23.1 Insulation of Piping

installation instruction Wärtsilä Finland Oy Power Plants

Doc. id: WDAAA116783 e

Date: 19-Sep-2002

Page: 1 (21)

Status: APPROVED

Made/Approved: MJU001 / SPR001

Name: 23.1 Insulation of piping

Subject: Power Plant Installation Instructions

Print Date 16-Apr-2004 9:16

Table of contents 1. Before insulation ..................................................................................................................... 3

2. Pipelines to be insulated......................................................................................................... 3

3. Thickness of insulation........................................................................................................... 4

4. Insulation materials ................................................................................................................. 5

4.1. Standard insulation channels ............................................................................................. 5

4.2. Elbows ................................................................................................................................ 5

4.3. Cover materials and equipment.......................................................................................... 5

5. Insulation of pipes ................................................................................................................... 7

5.1. Pipes ≤ DN300 ................................................................................................................... 7

5.2. Pipes > DN300 ................................................................................................................... 8

5.3. Support rings ...................................................................................................................... 8

5.4. Cover joints......................................................................................................................... 9

5.5. Trace heated pipes........................................................................................................... 10

6. Insulation of elbows, tees and reducers ............................................................................. 10

7. Insulation of flanges.............................................................................................................. 12

8. Insulation of valves ............................................................................................................... 15

9. Insulation of pipe supports................................................................................................... 16

10. Insulation of bellows ............................................................................................................. 17

10.1. Rubber bellows................................................................................................................. 17

10.2. Steel bellows .................................................................................................................... 17

11. Insulation of exhaust gas pipes and bellows...................................................................... 18

11.1. General............................................................................................................................. 18

11.2. Insulation pillows (connection of turbo charger) ............................................................... 18

Insulation boxes....................................................................................................................... 19

Wärtsilä Finland Oy Power Plants

Doc id: WDAAA116783 e

Date: 19-Sep-2002

Page: 2 (21)

11.3. Vertical and horizontal parts ............................................................................................. 20

Vertical parts............................................................................................................................ 20

Horizontal parts........................................................................................................................ 21



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1. Before insulation • All pipes shall have been assembled. • Pressure, cleaning and other necessary tests shall have been made. • The surface of pipelines to be insulated shall have been cleaned and dried. • The pipes should be painted with a primer, at least the welding joints.

2. Pipelines to be insulated Pipelines shall be insulated when thermal losses of the pipeline and personnel safety require it. 1. Pipelines, which shall be insulated for thermal losses, are:

• All pipelines which are trace-heated. • Exhaust gas pipes. • All pipelines including heat-recovery. • Pipelines between lube oil separator and diesel engine or system oil tank. • Pipelines between nozzle temperature control unit and diesel engine.

2. Pipelines which shall be insulated for personnel safety: • All pipes with surface temperature over 60°C, which are in accessible places

from operator’s point of view.



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3. Thickness of insulation

Ζ NOTE: This table does not apply to insulation of pipes in units and modules where ambient temperature is below –10 °C.

Type Pipe size Temperature of the contents (°C) and insulating material thickness, mm

STD DN Pipe outside diameter, mm

0 - 199 °C 200 - 450 °C

10 17.2 30 40 15 21.3 30 40 20 26.9 30 40 25 33.7 30 50 32 42.4 50 50 40 48.3 50 50 50 60.3 50 50 65 76.1 50 80 80 88.9 50 80 100 114.3 80 80 125 139.7 80 80 150 168.3 80 80 200 219.1 80 80 250 273 80 80

Insu

latio

n ch

anne

l, de

nsity

100

kg/

m3

300 323.9 80 100 350 355.6 80 100 400 406.4 100 100 500 508 100 100 600 610 100 100 700 711 100 100 800 813 100 100 900 914 100 100

1000 1016 100 100 1100 1118 100 100 1200 1220 100 100 1300 1320 100 100 1400 1420 100 100 1500 1520 100 100

Insu

latio

n ca

rpet

s, d

ensi

ty 8

0 kg

/m3

1600 1620 100 100

Ζ NOTE: Units and modules are calculated for surface temperature only, not considering the clamps like above.



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4. Insulation materials

4.1. Standard insulation channels

Insulation channels Pipe diameter

No trace or Electrical trace ø12 steam trace

Nominal Outer diameter

Inner diameter x thickness

PAROC™ channel type

inner diameter x thickness

PAROC™ channel type

DN15 21,3 22 x 30 PV-E 22-30 35 x 30 PV-E 35-30

DN20 26,9 28 x 30 PV-E 28-30 42 x 50 PV-E 42-50

DN25 33,7 35 x 30 PV-E 35-30 49 x 50 PV-E 49-50

DN32 42,4 42 x 50 PV-E 42-50 54 x 50 PV-E 54-50

DN40 48,3 49 x 50 PV-E 49-50 60 x 50 PV-E 60-50

DN50 60,3 60 x 50 PV-E 60-50 76 x 50 PV-E 76-50

DN65 76,1 76 x 50 PV-E 76-50 89 x 50 PV-E 89-50

DN80 88,9 89 x 50 PV-E 89-50 102 x 50 PV-E 102-50

DN100 114,3 114 x 80 PV-E 114-80 127 x 80 PV-E 127-80

DN125 139,7 140 x 80 PV-E 140-80 159 x 80 PV-E 159-80

DN150 168,3 169 x 80 PV-E 169-80 178 x 80 PV-E 178-80

DN200 219,1 219 x 80 PV-E 219-80 230 x 80 PV-E 230-80

DN250 273 273 x 80 PV-E 273-80 289 x 80 PV-E 289-80

DN300 323,9 324 x 80 PV-E 324-80 - -

Table: Standard insulation channels

4.2. Elbows When elbos are insulated this should be done by pressing wool into the elbo, insulation channel should only be used at the ends of the elbo. Normal consumption of this wool should be about:

- 15 kg/100 elbo ≤ DN50 - 30 kg/100 elbo ≥ DN65 =

=

=

4.3. Cover materials and equipment



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The insulation needs to be covered to protect the insulation from water and dirt and also to get a more pleasant look and work finish. The material of the cover should be aluminium, in some cases galvanised sheets are used. The normal width of these plates=is 1m and the thickness is depending on the pipe to cover. Pipes equal and smaller than DN50 should use thickness 0,5mm and pipes above should use 0.7…0.8mm. Exhaust gas pipes should have a cover plate of at least 1,0mm thickness.= Blind rivets are used to keep the cover on place. These are normally of some alloyed material. On straight pipe there should be 7pcs/m and for a bend 8 pcs should be enough. A typical blind rivet size is 3,2 x 10mm.



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5. Insulation of pipes

5.1. Pipes ≤ DN300 1. Straight pipes with ≤ DN300 shall be insulated with mineral wool groove. If pipes are

trace heated the channel shall be of one size bigger than the nominal diameter of the pipe.

2. The groove shall be fitted so that the longitudinal joint faces downward refer to Figure 1.

3. The groove shall be fastened with 0.8 mm annealed and galvanised steel wire at distance of 300 mm as shown in Figure 1.

Figure 1. Insulation of pipes ≤ DN300



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5.2. Pipes > DN300

Straight pipes with > DN300 shall be insulated with mineral wool mat. The mat shall be fastened with wire netting at outside as shown in Figure 2. Thickness of insulation is shown in the table on page 4. The insulation mat shall be covered with galvanised steel sheet or with aluminium sheet. Thickness of sheet shall be 0.7…0.8 mm for normal pipes and 1.0 mm for exhaust gas pipes. Longitudinal and transversal joints of sheet shall have overlap min. 50 mm, refer to Figure 2. Fastening of sheet shall be made with self-tapping screws 3.5 x 13 or pop-rivets 3.2 x 10 at distance of 200 mm.

Figure 2. Insulation of pipes > DN300

5.3. Support rings A supporting ring shall be made of:

• a 3 mm thick plate ring spot welded onto the exhaust gas pipe, refer to Figure 3 item 1.

• a 3 mm thick ring of 30 mm high flat bar iron spot welded onto the plate ring, refer to Figure 3 item 2.

Figure 3. Supporting ring



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5.4. Cover joints

Figure 4. Cover joints

Outside diameter of insulation du 150 < du < 300 < 600 < 800 > 800 a b c a b c a b c a b c

3.5 8 2 5.5 10 3 7.5 12 4 9.5 12 5

Table 1. Dimensions for beading type A mm



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5.5. Trace heated pipes

Insulation shall be done according to Figure 5. Pay attention to: • No insulation on material shall be left between main pipe and trace heating pipe

or cable. • In case of trace heating cable be sure that cable is not damaged during

insulation work.

Figure 5. Insulation of trace heated pipes

6. Insulation of elbows, tees and reducers Elbows shall be insulated with separate insulation groove or with loose mineral wool. Loose mineral wool shall be fastened with wire netting at outside, refer to Figure 2. Thickness of insulation and covering material is same as with straight pipes. Joints shall be made to overlap, covering shall be made of 3-8 pieces of sections as shown in Figure 6.

Figure 6. Elbow cover



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Figure 7. Branch connection cover

Figure 8. Cover joint type A or B



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7. Insulation of flanges

Normally flanges are not insulated, but if safety of personnel so requires or in case thermal losses need to be minimised flanges and valves shall be insulated. Flange joint shall be terminated according to Figure 9 so that fixing bolts can be drawn out without damage of insulation.

Figure 9. Termination of insulation at flange joint When flanges and valves are to be insulated the cover shall be removable, refer to Figure 10 and Figure 12.



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Figure 10. Insulation boxes for flanges

DN δ (mm) D (mm) L (mm) 10 - 25 20 215 300 32 - 50 20 285 305 65 - 80 30 350 330

100 - 150 30 470 380 200 30 520 410

250 - 300 30 625 470 350 - 400 30 760 530

Exhaust gas pipes 500 - 600 100 1210 630 700 - 800 100 1500 670

900 - 1000 100 1700 720 1100 - 1200 100 1930 720

Table 2. Dimensions for insulation boxes, flanges



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Figure 11. Protective collar of insulation box



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8. Insulation of valves

Valves can be left without insulation if nothing else is specified. If the valves have to be insulated, insulation boxes or blankets should be used, see the illustration below for examples.

Figure 12. Insulation boxes/blankets for valves



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9. Insulation of pipe supports

Insulation of pipe supports shall be done according to Figure 13.

Figure 13. Insulation of pipe support



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10. Insulation of bellows

10.1. Rubber bellows

Figure 14. Rubber bellows should not be insulated

10.2. Steel bellows

Figure 15. Insulation of steel bellows

DN ~d D 15 83 105 20 90 115 25 96 125 32 145 150 40 150 160 50 163 175 65 180 195 80 190 210

100 277 277



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DN ~d D 125 302 302 150 330 330 200 382 385 250 435 460 300 486 525 350 518 590 400 610 670

Table 3. Dimensions for insulation boxes, steel bellows

11. Insulation of exhaust gas pipes and bellows

11.1. General Exhaust gas pipes inside the power plant building are to be insulated. Likewise, exhaust gas pipes outside the building must be insulated all way long up to the first flange of stack pipe(s). The insulation is performed in order to minimise thermal losses resulting in a temperature rise in the power plant building. The exhaust gas bellow can be insulated either by insulation pillows (see drawing WDAAA194461) or insulation boxes. In tables 4 and 5 are the dimensions of the insulation pillow elements given for various types of flexible bellows. The insulation should be easily removable in order to make the maintenance work.

11.2. Insulation pillows (connection of turbo charger) Mount the insulation pillows according to the following instructions and Figure 16. 1. Mount the insulation pillows on the bellow. 2. Fasten the pillow with straps (3 pieces.).



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Figure 16. Exhaust gas bellows insulated with insulation pillows

DN Length Pcs / Bellow Breadth Thickness Bands / Pillow 200 1080 1 356 50 2 250 1250 1 376 50 2 300 1440 1 396 50 2 350 1600 1 390 50 2 400 1755 1 528 50 2 450 1930 1 528 50 2 500 2090 1 528 50 2 600 1210 2 528 50 2 700 1370 2 520 50 2

Table 4. Dimensions for insulation pillows for bellows type 4V60B0020

DN Length Pcs / Bellow Breadth Thickness Bands / Pillow 600 1450 2 660 50 3 700 1370 2 660 50 3 800 1545 2 660 50 3 900 1710 2 660 50 3 100

0 1860 2 660 50 3

Table 5. Dimensions for insulation pillows for bellows type 4V60B0133

Insulation boxes It is also possible to insulate the exhaust gas bellows with insulation boxes, if needed (50 mm insulation only).

S



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Figure 17. Insulation boxes for exhaust gas bellows

DN S D L 500 - 600 100 1210 820 700 - 800 100 1500 820

900 - 1000 100 1700 820 1100 - 1200 100 1930 820

Table 6. Dimensions for insulation boxes, exhaust gas bellows

11.3. Vertical and horizontal parts

Vertical parts The vibrations, which occur in the exhaust gas piping system, demand a proper and stable fixing of the insulation material to the vertical parts of the pipe according to Figure 18. This is carried out by means of supporting rings attached to the vertical exhaust gas pipe. The supporting rings prevent the insulation material from slipping down the pipe when it is vibrating. The rings shall on vertical pipes be placed in between each insulation mat (pitch of 900 mm). The supporting rings shall also function as fixing rings for the cover plate sheets. Longitudinal and transversal joints of cover sheet shall have an overlap of min 50 mm. Fastening of sheet shall be made with self-tapping screws or pop-rivets at a distance of 200 mm.

Figure 18. Insulation of vertical parts in the exhaust gas piping



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Horizontal parts The horizontal parts of the exhaust gas pipes shall be insulated in the same way as the vertical parts concerning fastening and overlapping according to Figure 19. The main mission of the supporting rings on horizontal pipes is to function as fixing rings for the cover plate sheets. The pitch between the supporting rings shall be 900 mm on horizontal pipes. Insulation boxes that cover flanges and bellows shall be easy to remove. Notice shall be taken to the fact that they are moveable along the surface of the pipe cover plate. Same types of locks as on the flexible bellow insulation box above turbo charger are recommended for easy removal of the insulation. The pipe shall be equipped with extra supporting rings at joints. These will function as fixing rings for the end of the cover sheet as well as they will keep the insulation mat in position. Flanges and bellows shall be insulated according to Figure 10, Figure 16 and Figure 17.

Figure 19. Insulation of horizontal parts in the exhaust gas piping

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23.1 Insulation of Piping