Section 11

Insulation and Heat Tracing

THERMAL INSULATION

Insulation is defined as any material that resists the transfer of heat energy. The purpose of
thermal insulation is therefore either to keep heat confined in the mechanical system or to keep it
excluded from the system by preventing or resisting heat transfer. Typical insulation details are
shown in Figure 11-1.

The four functions of

insulation for hot piping and
equipment are:
 Conserve heat
 Protect personnel
 Maintain temperature for
process control
 Preventing fluid freezing
in cold climates
There are two basic types of
thermal insulation:
 Mass Insulation
 Reflective Insulation

Mass insulation is made up

of small pockets or spaces
that trap air or gases that are
separated by solid
structures. The voids
provide resistance to the
heat transfer process.

FIGURE 11-1 - TYPICAL INSULATION DETAILS

Mass type insulation includes:
Calcium Silicate which is a compound of lime and silica with reinforcement fibers molded into pipe
o
shapes, sizes, including elbows. It is used in applications with system temperatures up to 1200 F.
Even though the dust caused by working with Calcium Silicate may be a safety concern, the
insulation material is more rigid and more durable than other insulating materials.
Mineral-Fiber Insulation which is available in both blankets and shapes. It is made from rock and
slag fibers which have been bonded together. It is used in applications with system temperatures
o
to 1500 F.

© 1996 Bechtel Corp. Piping/Mechanical Handbook 11-1

Section 11 Insulation and Heat Tracing

Glass Type insulation is available in several forms including glass wool, fiber board, and felted
glass fibers. Some forms of glass type insulation are designed for temperature services up to
o
1000 F.

Reflective insulation materials

include Aluminum or Stainless
Steel sheets or foil used for the
construction of reflective
blankets. The temperature limits
for the aluminum materials are
o
approximately 1000 F. The
stainless steel materials are
adequate for temperature ranges
o
up to 1500 F.

The inner layer of insulation is

normally installed as the
insulating material and the outer
metal cover is installed to protect
the insulation from damage.
Insulating jackets or protective
covers are usually aluminum or
stainless steel sheeting.

Personnel protection insulation is

normally provided on hot piping
that is not required to be
insulated for design
requirements but which can be
reached by a person standing on
the ground or the nearest
platform. Normally personnel
FIGURE 11-2 - TYPICAL PIPE INSULATION SECUREMENT protection insulation is provided
DETAILS on uninsulated piping with
operating temperatures above
o
140 F and within 7 feet of the
ground or 3 feet from the
platform edges or ladders.

Flange connections typically have removable sections or a flexible blanket assembly placed over
the joint which permit easy future removal. Nameplates, code plates, pipe plugs and blind nipples
should be left exposed or have a small removable section of insulation placed over them.

Removable insulation covers should be:

 One piece construction wherever possible
 Fabricated in multiple sections when a one piece cover exceeds 60 pounds total weight
 Constructed with edges that butt tightly together to minimize heat loss and provide a cover of
neat finished appearance
 Resistant to water, oil, and steam

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 Insulation and Heat Tracing Section 11

 Constructed to prevent the entry of fluids or moisture into the internal insulating material
 Constructed to fit snugly around the contours of the component being insulated, including
valves, flanges, straight pipe, and fittings
 Constructed with no sharp edges or protrusions on the outer surface

Equipment Insulation

Equipment insulation blocks, boards, or blankets are normally attached to the equipment surface
with joints staggered and the edges tightly butted and sealed with insulation cement, except in
those cases where expansion or contraction joints are provided. Typical equipment insulation
details are shown in Figure 11-3. Insulation is normally attached by one of the following methods:
 Vendor furnished and installed attachment devices
 Welded attachments installed to secure the insulation
 Stainless steel, copper coated steel, or aluminum steel wire
 Stainless steel or aluminum bands

Insulation Jacketing and Surface Finish

Prior to the installation of the insulation jacketing, the installed insulation must be verified to be
complete and properly installed. Joints provided for thermal expansion or contraction must be
filled with insulating mastic material or mineral fiber batting.

The jacketing on both piping and equipment insulation should be fastened with bands wherever
possible. When bands cannot be used due to the piping or equipment configuration, the
jacketing may be secured with sheet metal screws. Typical details for securing insulation to
piping is shown in Figure 11-2.

Jacketing joints and openings must be sealed with a caulking material when the insulation system
contains a moisture or vapor barrier and the system is installed outdoors. Removable insulation
jacketing must overlap adjacent pipe by an amount equal to the insulation overlap.

ACOUSTICAL INSULATION

Acoustical insulation, like thermal insulation has two layers. The absorptive layer typically
consists of a glass or mineral fiber and the barrier layer being loaded vinyl, such as Sound Fab
manufactured by Sound Coat Company or loaded mastic, such as Muffl-Lag manufactured by
Childress Products Company. Some installations will have thermal insulation already existing and
in those instances, the acoustical absorptive layer is applied directly over the thermal insulation
without modifying the thermal system.

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Section 11 Insulation and Heat Tracing

FIGURE 11- 3 - TYPICAL EQUIPMENT INSULATION DETAILS

HEAT TRACING

Four typical heat trace systems include:

 Electrical Heat Trace
 Bare Steam Trace
 Heat Transfer Cemented Steam Trace
 Hot Water

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 Insulation and Heat Tracing Section 11

Electrical heat trace systems are installed by simply wrapping electrical trace around piping and
equipment to provide mild winterization protection. Some high temperature piping systems
require the use of a layer of insulation between the pipe and heat trace to avoid damage to the
heat trace.

Bare Heat Transfer Cemented Steam Trace and Hot Water Trace systems are applied by placing
and banding tubing along the piping runs and looping the tubing around equipment and valves.
The function of the steam trace is to maintain the process fluids at temperature levels that provide
proper flow characteristics.

Insulation Materials

Insulation materials made from asbestos and certain other fibers can pose serious health hazards
and special precautions must be taken when handling these materials. Check the manufacturer’s
Material Safety Data Sheet (MSDS) for special handling instructions.

1996:Rev.2 Piping/Mechanical Handbook 11-5