Solutions for industrial pipe work insulation Technical Insulation November 2006
Prefabricated insulation components for superior pipe work insulation Pipes are a crucial component in industrial processes. Whether in power plants or process industries, well-designed and efficient pipe work is a prerequisite for a properly functioning operation. A demanding application It is obviously also highly advantageous if the insulation installation process is as easy and fast as possible. As well as making the installation itself more economical and reducing the amount of shutdown time, it also leads to more error-free installation, which increases the long-term reliability of the insulation. An effective solution Paroc considered these requirements when developing solutions for industrial pipe work insulation, which consist of industrially manufactured, mutually compatible insulation components for straight pipes and pipe elbows. In terms of life-long optimal performance, and speed and ease of installation, industrial insulation solutions are unrivalled, their pipe section structure enabling the preservation of cladding systems throughout any work done. These solutions comprise standard pipe insulation, multilayer pipe insulation and pipe elbow insulation. For more demanding conditions, the principal solution is compatible multilayer insulation. Fast, economical installation One of the primary advantages of Paroc s multilayer insulation solutions over wired mat insulations is the ease and accuracy of the installation process. Because of the extremely high dimensional accuracy and compatibility of the factory-made components, such as bends and segments, installation is straightforward and easy and results in a technically superior insulation performance. The components do not need to be further measured or modified on-site, nor do they require any of the additional metal supporting structure associated with wired mats. This eliminates a common cause of heat loss. The benefits of Paroc s industrial insulation solutions are particularly significant when insulating pipe elbows. The same material, with the same properties, is used - but without the need for the on-site cutting and supporting rings that make installing traditional mat insulation so time consuming. The installation of the prefabricated insulation components is significantly faster than with wired mat insulations. This results in substantial savings in direct and indirect costs. Installation requires fewer installers, and less equipment, including scaffolding. The work is also easier to schedule and takes less time. Because of the highly accurate dimensioning of Paroc s factory-made solutions, there is practically no wasted insulation left over, which keeps the site tidy and is a visible example of how cost-effective the solution is. Paroc s solutions for industrial pipe work insulation For industrial use, we have a large range of pipe sections designed for various requirements. The table on page 3 shows the main products and combinations of products for different applications. The insulating layers that are shown in the table are Paroc recommendations, but it is also possible to use fewer layers. In cases where PAROC Section or PAROC Segment is required, PAROC Section 140 or PAROC Segment 140 may also be used. All products which have DL in their product name are single products based on two product pieces, one fitted inside the other. In temperatures of over 250 C, at least two layers of insulation are recommended. We highly recommend the use of products with a density of 140 kg/m 3 as a first layer when the pipe temperature is over 350 C (see table). Benefits of PAROC industrial pipe work insulation system: Minimal heat losses due to multilayer overlapping. Same insulation capacity for both straight pipe sections and elbow insulations. High mechanical strength, even at high temperatures. A density of up to 140 kg/m 3 provides the best solution for high temperatures and demanding conditions. Easy to install. No additional support required. Compatible pipe sections and elbow insulations. No unnecessary waste resulting from on-site dimensioning. Faster and more economical installation. Wide selection of sizes helps in achieving the right thicknesses for standard and special pipe work. Consistent dimensions Exact outer diameters Well-fitting pipe insulations fitted one on top of the other 2
Insulate effectively By using PAROC Lock and PAROC Lock 140 pipe sections, heat loss can be reduced by at least 25-30% compared to wired mat insulation. If a certain maximum heat loss in the pipeline is required, the insulation thickness can be reduced significantly. This reduces the insulation material costs, cladding costs and labour costs. The total reduction in costs is about 25%. In addition, the installation time is shorter, which means scaffolding and other equipment is needed for less time, and general on-site costs are lower. Furthermore, the insulation does not sag over time, so its thickness and effectiveness remain consistent for the whole lifetime of the pipeline. High temperature pipe insulation is always a multilayer construction. The number of layers can be reduced by using PAROC Lock and PAROC Lock 140 pipe sections. Paroc s solutions for industrial pipe work insulation Temp. Insulation thickness Insulation for straight pipes Insulation for pipe elbows Insulating layer Insulating layer C s, mm 1. 2. 3 1. 2. 3 250 < 120 PAROC Section PAROC Segment > 250 120 PAROC Section DL (PAROC Section + PAROC Section) > 350 > 120 PAROC Section DL1 PAROC Section 1) (PAROC Section 140 + PAROC Section) 250 160 with PAROC Lock and PAROC Lock 140 PAROC Lock PAROC Segment DL (PAROC Segment + PAROC Segment) PAROC Segment DL1 (PAROC Segment 140 + PAROC Segment) PAROC Segment DL (PAROC Segment + PAROC Segment) > 250 > 160 PAROC Lock PAROC Section PAROC Segment DL (PAROC Segment + PAROC Segment) > 350 > 160 PAROC Lock 140 PAROC Section PAROC Segment DL 140 2) (PAROC Segment 140 + PAROC Segment 140) > 320 PAROC Lock 140 PAROC Section DL (PAROC Section + PAROC Section) PAROC Segment DL 140 2) (PAROC Segment 140 + PAROC Segment 140) PAROC Segment PAROC Segment PAROC Segment 1) PAROC Segment DL (PAROC Segment + PAROC Segment) 1) Instructions concerning one and double layer insulation solutions are meant to prevent gaps forming in the insulation. If the total insulation thickness is so great that the thickness of available products in two layers is not sufficient, three or more layers of insulation are used. 2) When PAROC Lock 140 is used as the first layer of insulation in a straight pipe, the first layer of the pipe elbow is insulated with PAROC Segment 140 in layers until it has the same insulation thickness as PAROC Lock 140. 3
Double layer pipe insulation solutions With double layer insulation solutions, two products are handled as one, drastically cutting down installation work. Each package includes all of the products required for both the inner and outer layers, eliminating unnecessary waste. The parts are precision measured during production to ensure compatibility and a good fit, while handling and pairing them is straightforward since they arrive fitted together, one inside the other. Thus, such a solution saves on work and costs, helps keep the site tidy and provides first class insulation characteristics. Large pipe elbows Paroc has developed a special solution for pipe elbow insulation that performs just as effectively as straight pipe insulation. These prefabricated insulation components are cut into precisely-dimensioned segments and provide a professional solution for the insulation of large pipe elbows. The benefits of double layer insulation can also be utilised in pipe elbows by using double layer segments, where the seams are sealed in order to minimise heat loss. We produce segments for 90 pipe elbows with a standard radius of 1.5 x D and 2.5 x D (see table). Upon request we can produce segments for any elbow radius and insulation thickness. For more information please contact your local Paroc representative. PAROC segments PAROC segments for 90 pipe elbows Standard radius 1.5 x D and 2.5 x D Inner diameter of segment Outer diameter of segment Max insulation thickness Radius of pipe elbow Segments for 90 elbow Pieces/package mm mm mm mm pcs Poland Finland R=1.5 D 127 323 100 171 4 13 13 140 336 100 190 4 14 14 168 414 120 229 4 11 11 178 414 120 245 4 11 11 194 440 120 270 4 10 8 208 492 140 290 4 9 8 219 544 160 305 4 8 7 230 544 160 320 4 8 7 259 661 200 366 4 7 6 273 673 200 381 4 6 5 295 700 200 413 4 6 5 324 726 200 457 6 9 7 356 752 200 534 6 7 6 406 804 200 610 8 9 7 457 856 200 686 8 8 7 508 986 240 762 8 7 6 558 1038 240 837 8 6 5 612 1168 280 914 8 5 5 714 1311 300 1067 10 6 5 762 1285 260 1143 10 6 5 813 1298 240 1219 12 6 5 914 1311 200 1372 12 6 5 1016 1298 140 1524 12 4 R=2.5 D Example 140 466 160 350 4 7 6 168 570 200 420 4 6 5 219 817 300 510 6 7 6 273 869 300 650 6 6 5 324 921 300 775 6 5 4 356 960 300 850 8 6 5 406 1012 300 970 8 5 4 457 1051 300 1123 10 6 5 508 1103 300 1245 10 5 4 612 1207 300 1525 10 4 3 630 1233 300 1600 12 5 4 714 1311 300 1778 12 4 4 813 1290 240 2033 12 4 3 914 1311 200 2285 12 3 3 1016 1298 140 2540 14 3 Double layer segment solution on a pipe elbow continues with a PAROC Lock pipe section. 4
Installation instructions for PAROC segments Installing segments and pipe sections. In bigger pipe elbows we recommend two bindings per segment. 1. Begin installation by placing the PAROC Lock pipe section on the straight pipe close to the welding joint, with the male part overlapping the joint. From the opposite end of the pipe elbow, install a PAROC Segment onto the elbow so that the end of the segment and the cut end of the pipe section meet. Align the central line on the segment with the central line of the pipe when viewed from the side of the pipe elbow. 2. Install the required number of segments on the pipe elbow, aligning the central line markings. Attach the segments with a wire or steel band, with e.g. one steel band per segment, in the middle. This will ensure adequate binding of the segment, with the bindings shaping the back of the pipe elbow in a manner which facilitates the installation of cladding. Installing prefabricated segments is a technically effective, fast and economical way of insulating pipe elbows. By having a pipe elbow insulated with PAROC segments, you can cut costs, gain quality improvements and reduce unnecessary heat loss thanks to the segments dimensional accuracy. Such accuracy provides major added value compared to on-site wired mat installation by eliminating the need to measure or fabricate external cladding on-site, and the requirement for any reinforcements, while still providing tightly fitting seams. Easily installed cladding makes a good result even more likely. The segments are attached to the pipe elbow with wire or steel bandaging, taking account of any site requirements, such as those set by the operating temperature. On the segments, central lines have been marked following the curvature of the pipe elbow, in order to facilitate installation. The cutting surfaces of the segments at the ends of the elbow should be perpendicular to the central line of the straight pipe. We would be delighted to give you a practical demonstration of this system. Please contact your local Paroc representative. 3. In double layer insulation, attach each layer separately, overlapping the seams by approx. 50 mm. Apply the inner layer using one binding (as mentioned in section 2) and the outer layer with one or two bindings per segment, approximately 50 mm from the ends of the insulated part. The amount of binding depends on the outer diameter of the pipeline. 4. Pipe elbows with a different curvature radius to those covered in this guide can be insulated using segments as per the diagram, by rotating the segments along the axis of the pipe elbow and aligning the central line markings at equally spaced intervals. The interval dimension (angle of rotation) is best achieved by experimenting: when insulation parts are rotated 180 with respect to each other (i.e. so that the marks are at opposite sides) they form a straight pipe section. 5
Selecting multilayer pipe sections and segments Selection table for multilayer pipe sections and segments Inner Nominal insulation thickness, mm diameter 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 mm Outer diameter, mm 12 52 72 92 115 15 52 72 92 115 18 62 82 102 115 141 22 62 82 102 128 141 28 72 92 102 128 154 35 72 92 115 141 154 180 193 42 82 102 128 141 167 180 206 48 92 115 128 154 167 193 206 54 115 128 154 180 193 219 57 115 141 154 180 193 219 60 115 141 154 180 206 219 245 258 64 128 141 167 180 206 219 245 258 70 128 154 167 193 206 232 245 271 76 141 154 180 193 219 232 258 271 89 154 167 193 206 232 245 271 284 310 323 102 167 180 206 219 245 258 284 297 323 336 108 167 193 206 232 245 271 284 310 323 349 114 180 193 219 232 258 271 297 310 336 349 121* 180 206 219 245 258 206 297 323 336 362 127 193 206 232 245 271 284 310 323 349 362 133 193 219 232 258 271 297 310 336 349 375 140 206 219 245 258 284 297 323 336 362 375 159 219 245 258 264 297 323 336 362 375 401 162* 219 245 258 284 297 323 336 362 388 401 168 232 245 271 284 310 323 349 362 388 414 427 453 466 492 178* 232 258 284 297 323 336 362 375 401 414 440 453 479 492 191 245 271 297 310 336 349 375 388 414 427 453 466 492 505 194 258 271 297 310 336 349 375 388 414 440 453 479 492 518 208 271 284 310 323 349 362 388 414 427 453 466 492 505 531 219 284 297 323 336 362 375 401 414 440 453 479 505 518 544 230 284 310 336 349 375 388 414 427 453 466 492 505 531 544 240 297 323 336 362 375 401 414 440 466 479 505 518 544 557 245 310 323 349 362 388 401 427 440 466 479 505 531 544 570 259 323 336 362 375 401 414 440 453 479 505 518 544 557 583 273 336 349 375 388 414 427 453 479 492 518 531 557 570 596 289 375 388 414 427 453 466 492 505 531 544 570 583 609 295 375 401 414 440 453 479 492 518 531 557 570 596 609 305 388 401 427 440 466 479 505 531 544 570 583 609 622 324 401 427 440 466 479 505 518 544 570 583 609 622 649 356 453 479 492 518 531 557 570 590 622 635 661 674 371 446 492 505 531 557 570 596 609 635 648 674 687 406 505 531 544 570 583 609 622 640 661 687 700 726 426 631 544 570 583 609 622 648 661 687 700 726 752 457 557 583 596 622 635 661 674 700 713 739 752 778 479 583 596 622 635 661 674 700 713 739 765 778 804 508 609 622 648 674 687 713 726 752 765 791 804 830 533 635 648 674 687 713 739 752 778 791 817 830 856 558 661 674 700 713 739 752 778 804 817 843 856 882 612 713 726 752 778 791 817 830 856 869 895 908 934 630 726 752 765 791 804 830 856 869 895 908 934 947 714 817 830 856 869 895 906 934 960 973 999 1012 1038 762* 856 882 908 921 947 960 986 999 1025 1038 1064 1077 813 908 934 947 973 999 1012 1038 1051 1077 1090 1116 1129 822* 921 947 960 986 999 1025 1038 1064 1077 1103 1116 1142 914 1012 1038 1051 1077 1090 1116 1129 1155 1168 1194 1220 1233 1016* 1116 1142 1155 1181 1194 1220 1233 1259 1272 1290 1311 1337 nnn Standard dimensions * Inner diameter available only in Finland Example Pipe DN 200, insulation thickness requirement 200 mm, product PAROC Section in two layers = PAROC Section DL: 1. Select pipe section size 406-100 mm (outer diameter 609 mm). 2. Select second layer 612-100 mm (outer diameter 817 mm). Orders: When ordering, always specify double layer solutions and list the pipe section and segment pairs to be used. The example mentioned in this brochure will be marked in the invoice and other documents as PSDL 406-100+100-817. PAROC Lock and PAROC Lock 140 product range 6
Insulating pipe elbows with prefabricated bends For the elbows of small and medium size pipelines, Paroc has developed PAROC Section Bends. Like PAROC segments for large pipe elbows, PAROC Section Bends perform just as effectively as Paroc s pipe sections for straight pipelines. Designed for pipe elbows of 90, PAROC Section Bends benefit from extremely accurate dimensioning. This means that the installation of the insulation can be very accurate, which in turn leads to optimal final performance. We produce bends for 90 pipe elbows with a standard radius of 1.5 x D (see table). Upon request, we can produce bends for any elbow radius and insulation thickness. For more information please contact your local Paroc representative. PAROC Section Bends for 90 pipe elbows Standard radius 1.5 x D Inner diameter of PAROC Section Bend mm Nominal insulation thickness mm Outer diameter of PAROC Section Bend mm Pieces/package 22 50 128 45 60 141 32 80 180 12 28 50 128 45 60 154 24 80 193 9 35 50 141 32 60 154 24 80 193 9 42 50 141 32 60 167 20 80 206 9 48 50 154 24 60 167 20 80 206 9 100 245 5 60 50 154 24 60 180 12 80 219 9 100 258 4 64 60 180 12 70 50 167 20 60 193 9 76 50 180 12 60 193 9 80 232 7 89 50 193 9 60 206 9 80 245 5 100 284 4 102 50 206 9 60 219 9 114 50 219 6 60 232 7 80 271 4 As the figures below demonstrate, PAROC Section Bends are designed to make installation as quick, easy and efficient as possible. Installation instructions for PAROC Section Bend 1. Place the PAROC Section Bend on a pipe. 2. Attach the bend ends with bands (one on each end). 3. Slide the bend into the middle of the pipe elbow. 4. The pipe elbow is insulated! 1 2 3 4 7
Paroc Group Oy Ab is one of the leading manufacturers of mineral wool insulation products and solutions in Europe. PAROC products and solutions include building insulation, technical insulation, marine insulation, structural stone wool sandwich panels and acoustics products. We have production facilities in Finland, Sweden, Lithuania and Poland. We have sales and representative offices in 13 countries in Europe. Done Information Oy Building Insulation produces a wide range of products and solutions for all traditional building insulation. The building insulation is mainly used for the thermal, fire and sound insulation of exterior walls, roofs, floors and basements, intermediate floors and partitions. Technical Insulation is used for thermal, fire and sound insulation in building techniques, industrial processes and pipe work, industrial equipment and ship structures. PAROC Fire Proof Panels are steelfaced lightweight panels with a core material of stone wool. Paroc panels are used for façades, partition walls and ceilings in public, commercial and industrial buildings. The information in this brochure represents the sole and comprehensive description of the condition of the product and its technical properties. However, the content of this brochure does not mean granting a commercial guarantee. In so far as the product is used in an area of use which is not provided for in this brochure, we cannot warrant its suitability for said area of use unless the suitability was expressly confirmed by us upon request. This brochure replaces all previous brochures. As a result of constant further development of our products we reserve the right to make alterations to brochures. PAROC OY AB Technical Insulation P.O.Box 294 FI-01301 Vantaa, Finland Tel. +358 204 55 4868 Fax +358 204 55 4745 technical.insulation@paroc.com www.paroc.com 1075TIEN1106 A M E M B E R O F P A R O C G R O U P