installation instruction

Wrtsil Finland Oy

Power Plants

Doc. id:

WDAAA116783 e

Date:

19-Sep-2002

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Status:

APPROVED

Made/Approved:

MJU001 / SPR001

Name:

23.1 Insulation of piping

Subject:

Power Plant Installation Instructions

Table of contents
1.

Before insulation ..................................................................................................................... 3

2.

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

3.

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

4.

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

5.

4.1.

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

4.2.

Elbows ................................................................................................................................ 5

4.3.

Cover materials and equipment.......................................................................................... 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
Print Date 16-Apr-2004 9:16

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

Vertical parts............................................................................................................................ 20
Horizontal parts........................................................................................................................ 21

1.

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Before insulation

2.

Wrtsil Finland Oy

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.

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 60C, which are in accessible places
from operators point of view.

3.

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Thickness of insulation

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

Insulation carpets, density 80 kg/m3

Insulation channel, density 100 kg/m3

STD

Pipe size

Temperature of the contents (C) and

insulating material thickness, mm

DN

Pipe outside
diameter, mm

0 - 199 C

200 - 450 C

10
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1600

17.2
21.3
26.9
33.7
42.4
48.3
60.3
76.1
88.9
114.3
139.7
168.3
219.1
273
323.9
355.6
406.4
508
610
711
813
914
1016
1118
1220
1320
1420
1520
1620

30
30
30
30
50
50
50
50
50
80
80
80
80
80
80
80
100
100
100
100
100
100
100
100
100
100
100
100
100

40
40
40
50
50
50
50
80
80
80
80
80
80
80
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100

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

Pipe diameter

Insulation channels
No trace or Electrical trace

12 steam trace

Nominal

Outer
diameter

Inner diameter x PAROC

thickness
channel type

inner diameter x PAROC

thickness
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 0.70.8mm. 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.

5.

Insulation of pipes

5.1.

Pipes DN300

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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

5.2.

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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 0.70.8 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.

5.3.

Insulation of pipes > DN300

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. S
upporting ring

5.4.

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Cover joints

Figure 4.

Cover joints
Outside diameter of insulation du

150 < du < 300

< 600

< 800

> 800

3.5

5.5

10

7.5

12

9.5

12

Table 1.

Dimensions for beading type A mm

5.5.

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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.

6.

Insulation of trace heated pipes

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

7.

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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.

Figure 10.

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Insulation boxes for flanges

DN

(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

Figure 11.

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Protective collar of insulation box

8.

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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

9.

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Insulation of pipe supports

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

Figure 13.

Insulation of pipe support

10.

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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

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

125

302

302

150

330

330

200

382

385

250

435

460

300

486

525

350

518

590

400

610

670

Table 3.

11.

Wrtsil Finland Oy

Dimensions for insulation boxes, steel bellows

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.).

Figure 16.

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Exhaust gas bellows insulated with insulation pillows

DN

Length

Pcs / Bellow

Breadth

Thickness

Bands / Pillow

200

1080

356

50

250

1250

376

50

300

1440

396

50

350

1600

390

50

400

1755

528

50

450

1930

528

50

500

2090

528

50

600

1210

528

50

700

1370

520

50

Table 4.

Dimensions for insulation pillows for bellows type 4V60B0020

DN

Length

Pcs / Bellow

Breadth

Thickness

Bands / Pillow

600

1450

660

50

700

1370

660

50

800

1545

660

50

900

1710

660

50

100
0

1860

660

50

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).

Figure 17.

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Insulation boxes for exhaust gas bellows

DN

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