Print this page Process Plant Insulation & Fuel Efficiency
A. Bhatia, B.E.
Course Outline
Prevention of heat
leakage by application of insulation is the simplest method of achieving energy
conservation. Some estimates have predicted that insulation in US industry alone
saves approximately 200 million barrels of oil every year.
The need for efficient thermal insulation has become more important with higher
operating temperatures and increasing energy costs. While placing insulation
onto a pipe or equipment is fairly easy, resolving issue such as what type of
insulation to use and how much requires understanding of various alternatives.
This 4-hour online course discusses the design considerations for thermal insulation
and is aimed at students, professional engineers, energy auditors, operational
& maintenance personnel and loss prevention engineers.
This course
includes a multiple-choice quiz at the end, which is designed to enhance the
understanding of the course materials.
Learning Objective
At the conclusion of this course, the student will be aware of:
- Application, characteristics and potential benefits of insulation to industry;
- Key properties of thermal insulation products;
- Selection aspects of insulating materials;
- Organic & Inorganic type of insulation materials;
- Classification of insulting materials on hot and cold surfaces;
- Forms and shapes of insulating materials;
- Insulation finishes, vapor retarders and weather barriers;
- Method of installation, hangers and supports;
- Recommended best practices, applicable codes & standards;
- Application areas such as pipelines, vessels, stacks, furnaces, kilns etc.;
- Conservation of energy; and
- Concept of economic
thickness of insulation and selection of right alternatives.
This course discusses the design considerations for thermal insulation and is aimed at Students, Professional Engineers, System Design Engineers working in Power, P&C, Refineries, Fertilizers, Metal & Mining, Manufacturing and Engineering industries, Sales & Marketing personnel, Energy Auditors, Operational & Maintenance Personnel, Health & Safety Personnel and Loss Prevention Engineers.
Course Introduction
The reduction of
heat loss by insulation is a practical means of achieving substantial economies
in energy. Benefits to industry include enormous cost savings, improved productivity,
and enhanced environmental quality.
The most important characteristics of an insulation material is low thermal
conductivity, low tendency toward absorbing water, and of course the material
should be inexpensive.
It is important that due regard to the required levels of thermal insulation
be given at the initial design stages of process plant. In too many cases the
insulation of process plant is an afterthought. Consequently there are cases
where proper levels of thermal insulation cannot be installed.
The type of insulation selected should be able to withstand whatever conditions
it will experience without degradation. In process industry, the most common
insulators are various types of calcium silicate or fiberglass. Calcium silicate
is generally more appropriate for temperatures above 225 °C (437 °F), while
fiberglass is generally used at temperatures below 225 °C.
Insulation is available in many forms, which can generally be applied easily,
and quickly without interrupting an operation or process. A variety of finishes
are used to protect the insulation from mechanical and environmental damage,
and to enhance appearance.
This course reviews the above criteria together with the types, characteristics
and properties of various thermal insulation materials. There is an outline
of energy conservation and therefore the cost savings.
Course
Content
The course content is in a PDF file Process Plant Insulation & Fuel Efficiency. You need to open or download this document to study this course.
Course Summary
Insulation reduces
the rate of heat flow between objects and the surroundings at different temperatures.
Insulation can be used to regulate process temperatures, protect workers from
serious injury, and save thousands of dollars in energy costs.
Insulation is used to perform one or more of the following functions:
- Reduce heat loss or heat gain to achieve energy conservation.
- Protect the environment through the reduction of CO2, NOx and greenhouse gases.
- Control surface temperatures for personnel and equipment protection
- Control the temperature of commercial and industrial processes.
- Prevent or reduce condensation on surfaces.
- Increase operating efficiency of heating/ventilation/cooling, plumbing, steam, process and power systems.
- Prevent or reduce damage to equipment from exposure to fire or corrosive atmospheres.
- Reduce noise from mechanical systems.
There are many factors to consider when thinking about insulation. The insulation itself should be a low thermal conductivity material with low water vapor permeability and it should be non-wicking. Insulation finishes with low emissivity materials such as polished Aluminum shall reduce heat losses through radiation.
Insulation materials
and the cladding shall be installed in such a way that water does not enter
the insulation material or between the insulation and the pipe / equipment surface
during design life. Surfaces to be insulated shall be clean and dry. The application
of the insulation shall not be started before the mechanical completion certificate
for coating has been issued.
Related Reading
Insulation Audit
and the Economic Thickness of Insulation
While this course "Process Plant Insulation &
Fuel Efficiency" provides an overview of insulating materials, various
types, properties and installation aspects, the second part of the course titled
"Insulation Audit and the Economic Thickness of Insulation" discusses
the assessment of heat losses and economics of using the optimum thickness of
insulation. This is a suggested reading and is continuation of this course.
Overview of
Refractory Materials
For high temperature applications, exceeding 1500°F, such as melting furnaces,
heat treatment furnaces, kilns, boilers etc, refractory materials in isolation
or in combination with insulation are used. Refer to course titled "Overview
of Refractory Materials" for further reading.
Quiz
Once
you finish studying the
above course content,
you need to
take a quiz
to obtain the PDH credits.
DISCLAIMER: The materials contained in the online course are not intended as a representation or warranty on the part of PDHonline.com or any other person/organization named herein. The materials are for general information only. They are not a substitute for competent professional advice. Application of this information to a specific project should be reviewed by a registered professional engineer. Anyone making use of the information set forth herein does so at their own risk and assumes any and all resulting liability arising therefrom.
