201516

GuidetoInsuCal

VERSION3.0.0.0
PRABHJYOTSINGH(6119913)
LAKHANPAL(6079997)

MECHANICALPIPINGLAYOUT|BHELPEMNOIDA

Contents
1. About InsuCal
2. Input to the program
2.1

Design Parameters
2.1.1 Standard
2.1.2 Cold Face Temperature
2.1.3 Ambient Temperature
2.1.4 Emissivity
2.1.5 Wind Velocity
2.1.6 Insulation Type
2.1.7 Insulation Material
2.1.8 Interface Temperature
2.1.9 Cladding Details

2.2

Operating Conditions
2.2.1 Hot face Temperature
2.2.2 Pipe OD
2.2.3 Minimum Thickness

3. Output of the Program

3.1 Individual Line
3.2

BOM and Multiple lines

4. Features of the Program

1.

About InsuCal

This is standalone application can be used to calculate thermal insulation thickness of power cycle
pipingsandgeneratingBOMforinsulationmaterials.Thethicknessdependsupondesignparametersof
insulation and the operating/design condition(s) of the pipe. The results also vary depending upon
whethertheprogramisrunforASTMC680orIS:14164methodofcalculation.
ThecurrentreleaseversionmaybeusedforextensivecalculationofASTMC680only.

2.

Input to the program

2.1 Design parameters

2.1.1 Standard
BHELPEM uses two different types of standards for determining the thermal insulation thickness of
pipingviz.ASTMC680andIS:14164.
ASTM C680 Standard is generally employed where higher margin for heat loss is considered. This
methodisextensivelyproposedinallNTPCprojects.
IS:14164isusedwherecostmarginandsavingsarethemainfocusandheatlosscanbepreventedin
minimumthicknesspossible.
ASimpleradiobuttoninInsuCalcanbeusedtoselecttherequiredtypeofmethodforcalculation.
2.1.2 Cold Face Temperature
Cold face temperature (C) is the outer face temperature of the pipe which is to be maintained after
applyinginsulation.
2.1.3 Ambient Temperature
Ambient temperature (C) is the surrounding temperature of the thermal power plant. There may be
caseswherethecustomerspecifiesdifferentambienttemperatureswithinandoutsideTGHall.Insuch
cases,twodifferentreportswithdifferentambienttemperatureswillhavetobegenerated.
2.1.4 Emissivity
Emissivityisthemeasureoftheratioofheatemittedthroughradiationanddependsuponthematerial,
textureorcolor.GenerallyAlsheetisemployedasthecladdingmaterialandititsemissivityrangesfrom
0.1to0.2.
2.1.5 Wind Velocity
Windvelocity(m/sec)isthesurroundingairvelocitywhichcarriestheheatgeneratedonthesurfaceof
thecladdingmaterial.


2.1.6 Insulation Type
Two different types of insulation can be employed piping systems viz. Single material insulation and
CompositeMaterialInsulation.Incompositetype,twodifferentmaterialswithdifferentconductivities
are used in combination to yield lesser diameter incase of high temperature as compared to that in
singletypeinsulation.Generally,materialwithlesserthermalconductivity(K)isappliedintheinnerside
of the insulation (Eg. Calcium Silicate), followed by material with slightly higher conductivity (Eg. LRB
Mattress).ThismethodismostlyemployedwhileusingIS:14164methodofcalculation.
ADropboxmenuiteminInsuCalcanbeusedtochangethetypeofinsulation.
2.1.7 Insulation Material
Various types of materials are employed for insulation in piping systems. The most commonly used
materials are Light Resign Bonded Mattress, Bonded Mineral RockWool Mattress or Calcium Silicate.
EvenCeramicFibersarealsobeingemployedforpipingwithoperatingtemperaturesabove500C.
Insulationmaterialcanbechangedalongwithitsconductivitycoefficienta&bbyselectingMaterial
Conductivity from the File menu. The default values are specified are of LRB Mattress and Calcium
Silicateforlowtemperatureandhightemperaturematerialrespectively.

2.1.8 Interface Temperature

This temperature sets the limit for use of lower density material in piping. All pipings with operating
temperature greater than the specified temperature make use of insulation material with higher
density.Thisistopracticallyreducerequiredinsulationthicknessincaseofhigheroperatingconditions.
LimitingTemperatureandDensityofthematerialcanbespecifiedintheInsulatingMaterialframebox
inInsuCal.
AnAdditionalfeaturefordetermininginterfacetemperatureusingASTMC680andIS:14164hasbeen
incorporatedinthisreleaseversion(2.9.0.0).
2.1.9 Cladding Details
TwoorThreedifferentcladding(2Gaugeor3Gauge)canbeappliedinaninsulationandtheselectionof
thegaugeisbasedonthediameterofthepipingoverinsulation.


Aradiobuttoncanbeusedtoselecttypeofgaugesandcorrespondingly,thelimitofdiametercanbe
set in the text box. The cladding material can be specified or selected from the dropdown list. The
different types of gauges available that can be employed can be selected from the dropdown list of
SWGgauges.
Generallythereare5differentgaugesavailablethatcanbeapplied;theseare16SWG,18SWG,20
SWG,22SWGand24SWG

2.2 Operating Conditions

2.2.1. Hot face temperature
Hotfacetemperature(C)istheoperating/designtemperatureofthepipeselectedforinsulation.This
temperaturehastobeabovethecoldfacetemperatureofthesystem.(Specifiedin2.1.2),otherwiseno
insulationisappliedinthepiping.
2.2.2 Pipe OD
Itistheouterdiaofthepipeinmminwhichinsulationistobeapplied.
BoththeoperatingconditionscanbespecifiedintheIndividuallineframebox.
2.2.3 Minimum Thickness
Some customers employ the use of minimum thickness of insulation as per their own criteria(s) or
specifications. This thickness can be specified after checking Minimum Thickness checkbox in the
Individuallineframebox.ThethicknesscanbeusedonlyinSinglematerialtypeofinsulation.

3.

Output of the Program

3.1

Individual Line

When insulation thickness of only a few lines are required or when the BOM is not required to be
generated,thenthisoptioncanbewidely.JustbyclickingtheCalculatebuttonintheIndividualline
orpresstheReturn/Enterkey,willgivethecalculatedinsulationthicknessasrequiredinadialogbox
alongwithotherinformationsuchasmattressweight,claddingweight,totalweightandcombinationof
layers.Ifanyofthedesignparametersoroperatingconditionsisinvalid,itwillpromptso.

3.2 BOM and Multiple lines

WhenBOMofinsulationmaterialsisrequiredforanentireproject,thismethodisused.Thestepsfor
thesameareasfollows:
1.ClicktheInputDataButton

Thewindowwillopenasshownbelow:

2.ClickBrowsetoselecttheinputfile

Theinputfilecanbea.txtora.csvfile.Theformatofinputshouldbeas:

ForSingleMaterialInsulation:

Serial Number, Line Description, Temperature (Hotface), Pipe OD, Length, No. of Bends less
than45,No.ofbendsgreaterthan45,Reducers,Elbow,Tees,Flanges,Valves,MinimumThickness.
i.e.Insinglelineofasystemhas13inputparameters.Theseinputsshouldbeincomaseparatedvalue
format.
Eg.1,MSHALFFLOW(BOILEREND),573,470,120,0,6,2,0,2,8,4,0
o

ForCompositeMaterialInsulation:

SerialNumber,LineDescription,Temperature(Hotface),PipeOD,Length,No.ofBendslessthan45,
No. of bends greater than 45, Reducers, Elbow, Tees, Flanges, Valves, Minimum Thickness of Higher
temperature material, Minimum Thickness of lower temperature material. i.e. In composite line of a
systemhas14inputparameters.Theseinputsshouldbeincomaseparatedvalueformat.
Eg.1,MSHALFFLOW(BOILEREND),573,470,120,0,6,2,0,2,8,4,0,0
If any of the parameters are missing or invalid characters are found or if the number of parameter(s)
dontmatch,anerrordialogisdisplayedalongwiththelineno.onwhichtheerrorhasoccurredandthe
loadingoffileiscancelled.
3.ClickOK
4.Specifytheoutputfilename(withoutextension)youwanttheBOMtohave.
5.ClicktheGenerateButton,whichwasinitiallydisabled.
6. If none of the design parameters or operating conditions is invalid, a dialog box will be displayed
prompting Report generated. will be flashed. The BOM under the specified output filename with
extension.docwillbegeneratedinthesamefolderastheInsuCalprogram.

Inaddition,theprogramwillalsochecktheoutputfilespecifiedalreadyexistsandaskstooverwrite,if
the user wishes to do so. It also checks if the already existing file is not open and If it is so, then the
outputfilewillNOTbegenerated.

4.

Features of the Program

1.Userfriendlyinterface
2.Promptandeasydataentryandchoosingparameterslikeinsulationcode,insulationmattressand
claddingtypes.
3.BesidesreportgenerationandBOMgenerationformultiplesystems,insulationthicknessfor
individualarepromptedinadialogbox.
4.Sameinputfileformatin.csvor.txtfileisusedforobtainingpipedetailssoastomaintainthe
standardandmakeprogramimplementableforexistinginputfilesaswell.