General Guidelines Insulation

GENERAL GUIDELINES FOR
INSULATION WORKS
ISSUED FOR
TENDER SPECIFICATION
BHEL : PSSR : SCT : 1361
This booklet is given as a general

guideline to this tenderers about insulation
works, However instructions given in the
drawings & other schedule issued during
execution of the work shall be final and
binding of the contractor.
Book No :
Bharat Heavy Electricals Limited

( A Govt. Of India Undertaking)
Power Sector Southern Region
690, Anna Salai , Nandanam,
Chennai – 600 035
NEYVELI LIGNITE CORPORATION LIMITED
2 X 250 MW NEYVELI TPS – II EXPANSION
INSTRUCTIONS FOR APPLICATION OF

THERMAL INSULATION
FOR
PIPING AND EQUIPMENTS
BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR SOUTHERN REGION
DOCUMENT TITLE: APPLICATION PROCEDURE OF BHEL :PSSR: NEYVELI:INSULATION
THERMAL INSULATION REV. NO. 00 DATE : 31.07.2008
FOR PIPING AND EQUIPMENTS SHEET OF
SECTION TITLE No. OF SHEETS
A METHOD OF APPLICATION OF 7
THERMAL INSULATION FOR PIPING
AND EQUIPMENTS AND MATERIAL
SPECIFICATION.
B THERMAL INSULATION (THICKNESS) 4

(PART – I) SCHEDULE FOR PIPING (Having Hot
Face Temp. Above 449 oC)
B THERMAL INSULATION (THICKNESS) 16

(PART – II) SCHEDULE FOR PIPING (Having Hot
Face Temp. 449 oC & Below)
C THERMAL INSULATION (THICKNESS) 2

SCHEDULE FOR EQUIPMENTS
D THERMAL INSULATION APPLICATION 15

DRAWINGS (STANDARD)
E BILL OF MATERIALS 2
SECTION - A
FOR PIPING AND EQUIPMENTS
SHEET 1 OF 7
1.0 INTRODUCTION
In a thermal power station or process plant, thermal insulation or heat lagging of piping
and equipments operating above 60 oC is essential for heat economy and protection of
operating personnel. Any pipe which is at a temperature higher than its surroundings
will loose heat and the amount of heat lost will depend upon the temperature of the fluid
and the thermal conductivity of the piping material / covering.
The heat lost through bare pipe increases with
a) Increase in the temperature of fluid conveyed

b) Decrease in ambient temperature and
c) Increase in wind velocity of the surroundings.
The heat so lost has high potential for work and the rapidly increasing cost of fuel in the
recent past has prompted to find all possible means to conserve energy. Providing
proper and adequate insulation on to the piping and equipments controls heat transfer
and maintains the required service temperature.
2.0 INSULATING MATERIALS
Thermal insulation shall be provided on piping and equipments as listed in the thermal
insulation thickness schedule given in Section “B” (for piping) and Section ”C”
(for equipments). The thickness schedule gives piping/equipment details, insulation
thicknesses for both calcium silicate (*) and bonded mineral rock wool mattresses (**)
and aluminium sheet thickness.
Calcium silicate of density 240 Kg/ m3 shall be provided as the first layer of insulation
where hot face temperature of the piping exceeds 449 oC and the subsequent layers
shall be of Lightly Resin Bonded Mineral (Rock) Wool mattresses of density
150 Kg/ m3 with GS hexagonal wire netting (13 mm aperture x 0.71 mm dia.) on
outer side.
Lightly Resin Bonded Mineral (Rock) Wool mattresses of density of 150 Kg/ M3 with
GS hexagonal wire netting (13 mm aperture x 0.71 mm dia.) on outer side shall be
provided for all the layers of insulation for piping having hot face temperature above
400 oC and upto 449 oC.
Lightly Resin Bonded Mineral (Rock) Wool mattresses of density 100 Kg/ M3 with
GS hexagonal wire netting (13 mm aperture x 0.71 mm dia.) on outer side shall be
provided for all the layers of insulation for piping having hot face temperature less than
or equal to 400 oC and for all equipments.
3.0 Aluminium cladding sheet shall be provided over Lightly Bonded (Rock) Wool
mattresses as per details given below :
18 SWG (1.22 mm thk.) For pipes with dia. over insulation 450 mm and above
and for all equipments.
20 SWG (0.91 mm thk.) For pipes with dia. over insulation 150 mm & above and
less than 450 mm.
22 SWG (0.71 mm thk.) For pipes with dia. over insulation less than 150 mm.
A1
SHEET 2 OF 7
4.0 Detailed application procedures are given in the following pages and detailed BOM as
per section ‘E’.
5.0 METHODS OF APPLICATION FOR CALCIUM SILICATE PRE-FORMED RIGID PIPE

COVERING
5.1 STORAGE
Calcium silicate preformed pipe Coverings should be kept dry during storage and at
erection site.
5.2 SURFACE PREPARATION
a) All Pipelines & Equipment surfaces should be dry, free from dust, rust, grease and
scales before application.
b) All hangers, brackets and pipe clamps etc. should be in position.
c) All surfaces should be brush-coated with a suitable anti-corrosive primer wherever

necessary before they are insulated.
d) Necessary pressure-test for the pipes to be carried out before insulation.
e) All the joints to be tightened so that there is no leakage.
5.3 MECHANICAL SECUREMENT OF PIPE COVERINGS.
a) For securing insulation on horizontal pipes, circumferential bands of Aluminium (20 mm

x 0.6 mm) are used in addition to G.I. binding wires. The spacing between binding wires
shall be 300 mm and between Aluminium bands to be 450 mm. Support for insulation
and aluminium sheets shall be as per drg no. PE-4-999-169-04.
b) For securing insulation on vertical pipes, support rings fabricated from M.S. flats, cleats
etc. are used which provide support for insulation and prevents its downward
displacement. (Refer Drg No. PE-4-999-169-05)
5.4 INSULATION OF PIPES
a) All unavoidable gaps in the circumferential or longitudinal joints should be filled with
HYSIL Calcium Silicate Plastic Composition (Hysil Powder).
b) For single layer of insulation, circumferential joints should be staggered.
c) In case of half round pipe coverings, one half of the starting pair should be cut to
half-length. Subsequently full-length pieces should be fitted, that will stagger the
circumferential joints. The longitudinal joint will come in a line.
(Refer Drg No. PE-DG-999-169-M001 Fig 1)
A2
SHEET 3 OF 7
d) In case of curved segments and bevelled lags alternate segment of half length and full
length to be used in the starting set. Now use of full-length segments subsequently, will
stagger the circumferential joint.
(Refer Drg No. PE-DG-999-169-M001 Fig 1)
e) For multilayers of insulation, circumferential joints shall be staggered by at least

150 mm and longitudinal joints shall be staggered by at least 50 mm from 1 st layer
joints. (Refer Drg No. PE-DG-999-169-M001 Fig 1)
f) Staggering the second layer of circumferential joints from 1st layer circumferential joints
can be achieved by varying the second layer length from 1st layer lengths of pipe
coverings.
g) For securing insulation to pipe, use binding wire and metal band (20 mm width and
0.6 mm thick).
h) Each section of insulation should be held in place by at least two nos. circumferential
bands / wires.
i) The spacing between the bands should not be more than 450 mm.
j) At each end of pipe coverings, the distance between the end of pipe covering and the
band / wire should not be less than 50 mm.
k) The wire should be tightened by twisting and the ends of wire to be pressed on to the
insulating material.
5.5 INSULATION OF FITTINGS
a) Insulation of valves and bends etc. should be done using performed pipe coverings as
far as practicable (Refer Drg No. PE-DG-999-169-M001 Fig 3, 4)
b) Thickness of the pipe covering near flanges should be such that it clears the
flange O.D. Now pipe covering can be provided on flanges as shown in Drg No.
PE-DG-999-169-M001 Fig 2.
c) Sufficient space should be provided to enable withdrawal of flange bolts while working
on pipeline with minimum disturbance of insulation.
d) Space provided for bolts withdrawal should be filled with Calcium Silicate powder paste.
e) Similarly the valve can be insulated as shown in Drg No. PE-DG-999-169-M002 Fig 3.
However the gland section should be kept exposed for routing maintenance.
f) For bends, pipe coverings to be cut as per the bend radius and to be fitted on the bend
as shown in (Refer Drg No. PE-DG-999-169-M002 Fig 4). Any unavoidable gaps should
be filled with Calcium silicate Powder.
A3
SHEET 4 OF 7
5.6 EXPANSION JOINTS
a) Due to difference in expansion coefficients of metal and insulating material, it is

necessary to make allowance for differential movement between hot surface insulation.
Expansion joints should be provided at the spacing as per following :-
Temperature oC Spacing Interval (m)

Upto 200 5
200 - 300 4
300 - 400 2.7
Above 400 2
b) At the expansion joint sufficient gap should be provided. The gap should be tightly
packed with fibrous insulation, which in turn to be covered with performed section just
as in case of flanges.
6.0 METHOD OF APPLICATION FOR CALCIUM SILICATE POWDER (ASBESTOS

FREE - PLASTIC COMPOSITION)
Calcium Silicate Plastic Composition is to be applied by Hand trowelled method. Slurry

of calcium silicate is formed by mixing calcium silicate powder with requisite water
(i.e. 1.8 times by weight of Dry Powder) and suitable binders such as Sodium Silicate to
make consistent workable mixture. The commercial grade / Refractory grade binder i.e.
Sodium Silicate is mixed in the ratio of 5 to 6 percent by weight of powder. (Sodium
Silicate should be mixed after adding water in the powder). The mortar thus formed is to
be applied for filling of gaps / joints between the block / pipe coverings during
installation by hand trowelling.
7.0 METHOD OF APPLICATION FOR ROCKWOOL MATTRESSES
The method of application is a highly skilled job. Badly fitted / laid insulation can lead to
greater heat loss, higher cold surface temperature than that estimated and frequent
maintenance. Following are important points to be considered during the application of
the insulation.
7.1 Before applying insulation, it should be ensured that all instrument tappings, clamps,
lugs and other connections on the surface to be insulated have been properly installed
as per relevant drawings.
7.2 All surfaces to be insulated shall be cleaned of all foreign materials such as dirt,
grease, loose scale, moisture etc.
7.3 Welding of lugs, attachments, clips etc. on the surface to be insulated for supporting
insulation shall not be carried out without the permission of the authorised person.
7.4 All flanged joints shall be insulated only after final tightening and testing.
7.5 The insulation shall be applied to all surfaces when they are at ambient temperature.
A4
SHEET 5 OF 7
7.6 The indicated thicknesses of insulation (as indicated in Section 'B' & 'C') are minimum
requirement, which should be maintained. Any change in the thickness of the insulation
should be done only after prior approval of the design engineer.
7.7 The day-to-day insulation work should be covered with suitable protective materials to
prevent the rain water entry, if same is expected.
7.8 Where more than one layer of insulation is involved, mattresses should have
longitudinal joints staggered by at least 50 mm and they must be held in close contact
with face of pipes / fittings by means of binding wires / Aluminium bands / seals.
Circumferential joints of multilayer insulation should also be staggered by at least
150 mm. (Refer Drg. No. PE-4-999-169-01).
7.9 For the first layer of insulation and in case of multi layer of insulation, hexagonal wire
netting will be facing on outer side of the mattress.
7.10 Insulation mattresses shall be held in place by fastening over with binding wire. Care
should be taken to see that the flexible insulation mattresses are not unduly
compressed. The ends of binding wire shall be lightly twisted together, bent over and
pressed into the insulation. Spacing between binding wires shall be at intervals of
300 mm.
In addition Aluminium bands shall also be provided at 300 mm intervals for diameters
greater than 500 mm. (Refer Drg. No. PE-4-999-169-01)
7.11 Where junctions between bodies of different diameters occur and difference in
insulation thickness is specified, the greater thickness is to be continued for a length
equal to one diameter of the smaller body and then smoothly tapered to the required
smaller thickness over a length equal to two diameters of the small body.
7.12 The insulation shall be cut to fit the piping O.D / equipment and shall be wrapped on the
piping / equipment and held in position with proper support and wires. All the joints
should be properly staggered and tightly butted and adjacent edges laced together with
lacing wire. (Refer Drg. No. PE-4-999-169-01)
7.13 The insulation of valves and flange joints shall be enclosed in a removable jacketing so
that it may be removed without disturbing the concerned equipment or piping. The
thickness of insulation shall be same as that of the pipe line in which these valves and
fittings are located. (Refer Drg. No. PE-4-999-169-06 and PE-4-999-169-07.)
7.14 Steam / Air / Gas leakages in and around the pipes to be insulated shall be attended
before applying insulation.
7.15 In order to provide support to Aluminium cladding spacer rings made out of 20 x 3 mm
M.S. flats shall be fixed at equal intervals of approximately 850 mm spacing and at
every circumferential joints. These rings shall be fixed with ‘L’ type lugs and shall be
fabricated from 20 x 3 mm M.S. flats. To reduce heat conductivity through these lugs
20 mm x 3 mm size ceramic mill board shall be used between rings and lugs.
(Refer Drg No. PE-4-999-169-04 and PE-4-999-169-13)
7.16 Spacing between supporting rings for vertical piping shall be 3 mtrs. Support rings are
to be provided only when the vertical height exceeds 3 mtrs.
(Refer Drg No. PE-4-999-169-03 and PE-4-999-169-05)
A5
SHEET 6 OF 7
7.17 For vertical pipes since support ring is provided at every 3 mtrs interval, only two
spacer rings shall be provided in between support rings.
7.18 Insulation support s shall have one coat of bituminous paint.
7.19 Wherever the end of hanger clamp assembly protrudes out of the insulation at the
bottom suitable box structure are to be provided. Pipe hangers and supports should be
covered in such a way that the moisture can not penetrate into the insulation.
7.20 It is very important that sheet metal cladding should be done by a well-experienced and
competent fabricator. Person doing the job can alter the method of fixing of cladding
sheet only after consulting the concerned design engineer.
7.21 The longitudinal joint in the outer cladding sheet should always be at the lower half of
the circumference for horizontal piping so that no rain water enters the insulation
through the joints. (Refer Drg. No. PE-4-999-169-01)
7.22 The joints of outer cladding should be staggered axially.
7.23 Inside surface of Aluminium sheet shall be coated with one coat of Bituminous paint.
7.24 The cladding sheet shall be provided directly over the insulation. Suitable flashing and
weather proofing shall be provided at all nozzles, manholes and other projections to
prevent the entrance of water.
7.25 Loose wool can be taken from wool mattresses, wherever required.
7.26 Sealing compound to be applied on all cladding sheet joints.
7.27 Aluminium sheet covering on outdoor horizontal pipes shall be provided with 3 mm
drain hole at bottom centre line at 6 mtr intervals.
7.28 Equipment name plates shall not be insulated.
7.29 Clips made out of sheet shall be riveted inside the box for insulation of valves and
flanges to hold the insulation in box. (Refer Drg. No. PE-4-999-169-06)
7.30 The insulation local to the inspection points of the critical piping shall be removable.
A6
SHEET 7 OF 7
IMPORTANT POINTS TO BE TAKEN CARE DURING APPLICATION
i) Binding wires for all layers of insulation will be at distance of 300 mm.
ii) In addition Aluminium bands / seals also to be provided at distance of 300 mm for sizes
above 500 mm.
iii) Aluminium bands / seals to be provided over aluminium sheets at distance of 500mm.
iv) Ceramic mill boards to be used between all ‘L’ type lugs and the support rings.
v) Inside surface of Aluminium sheets to have 1 coat of bituminous paint applied

uniformly.
vi) Gaps to be properly filled with loose wool taken from mattresses.
vii) End of hanger clamp assembly protruding out of insulation at the bottom should be
suitably boxed with Aluminium sheets.
viii) Valves to be insulated properly in box structure as given in enclosed drawings.
ix) Multilayer longitudinal and circumferential joints should be staggered.
A7
SECTION B
(PART – I)
THERMAL INSULATION SCHEDULE FOR PIPING (HAVING HOT FACE TEMP. ABOVE 449 OC)
--------------------------------------------------------------------------
PROJECT TITLE: 2 x 250 MW NEYVELI TPS – II EXPANSION
PROJECT STAGE: CONTRACT
DESIGN PARAMETERS:-
COLD FACE TEMPERATURE IN DEG C 60
AMBIENT TEMPERATURE IN DEG C 30
EMISSIVITY (DIMENSIONLESS) 0.2
WIND VELOCITY IN M/SEC. 0
INSULATION MATERIAL CALCIUM SILICATE FOR 1ST LAYER

(FOR HOT FACE TEMP. ABOVE 449 OC) (DENSITY 240 KG/M3) &
LRB MATTRESS FOR SUBSEQUENT LAYERS

(DENSITY 150 KG/M3)
CLADDING MATERIAL ALUMINIUM SHEET
CLADDING MATERIAL GUAGE 18 SWG

FOR DIA.OVER INSUL. = > 450 MM

FOR DIA.OVER INSUL. = > 150 MM < 450 MM

FOR DIA.OVER INSUL. < 150 MM
THERMAL CONDUCTIVITY VS. MEAN TEMPERATURE EQUATION:-
(K IS THERMAL CONDUCTIVITY IN W/M.C AND T IS MEAN TEMP. IN DEG C)
FOR CALCIUM SILICATE: K= .0473 + .00014 *T
FOR LRB MATTRESSES: K= .03 + .0002 *T
B1
*-CALCIUM SILICATE
**-LRB MATTRESSES
SL.NO. DESCRIPTION
H.F. PIPE PIPE BENDS BENDS REDUCERS ELBOWS TEES FLANGES VALVES INSUL.THICK.
TEMP O.D. LENGTH (<=45) (>45)
DEG C MM M NO. NO. NO. NO. NO. NO. NO. MM
* **
1 MS-FULL FLOW
537.0 559.0 50.00 0 6 0 2 4 0 0 40 150
(75+75)
2 MS-HALF FLOW
537.0 323.9 230.00 1 12 3 9 7 0 4 40 135
(75+60)
3 HRH FULL FLOW
537.0 660.0 63.00 1 5 0 3 2 0 0 40 150
(75+75)
4 HRH HALF FLOW
537.0 558.8 210.00 0 9 1 13 2 0 2 40 150
(75+75)
5 HP BYPASS-A (P91)
537.0 273.0 17.00 0 0 0 5 0 0 2 40 135
(75+60)
6 HP BYPASS-B (P91)
537.0 273.0 21.00 0 0 0 5 0 0 2 40 135
(75+60)
7 LP BYPASS-A
537.0 508.0 34.00 0 0 0 7 0 0 0 40 150
(75+75)
8 LP BYPASS-A
537.0 610.0 5.00 0 0 0 0 0 0 0 40 150
(75+75)
9 LP BYPASS-B
537.0 508.0 33.00 0 0 0 7 0 0 0 40 150
(75+75)
10 LP BYPASS-B
537.0 610.0 5.00 0 0 0 0 0 0 0 40 150
(75+75)
11 HP BYPASS-A (P22)
480.0 355.6 1.00 0 0 1 0 0 0 0 25 135
(75+60)
B2
*-CALCIUM SILICATE
**-LRB MATTRESSES
SL.NO. DESCRIPTION
* **
12 HP BYPASS-B (P22)
480.0 355.6 2.00 0 0 1 0 0 0 0 25 135
(75+60)
13 HP BYPASS
540.0 273.0 4.00 0 0 0 0 0 0 0 40 135
(75+60)
14 MAIN STEAM TO AUX. PRDS
540.0 219.1 1.50 0 0 0 0 0 0 0 40 135
(75+60)
15 MS AUX PRDS CONTROL STN
537.0 168.3 3.00 0 0 2 1 0 0 2 25 125
(75+50)
537.0 219.1 20.00 0 0 6 1 1 0 3 40 135
(75+60)
17 MS TO AUX PRDS
537.0 168.3 1.00 0 0 0 0 0 0 0 25 125
(75+50)
18 LINE DRAIN & VENT
537.0 33.4 40.00 0 0 10 0 10 0 0 25 100
(50+50)
19 MS LINE DRAINS & VENTS
537.0 60.3 40.00 0 0 14 0 0 0 0 25 110
(60+50)
20 MS LINE DRAINS & VENTS
537.0 33.4 180.00 0 0 20 0 0 0 0 25 100
(50+50)
21 MS STOP VALVE BYPASS
537.0 60.3 10.00 0 0 8 0 0 0 0 25 110
(60+50)
22 HOT REHEAT LINE DRAIN & VENT
537.0 60.3 80.00 0 0 22 0 4 0 0 25 110
(60+50)
B3
*-CALCIUM SILICATE
**-LRB MATTRESSES
SL.NO. DESCRIPTION
* **
537.0 48.3 20.00 0 0 8 0 0 0 0 25 100
(50+50)
537.0 33.4 100.00 0 0 16 0 0 0 0 25 100
(50+50)
25 HPBP WARM UP LINE & LINE DRAIN
537.0 60.3 80.00 0 0 14 0 4 0 2 25 110
(60+50)
26 LP BYPASS WARM UP LINE & LINE DRAIN
537.0 60.3 150.00 0 0 34 0 4 0 0 25 110
(60+50)
27 LP BYPASS LINE DRAIN & VENT
537.0 60.3 80.00 0 0 24 0 0 0 0 25 110
(60+50)
28 LP BYPASS LINE DRAIN & VENT
537.0 33.4 30.00 0 0 6 0 0 0 0 25 100
(50+50)
29 IMPULSE PIPE
537.0 33.4 100.00 0 0 50 40 0 0 0 25 100
(50+50)
30 IMPULSE PIPE
537.0 33.4 150.00 0 0 80 40 0 0 0 25 100
(50+50)
475.0 355.6 2.00 0 0 0 2 0 0 2 25 135
(75+60)
32 MS TO AUX PRDS
475.0 323.9 3.00 0 0 3 2 1 0 0 25 135
(75+60)
B4
SECTION B
(PART – II)
THERMAL INSULATION SCHEDULE FOR PIPING (HAVING HOT FACE TEMP. 449 OC & BELOW)
-----------------------------------------------------------------------------
PROJECT STAGE: CONTRACT
DESIGN PARAMETERS:-
WIND VELOCITY IN M/SEC. 0
MATERIALS:-
INSULATION MATERIAL LRB MATTRESSES

(HOT FACE TEMP. <= 449 OC)
MATERIAL DENSITY IN KG/CUB.M 150 (FOR ALL LAYERS)

FOR HOT FACE TEMP. > 400 OC <= 449 OC
MATERIAL DENSITY IN KG/CUB.M 100 (FOR ALL LAYERS)

FOR HOT FACE TEMP. <= 400 DEG C

FOR DIA.OVER INSUL. = > 450 MM

FOR DIA.OVER INSUL. = > 150 MM < 450 MM

FOR DIA.OVER INSUL. < 150 MM
FOR 150 KG/CUB.M DENSITY MATERIAL: K= .03 + .0002 *T
FOR 100 KG/CUB.M DENSITY MATERIAL: K= .03 + .0002 *T
B5
SL.NO. DESCRIPTION
1 CRH FULL FLOW AS

348.7 711.2 18.00 0 1 0 4 2 0 1 115
(75+40)
2 CRH FULL FLOW CS
348.7 711.2 42.00 0 4 0 3 1 0 0 115
(75+40)
3 CRH HALF FLOW BOILER SIDE
348.7 457.2 103.00 0 0 2 10 0 0 0 115
(75+40)
348.7 711.2 1.00 0 0 0 2 3 0 0 115
(75+40)
348.7 508.0 0.00 0 0 2 0 1 0 0 115
(75+40)
6 HP BYPASS-A (P22)
330.0 457.2 8.00 0 0 1 2 0 0 2 115
(75+40)
7 HP BYPASS-B (P22)
330.0 457.2 8.00 0 0 1 2 0 0 0 115
(75+40)
8 BFPD
247.6 368.0 23.00 0 0 0 14 0 0 6 75
9 FULL FLOW
247.6 368.0 195.00 0 0 0 30 8 0 1 75
10 HEATER BYPASS
247.6 368.0 2.00 0 0 0 1 0 0 4 75
11 STATION BYPASS
247.6 168.3 7.00 0 0 2 0 0 0 1 75
12 STATION BYPASS
247.6 219.1 8.00 0 0 8 4 6 0 2 75
13 DRAIN & VENT

247.6 33.4 100.00 0 0 0 50 0 0 0 50
B6
SL.NO. DESCRIPTION
14 INDIVIDUAL LINE
163.4 273.0 45.00 0 0 0 7 0 0 6 50
15 INDIVIDUAL LINE
163.4 368.0 0.00 0 0 1 0 0 0 0 75
16 EXTRACTION PIPING TO HPH # 5

406.9 219.1 8.00 0 0 3 0 0 0 2 150
(75+75)
406.9 323.9 7.00 0 0 0 1 1 0 3 150
(75+75)
406.9 323.9 7.00 0 0 4 0 0 0 0 150
(75+75)
19 DRIP LEG
406.9 114.3 2.00 0 0 0 0 0 0 2 125
(75+50)
406.9 60.3 30.00 0 0 6 0 0 0 0 115
(75+40)
406.9 33.4 40.00 0 0 10 0 0 0 0 100
(50+50)
22 HPD F/T DRAIN MANIFOLD
400.0 323.9 3.00 0 0 1 0 0 0 1 150
(75+75)
23 DRAIN MANIFOLD
400.0 355.6 4.00 0 0 0 0 0 0 1 165
( 1 X75+50+40)
24 CRH TO AUX. PRDS
365.0 114.3 1.00 0 0 0 0 0 0 0 115
(75+40)
25 TURBINE GS FROM CRH
348.7 88.9 15.00 0 0 5 0 0 0 0 90
(50+40)
26 TURBINE GS EXHAUST TO ATMOS
348.7 273.0 80.00 0 0 10 0 0 0 0 115
(75+40)
B7
SL.NO. DESCRIPTION
27 CRH AUX PRDS BYPSSS

348.7 114.3 3.00 0 0 2 0 0 0 4 90
(50+40)
348.7 168.3 4.00 0 0 1 1 0 0 3 100
(50+50)
348.7 88.9 1.00 0 0 0 1 0 0 0 90
(50+40)
30 CRH TO AUX PRDS
348.7 114.3 12.00 0 0 4 0 1 0 1 90
(50+40)
31 CRH TO AUX PRDS
348.7 168.3 20.00 0 0 7 1 1 0 0 100
(50+50)
32 CRH TO AUX PRDS
348.7 88.9 1.00 0 0 0 1 0 0 0 90
(50+40)
33 DRIP LEG
348.7 114.3 2.00 0 0 0 0 0 0 2 90
(50+40)
348.7 33.4 40.00 0 0 10 6 6 0 0 80
(40+40)
35 CRH NRV DRAIN HP F/T & VENT FT & VENT
348.7 60.3 80.00 0 0 19 0 0 0 0 80
(40+40)
36 CRH NRV DRAIN HP F/T & VENT FT & VENT
348.7 33.4 20.00 0 0 6 0 0 0 0 80
(40+40)
37 IMPULSE PIPE
348.7 21.3 200.00 0 0 50 0 0 0 0 75
38 EXTRACTION STEAM TO HPH- 6

346.9 273.0 40.00 0 0 10 0 1 0 2 115
(75+40)
39 DRIP LEG
346.9 114.3 3.00 0 0 0 0 3 0 3 90
(50+40)
B8
SL.NO. DESCRIPTION
40 DRAIN & VENT

346.9 33.4 35.00 0 0 10 0 0 0 0 80
(40+40)
41 CRH TO DEAERATOR PEGG
346.9 273.1 20.00 0 0 5 1 1 0 3 115
(75+40)
346.9 508.0 1.00 0 0 0 1 0 0 0 115
(75+40)
330.0 33.4 40.00 0 0 10 4 6 0 0 80
(40+40)
44 EXT. LINE S.V DISCH
330.0 406.4 30.00 0 0 12 0 0 0 3 115
(75+40)
330.0 273.0 3.00 0 0 3 0 0 2 0 115
(75+40)
330.0 219.1 2.00 0 0 2 0 0 2 0 100
(50+50)
47 LINE DRAIN
330.0 33.4 40.00 0 0 18 0 0 0 0 80
(40+40)
48 D/A SAFETY VALVE DISCH
320.0 323.9 2.00 0 0 1 0 0 3 0 115
(75+40)
49 D/A SAFETY VALVE DISCH
320.0 406.4 25.00 0 0 8 0 0 0 3 115
(75+40)
50 MS TO AUX PRDS
320.0 323.9 8.00 0 0 3 1 0 0 2 115
(75+40)
51 MS TO AUX PRDS
320.0 323.9 10.00 0 0 1 1 5 2 0 115
(75+40)
52 HT STN HEADER (FOR TWO UNITS)
320.0 168.3 120.00 0 0 0 0 2 0 5 100
(50+50)
B9
SL.NO. DESCRIPTION
53 HT UNIT HEADER
320.0 168.3 6.00 0 0 1 0 3 0 2 100
(50+50)
54 HT UNIT HEADER
320.0 168.3 20.00 0 0 5 0 3 0 3 100
(50+50)
55 HT UNIT & STN INTER CONN.
320.0 168.3 8.00 0 0 4 0 0 0 0 100
(50+50)
56 AUX. STEAM TO AIR HEATER CLEANING DEVICE
320.0 114.3 20.00 0 0 6 0 0 0 0 90
(50+40)
57 DRIP LEG FOR HT & LT AUX. STEAM HEADERS
320.0 114.3 6.00 0 0 0 0 0 0 8 90
(50+40)
320.0 33.4 150.00 0 0 40 30 45 0 0 80
(40+40)
59 DRAIN HEADER TO FLASH PIPE
320.0 114.3 40.00 0 0 8 0 1 0 2 90
(50+40)
60 FLASH PIPE
320.0 406.4 3.00 0 0 0 1 0 0 1 115
(75+40)
61 FLASH PIPE VENT & DRAIN
320.0 219.1 3.00 0 0 4 0 0 0 1 100
(50+50)
62 IMPULSE PIPE
320.0 21.3 500.00 0 0 150 0 0 0 0 75
63 AS & CRH TO D/A

285.8 508.0 40.00 0 0 10 0 5 0 0 115
(75+40)
64 AUX STEAM TO DEA PEGG BYPASS
285.8 457.0 15.00 0 0 4 1 2 0 1 90
(50+40)
285.8 508.0 10.00 0 0 3 2 0 0 2 115
(75+40)
B 10
SL.NO. DESCRIPTION
66 EXTN. STEAM TO DEAERATOR

285.8 406.4 35.00 0 0 9 3 0 0 3 90
(50+40)
67 EXTN. STEAM TO DEAERATOR
285.8 323.9 1.00 0 0 0 1 0 0 0 90
(50+40)
68 DRIP LEG
285.8 219.1 3.00 0 0 0 0 0 0 3 80
(40+40)
285.8 33.4 160.00 0 0 30 14 25 0 0 75
70 TURBINE GS FROM AUX. STEAM

285.8 88.9 50.00 0 0 10 1 1 0 0 80
(40+40)
285.8 33.4 80.00 0 0 20 6 8 0 0 75

285.8 48.3 30.00 0 0 10 0 5 0 0 75
73 FEED WATER TO ECONOMISER

260.0 368.0 2.00 0 0 0 0 0 0 0 90
(50+40)
74 D/A START UP OPER. VENT TO ATMOS.
250.0 60.3 3.00 0 0 6 0 2 0 0 75
75 SH SPRAY UP TO BLOCK VALVES

247.6 168.3 40.00 0 0 8 1 0 0 0 75
76 IMPULSE PIPE
247.6 33.4 70.00 0 0 40 30 0 0 0 50

220.0 219.1 20.00 0 0 5 1 1 0 4 75

220.0 219.1 1.00 0 0 0 0 0 0 0 75
B 11
SL.NO. DESCRIPTION
79 AUX STEAM TO DEAERATOR PEGGING

220.0 457.0 5.00 0 0 0 1 1 0 0 75
80 AUX STEAM TO DEAERATOR PEGGING

220.0 219.1 8.00 0 0 0 2 0 0 0 75
81 D/A INITIAL HEATING

220.0 114.3 30.00 0 0 8 0 0 0 1 75
82 D/A INITIAL HEATING

220.0 273.0 10.00 0 0 3 0 0 0 1 75
83 LT STN HEADER (FOR TWO UNITS)

220.0 273.0 120.00 0 0 0 0 6 0 7 75
84 LT UNIT HEADER
220.0 273.0 20.00 0 0 5 0 9 0 1 75
85 LT UNIT & STN INTER CONN.

220.0 273.0 10.00 0 0 6 0 0 0 0 75
86 AUX. STEAM FOR SCAPH & F.O ATOMISATION

220.0 219.1 15.00 0 0 6 0 0 0 0 75
87 AUX. STEAM TO LIGNITE HANDLING

220.0 60.3 30.00 0 0 8 0 0 0 0 50
88 F.O. HEATING FROM STN. HDR

220.0 168.3 20.00 0 0 6 0 0 0 0 75
89 F.O. TRACING
220.0 60.3 20.00 0 0 6 0 0 0 0 50
90 F.O. HEATING IN DECANTING AREA

220.0 88.9 10.00 0 0 6 0 1 0 0 50
91 LT STN HDR TO F.O. HEATING

220.0 114.3 15.00 0 0 4 0 0 0 0 75
B 12
SL.NO. DESCRIPTION
92 STEAM TO DESUPER HEATER

220.0 168.3 60.00 0 0 7 0 0 0 1 75
93 DESUPER HEATER TO COMMON TURBINE HDR

220.0 219.1 30.00 0 0 4 2 1 0 0 75
94 WET STEAM TO IP TURBINE

220.0 88.9 20.00 0 0 6 2 2 6 1 50
95 WET STEAM TO HP TURBINE

220.0 60.3 15.00 0 0 6 0 0 6 1 50
96 DRAIN TO HP F/T
220.0 114.3 20.00 0 0 5 0 0 0 1 75
97 DRAIN TO HP F/T
220.0 33.4 30.00 0 0 6 0 0 0 0 50
98 AUX. STEAM TO EJECTOR

220.0 114.3 80.00 0 0 12 2 1 0 0 75

220.0 168.3 15.00 0 0 3 3 3 0 0 75

220.0 60.3 8.00 0 0 4 0 0 0 0 50
101 AUX. STEAM TO STARTING EJECTOR

220.0 114.3 10.00 0 0 4 0 0 0 0 75
102 LPD F/T DRAIN MANIFOLD

210.0 323.9 3.00 0 0 1 0 0 0 1 75
103 HPFT VENT

210.0 914.0 5.00 0 0 1 0 0 0 2 100
(50+50)
104 UNIT F/T VENT
210.0 406.4 10.00 0 0 3 0 0 0 1 75
B 13
SL.NO. DESCRIPTION
105 UNIT F/T MANIFOLD

210.0 323.9 3.00 0 0 0 0 0 0 1 75
106 UNIT F/T MANIFOLD

210.0 219.1 3.00 0 0 0 0 0 0 1 75
107 HPH-6 DRAIN TO HPH-5

208.7 219.1 18.00 0 0 9 5 2 0 4 75
108 HPH-6 TO DEARATOR

208.7 219.1 38.00 0 0 7 2 0 0 4 75
109 HPH-6 TO HPDFT

208.7 219.1 26.00 0 0 4 2 0 0 2 75
110 HPH-6 TO HPDFT

208.7 273.1 1.00 0 0 0 2 0 0 1 75
111 HPH 6 VENT TO D/A

208.7 60.3 40.00 0 0 10 1 0 0 3 50
112 HPH 6 START UP VENT

208.7 33.4 2.00 0 0 2 0 0 0 0 50
113 HPH 6 RV DISC PPG

208.7 168.3 20.00 0 0 5 0 0 1 0 75
114 EXTRACTION STEM TO LPH3

175.9 508.0 13.00 0 0 4 2 0 0 3 75
115 DRIP LEG

175.9 323.9 2.00 0 0 0 0 2 0 0 75

175.9 60.3 40.00 0 0 12 0 0 0 0 40

175.9 33.4 30.00 0 0 8 0 0 0 0 40
B 14
SL.NO. DESCRIPTION
118 BFP SUCTION

170.0 273.0 6.00 0 0 0 0 0 0 0 50
119 BFP TO PRDS

170.0 60.3 1.00 0 0 0 0 0 0 0 40
120 BFP TO HP BYPASS SPARY

170.0 114.3 1.00 0 0 0 0 0 0 0 50
121 HPH5 DRAIN TO DEAERATOR

169.0 219.1 46.00 0 0 13 1 1 0 2 50

169.0 168.3 0.00 0 0 0 0 0 0 1 50

169.0 219.1 4.00 0 0 1 0 0 0 1 50
124 HPH5 DRAIN TO HPFT

169.0 219.1 17.00 0 0 6 0 0 0 1 50

169.0 219.1 1.00 0 0 2 2 0 0 0 50

169.0 273.1 1.00 0 0 0 0 0 0 1 50

169.0 168.3 0.00 0 0 0 1 0 0 1 50

169.0 273.0 0.00 0 0 0 1 0 0 0 50
129 HPH 5 VENT TO D/A

169.0 60.3 40.00 0 0 10 1 0 0 3 40
130 HPH 5 START UP VENT

169.0 33.4 2.00 0 0 2 0 0 0 0 40
B 15
SL.NO. DESCRIPTION
131 HPH 5 RV DISC. PPG

169.0 168.3 20.00 0 0 5 0 0 1 0 50
132 HPBP SPRAY AS

163.4 88.9 4.00 0 0 4 2 0 0 0 50
133 HPBP SPRAY CS

163.4 114.3 1.00 0 0 6 3 1 0 7 50
134 HPBP SPRAY CS

163.4 88.9 33.00 0 0 4 6 0 0 2 50
135 HPBP FROM EMERGENCYSPRAY

163.4 114.3 150.00 0 0 20 0 2 0 2 50

163.4 33.4 50.00 0 0 18 0 0 0 0 40
137 BOILER FEED RECURCULATION

163.4 114.3 144.00 0 0 24 0 0 0 6 50
138 RH SPRAY UP TO BLOCK VALVE

163.4 88.9 130.00 0 0 20 1 3 0 6 50
139 SPRAY WATER PIPING FROM BFP TO AUX. PRDS UPT NRVS & BYPASS
163.4 60.3 40.00 0 0 8 4 12 0 0 40
140 SPRAY WATER FROM EMERGENCY BFP

163.4 60.3 20.00 0 0 3 0 1 0 0 40
141 SPRAY WATER TO HC DESUPER HEATER

163.4 60.3 2.00 0 0 3 0 0 0 0 40
142 SPRAY WATER FOR LT DESUPER HEATER

163.4 60.3 40.00 0 0 8 4 11 0 0 40
143 BOILER FEED SUCTION

160.1 273.0 165.00 0 0 14 6 0 0 3 50
B 16
SL.NO. DESCRIPTION
144 BOILER FEED SUCTION

160.1 355.6 0.00 0 0 0 6 0 0 3 75
145 BOOSTER PUMP DISCH

160.1 273.0 57.00 0 0 12 3 3 1 3 50
146 BOOSTER PUMP SUCTION R.V. DISCH.

160.1 33.4 30.00 0 0 15 0 0 0 0 40
147 BFP LEAK OFF

160.1 60.3 15.00 0 0 12 0 0 0 0 40
148 LINE DRAIN & VENTS

160.1 33.4 30.00 0 0 15 0 0 0 0 40
149 DEAERATOR OVER FLOW BYPASS

160.1 114.3 3.00 0 0 2 0 0 0 1 50
150 DEAERATOR OVER FLOW CONTROL STATION

160.1 114.3 1.00 0 0 1 1 0 0 3 50

160.1 219.1 2.00 0 0 1 1 0 0 1 50

160.1 88.9 1.00 0 0 0 1 0 0 0 50
153 DEAERATOR OVER FLOW

160.1 114.3 76.00 0 0 22 2 5 0 0 50

160.1 219.1 2.00 0 0 0 1 1 0 0 50

160.1 88.9 1.00 0 0 0 2 0 0 0 50
156 DEAERATOR DRAIN TO CST

160.1 114.3 100.00 0 0 11 0 1 0 1 50
B 17
SL.NO. DESCRIPTION
157 LPFT VENT

150.0 813.0 5.00 0 0 1 0 0 0 2 75
158 LPH-3 TO DEAERATOR

121.1 323.8 65.00 0 0 11 0 2 6 0 50
159 LPH3 BYPASS

121.1 273.0 1.00 0 0 0 0 0 0 1 50

121.1 33.4 200.00 0 0 25 0 0 0 0 40

121.1 60.3 15.00 0 0 5 0 0 0 0 40
162 STARTING EJECTOR EXHAUST

110.0 219.1 5.00 0 0 1 0 0 0 0 50
163 STARTING EJECTOR EXHAUST

110.0 323.9 30.00 0 0 5 0 0 0 1 50
164 UNIT F/T DRAIN

110.0 219.1 3.00 0 0 0 0 0 0 1 50
165 UNIT F/T DRAIN

110.0 114.3 10.00 0 0 6 0 0 0 0 50
166 UNIT F/T DRAIN

110.0 33.4 3.00 0 0 0 0 0 0 0 40
167 EXTRACTION STEAM TO LPH-2

108.1 610.0 8.00 0 0 5 1 2 0 3 75
168 DRIP LEG

108.1 323.9 2.00 0 0 0 0 0 0 2 50

108.1 60.3 40.00 0 0 12 0 0 0 0 40
B 18
SL.NO. DESCRIPTION

108.1 33.4 30.00 0 0 8 0 0 0 0 40

100.0 33.4 200.00 0 0 40 0 0 0 0 40
172 GSC DRAIN TO LPD F/T & ATMOS.

99.9 88.9 30.00 0 0 12 2 2 2 2 25
173 GSC DRAIN TO LPD F/T & ATMOS.

99.9 33.4 2.00 0 0 2 0 0 0 0 25
174 LPH-3 ALT. DRAIN TO LPDFT

98.8 168.3 20.00 0 0 6 1 0 0 2 40

98.8 219.1 2.00 0 0 0 1 0 0 1 40

98.8 168.3 0.00 0 0 0 1 0 0 0 40
177 LPH-3 DRAIN TO LPH-2

98.8 168.3 15.00 0 0 7 1 1 0 3 40
178 LPH 3 VENT TO COND

98.8 60.3 20.00 0 0 6 0 1 0 1 25
179 LPH-3,2,1 START UP VENT

98.8 33.4 10.00 0 0 6 0 0 0 0 25
180 LPH 3 RV DISC. PPG

98.8 114.3 15.00 0 0 5 0 0 1 0 40
181 LPH 2 BYPASS

95.0 273.0 2.00 0 0 0 2 1 0 1 40
182 LPH 2 BYPASS

95.0 219.1 4.00 0 0 0 2 0 0 0 40
B 19
SL.NO. DESCRIPTION
183 LPH 2 TO LPH3

95.0 323.8 5.00 0 2 2 0 1 0 2 40
184 DC TO LPD F/T LINE VENT

85.0 33.4 10.00 0 0 5 0 0 0 0 25

77.5 219.1 15.00 0 0 5 2 0 0 2 40

77.5 273.1 2.00 0 0 0 1 0 0 1 40
187 LPH-2 TO LPH-1 DRAIN

77.5 219.1 10.00 0 0 9 2 1 0 4 40

77.5 60.3 20.00 0 0 6 0 1 0 1 25
189 LPH 2 RV DISC. PPG

77.5 114.3 15.00 0 0 5 0 0 1 0 40
190 DRAIN COOLER TO LPFT

75.2 273.0 30.00 0 0 6 0 0 0 1 40

75.2 88.9 3.00 0 0 2 0 1 0 1 25
192 LPH1 DRAIN TO DRAIN COOLER

72.5 219.1 25.00 0 0 11 0 0 0 0 40
193 LPH 1 BYPASS/CONDENSATE

72.0 323.9 4.00 0 0 0 0 0 0 1 40
194 LPH 1 TO LPH2

72.0 323.9 4.00 0 0 0 0 0 0 2 40
195 FLASH PIPE VENT & DRAIN

320.0 88.9 30.00 0 0 6 0 0 0 0 90
(50+40)
B 20
SECTION C
THERMAL INSULATION SCHEDULE FOR EQUIPMENTS
------------------------------------------
PROJECT STATUS: CONTRACT
DESIGN PARAMETERS:-
WIND VELOCITY IN M/SECD. 0
MATERIALS:-
INSULATION MATERIAL LRB MATTRESSES
MATERIAL DENSITY IN KG/CUB.M 100
K= .03 + .0002 *T
C1
SL.NO. DESCRIPTION NO. OF H.F.TEMP EQUIP. O.D. EQUIP.LENGTH INSUL.THICK. BARE AREA CLAD.AREA
EQUIPS. PER EQUIP. PER EQUIP.
NO. DEG C MM MM MM SQ.M SQ.M
1.0 L.P. HEATER 1 1 100.0 1200 11310 25 44.9 47.3
2.0 L.P HEATER 2 1 150.0 1060 11110 25 38.8 41.0
3.0 L.P HEATER 3 1 210.0 1060 11110 50 38.8 43.3
4.0 DEAERATOR 1 350.0 2228 9000 110 70.8 82.0

(60+50)
5.0 DEAERATOR STORAGE TANK 1 250.0 3636 26700 75 325.8 343.7
6.0 H.P HEATER 5 1 215.0 1500 12230 50 61.2 66.5
7.0 H.P HEATER 6 1 270.0 1522 13000 75 65.8 74.3
8.0 BFP BOOSTER PUMP 3 170.0 0 1000 25 0.0 0.2
9.0 BFP MAIN PUMP 3 170.0 1000 1500 40 6.3 7.5
10.0 BFP SUCTION STRAINER 3 170.0 630 1200 40 3.0 3.8
11.0 GLAND STEAM CONDENSER 1 400.0 570 2000 120 4.1 7.3
(60+60)
12.0 DRAIN COOLER 1 60.0 610 5300 25 10.7 11.9
13.0 L.P. FLASH TANK 1 150.0 1600 2400 25 16.1 17.2
14.0 H.P. FLASH TANK 1 210.0 2400 3600 50 36.2 39.7
15.0 ATMOSPHERIC FLASH TANK 1 210.0 1200 1800 50 9.0 10.8
16.0 MAIN STEAM STRAINER 2 540.0 560 1650 190 3.4 8.5
( 2 X75+40)
17.0 HRH STRAINER 2 540.0 945 1700 210 6.4 13.8

( 2 X75+60)
18.0 EJECTOR ( MAIN ) 2 250.0 1200 2300 75 10.9 13.9
19.0 STARTING EJECTOR 1 250.0 324 1750 60 1.9 3.1
C2
SECTION D
SECTION E
TITLE: BHEL :PSSR: NEYVELI:INSULATION
BILL OF MATERIAL
REV. NO. 00 DATE: 31.07.2008
SHEET 1 OF 2
S.No. MATERIAL DESCRIPTION WEIGHT QUANTITY
A CALCIUM SILICATE PREFORMED PIPE

INSULATION 240 Kg/Cub.M
Sl. No. OF PIPING # PIPE O.D IN MM #

INSULATION THICKNESS IN MM
(These to be marked properly with stencils on

each package of pipe section)
A1 3 # 660 # 40 120 Mtr
A2 8, 10 # 610 # 40 15 Mtr
A3 1, 4 # 558.8 # 40 405 Mtr
A4 7, 9 # 508 # 40 105 Mtr
A5 11, 12, 31 # 355.6 # 25 15 Mtr
A6 2 # 323.9 # 40 320 Mtr
A7 32 # 323.9 # 25 10 Mtr
A8 5, 6, 13 # 273 # 40 70 Mtr
A9 14, 16 # 219.1 # 40 35 Mtr
A10 15, 17 # 168.3 # 25 10Mtr
A11 19, 21, 22, 25, 26, 27 # 60.3 # 25 495 Mtr
A12 23 # 48.3 #25 25 Mtr
A13 18, 20, 24, 28, 29, 30 # 33.4 # 25 690 Mtr
B CALCIUM SILICATE POWDER 2800 Kgs.
SODIUM SILICATE OF COMMERCIAL GRADE

C. 300 Ltrs.
(BINDER FOR CALCIUM SILICATE POWDER)
TITLE: BHEL :PSSR: NEYVELI:INSULATION
BILL OF MATERIAL
REV. NO. 00 DATE: 31.07.2008
SHEET 2 OF 2
S.No MATERIAL DESCRIPTION DENSITY/SIZE/THK UNIT QUANTITY

D BONDED MINERAL (ROCK) WOOL
MATTRESSES
1 Bonded mineral (rock) wool 150 Kg/ Cub. M Sq.M 40 mm - 50
mattresses with one side GS wire 50 mm - 1650
netting of 13 mm x 0.71 mm size
stitched with 0.4 mm GS wire 60 mm - 1250
75 mm - 4300
2 Bonded mineral (rock) wool 100 Kg/ Cub. M Sq.M 25 mm - 550

mattresses with one side GS wire 40 mm - 2950
netting of 13 mm x 0.71 mm size
stitched with 0.4 mm GS wire 50 mm - 4300
60 mm - 150
75 mm - 1850
E ALUMINIUM SHEETS 18 SWG Kg 21, 800

(Gr. 19000 - H2) 20 SWG Kg 13, 100
22 SWG Kg 1, 000
F ANCILLARY MATERIAL
1 Binding Wire, galvanised steel 1.01 mm Dia Kg 1200
2 Lacing wire, galvanised steel 0.9 mm Dia Kg 1000
3 MS flats/straps 20 mm x 3 mm Kg 3100
4 Sealing compound Self setting paste type Kg 400
5 ST screw with washers, stainless steel No.8 x 19.0 mm long Set 1, 79, 500
6 Ceramic mill board 3 mm thick Kg 400
7 MS rivets 3 mm dia & 12 mm long Nos. 34, 200
8 Bolts & Nuts 10 mm dia. & 60 mm long set 2900

10 mm dia. & 40 mm long set 2900
10 mm dia. & 25 mm long set 2900
9 Anodised aluminium bands 20 mm x 0.6 mm Kg 3100
10 Seals for aluminium bands To suit Al bands. Kg 300
11 GI toggle clips -- Nos. 1100
NOTE: QUANTITIES MENTIONED ABOVE ARE FOR ONE UNIT. ORDER AND SUPPLY WILL BE
FOR TWO UNITS.
BHEL, PS-PEM, PPEI BLDG, SECTOR - 16 A, NOIDA - 201301

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GENERAL GUIDELINES FOR

This booklet is given as a general

Bharat Heavy Electricals Limited

2 X 250 MW NEYVELI TPS – II EXPANSION

INSTRUCTIONS FOR APPLICATION OF

BHARAT HEAVY ELECTRICALS LIMITED

SECTION TITLE No. OF SHEETS

B THERMAL INSULATION (THICKNESS) 4

B THERMAL INSULATION (THICKNESS) 16

C THERMAL INSULATION (THICKNESS) 2

D THERMAL INSULATION APPLICATION 15

The heat lost through bare pipe increases with

a) Increase in the temperature of fluid conveyed

2.0 INSULATING MATERIALS

5.0 METHODS OF APPLICATION FOR CALCIUM SILICATE PRE-FORMED RIGID PIPE

5.2 SURFACE PREPARATION

b) All hangers, brackets and pipe clamps etc. should be in position.

c) All surfaces should be brush-coated with a suitable anti-corrosive primer wherever

d) Necessary pressure-test for the pipes to be carried out before insulation.

e) All the joints to be tightened so that there is no leakage.

5.3 MECHANICAL SECUREMENT OF PIPE COVERINGS.

a) For securing insulation on horizontal pipes, circumferential bands of Aluminium (20 mm

5.4 INSULATION OF PIPES

b) For single layer of insulation, circumferential joints should be staggered.

e) For multilayers of insulation, circumferential joints shall be staggered by at least

5.5 INSULATION OF FITTINGS

5.6 EXPANSION JOINTS

a) Due to difference in expansion coefficients of metal and insulating material, it is

Expansion joints should be provided at the spacing as per following :-

Temperature oC Spacing Interval (m)

6.0 METHOD OF APPLICATION FOR CALCIUM SILICATE POWDER (ASBESTOS

Calcium Silicate Plastic Composition is to be applied by Hand trowelled method. Slurry

7.0 METHOD OF APPLICATION FOR ROCKWOOL MATTRESSES

7.18 Insulation support s shall have one coat of bituminous paint.

7.22 The joints of outer cladding should be staggered axially.

7.26 Sealing compound to be applied on all cladding sheet joints.

7.28 Equipment name plates shall not be insulated.

IMPORTANT POINTS TO BE TAKEN CARE DURING APPLICATION

v) Inside surface of Aluminium sheets to have 1 coat of bituminous paint applied

viii) Valves to be insulated properly in box structure as given in enclosed drawings.

ix) Multilayer longitudinal and circumferential joints should be staggered.

PROJECT TITLE: 2 x 250 MW NEYVELI TPS – II EXPANSION

PROJECT STAGE: CONTRACT

COLD FACE TEMPERATURE IN DEG C 60

AMBIENT TEMPERATURE IN DEG C 30

EMISSIVITY (DIMENSIONLESS) 0.2

WIND VELOCITY IN M/SEC. 0

INSULATION MATERIAL CALCIUM SILICATE FOR 1ST LAYER

LRB MATTRESS FOR SUBSEQUENT LAYERS

CLADDING MATERIAL ALUMINIUM SHEET

CLADDING MATERIAL GUAGE 18 SWG

CLADDING MATERIAL GUAGE 20 SWG

CLADDING MATERIAL GUAGE 22 SWG

THERMAL CONDUCTIVITY VS. MEAN TEMPERATURE EQUATION:-

(K IS THERMAL CONDUCTIVITY IN W/M.C AND T IS MEAN TEMP. IN DEG C)

FOR CALCIUM SILICATE: K= .0473 + .00014 *T

FOR LRB MATTRESSES: K= .03 + .0002 *T

PROJECT TITLE: 2 x 250 MW NEYVELI TPS – II EXPANSION