4.3.3 Appearance
Appearance requirements sometimes determine the type of jacket or
finish material that must be used. Applications that require a
continuously high degree of cleanliness can specify a jacket material that
has a gloss white or polished stainless steel finish to facilitate both
identification and removal of surface contamination. Embossed surface
finishes on metal jacket materials can be used to make minor surface
damage less visible to casual observation; however, it is more difficult to
clean embossed jackets. Smooth finishes are more reflective, and
damage is more easily visible.
4.3.4 Leak Detection
4.3.4.1 Leak detection is a regulatory requirement for some chemical
processes. If insulating piping and equipment that contains
chemicals that fall within the leak detection classification, it is
necessary to design the insulation to permit detection of leaks at
flanges, valves, and other locations that can be prone to leakage.
4.3.4.2 Leak detection provision can be done in hot systems by not
insulating leak-prone items or by using removable reusable
insulation as specified in PIP INSR1000. This approach is not an
option for low-temperature systems because there would be no
vapor seal and condensation or ice formation can occur. Low-
temperature systems require special consideration and should be
handled on a case-by-case basis.
4.3.5 Absorption Resistance
The absorption resistance of the insulation material is an important
attribute if insulating piping and equipment that contain flammable or
explosive chemicals. If leaks occur and the insulation absorbs the
chemical, it is possible to build up enough of the flammable or explosive

chemical to achieve auto-ignition. It may be necessary to use an

appropriate closed-cell insulation that is compatible with the chemical and
does not absorb leaks. It is desirable to provide drainage to enable the
leaking chemical to escape from the insulation in a controlled fashion.
4.3.6 Emissivity
4.3.6.1 Emissivity is a measure of a body’s ability to radiate energy. A
body that radiates a large amount of energy has an emissivity
close to 1, while a material that is a poor radiator has a low
emissivity. All materials have a characteristic emissivity. New
aluminum jacket has an emissivity of about 0.04, while PVC
jacket has an emissivity of about 0.9. The emissivity value can
change as the surface characteristics of the insulation change
with time.
4.3.6.2 The surface temperature of an insulation system is a function of
the emissivity of the jacket material. On a hot insulation system,
with all other factors held constant, the outer surface
temperature of the insulation jacket is reduced by using a higher
emissivity jacket. If personnel protection is an important criteria,
it may be possible to reduce insulation thickness by using a high
emissivity jacket. On a cold insulation system, the jacket
temperature can be raised by using a higher emissivity jacket. If
condensation control is an important criteria, the surface
temperature can be raised by using a higher emissivity jacket.
5. Corrosion under Insulation

5.1 A full discussion of corrosion under insulation is beyond the scope of this
Practice. There are numerous articles available in the technical literature
referenced in this Practice. An article in the ASM Metals Handbook, Volume 13,
Ninth Edition, page 1144 through page 1147 covers the subject of corrosion
under thermal insulation.
5.2 Stress corrosion cracking (SCC) occurs if a susceptible material is exposed to a
specific cracking agent while a tensile stress is present. The stress can be directly
applied, such as internal pressure or a piping load, or it can be residual from
forming or welding operations. There is disagreement about many aspects of the
SCC cause and prevention; however, there is agreement that SCC of 300 series
austenitic stainless steel requires water at the metal surface, some level of free
chloride ion and a temperature above approximately 140°F (60°C) and below
300°F (150°C ). The source of chloride can be from leachable chloride inherent
in the insulation or from atmospheric chloride that enters the insulation system
from rain or wash down water. Certain types of insulation are higher in leachable
chloride than others. ASTM C871 describes the standard testing procedure for
determining leachable chloride in insulation material. As a general rule,
atmospheric chloride is higher close to the seashore than inland, and is higher in
industrial areas than in rural areas. The ASM Metals Handbook, Ninth Edition,

Volume 13, page 909 provides a map showing relative levels of chloride in
rainwater in the U.S.
5.3 Mitigation efforts for corrosion under insulation include the following:
a. Proper installation and maintenance of insulation weather jacketing to
prevent water ingress
b. Use of low chloride insulation materials
c. Coating the metal to prevent water contact.
NACE RP 0198-2004 describes control measures for mitigating corrosion under
thermal insulation. Common coatings for mitigating corrosion under thermal
insulation are epoxy phenolic and coal tar epoxies. PIP CTSE1000 provides
more information on coatings.
6. Insulation Material Selection
6.1 General
6.1.1 The appropriate insulation material for a given project is selected on the
basis of design criteria that are appropriate for that specific project.
Some important design criteria are as follows:
a. Operating temperature
b. Strength, rigidity, and the ability to resist mechanical abuse and
vibration
c. Absorption resistance
d. Water vapor permeation resistance
e. Fire resistance
6.1.2 Not all insulation materials perform equally well with respect to these
design criteria. Each insulation type has strengths and weaknesses and
the strengths of the material selected for a specific job should be
matched to the most important design criteria for that job. For example,
a low permeation material should be chosen for a low-temperature
application in which permeation resistance is needed to prevent
condensation on the surface of the insulated item. A rigid high
compressive strength material should be chosen in situations in which
mechanical abuse is likely.
6.2 ASTM Considerations

6.2.1 ASTM has identified many of the important material properties that
support specific design criteria. There are ASTM test methods for:
a. Strength
b. Dimensional stability
c. Surface burning characteristics

d. Water absorption
e. Water vapor permeability
f. Water wicking
g. Water vapor sorption
The ASTM standards that define the requirements for specific insulation
materials do so in terms of performance in these various tests.
6.2.2 By comparing the minimum performance requirements defined by
ASTM, it is possible to compare different material types to determine
which is best for a given application. However, it should be remembered
that the ASTM values are minimum requirements and that in some cases,
critical values are not included in the ASTM standard for a given
material. For example, the standard for mineral fiber, ASTM C547 does
not have a requirement for water absorption. Instead, mineral fiber is
evaluated for water vapor “sorption” using ASTM C1104. ASTM C1104
does not expose the mineral fiber to direct immersion. Instead, it is
exposed to water vapor, a less demanding requirement that does not
indicate how mineral fiber performs if immersed in water. In other cases,
the properties of the insulation change with exposure to elevated
temperature. Both perlite and mineral fiber become much more
absorbent if exposed to temperatures that are sufficiently high to burn
away the binder that is applied when the insulation is made.
6.2.3 There is no ASTM test for water wicking except for aircraft-type glass
fiber blanket as published in ASTM C800. Some manufacturers test
material using the ASTM C800 procedure however, the appropriateness
of this procedure for all materials has not been demonstrated. The
relevance of the procedure to real world applications is also not clear. If
in doubt about the appropriate use of a specific insulation material
contact the owner’s representative for guidance.
6.3 Insulation Materials Properties Table

Table 1/1M is provided to assist in selecting materials for a specific application.
Table 1/1M, at the end of the Practice, is a compilation of material properties
defined by ASTM standards for generic material types. Not all materials are
evaluated by the same ASTM tests and in those cases in which a test does not
apply to a material, the table is left blank. Purchaser should review current
ASTM standards to confirm relevant material properties listed in Table 1/1M.
7. Extent of Insulation
7.1 Extent of insulation refers to what can and cannot be insulated during a project.
PIP datasheets INSH1000-D3 and INSC2001 can be used to specify the extent of
insulation for a project. The extent of insulation varies depending on the design
criteria. For example, in the case of heat conservation, flanges, valves, or other
potentially high maintenance items can be left uninsulated to facilitate leak
detection and repairs. In the case of cold conservation, piping items cannot be

left uninsulated because condensation and ice formation can occur. As a general
rule, all low-temperature surfaces should be insulated. Both heat conservation
and process stability applications should be insulated as much as possible to
ensure these criteria are met.
7.2 If insulating only for mitigating personnel protection, the extent of insulation is
quite different than for heat or cold conservation. Personnel protection insulation
is only applied to those surfaces with which personnel can make contact under
normal operating conditions. If the normal operating temperature exceeds 140 F
(60°C), personnel protection insulation is required on all surfaces to 7-feet above
grade or platforms, and 3-feet horizontally from the periphery of platforms,
walkways, or ladders. In some circumstances, guards or barriers can be
substituted for insulation to provide personnel protection if insulation would
impair the function of the equipment. A guard is positioned near the pipe or
equipment to prevent personnel contact at a specific location. Guards can be
fabricated from a variety of materials including sheet or expanded metal.
Barriers or signs are used to prevent access to areas where hot equipment is
present. An example of a barrier is a chain that bars access to a ladder that leads
to a platform where hot equipment is operating. Hot items that typically cannot
be insulated are refractory-lined vessels, condensers, or equipment that can be
subject to corrosion under insulation.
8. Insulation Thickness
8.1 General
8.1.1 Insulation thickness depends on the design criteria applied to the project.
Insulation that is intended to conserve heat is usually installed with a
different thickness than insulation designed to protect personnel. There
are many variables that influence insulation thickness including:
a. Operating temperature
b. Average ambient weather conditions
c. Insulation material
d. Jacket material
e. Substrate material of construction
f. Basic Design Criteria (paragraph 4.2)
8.1.2 Because each project is unique, the insulation thickness should be
calculated specifically for each project. Generic thickness tables are not
provided in this Practice because any thickness calculated by 3E Plus is
completely dependent upon project specific variables. Instead,
information is provided in this Practice on when to use 3E Plus.
8.1.3 Project-specific data sheets, PIP INEG1000-D2 and PIP INEG1000-D3,
formatted to record the variables required for 3E Plus calculations, are
furnished in the appendix of this Practice. Additional data sheets are

furnished to record project specific thicknesses calculated by 3E Plus

using project specific parameters.
8.1.4 Blank thickness data sheets are provided to record the calculated
thicknesses for both hot and cold services. The datasheets are included
in PIP INSC1000 and PIP INSH1000.
8.2 3E Plus
8.2.1 3E Plus can be downloaded free of charge from the NAIMA website at
www.pipeinsulation.org. The system of mathematical heat flux
equations used in the 3E Plus analysis is based on the equations
published in ASTM C680 and is applicable to most systems normally
insulated with bulk-type insulations. 3E Plus can be used to calculate
thickness for different design criteria. It can calculate thickness for
personnel protection based on easily obtained process data.
8.2.2 3E Plus can also calculate an economic thickness that is optimized based
on a series of economic variables that must be supplied by the designer.
To obtain an accurate economic thickness, these variables must be
determined for each project. Using the defaults supplied in the program
does not produce an accurate result. The 3E Plus user’s guide provides a
detailed description of the basis for the economic analysis that goes
beyond the scope of this discussion. Among the data required by 3E Plus
is climate information that requires both ambient temperature and wind
speed. Both affect heat transfer. Climate data for many locations in the
U.S. is available at www.noaa.gov, the website of the National Oceanic
and Atmospheric Administration (NOAA). The actual climatic data used
depends upon the design criteria of the project and the location of the
item to be insulated.
8.2.3 Insulation used for condensation control should be designed for the
expected humidity conditions. 3E Plus can be used for the design of low-
temperature systems. If a low process temperature is specified, 3E Plus
should be supplied with the ambient temperature and relative humidity.
The highest expected relative humidity at the highest expected ambient
temperature can provide the worst-case dewpoint temperature. The
insulation thickness should be selected so that the surface temperature of
the insulation jacket is greater than the calculated dewpoint temperature.
The surface temperature of the insulation system can be significantly
altered by changing the emissivity of the jacket. Using a jacket material
with an emissivity close to 1 raises the temperature of the jacket surface
and reduces the thickness of insulation required. 3E Plus can be used to
calculate the effect of emissivity on surface temperature. If making
condensation control calculations, it is important to include an accurate
wind speed because the required thickness for condensation control goes
up as wind speed drops. An under estimate of wind speed can result in
excessive thickness and an over estimate can result in unwanted
condensation on the jacket surface.

8.2.4 Process stability requirements are also project specific. 3E Plus can
calculate heat loss or heat gain for user-specified operating conditions.
The allowable amount of heat loss or gain depends upon the process and
should be determined for the specific project in consultation with the
process designer.
9. Type Codes
9.1 General
9.1.1 Insulation type codes should be used on P&IDs, data sheets, piping
isometrics, and other project documents.
9.1.2 Insulation type codes consist of up to four characters. The first two
characters are defined in this Practice. The second two characters can be
used to define additional requirements such as combination systems or
special requirements.
9.2 Hot Insulation Types

9.2.1 HC - Heat Conservation Insulation
9.2.1.1 Heat conservation insulation should be designated with the
code HC.
9.2.1.2 The primary consideration for using heat conservation insulation
should be economics.
9.2.1.3 Design of heat conservation insulation should be based on local
average ambient climatic conditions and project economics.
9.2.1.4 Heat conservation insulation should be used if normal operating
temperature exceeds 140°F (60°C), unless loss of heat is
desirable.
9.2.2 PS – Process Stability Insulation
9.2.2.1 Process stability insulation should be designated with the
code PS.
9.2.2.2 The primary consideration for using process stability insulation
should be control of process temperatures, including impact
because of sudden changes in ambient conditions.
9.2.2.3 Design of process stability insulation should be based on
anticipated extremes in ambient conditions.
9.2.3 PP – Personnel Protection Insulation
9.2.3.1 Personnel protection insulation should be designated with the
code PP.
9.2.3.2 The primary consideration for using personnel protection
insulation should be to limit the temperature of exposed
surfaces.

9.2.3.3 Design of personnel protection insulation should be based on

summer dry bulb temperature and low wind velocity to reflect a
worst-case condition.
9.2.3.4 Personnel protection insulation should be used if normal
temperature of a surface exceeds 140 F (60 C) and if the
surface is in an area that is accessible to personnel. Accessible
area is defined as an area in which personnel regularly perform
duties other than maintenance during plant operation.
9.2.3.5 Personnel protection should be provided to 7 feet (2.13 m) above
grade or platforms and 3 feet (0.91 m) horizontally from the
periphery of platforms, walkways, or ladders.
9.2.3.6 Personnel protection should consist of insulation, shields,
guards, or barriers.
9.2.3.7 If corrosion under the insulation is a concern, or if heat loss is
desirable, use of fabricated shields/guards in lieu of insulation
should be considered.
9.2.4 PF – Prevention from Freezing Insulation
9.2.4.1 Freeze prevention insulation should be designated with the code PF.
9.2.4.2 The primary consideration for the use of this category is
protection from freezing.
9.2.4.3 Design of prevention from freezing insulation should be based
on local climatic conditions.
9.2.4.4 Prevention from freezing insulation can be combined with other
types of insulation.
9.3 Cold Insulation Types

9.3.1 CC – Cold Service Insulation
9.3.1.1 Cold service insulation should be designated with the code CC.
9.3.1.2 The primary consideration for using cold service insulation
should be based on maximum allowable heat gain.
9.3.1.3 The design of cold service insulation should be based on control
of heat gain and limiting surface condensation if the operating
temperature is below ambient.
9.3.1.4 Cold service insulation should be sealed against atmospheric
moisture intrusion and subsequent wetting/icing of the
insulation. Sealing normally involves special consideration for
design of equipment and insulation support details.
9.3.2 CP – Condensation Control Insulation
9.3.2.1 Condensation control insulation should be designated with the
code CP.

9.3.2.2 The only consideration for use of condensation control

insulation should be control of external surface condensation.
9.3.2.3 Design of condensation control insulation should be based on
the normal operating temperature and local climatic conditions.
In some humid climates, it is impractical to prevent
condensation 100 percent of the time.
9.3.2.4 Use of surface finishes to control surface emissivity can be
considered to reduce insulation thickness.
9.4 Insulation Types for Traced and Energy Transfer Jacketed Systems
9.4.1 General Considerations
9.4.1.1 The primary consideration for using tracing or heat transfer
jacketing and associated insulation should be control of process
temperatures.
9.4.1.2 Design of insulation should be based on the operating
temperature, heat transfer jacketing temperature, or the tracer
temperature. The same insulation thickness as that for heat
conservation (HC) or cold service (CC), as appropriate, should
be used unless design optimization dictates a different thickness.
9.4.1.3 Optimization of the tracer or heat transfer jacketing design and
insulation thickness should be required if specified.
9.4.1.4 Oversize insulation should be considered to accommodate
tracer(s) or heat transfer jacketing.
9.4.1.5 Grooving of insulation to accommodate tracing is not allowed,
unless specified by the purchaser.
9.4.2 ET – Electric Traced
Electric tracing and associated insulation should be designated with the
code ET.
9.4.3 ST – Steam Traced
Steam tracing and associated insulation should be designated with the
code ST.
9.4.4 SJ – Steam Jacketed
Steam jacketing and associated insulation should be designated with the
code SJ.
9.4.5 HT – Hot Fluid Traced
Hot fluid tracing (except steam) and associated insulation should be
designated with the code HT.
9.4.6 HJ – Hot Fluid Jacketed
Hot fluid jacketing and associated insulation should be designated with
the code HJ.

9.4.7 CT – Chilled Fluid Traced

Chilled fluid tracing and associated insulation should be designated with
the code CT.
9.4.8 CJ – Chilled Fluid Jacketed
Chilled fluid jacketing and associated insulation should be designated
with the code CJ.
9.5 AC – Acoustic Control Insulation

9.5.1 Acoustic control insulation should be designated with the code AC.
9.5.2 The primary consideration for use of acoustic control insulation should
be control of noise.
9.5.3 Normally, acoustic control insulation should have a dedicated design for
each application.
9.5.4 Special consideration of insulation materials and jacketing is normally
required.
9.5.5 Acoustic control insulation can be combined with other types of
insulation.
9.6 FP – Fire-Protection Insulation

9.6.1 Fire-protection insulation should be designated with the code FP.
9.6.2 The primary consideration for use of fire-protection insulation should be
control of the rate of heat gain in a fire.
9.6.3 Design of fire-protection insulation should be based on maximum
allowable heat gain, fire case characteristics, allowable time duration,
and process characteristics.
9.6.4 Refer to API RP521, API Publication 2218, and API RP2001 for
additional information on fire protective insulation.
9.6.5 Fire-protection insulation can be combined with other types of
insulation.

Table 1: Insulation Materials Properties Table
Calcium Calcium Calcium Flexible Flexible

Silicate Pipe Silicate Pipe Silicate Pipe Elastomeric Elastomeric
Material Properties & Block & Block & Block Cellular Cellular
C533-09, C533-09, C533-097, C 534-08, C 534-08,
Type 1 Type 1 Type 1A Grade 1 & 3 Grade 2
(Block) (Pipe) (Block)
Max Temp, °F 1200 1200 1200 220 350
Min Temp, °F 140 140 140 -297 -297
consult consult
Density, lb/ft³ 15.0 (max) 15.0 (max) 22.0 (max)
manufacturer manufacturer
Compressive strength,
min., psi 100 N.A. 100 N.A. N.A.
(C165, unless noted)
2%, max, 2%, max, 2%, max,
7%, max, 7%, max,
Dimensional Stability (C356, (C356, (C356,
(C534, 220°F) (C534, 350°F)
1200°F) 1200°F) 1200°F)
0.20% by vol. 0.20% by vol.
Absorption, max. 4x dry weight 4x dry weight 4x dry weight
(C209) (C209)
0.10 perm-in. 0.10 perm-in.
(E96, (E96,
Water Vapor desiccant desiccant
N.A. N.A. N.A.
Transmission/ method, method,
50% RH, 50% RH,
73°F) 73°F)
Surface burning consult consult
characteristics (E84): manufacturer manufacturer
Flame spread 0 0 0
Smoke developed 0 0 0
Apparent thermal
conductivity (k),
2
Btu-in./h-ft -°F, at mean
temperature (°F) k °F k °F k °F k °F k °F
0.41 100 0.41 100 0.50 100 0.16 -238 0.16 -238
0.45 200 0.45 200 0.54 200 0.18 -148 0.18 -148
0.50 300 0.50 300 0.58 300 0.25 -20 0.25 -20
0.55 400 0.55 400 0.61 400 0.26 0 0.26 0
0.60 500 0.60 500 0.64 500 0.28 75 0.30 75
0.66 600 0.66 600 0.67 600 0.30 120 0.32 120
0.71 700 0.71 700 0.70 700 0.31 150 0.34 150
0.42 300

Table 1: Insulation Materials Selection Table (Continued)
Mineral Mineral Mineral

Cellular
Fiber Pipe Fiber Pipe Fiber Pipe
Glass Block
C547-07 C547-07 C547-07
Material Properties C552-07
Type I, Type II, III Type IV,
Grade 1,
Grade A Grade A Grade A
Types I, II, III
Grade B Grade B Grade B
Max Temp, °F 850 1200 1000 800

Min Temp, °F N.A. N.A. N.A. -450
consult consult consult 6.12 (min)
Density, lb/ft³
manufacturer manufacturer manufacturer 8.62 (max)
Compressive strength, 60
min., psi N.A. N.A. N.A. (capped per
(C165, unless noted) C240)
2%, max, 2%, max,
2%, max,
Dimensional Stability (C356, (C356, N.A.
(C356, 850°F)
1200°F) 1000°F)
5% by weight 5% by weight 5% by weight 0.5% by weight
Absorption, max.
(C1104) (C1104) (C1104) (C552)
0.005 (max),
in.thk./h·ft2·in. Hg
Water Vapor
N.A. N.A. N.A. (E96, water
Transmission/
method,
73°F to 90°F)
Flame spread /
smoke
Surface burning developed
characteristics (E84): varies for Type
II and III fab
methods
Flame spread 25 25 25 5
Smoke developed 50 50 50 0
Apparent thermal (block only)
conductivity (k), (consult manuf.
2
Btu-in./h-ft -°F, at mean for pipe)
temperature (°F) k °F k °F k °F k °F
0.25 100 0.25 100 0.25 100 0.20 -150
0.31 200 0.31 200 0.31 200 0.22 -100
0.40 300 0.37 300 0.37 300 0.24 -50
0.51 400 0.45 400 0.45 400 0.27 0
0.64 500 0.54 500 0.54 500 0.30 50
0.65 600 0.65 600 0.31 75
0.77 700 0.77 700 0.33 100
0.40 200
0.48 300
0.58 400

Rigid Rigid Rigid

Cellular Cellular Cellular Mineral Mineral
Polyiso- Polyiso- Polyiso- Fiber Fiber
Material Properties cyanurate cyanurate cyanurate Blanket Blanket
C591-08 C591-08 C591-08 C592-08 C592-08
Grade 2 Grade 2 Grade 2 Type I Type II
Type IV Type II Type III
Max Temp, °F 300 300 300 850 1200

Min Temp, °F -297 -297 -297 N.A. N.A.
Density, lb/ft³ 2.0 (min) 2.5 (min) 3.0 (min) 10.0 (max) 12.0 (max)
min., psi 22 30 45 N.A. N.A.
4%, max, 158°F, 97% RH (D2126)
4%, max, 4%, max,
Dimensional Stability 1%, max, -40°F, amb. RH (D2126)
(C356, 850°F) (C356, 1200°F)
2%, max, 212°F, amb. RH (D2126)
2.0% by vol. 1.0% by vol. 1.0% by vol.
5% by weight 5% by weight
Absorption, max. (C272, Proc. (C272, Proc. (C272, Proc.
(C1104) (C1104)
A) A) A)
4.0 perm-in. 3.5 perm-in. 3.0 perm-in.
Water Vapor
(E96, desiccant (E96, desiccant (E96, desiccant N.A. N.A.
Transmission/
method, 73°F) method, 73°F) method, 73°F)
Surface burning consult consult consult
characteristics (E84): manufacturer manufacturer manufacturer
Flame spread 25 25
Smoke developed 50 50
Apparent thermal (block only) (block only) (block only)
conductivity (k), (consult manuf. (consult manuf. (consult manuf.
2
Btu-in./h-ft -°F, at mean for pipe) for pipe) for pipe)
0.13 -200 0.13 -200 0.14 -200 0.25 75 0.25 75
0.15 -150 0.15 -150 0.16 -150 0.27 100 0.27 100
0.17 -100 0.17 -100 0.18 -100 0.34 200 0.34 200
0.19 -50 0.19 -50 0.20 -50 0.43 300 0.42 300
0.20 0 0.20 0 0.21 0 0.55 400 0.53 400
0.19 50 0.19 50 0.20 50 0.70 500 0.64 500
0.20 75 0.20 75 0.21 75 0.75 600
0.24 150 0.24 150 0.25 150 0.86 700
0.27 200 0.27 200 0.28 200

Mineral Expanded Expanded Mineral Mineral

Fiber Perlite Perlite Fiber Board Fiber Board
Material Properties Blanket Block and Block and & Block & Block
C592-08 Pipe Pipe C612-04 C612-04
Type III C610-09 C610-09 Type IA Type IB
(block) (pipe)
Max Temp, °F 1200 1200 1200 450 450
Min Temp, °F N.A. 80 80 N.A. N.A.
10.0 (min) 10.0 (min)
Density, lb/ft³ 8.0 (max) 8.0 (max) 8.0 (max)
14.0 (max) 14.0 (max)
Compressive strength, 0.17
min., psi N.A. 70 70 N.A. (Category 2
(C165, unless noted) only)
2%, max, 2%, max,
length length
4%, max, 2%, max, 2%, max,
Dimensional Stability 2%, max, width 2%, max, width
(C356, 1200°F) (C356, 450°F) (C356, 450°F)
8%, max, thick 8%, max, thick
(C356, 1200°F) (C356, 1200°F)
1.25% by
50% by weight, 50% by weight, 5% by weight 5% by weight
Absorption, max. weight
@600°F (C610) @600°F (C610) (C1104) (C1104)
(C1104)
Water Vapor
N.A. N.A. N.A. N.A. N.A.
Transmission/
Surface burning
characteristics (E84):
Flame spread 25 0 0 25 25
Smoke developed 50 5 5 50 50
Apparent thermal
conductivity (k),
2
0.24 75 0.48 100 0.48 100 0.26 75 0.26 75
0.26 100 0.53 200 0.53 200 0.28 100 0.27 100
0.31 200 0.59 300 0.59 300 0.36 200 0.34 200
0.37 300 0.64 400 0.64 400 0.46 300 0.42 300
0.44 400 0.69 500 0.69 500
0.52 500 0.75 600 0.75 600
0.60 600 0.80 700 0.80 700
0.70 700

Mineral Mineral Mineral Mineral

Fiber Board Fiber Board Fiber Board Fiber Board
Material Properties & Block & Block & Block & Block
C612-04 C612-04 C612-04 C612-04
Type II Type III Type IVA Type IVB
Max Temp, °F 850 1000 1200 1200

Min Temp, °F N.A. N.A. N.A. N.A.
Density, lb/ft³ 8.0 (max) 10.0 (max) 12.0 (max) 12.0 (max)
Compressive strength, 0.17 0.08 0.35 0.35
min., psi (Category 2 (Category 2 (Category 2 (Category 2
(C165, unless noted) only) only) only) only)
2%, max, 2%, max, 2%, max, 2%, max,
Dimensional Stability
(C356,850°F) (C356, 1000°F) (C356, 1200°F) (C356, 1200°F)
5% by weight 5% by weight 5% by weight 5% by weight
Absorption, max.
(C1104) (C1104) (C1104) (C1104)
Water Vapor
N.A. N.A. N.A. N.A.
Transmission/
Surface burning
Apparent thermal
conductivity (k),
2
0.25 75 0.25 75 0.25 75 0.24 75
0.27 100 0.27 100 0.27 100 0.25 100
0.35 200 0.35 200 0.34 200 0.30 200
0.44 300 0.44 300 0.44 300 0.36 300
0.55 400 0.55 400 0.55 400 0.42 400
0.70 500 0.70 500 0.70 500 0.53 500
0.90 600 0.85 600 0.63 600
1.00 700 0.75 700

Rigid Rigid Rigid Rigid

Cellular Cellular Cellular Cellular
Phenolic Phenolic Phenolic Phenolic
Material Properties
C1126-04 C1126-04 C1126-04 C1126-04
Type II Type II Type III Type III
Grade 1 Grade 2 Grade 1 Grade 2
Max Temp, °F 257 257 257 257

Min Temp, °F -290 -40 -290 -40
Cell Structure closed open closed open
Density, lb/ft³ 2.0 (min) 2.0 (min) 2.0 (min) 2.0 (min)
min., psi 18 18 18 18
2%, max, 158°F, 97% RH
2%, max, 158°F, 97% RH
2%, max, -40°F, amb. RH
Dimensional Stability 2%, max, -40°F, amb. RH
2%, max, 257°F, amb. RH
(D2126)
(D2126)
3.0% by vol., 8.0% by vol., 3.0% by vol., 8.0% by vol.,
Absorption, max. foam core foam core foam core foam core
(C209) (C209) (C209) (C209)
0.9 perm-in. 0.9 perm-in. > 4.0 perm-in.
N/A
Water Vapor (core) (core) (core)
Transmission/ (E96, desiccant (E96, desiccant (E96, desiccant
method) method) method)
Surface burning foam core, foam core, foam core, foam core,
characteristics (E84): no facings no facings no facings no facings
Apparent thermal (foam core) (foam core) (foam core) (foam core)
conductivity (k),
2
0.10 -250 0.10 -250
0.11 -200 0.11 -200
0.12 -150 0.12 -150
0.13 -100 0.13 -100
0.13 -50 0.13 -50
0.13 0 0.13 0
0.13 40 0.21 40 0.13 40 0.21 40
0.13 75 0.23 75 0.13 75 0.23 75
0.15 110 0.25 110 0.15 110 0.28 110
0.18 150 0.28 150

Table 1M: Insulation Materials Properties Table
Calcium Calcium Calcium Flexible Flexible

Silicate Pipe Silicate Pipe Silicate Pipe Elastomeric Elastomeric
Material Properties & Block & Block & Block Cellular Cellular
C533-09, C533-09, C533-09, C 534-08, C 534-08,
Type 1 Type 1 Type 1A Grade 1 & 3 Grade 2
(Block) (Pipe) (Block)
Max Temp, °C 649 649 649 104 175
Min Temp, °C 60 60 60 -183 -183
consult consult
Density, kg/m³ 240 (max) 240 (max) 352 (max)
manufacturer manufacturer
min., kPa 688 N.A. 688 N.A. N.A.
2%, max, 2%, max, 2%, max, 7%, max, 7%, max,
(C356, 649°C) (C356, 649°C) (C356, 649°C) (C534, 104°C) (C534, 175°C)
0.20% by vol. 0.20% by vol.
Absorption, max. 4x dry weight 4x dry weight 4x dry weight
(C209) (C209)
-10 -10
1.44 x 10 1.44 x 10
(E96, (E96,
Water Vapor desiccant desiccant
N.A. N.A. N.A.
Transmission/ method, method,
50% RH, 50% RH,
73°F) 73°F)
Surface burning consult consult
characteristics (E84): manufacturer manufacturer
Flame spread 0 0 0
Smoke developed 0 0 0
Apparent thermal
conductivity (k),
W/mK, at mean
temperature (°C) k °C k °C k °C k °C k °C
0.059 38 0.059 38 0.072 38 0.023 -150 0.023 -150
0.065 93 0.065 93 0.078 93 0.028 -100 0.028 -100
0.072 149 0.072 149 0.084 149 0.036 -29 0.036 -29
0.079 204 0.079 204 0.088 204 0.038 -18 0.038 -18
0.087 260 0.087 260 0.092 260 0.040 24 0.043 24
0.095 316 0.095 316 0.097 316 0.043 50 0.047 50
0.102 371 0.102 371 0.101 371 0.045 66 0.049 66
0.061 150

Table 1M: Insulation Materials Selection Table (Continued)
Mineral Mineral Mineral

Cellular
Fiber Pipe Fiber Pipe Fiber Pipe
Glass Block
C547-07 C547-07 C547-07
Material Properties C552-07
Type I, Type II, III Type IV,
Grade 1,
Grade A Grade A Grade A
Types I, II, III
Grade B Grade B Grade B
Max Temp, °C 454 649 538 427

Min Temp, °C N.A. N.A. N.A. -268
consult consult consult 98 (min)
Density, kg/m³
manufacturer manufacturer manufacturer 138 (max)
415
(capped per
min., kPa N.A. N.A. N.A.
C240)
242 uncapped
2%, max, 2%, max, 2%, max,
Dimensional Stability N.A.
(C356, 454°C) (C356, 649°C) (C356, 538°C)
5% by weight 5% by weight 5% by weight 0.5% by weight
Absorption, max.
(C1104) (C1104) (C1104) (C552)
0.007 (max),
ng∙Pa-1∙s-1∙m-1
Water Vapor
N.A. N.A. N.A. (E96, water
Transmission/
method,
73°F to 90°F)
Flame spread /
smoke
Surface burning developed
characteristics (E84): varies for Type
II and III fab
methods
Apparent thermal (block only)
conductivity (k), (consult manuf.
W/mK, at mean for pipe)
temperature (°C) k °C k °C k °C k °C
0.036 38 0.036 38 0.036 38 0.029 -101
0.045 93 0.045 93 0.045 93 0.032 -73
0.058 149 0.053 149 0.053 149 0.035 -46
0.074 204 0.065 204 0.065 204 0.039 -18
0.092 260 0.078 280 0.078 280 0.043 10
0.094 316 0.094 316 0.045 24
0.111 371 0.111 371 0.048 38
0.058 93
0.069 149
0.084 204

Rigid Rigid Rigid

Cellular Cellular Cellular Mineral Mineral
Polyiso- Polyiso- Polyiso- Fiber Fiber
Material Properties cyanurate cyanurate cyanurate Blanket Blanket
C591-08 C591-08 C591-08 C592-08 C592-08
Grade 2 Grade 2 Grade 2 Type I Type II
Type IV Type II Type III
Max Temp, °C 150 150 150 649 649

Min Temp, °C -183 -183 -183 N.A. N.A.
Density, kg/m³ 32 (min) 40 (min) 48 (min) 160 (max) 192 (max)
min., kPa 150 240 310 N.A. N.A.
4%, max, 65°C, 97% RH (D2126)
4%, max, 4%, max,
Dimensional Stability 1%, max, -40°C, amb. RH (D2126)
(C356, 454°C) (C356, 649°C)
2%, max, 100°C, amb. RH (D2126)
2.0% by vol. 1.0% by vol. 1.0% by vol.
Absorption, max. (C272, Proc. (C272, Proc. (C272, Proc.
(C1104) (C1104)
A) A) A)
5.8 (max), 5.1 (max), 4.4 (max),
ng∙Pa-1∙s-1∙m-1 ng∙Pa-1∙s-1∙m-1 ng∙Pa-1∙s-1∙m-1
Water Vapor
(E96, desiccant (E96, desiccant (E96, desiccant N.A. N.A.
Transmission/
method, method, method,
23° C) 23° C) 23° C)
Surface burning consult consult consult
characteristics (E84): manufacturer manufacturer manufacturer
Flame spread 25 25
Smoke developed 50 50
Apparent thermal (block only) (block only) (block only)
conductivity (k), (consult manuf. (consult manuf. (consult manuf.
W/mK, at mean for pipe) for pipe) for pipe)
0.019 -129 0.019 -129 0.020 -129 0.036 24 0.036 24
0.022 -101 0.022 -101 0.023 -101 0.039 38 0.039 38
0.025 -73 0.025 -73 0.026 -73 0.049 93 0.049 93
0.027 -46 0.027 -46 0.029 -46 0.062 149 0.060 149
0.029 -17 0.029 -17 0.030 -17 0.079 204 0.076 204
0.027 10 0.027 10 0.029 10 0.101 260 0.092 260
0.029 24 0.029 24 0.030 24 0.108 316
0.035 66 0.035 66 0.036 66 0.124 371
0.039 93 0.039 93 0.040 93

Mineral Expanded Expanded Mineral Mineral

Fiber Perlite Perlite Fiber Board Fiber Board
Material Properties Blanket Block and Block and & Block & Block
C592-08 Pipe Pipe C612-04 C612-04
Type III C610-09 C610-09 Type IA Type IB
(block) (pipe)
Max Temp, °C 649 649 649 232 232
Min Temp, °C N.A. 27 27 N.A. N.A.
160 (min) 160 (min)
Density, kg/m³ 96 (max) 96 (max) 96 (max)
224 (max) 224 (max)
Compressive strength, 1.2
min., kPa N.A. 483 483 N.A. (Category 2
(C165, unless noted) only)
2%, max, 2%, max,
length length
4%, max, 2%, max, 2%, max,
Dimensional Stability 2%, max, width 2%, max, width
(C356, 649°C) (C356, 232°C) (C356, 232°C)
8%, max, thick 8%, max, thick
(C356, 649°C) (C356, 649°C)
1.25% by 50% by weight, 50% by weight,
Absorption, max. weight @316°C @316°C
(C1104) (C1104)
(C1104) (C610) (C610)
Water Vapor
N.A. N.A. N.A. N.A. N.A.
Transmission/
Surface burning
Flame spread 25 0 0 25 25
Smoke developed 50 5 5 50 50
Apparent thermal
conductivity (k),
W/mK, at mean
0.035 24 0.069 38 0.069 38 0.037 24 0.037 24
0.038 38 0.076 93 0.076 93 0.040 38 0.039 38
0.045 93 0.085 149 0.085 149 0.052 93 0.049 93
0.053 149 0.092 204 0.092 204 0.066 149 0.060 149
0.063 204 0.099 260 0.099 260
0.075 260 0.108 316 0.108 316
0.087 316 0.115 371 0.115 371
0.101 371

Mineral Mineral Mineral Mineral

Fiber Board Fiber Board Fiber Board Fiber Board
Material Properties & Block & Block & Block & Block
C612-04 C612-04 C612-04 C612-04
Type II Type III Type IVA Type IVB
Max Temp, °C 454 538 649 649

Min Temp, °C N.A. N.A. N.A. N.A.
Density, kg/m³ 96 (max) 160 (max) 192 (max) 192 (max)
Compressive strength, 1.2 0.6 2.4 2.4
min., kPa (Category 2 (Category 2 (Category 2 (Category 2
(C165, unless noted) only) only) only) only)
2%, max, 2%, max, 2%, max, 2%, max,
(C356,454°C) (C356, 538°C) (C356, 649°C) (C356, 649°C)
5% by weight 5% by weight 5% by weight 5% by weight
Absorption, max.
(C1104) (C1104) (C1104) (C1104)
Water Vapor
N.A. N.A. N.A. N.A.
Transmission/
Surface burning
Apparent thermal
conductivity (k),
W/mK, at mean
0.036 24 0.036 24 0.036 24 0.035 24
0.039 38 0.039 38 0.039 38 0.036 38
0.050 93 0.050 93 0.049 93 0.043 93
0.063 149 0.063 149 0.063 149 0.052 149
0.079 204 0.079 204 0.079 204 0.061 204
0.101 260 0.101 260 0.101 260 0.076 260
0.130 316 0.123 316 0.091 316
0.144 371 0.108 371

Rigid Rigid Rigid Rigid

Cellular Cellular Cellular Cellular
Phenolic Phenolic Phenolic Phenolic
Material Properties
C1126-04 C1126-04 C1126-04 C1126-04
Type II Type II Type III Type III
Grade 1 Grade 2 Grade 1 Grade 2
Max Temp, °C 141 141 141 141

Min Temp, °C -179 -40 -179 -40
Cell Structure closed open closed open
Density, kg/m³ 32 (min) 32 (min) 32 (min) 32 (min)
min., kPa 124 124 124 124
2%, max, 65°C, 97% RH
2%, max, 65°C, 97% RH
2%, max, -40°C, amb. RH
Dimensional Stability 2%, max, -40°C, amb. RH
2%, max, 141°C, amb. RH
(D2126)
(D2126)
3.0% by vol., 8.0% by vol., 3.0% by vol., 8.0% by vol.,
Absorption, max. foam core foam core foam core foam core
(C209) (C209) (C209) (C209)
1.3 (max), 1.3 (max), >5.8 (max),
ng∙Pa-1∙s-1∙m-1 N/A ng∙Pa-1∙s-1∙m-1 ng∙Pa-1∙s-1∙m-1
Water Vapor
(E96, desiccant (E96, desiccant (E96, desiccant
Transmission/
method, method, method,
23° C) 23° C) 23° C)
Surface burning foam core, foam core, foam core, foam core,
characteristics (E84): no facings no facings no facings no facings
Apparent thermal (foam core) (foam core) (foam core) (foam core)
conductivity (k),
W/mK, at mean
0.015 -157 0.015 -157 0.015 -157 0.015 -157
0.016 -129 0.016 -129 0.016 -129 0.016 -129
0.017 -101 0.017 -101 0.017 -101 0.017 -101
0.019 -73 0.019 -73 0.019 -73 0.019 -73
0.019 -46 0.019 -46 0.019 -46 0.019 -46
0.019 -17 0.019 -17 0.019 -17 0.019 -17
0.019 4 0.019 4 0.019 4 0.019 4
0.019 24 0.019 24 0.019 24 0.019 24
0.022 43 0.022 43 0.022 43 0.022 43
0.026 65 0.026 65

ASSOC. PIP: DOCUMENTATION
PIP INEG1000-D1
INEG1000 REQUIREMENTS SHEET
PAGE 1 OF 1
INSULATION DESIGN GUIDE OCTOBER 2010
NO. DATE REVISION DESCRIPTION BY CHECKED APPROVED
PROJECT NO. PROJECT DOCUMENT NUMBER

FACILITY NAME
LOCATION
PIP DOC NUMBER / TITLE REV DATE NOTES
PROJ DOC NUMBER
INEG1000-D2 YES NO HOT SERVICE INSULATION DESIGN
PARAMETERS
INEG1000-D3 YES NO COLD SERVICE INSULATION DESIGN
PARAMETERS
NOTES:
ASSOC. PIP: HOT SERVICE INSULATION
INEG1000 DESIGN PARAMETERS PIP INEG1000-D2
PAGE 1 OF 1
PROJECT NO. PROJECT DOCUMENT NO.

FACILITY NAME
LOCATION
HEAT CONSERVATION DESIGN BASIS:

Ambient temperature (average annual) °C °F
Wind speed (average annual) m/s mph
Insulation finish emissivity
Minimum insulation thickness mm in.
PERSONNEL PROTECTION DESIGN BASIS:

Ambient temperature (average summer maximum) °C °F
Maximum surface temperature °C °F
Wind speed m/s mph
ECONOMIC THICKNESS CALCULATION BASIS:

Interest rate %
Effective income tax %
Annual insulation maintenance %
Annual physical plant maintenance %
Annual fuel inflation rate %
Physical plant annual operating hours hr/year
Physical plant depreciation period years
New insulation depreciation period years
First year cost of energy (Natural Gas) $/Mm³ $/Mft³
Heating value J/m³ Btu/ft³
First year cost of energy ( ) ( )
Heating value ( )
Design factor for thermal conductivity
Design factor for piping complexity simple complex
Productivity factor
Insulation installation labor rate $/hr
Pipe Insulation Block Insulation
DN 50 x 50 mm 50 mm
Insulation material cost NPS 2 x 2 in. 2 in.
$/m $/ft $/m² $/ft²
$/m $/ft $/m² $/ft²
$/m $/ft $/m² $/ft²
$/m $/ft $/m² $/ft²
NOTES:
ASSOC. PIP: COLD SERVICE INSULATION
INEG1000 DESIGN PARAMETERS PIP INEG1000-D3
PAGE 1 OF 1
PROJECT NO. PROJECT DOCUMENT NO.

FACILITY NAME
LOCATION
HEAT GAIN LIMIT DESIGN BASIS:

Maximum heat gain - insulation surface W/m² Btu/hr•ft²
Design ambient temperature °C °F
Wind speed (average annual) m/s mph
CONDENSATION CONTROL DESIGN BASIS:

Design ambient temperature °C °F
Design relative humidity %
Design dew point temperature °C °F
Wind speed m/s mph
NOTES:

Insulation Design Guide

Hochgeladen von

Dokumentinformationen

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Insulation Design Guide

Hochgeladen von

Copyright:

Verfügbare Formate

REAFFIRMATION WITH EDITORIAL REVISION

Process Industry Practices

This Practice is subject to revision at any time.

Not printed with State funds

Process Industry Practices

Process Industry Practices Page 1 of 33

2.1 Process Industry Practices (PIP)

2.2 Industry Codes and Standards

American Petroleum Institute (API)

Page 2 of 33 Process Industry Practices

– ASTM C591 – Standard Specification for Unfaced Preformed Rigid

2.3 Other References

Federal Energy Administration Report

3.2 Closed-Cell Insulations

Process Industry Practices Page 3 of 33

3.3 Fibrous Insulations

Page 4 of 33 Process Industry Practices

3.4 Granular Insulations

3.5 Jacket Materials and Accessories

Process Industry Practices Page 5 of 33

manufacture. The benefit of this finish is that minor surface

Page 6 of 33 Process Industry Practices

Zinc embrittlement occurs if the zinc coating melts and the

3.6 Vapor Barriers

4. Insulation System Design

Process Industry Practices Page 7 of 33

4.2 Basic Design Criteria

Page 8 of 33 Process Industry Practices

insulation thickness exceeds the value of the additional energy

Process Industry Practices Page 9 of 33

emissivity also reduces the surface temperature and is a method

Page 10 of 33 Process Industry Practices

4.2.6 Cold Service Insulation

4.3 Other Design Criteria

Process Industry Practices Page 11 of 33

be necessary to select a jacket material that is resistant to the specific

Page 12 of 33 Process Industry Practices

chemical to achieve auto-ignition. It may be necessary to use an

5. Corrosion under Insulation

Process Industry Practices Page 13 of 33

6. Insulation Material Selection

6.2 ASTM Considerations

Page 14 of 33 Process Industry Practices

6.3 Insulation Materials Properties Table

Process Industry Practices Page 15 of 33

Page 16 of 33 Process Industry Practices

furnished to record project specific thicknesses calculated by 3E Plus

Process Industry Practices Page 17 of 33

9.2 Hot Insulation Types

Page 18 of 33 Process Industry Practices

9.2.3.3 Design of personnel protection insulation should be based on

9.3 Cold Insulation Types

Process Industry Practices Page 19 of 33

9.3.2.2 The only consideration for use of condensation control

Page 20 of 33 Process Industry Practices

9.4.7 CT – Chilled Fluid Traced

9.5 AC – Acoustic Control Insulation

9.6 FP – Fire-Protection Insulation

Process Industry Practices Page 21 of 33

Table 1: Insulation Materials Properties Table

Calcium Calcium Calcium Flexible Flexible

Page 22 of 33 Process Industry Practices

Table 1: Insulation Materials Selection Table (Continued)

Mineral Mineral Mineral