Kooltherm FM. Quick Guide. HVAC & Building Services Pipe Insulation System. UK & Ireland

Transcription

1 Kooltherm FM Quick Guide HVAC & Building Services Pipe Insulation System UK & Ireland

2 Contents Introduction 3 Kooltherm FM Pipe Insulation 4 Features & Benefits 6 Recommended Thickness 8 Kooltherm Pipe Supports 12 Kooltherm FireSleeves 14 Technical Data 16 Case Studies 17 Market Sectors 18 2

3 Introduction Kingspan is a market leading manufacturer of premium performance pipe insulation products and systems. Kingspan premium performance insulation products are the thinnest and most efficient products commonly available for the insulation of pipework in building services / HVAC, process and petrochemical applications and refrigeration services. Premier and Premier Plus Kingspan prides itself on offering a service to specifiers, consultants and contractors, seeking to improve the energy performance of buildings and reduce energy costs. With the superior Kingspan Kooltherm FM product range and renowned Pipeline Technical Advisory Service, Kingspan have combined the best offerings and produced the Premier and Premier Plus service packages. Designed for the needs of all projects, the Kooltherm FM Premier and Premier Plus Service guarantees manufacturing excellence, first class customer service and unrivalled expertise both offsite and on-site. Building Information Modelling (BIM) Kingspan Kooltherm FM Pipe Insulation is now available as a freely downloadable BIM file from the BIM Store and from the Kingspan Insulation website and is available in the leading Revit format. For further information, please contact the Pipeline Technical Advisory Service. 3

4 Kooltherm FM Pipe Insulation Kooltherm FM HVAC & Building Services Pipe Insulation Kooltherm FM Pipe Insulation comprises sections of Kooltherm FM Insulation faced with a factory-applied foil vapour barrier jacket autohesively bonded to the insulation core during manufacture. Kooltherm FM Pipe Insulation is CE Marked in accordance with BS EN Kooltherm FM Pipe Insulation is available in a range of thicknesses to suit different performance specifications and may be used on mild steel, stainless steel, carbon steel, copper and plastic pipework in standard and non-standard pipe diameters. Kooltherm FM Pipe Insulation is manufactured using state of the art continuous and slotted board technologies. Both methods feature the use of a unique bore coated liner and minimise production wastage. Kooltherm FM Pipe Insulation manufactured on the continuous process is supplied in 1 metre lengths and pipe insulation manufactured from slotted board is supplied in metre lengths. Kooltherm FM Pipe insulation is available in a standard density of 37 kg/m 3. Higher density pipe insulation sections and insulated pipe supports fabricated from 60 kg/m 3, 80 kg/m 3 and 120 Kg/m 3 densities are also available. Kooltherm Insulated Pipe Support System Kooltherm Insulated Pipe Support Inserts provide optimal load bearing capacity whilst offering protection against insulation compression. Designed for use in pipe supports, hanger brackets and clamps, they will support the compressive loads imposed by horizontal pipework carrying water or other liquids. 4

5 Vapour Barrier Jacket All Kooltherm FM Pipe insulation products and systems are faced, as standard, with an extremely durable and protective low vapour permeability aluminium foil or theatre black vapour barrier jacket reinforced with a glass scrim. The vapour barrier jacket is factory-applied to avoid onsite application, which carries the risk of vapour barrier damage and with it, a risk to the integrity of the system. This also reduces the labour cost for installation of the Kooltherm FM Pipe Insulation System. A matching self adhesive tape is available to complete the vapour barrier at joints and breaks. 5

6 Features & Benefits Thermal Performance With a 25 year aged thermal conductivity as low as W/m K (at 10 C mean), Kooltherm FM Pipe Insulation is the most thermally efficient insulation material commonly used. A low thermal conductivity allows specified thermal performance standards to be achieved with thinner insulation. The superior thermal performance of Kooltherm FM Pipe Insulation derives mainly from its closed cell properties. Its closed cell structure has been optimised to resist heat transfer. The closed cells have a small solid to void volume ratio, are small and uniform in size, and their construction very fine with extremely thin walls and minimum point contacts (struts). They are filled with a thermally efficient CFC/ HCFC-free blowing agent that has zero Ozone Depletion Potential (ODP) and low Global Warming Potential (GWP). As a result of its closed cell, fibre free structure, Kooltherm FM Pipe Insulation is unaffected by air infiltration problems that can be experienced with mineral fibre and which can reduce thermal performance. Cellular Glass Calcium Silicate Nitrile Rubber Rock Mineral Fibre Expanded polystyrene (EPS) Glass Mineral Fibre Extruded Polystyrene (XPS) Polyisocyanurate Kooltherm FM Moisture Resistance Kooltherm FM Pipe Insulation has a 90% (or greater) closed cell structure, which makes it non-wicking and highly resistant to moisture penetration. The risk of moisture absorption into the insulation is effectively eliminated as the factory-applied facing to Kooltherm FM Pipe Insulation products and systems provides a high performance vapour barrier jacket. 6

7 Fire Kooltherm FM Pipe Insulation products and systems have a densely cross-linked structure that makes them difficult to ignite and when subjected to fire, the outer surface forms a strong carbonaceous layer that limits heat generation and retards further flame spread. The excellent fire and smoke performance characteristics of Kooltherm FM Pipe Insulation products and systems clearly demonstrates their suitability for the designated application, with best in class European Reaction to Fire performance of B L,s1,d0. Kooltherm FM Pipe Insulation is FM Approved per Approval Standard Class Fire Test Classifications (Kooltherm FM Insulation) Property Test Method Typical Result Reaction to fire EN B L - s1, d0 Surface Burning Characteristics ASTM E 84 Class A/1 Fire propagation BS Index of performance (l) not exceeding 12 and sub-index (i 1 ) not exceeding 6* Flame spread BS Class 1* * These test results combined enable a Class 0 classification to the Building Regulations in England & Wales, Northern Ireland and the Republic of Ireland, and a Low Risk classification to the Building Standards in Scotland. Environmental Kooltherm FM Pipe Insulation can directly contribute towards the award of several credits under the previous and current versions of BREEAM. The product holds a highest possible BRE Green Guide rating of A+ and is manufactured to a BS EN ISO 14001: 2004 scheme, qualifying for the Responsible Sourcing credit. In addition, Kingspan Industrial Insulation offers a 'zero landfill, take-back' scheme, using waste product collected from off-site manufacturers for recycling or energy recovery. Manufactured to BS EN ISO 9001: 2008 Certificate No /1 Manufactured to BS EN ISO 9001: 2008 Certificate No QMS BS EN ISO 14001: 2004 Certificate No EMS BS OHSAS 18001: 2007 Certificate No HS 7

8 Recommended Thickness Insulation Thickness Table to Control Heat Loss: BS 5422:2009 Water at 60 C Water at 75 C Steel Pipe Size Kooltherm FM max. heat loss Kooltherm FM max. heat loss NB NB OD ε=0.05 ε=0.9 ε=0.05 ε=0.9 (inches) (mm) (mm) silver black (W/m) silver black (W/m) 3 / ½ ¾ ¼ ½ ½ Estimated Mean Temperature of Insulation: +50 C Ambient Air Temperature: +15 C Surface Emissivity e (Outer Surface): 0.05 / 0.9 Assumed Thermal Conductivity (k value) of Kooltherm FM 37kg/m 3 Insulation: W/m. K Table 1: Indicative Thickness (mm) of Insulation for Non-Domestic Hot Water (60 C) and Low Temperature Heating Service Areas (75 C) to Control Heat Loss (Based on Non-domestic Building Services Compliance Guide: 2013 Edition, Section 11; TIMSA HVAC Guide Sections & 6.2.2; and BS 5422:2009 Tables 15 & 18) 8

9 Insulation Thickness Table to Control Heat Loss: ECA & Y50 Enhanced Water at 60 C Water at 75 C Steel Pipe Size Kooltherm FM max. heat loss Kooltherm FM max. heat loss NB NB OD ε=0.05 ε=0.9 ε=0.05 ε=0.9 (inches) (mm) (mm) silver black (W/m) silver black (W/m) 3 / ½ ¾ ¼ ½ ½ Estimated Mean Temperature of Insulation: +50 C Ambient Air Temperature: +15 C Surface Emissivity ε (Outer Surface): 0.05 / 0.9 Assumed Thermal Conductivity (k value) of Kooltherm FM 37kg/m 3 Insulation: W/m. K Table 2: Indicative Thickness (mm) of Insulation for Non-Domestic Hot Water (60 C) and Low Temperature Heating Service Areas (75 C) to Control Heat Loss (Based on NES Y50 Enhanced and Enhanced Capital Allowance thickness tables) 9

10 Recommended Thickness Insulation Thickness Table to Control Heat Gain & Control Condensation Water at 0 C Water at 5 C Water at 10 C Steel Pipe Size max max max Kooltherm FM heat gain Kooltherm FM heat gain Kooltherm FM heat gain NB NB OD ε=0.05 ε=0.9 ε=0.05 ε=0.9 ε=0.05 ε=0.9 (inches) (mm) (mm) silver black (W/m) silver black (W/m) silver black (W/m) 3 / ½ ¾ ¼ ½ ½ * * * * * * * * * * * * * * * * * * Ambient Air Temperature: +25 C Relative Humidity: 80% Surface Emissivity ε (Outer Surface): 0.05 / 0.9 Assumed Thermal Conductivity (k value) of Kooltherm FM 37kg/m 3 Insulation: W/m. K Table 3: Indicative Thickness (mm) of Insulation required for cold and chilled water supplies to control heat gain and control condensation *For pipes and vessels of diameter greater than 273mm, the items shall be assumed to be 273mm for calculation purposes (Based on Non-domestic Building Services Compliance Guide: 2013 Edition, Section 11; TIMSA HVAC Guide Sections & 7.2; and BS 5422:2009, Tables 6, 8, 10 & 11) 10

11 Insulation Thickness Table to Protect Against Freezing Steel Pipe Size Pipe Location NB NB OD ID (inches) (mm) (mm) (mm) Indoor Outdoor ½ ¾ ¼ ½ ½ Copper Pipe Size Pipe Location NB ID (mm) (mm) Indoor Outdoor Ambient Air Temperature Indoor: 6 C Ambient Air Temperature Outdoor: 10 C Initial Water Temperature: +2 C Evaluation Period: 12 hours Permitted Ice Formation: 50% Assumed Thermal Conductivity (k value) of Insulation: Kooltherm FM W/m. K Table 4: Minimum Thickness (mm) of Insulation required to give protection against freezing under specified commercial and institutional conditions (based on BS 5422:2009 Table 29) 11

12 Kooltherm Insulated Pipe Support Inserts Kooltherm Insulated Pipe Support Inserts are available to suit a full range of pipe diameters and in a full range of insulation thicknesses as shown in the following table; however, special sizes are available on request. In addition to allowing a continuous vapour barrier on below ambient systems, thermal analysis of a +75 C LTHW system to EN ISO 10211:2007 has shown that Kooltherm Insulated Pipe Support System can limit heat loss by up to 4x more than rubber lined pipe clips, 5x more than metal pipe clips and 10x more than hardwood pipe support inserts. Conventional Pipe Support Methods Pipe Support fixed direct to pipework Pipe support Rubber lined pipe support Thermal analysis* illustrates heat loss of up to 4 x greater than through the Kooltherm Insulated Pipe Support System. Timber support Timber support insert Thermal analysis* illustrates significant heat loss of up to 10 x greater than through the Kooltherm Insulated Pipe Support System. *When analysed in accordance with BS EN ISO 10211: 2007 Pipe support Load bearing calculations for the standard range of Kooltherm Insulated Pipe Support Inserts are based upon the minimum compressive strength of the relevant density and include a safety factor of five. They are designed to support the maximum static compressive loads imposed by horizontal water filled mild steel and copper pipework with hanger supports spaced at the maximum centres shown below. Kooltherm Insulated Pipe Support Inserts are not designed to accommodate pipe anchor loads and stresses. Steel Pipe Steel Pipe Size Kooltherm Insulated Pipe Support Inserts DN DN OD Length Max. Load Spreader Plate Support Distance Density (in) (mm) (mm) (mm) (kg) (mm) (m) (kg/m 3 ) ½ none 3 60 ¾ none none ¼ none ½ ½ Values given are based upon Kooltherm insulated pipe support inserts with an integral metal spreader plate. 12

13 * Kooltherm Insulated Pipe Support Inserts are supplied with a self-adhesive lap. Kooltherm FM Pipe Insulation sections should be vapour sealed to the pipe support. Copper Pipe Steel Pipe Size Kooltherm Insulated Pipe Support Inserts DN DN OD Length Max. Load Spreader Plate Support Distance Density (in) (mm) (mm) (mm) (kg) (mm) (m) (kg/m 3 ) none none none none none Values given are based upon Kooltherm insulated pipe support inserts with an integral metal spreader plate. 13

14 Kooltherm FireSleeve Kooltherm FireSleeves are a unique combination of high performance phenolic insulation, intumescent and stainless steel. These innovative products act as a 2 hour fire stop to BS EN 1366, on both steel and copper pipe service penetrations through timber frame and block wall applications, and incorporate the excellent fire and smoke performance of Kooltherm FM Pipe Insulation. Kooltherm FireSleeves comprise of an outer sleeve of 0.5mm thick stainless steel which is clasp fastening and 205mm in length. It is lined with intumescent material. The stainless steel sleeve, encloses a 300mm length of Kooltherm FM Pipe Insulation which is also lined with intumescent material. Kooltherm FireSleeves can be supplied in the following sizes: Steel NB 20mm 25mm 30mm 35mm (mm) thick thick thick thick Copper NB 20mm 25mm 30mm (mm) thick thick thick Kooltherm FireSleeves have been tested to BS EN 1366 by BM Trada and receive 120 minutes fire integrity and 60 minutes thermal insulation. 14

15 l Prepare opening in the wall, with minimal disturbance to surrounding structure. l Open Kooltherm FireSleeve and install the 300mm lined Kooltherm Insulation onto the pipe. Fit the 205mm stainless steel fire sleeve over the intumescent lined Kooltherm FM Pipe Insulation and ensure that the stainless steel clasp is fully engaged. l Ensure the Kooltherm FireSleeve is positioned centrally within the opening. l Seal any gaps of 5mm or less around the exterior surface of the Kooltherm FireSleeve with a 2hr. l Fire Rated Intumescent Mastic. Large gaps over 5mm should be filled with an appropriate fire rated filler or mortar. l Install Kooltherm FM Pipe Insulation flush to the Kooltherm FireSleeve and vapour seal in accordance with the project specification

16 Technical Data General Physical Properties (Kooltherm FM Insulation System) Property Test Method Unit Typical Value Nominal Density (EN ISO 845) / kg/m (ASTM D 1622) Thermal Conductivity (EN 12667) / W/m. K at +10 C (ASTM C 518) Colour Pink Grey Grey Grey Closed Cell Content (EN ISO 4590) Method 1 / (ASTM D 2856) Method B % 90 Operating Temperature: Pipe Section Upper Limit C Lower Limit C Slotted Board Pipe Section Upper Limit C +100 Lower Limit C 0 Minimum Compressive (EN 826) / (ASTM D 1621) Strength at +23 C Parallel kpa Perpendicular kpa General Physical Properties (Vapour Barrier Jacket) Property Test Method Unit Typical Value Weight (EN ISO 536) g/m Thickness (EDANA) µm Tensile Strength MD/CD (EN ) N/15 mm > 30 / > 50 Water Vapour Transmission (ASTM F 1249) g/m 2.24 hr < 0.1 (ASTM E 96) g/m 2.24 hr 0.01 Fire Test Classifications (Kooltherm FM Insulation) Property Test Method Typical Result Reaction to fire EN B L s1, d0 Surface Burning Characteristics ASTM E 84 Class A/1 Fire propagation BS Index of performance (l) not exceeding 12 and sub-index (i 1 ) not exceeding 6* Flame spread BS Class 1* * These test results combined enable a Class 0 classification to the Building Regulations in England & Wales, Northern Ireland and the Republic of Ireland, and a Low Risk classification to the Building Standards in Scotland. Kooltherm FM Pipe Insulation and Kooltherm Insulated Pipe Supports are CE Marked in accordance with BS EN All Kingspan cardboard packaging uses 100% recycled content and is 100% recyclable. BIM files are now available for free download from 16

17 Case Studies Westfield Shopping Centre The Venetian Macao-Resort-Hotel The Engine Shed, Lincoln University Silverstone UTC Image supplied courtesy of DB Photography Birmingham Library Marks & Spencer 17

18 Market Sectors Marine Terminal & LNG Industrial Hotel Retail Processing Leisure 18

19 Apartments Infrastructure Commercial Healthcare Education 19

20 An Introduction to Kingspan KoolDuct Overview The heating, ventilation and air conditioning (HVAC) industry is in the midst of a dynamic era, however air distribution ductwork remains virtually unchanged since the early 1900s. Several factors have introduced the need to revolutionise HVAC ductwork. Energy use has continued to escalate, and thus the demand for energy reducing solutions has intensified. Requirements for clean air are becoming increasingly prevalent. Speed of construction has become a valuable asset. Floor space and headroom are under constant pressure. Traditionally, HVAC ductwork is constructed from galvanised sheet steel, which is installed first and then insulated separately as a second operation. The Kingspan KoolDuct System however, is an advanced and innovative pre insulated rectangular HVAC ductwork system, which is installed in a single fix. The Kingspan KoolDuct System eliminates virtually all of the problems associated with galvanised sheet steel, mineral fibre duct board and pre insulated rigid polyisocyanurate (PIR) ductwork systems whilst, at the same time, offering additional advantages to the specifying engineer, the architect, the M&E contractor, the fabricator, the facilities manager, the property developer and the building owner. Ductwork fabricated from The Kingspan KoolDuct System can reduce air leakage rates to a fraction of those typical of rectangular sheet metal ductwork. This cutting edge System thus offers the triple benefits of cutting energy use, cutting operational carbon dioxide (CO 2 ) emissions and cutting costs. As a result, The Kingspan KoolDuct System should be considered the ductwork system of choice, where low embodied environmental and low operational environmental impacts are key requirements. Kingspan KoolDuct System Plenum Box Tiger Clip Coupling System Aluminium Grip Coupling System Tiger Support & Wire Hanger Assembly Volume Control Damper 20

21 4 bolt Coupling System Pre insulated Circular Duct Steel Channel Support & Threaded Rods Reinforcement System Fire Damper Turning Vanes Access Panel What is The Kingspan KoolDuct System? The Kingspan KoolDuct System comprises premium performance Kingspan KoolDuct panels, fabrication methods, coupling systems and a complete line of accessories to produce pre insulated rectangular ductwork in sections up to 2.95 m long. Kingspan KoolDuct panels are available in a standard thickness of 30 mm. They comprise a non fibrous rigid thermoset modified resin insulation core faced with silver aluminium foil on one side and either silver or black coated aluminium foil on the other. In addition, there are several coupling systems available to suit different installation and project specification requirements. They include the 4 bolt, aluminium grip and Tiger Clip systems. The design of ductwork, including fittings, fabricated from The Kingspan KoolDuct System follows the same calculation principles and duct sizing methods as are used for ductwork constructed from galvanised sheet steel. Kingspan Insulation offers a complete product line, providing all materials, tools and accessories necessary for the effective fabrication of ductwork from The Kingspan KoolDuct System. Ductwork from The Kingspan KoolDuct System is only fabricated by specially trained fabricators who have completed The Kingspan KoolDuct System Training Course, and who are registered on The Kingspan KoolDuct System Competent Persons Database. The required standards of fabrication are detailed in The Kingspan KoolDuct System Fabrication Manual series of publications. 21

22 An Introduction to Kingspan Kooltherm FM Duct Insulation Overview The Kingspan Kooltherm FM Duct Insulation System is a premium performance thermal insulation designed for use on rectangular, circular and flat oval ductwork in HVAC / building services applications. It can be used to insulate ductwork, plenums and associated equipment, installed both indoors and outdoors, operating within the temperature range of 20 C to +80 C. Kingspan Kooltherm FM Duct Insulation is suitable for both new build and refurbishment projects in the residential, commercial, institutional, light industrial and leisure sectors. Moreover, it is especially suitable for high specification projects where non fibrous insulants may be preferred, for example: in the food, beverage and pharmaceutical industries; communication / server rooms in data centres; high relative humidity environments such as swimming pools; and clean air and hygiene controlled environments such as sterile areas of hospitals or laboratories. Kingspan Kooltherm FM Duct Insulation has been developed to provide premium performance with regards to insulation efficiency, fire resistance, smoke emissions, compressive strength and cost. Kingspan Kooltherm FM Duct Insulation Kingspan Kooltherm FM Duct Insulation comprises a non fibrous rigid thermoset phenolic insulation core, faced on one side (external face) with a 25.4 micron aluminium vapour barrier foil, and faced on the other side (internal face) with a glass tissue based facing. Both facings are autohesively bonded to the insulation core during manufacture. The insulation core is manufactured with a blowing agent that has zero Ozone Depletion Potential (ODP) and low Global Warming Potential (GWP). Kingspan Kooltherm FM Duct Insulation Insulation has a 90% (or greater) closed cell structure and a compressive strength that typically exceeds 100 kpa at 10% compression. The product can be V grooved through its internal face to accommodate the surface curvature of circular and flat oval ductwork with an outside diameter (O.D.) of 80 mm or greater*. The rigid nature of Kingspan Kooltherm FM Duct Insulation enables the specified thickness of insulation to be maintained at the corners of ductwork, and at locations where HVAC / building services equipment is specified. Non rigid glass and rock mineral fibre duct wrap products, on the other hand, risk being overstretched and compressed in these locations, potentially leading to a reduction in thermal performance. Steel channel & threaded rod support system Flat oval duct Figure 1: Fixing Details Kingspan Kooltherm FM Pipe Insulation installed on curved surfaces < 80 mm Ø Kingspan Kooltherm FM Flat Insulated Duct Support Insert installed to extend 50 mm either side of support Kingspan Kooltherm Insulated Pipe Support Insert installed on circular ductwork < 80 mm Ø 22

23 High strength contact adhesive applied in accordance with manufacturer recommendations Kingspan Kooltherm FM Duct Insulation installed on flat surfaces such that the insulation fixed to the top & bottom, overlaps the insulation fixed to the sides Its rigidity also enables the straightforward application of vapour barrier tape and finishing materials which, in turn, facilitates the creation of a continuous and fully sealed vapour barrier. This can provide a neater, cleaner, closer fitting and more aesthetically pleasing finish than that achievable with non rigid glass or rock mineral fibre duct wrap products. Kingspan Kooltherm FM Insulated Duct Support Inserts Kingspan Kooltherm FM Insulated Duct Support Inserts can be fabricated on site from Kingspan Kooltherm FM Duct Insulation. They can withstand the loads imposed by HVAC / building services ductwork at locations where ductwork supports and hangers are installed. Kingspan Kooltherm FM Duct Insulation can be fabricated on site to create two different types of Insulated Duct Support Inserts: l Kingspan Kooltherm FM Flat Insulated Duct Support Inserts; and l Kingspan Kooltherm FM Circular Insulated Duct Support Inserts. Rectangular duct Mechanical fixing firmly attached to duct wall Hanger bracket Self adhesive aluminium foil vapour barrier tape securely applied in a smooth & wrinkle free manner to extend 25 mm either side of joints, seams, exposed insulation edges, insulation terminations, pin punctures, retaining washers and other protrusions Kingspan Kooltherm FM Circular Insulated Duct Support Insert installed on circular ductwork 80 mm Ø & to extend 50 mm either side of support Circular duct Kingspan Kooltherm FM Duct Insulation V grooved through its internal face to accommodate curved surfaces 80 mm Ø 23

24 Kingspan Industrial Insulation Ltd Pembridge, Leominster, Herefordshire, HR6 9LA, United Kingdom Tel: +44 (0) Fax: +44 (0) Bree, Castleblayney, Co. Monaghan, Ireland Tel: Kingspan, Kooltherm and the Lion Device are Registered Trademarks of Kingspan Group plc in the UK, Ireland and other countries. All rights reserved. Kingspan Industrial Insulation Ltd reserves the right to amend product specifications without prior notice. All information, technical details and fixing instructions etc. included in this literature are given in good faith and apply to uses described. Recommendations for use should be verified as to the suitability and compliance with actual requirements, specifications and any applicable laws and regulations. For other applications or conditions of use, Kingspan Industrial Insulation Ltd offers a free Technical Advisory Service the advice of which should be sought for uses of Kingspan Industrial Insulation Ltd products that are not specifically described herein. Please check that your copy of the literature is current by contacting the Marketing Department. Published April 2015