University of Pennsylvania

Design Guide FINAL December 2012

SECTION 230700 INSULATION SYSTEMS 1.0 This section defines insulation system guidelines and requirements for piping, ductwork, and equipment insulation. (Interior piping and equipment, exterior piping, interior ductwork, and exterior ductwork). Insulation shall be applied to mechanical systems to limit heat loss or gain, prevent condensation, protect people from hot or extremely cold surfaces, and improve the operating efficiency of all systems. Insulation types and thicknesses for services are specified within this Section and are generally applicable to most projects. For specialty systems and for large specialty projects, studies of alternative insulation systems shall be initiated and justified on a case by case basis. Insulation materials approved for use in the University buildings shall have a fire hazard rating not to exceed 25 for flame spread and 50 for fuel contributed and smoke developed. All materials shall be factory tested as an assembly. Fire ratings shall be determined by the standard method of testing for surface+burning characteristics of building materials, ASTM E 84. Insulation ap+ proved for use shall have a UL label or a certified test report from an approved testing laboratory. Insulation materials shall not be installed on systems until all necessary tests have been conduct+ ed and insulated surfaces have been thoroughly cleaned and are in a dry state. Protect insulation during construction by covering with plastic to prevent accumulation of dust and debris. Protection should be kept in place until completion of construction. All adhesives sealers, vapor barrier coatings, etc. used in conjunction with insulation shall be compatible with the material to which they are applied. Any cement, sealer, or coating used shall be resistant to vermin and mold and shall be durable. Solvent based adhesives, coatings and sealants shall not be used in occupied areas. The use of solvent based adhesives, coatings and sealants for new construction shall be coordinated with building occupancy and other environ+ mental health and safety issues during construction. All insulation surfaces shall be durable and where exposed, protected from damage due to maintenance operations, vandalism, weather, and normal wear and tear. Pipe fittings, specialties, equipment and valves shall be protected using custom premolded fitting covers and insulation (as defined below) to allow frequent removal and reinstallation without damaging the jacket. A. Insulate all medium and high pressure (above 50 PSIG) steam piping fittings, flanges, valves, strainers, pressure reducing valves. For welded construction where routine ac+ cess is not required, insulation shall match piping insulation. For non+welded construc+ tion and specialties requiring access, custom made insulated canvas jackets with "Vel+ cro" type fastening devices shall be used. Where lower temperature systems (low pressure steam, hot water, refrigerant hot gas piping, etc.) are exposed in routinely accessed areas the same consideration as above shall be given for personnel safety. Systems subject to condensation such as chilled water systems shall be subject to the above insulation requirements.

2.0

3.0

4.0

5.0

6.0

7.0

8.0

B.

C.

9.0

Metallic components used for the installation of insulation systems shall be suitable for the in+ tended environment and shall not corrode. Exposed external corners on duct and equipment in+ sulation in occupied or mechanical areas shall be protected by corner beads consisting of 2 inch by 2 inch by 0.016 inch thick aluminum or 316 stainless steel.

INSULATION SYSTEMS

SECTION 230700 * PAGE 1

University of Pennsylvania

Design Guide FINAL December 2012

10.0

Insulation systems shall be specified to meet industry standards, and installation requirements shall, as a minimum, include the following: A. Insulation shall be continuous at all hangers, hanger rods, supports, sleeves, and open+ ings. Vapor seals must be provided for all cold surfaces and shall be continuous. Where supports must occur below insulation surface, the thickness shall be maintained over the support and extend sufficiently beyond the support to prevent condensation. Insulation shall be sealed where it terminates because of a valve, union, flange, etc. All insulation shall be arranged to permit expansion and contraction of systems without causing damage to the insulation or surface. The actual insulation thickness must be a least equal to the minimum specified at all loca+ tions, including supports in contact with cold surfaces. It is critical that insulation materials be installed in a professional manner with smooth and even surfaces. Scrap pieces of insulation shall not be permitted where a full+length sec+ tion will fit. Insulate pipe saddles and welded pipe standoffs at all points of pipe support. High density insulation inserts shall be used for pipe sizes 4 and larger, where pipe sad+ dles are located. High density insulation inserts for shields shall extend 1 on all sides of the shield. Shields shall be constructed of 16 gauge minimum galvanized steel. All valves and strainers shall be insulated for all welded piping construction as defined above. Custom+fabricated jackets shall be used where defined above. Strainers requiring insulation shall be insulated to permit removal of the basket without disturbing the insulation of the strainer. On ductwork or equipment, accessories shall be provided as required to prevent distor+ tion and sagging of insulation. Welded pins, adhesive, seal staples, vapor barrier coat+ ings, sealing tape, steel bands, and wire ties shall be provided as recommended by the insulation manufacturer. The following attachment methods are preferred: 1. 2. 3. 4. J. Mineral Fiber Board: Brushed on adhesive plus welded pins. (For use in me+ chanical rooms and exposed areas) Mineral Fiber Wrap: Brushed on adhesive with welded pins on bottom of ducts greater than 24 inches wide. Calcium Silicate: Non+corroding wire. Ceramic Fiber Insulation: Stainless steel bands.

B. C. D.

E. F.

G. H. I.

K.

Duct and equipment insulation shall cover all metal surfaces with full+thickness insulation. Duct standing seams require only minimal insulation to prevent condensation. If conden+ sation will not occur, insulation at standing seams can be reduced from the duct main in+ sulation. Equipment Insulation 1. Water pumps (Chilled Water, Glycol/Water Solution, Condenser Water, Conden+ sate Drainage for Air Conditioning Equipment, Cooling Tower Makeup Water, and Heat Exchanger Systems) shall be insulated with removable and replaceable square or rectangular covers consisting of full minimum 16 gauge aluminum or 316 stainless steel metal jackets reinforced at corners and edges and lined with insulation. Pumps with split casings shall be constructed with insulated housing in two or more sections with the upper section removable for access to the cas+ ing. Cover sections shall be flanged, gasketed, and joined with stainless steel sheet metal screws. Lube fittings and drain valves shall extend outside of insu+ lated covers. For Evaporators, Water Chillers, Air Separators, Humidifier Separators, Expan+ sion Tanks, Condenser Water Strainer, Water Storage Tanks and Water+to+ Water Heat Exchangers, fit board type insulation by scoring, cutting and mitering to fit the contour of the equipment. Fill all voids with insulating cement. Insulate the water boxes or heads of evaporators by fabricating an enclosure from No. 18

2.

INSULATION SYSTEMS

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University of Pennsylvania

Design Guide FINAL December 2012

3.

gauge thick galvanized steel sheet. Attach insulation to the inside of the enclo+ sure with adhesive. Slip enclosure over the insulation on the shell and draw tight. Where marine water boxes of chillers are to be insulated, insulate the wa+ ter box head separately to permit removal of the head. Alternately, equipment may be insulated with removable insulation covers cus+ tom made for equipment insulation, such as Pacor Rapidwrap. For these covers: Enclosures shall be encased in vinyl cloth, aluminized cloth, or a coated fiber+ glass cloth. Filler shall be aerogel, microlite AA or fiberglass blanket. Closure system shall be Velcro (high temperature for high temperature applications) or belts & straps. All covers shall be custom made and guaranteed to fit.

L.

Where deemed necessary by the A/E or the University Engineering Department, specific insulation details shall be added to the Contract Documents to improve the insulation per+ formance for specialty areas such as at roof drain bodies and horizontal rain water con+ ductors, or insulation in high humidity areas such as shower rooms and sterilizer areas may require special details for vapor barriers.

11.0

Insulation may be omitted on the following items at the discretion of the University Engineering Department: A. B. C. D. E. F. G. H. I. Exposed brass or copper pipe specified to be chrome plated (typically applies to toilet rooms). All fire protection. ASME stamps on equipment. Access plates of fan housings. Cleanouts or handholes. Factory+preinsulated flexible ductwork. Factory+preinsulated HVAC equipment. Manufacturers nameplates. Vibration+isolating connections.

12.0

The minimum insulation standards for University projects and for the services listed are as indi+ cated in the following Tables for Piping, Equipment, and Ductwork insulation. The A/E shall se+ lect the most suitable product for each individual service. Tables that follow are: Piping Insulation Schedule Mechanical Equipment Insulation Schedule Sheet Metal Ductwork Insulation Schedule

INSULATION SYSTEMS

SECTION 230700 * PAGE 3

University of Pennsylvania

Design Guide FINAL December 2012

PIPING INSULATION SCHEDULE Avg. Pipe Temp Degrees F 45 120 135

System or Service Refrigerant Suction Refrigerant Liquid Refrigerant Hot Gas Brine

Pipe Location Insulation Type Flexible Cellular Flexible Cellular Flexible Cellular Cellular Glass Mineral Fiber OR Flexible Cellular Cellular Glass Mineral Fiber OR Flexible Cellular Mineral Fiber OR Flexible Cellular Mineral Fiber OR Flexible Cellular Indoor X X(a) X X(a) X X(a) X X X X X X X(a) X X X X X X(a) X X X Outdoor Below Grade All Ser* vice

Jacket (e) Metal Fabric

Insulation Thickness, Inches Pipe Sizes, Inches 0.5*2 2.5*4 5*8 10*30 0.5 0.75 0.5 0.75 0.5 0.75 2 2 2 1.5 1.5 1.5 1.5 1 1 0.5 0.5 1 1 1 1 1 1 2.5 2.5 2.5 1.5 1.5 1.5 1.5 1 1 0.5 2.5 2.5 2.5 1.5 1.5 1.5 1.5 1 1 0.5 1.5 1 1 0.5 1.5 1.5

15

X X X

Chilled Water

50

Horizontal [and Vertical] Rainwater Conductors and Roof Drain Bodies Condensate Drains for Air Conditioning Equipment Runouts (<4) to [Finned Tube Radiation, Unit and Cabinet Unit Heaters, Induction and Fan Coil Units, and Terminal Boxes, and

55

60

X X

X(a) X

0.5 1

180

0.5

INSULATION SYSTEMS

SECTION 230700 * PAGE 4

University of Pennsylvania

Design Guide FINAL December 2012

PIPING INSULATION SCHEDULE Avg. Pipe Temp Degrees F

System or Service Hot Water Heating Coils] [Laboratory and] Domes tic Cold, Hot and Recircu lated Hot Water, Hu midification Water, Trap Primer Water

Pipe Location Insulation Type Indoor Outdoor Below Grade All Ser* vice

Jacket (e) Metal Fabric

Insulation Thickness, Inches Pipe Sizes, Inches 0.5*2 2.5*4 5*8 10*30

40 to 140

FOR MAINS: Mineral Fiber FOR BRANCHE S, DROPS AND RUNOUTS : Mineral Fiber OR Flexible Cellular Mineral Fiber

1.5

1.5

1.5

X X

1 1

Handi capped Fix ture Trap and Supply Hot Water Heating and Pumped Steam Con densate

40 to 140 190

X(b)

0.5

Mineral Fiber Cellular Glass OR Flexible Cellular Mineral Fiber OR Flexible Cellular Calcium Silicate OR Rock Wool Cellular Glass

X X X X X X X X X X X X(c)

X X X

1.5 1.5 1.5 1.5

2 2 2 2 1 1.5 0.75 4.5 4.5 3 3 4

2 2 2

2 2 2

Condenser Water

60 to 95

X X

1 1.5 0.5

1 1.5 1 5 5 3 3 4

1 1.5

High Pressure Steam. 125 235 psig

401

X X X X X

3.5 3.5 2.5 X

5.5 5.5 3.5 3.5 4

INSULATION SYSTEMS

SECTION 230700 * PAGE 5

University of Pennsylvania

Design Guide FINAL December 2012

PIPING INSULATION SCHEDULE Avg. Pipe Temp Degrees F 337

System or Service High Pressure Steam, 100 psig Medium Pressure Steam, 50 psig Low Pressure Steam, 15 psig High Pressure Condensate Medium Pressure Condensate Atmospheric and Low Pressure Condensate Flash Tank Vents and Condensate Tank/Receiv er Vents (e) Softened Water

Pipe Location Insulation Type Mineral Fiber Cellular Glass Mineral Fiber Cellular Glass Mineral Fiber Cellular Glass Mineral Fiber Cellular Glass Mineral Fiber Cellular Glass Mineral Fiber Cellular Glass Mineral Fiber Indoor X X X(c) X X X(c) X X X(c) X X X(c) X X X(c) X X X(c) X X X X X X X X Outdoor Below Grade All Ser* vice X

Jacket (e) Metal Fabric

Insulation Thickness, Inches Pipe Sizes, Inches 0.5*2 2.5*4 5*8 10*30 2.5 2.5 4 2 2 4 1.5 1.5 4 2.5 2.5 4 2.5 2.5 3 1.5 1.5 3 1 1 3 3 4 3 3 4 3 3 4 3 3 3 3 3 3 2 2 3 1 1 3.5 3.5 4 3 3 4 3 3 4 3.5 3.5 3 3.5 3.5 3.5 3.5 3.5 3.5 1 1 3.5 3.5 4 3.5 3.5 4 3.5 3.5 4 3.5 3.5 3 3.5 3.5 3.5 3.5 3.5 3.5 1 1

X X

298

X X

250

X X

337

X X

298

X X

250

X X

337

40 85

Mineral Fiber OR Flexible Cellular Mineral Fiber Mineral Fiber Calcium Silicate OR Mineral Fiber

0.5

0.5

0.5

0.5

X X X X X X X X X X X X X X X

0.5 2 2 1.5 1.5 1.5

0.5 2 2 1.5 1.5 1.5 4

0.5 2 2 2 2 2 6.5

0.5 2 2 2 2 2 6.5

Heat Traced Lines Heated Fuel Oil Diesel Gas Engine Exhaust (including silencer)

40 50

900

2.5

INSULATION SYSTEMS

SECTION 230700 * PAGE 6

University of Pennsylvania

Design Guide FINAL December 2012

PIPING INSULATION SCHEDULE Avg. Pipe Temp Degrees F

System or Service

Pipe Location Insulation Type Indoor Outdoor Below Grade All Ser* vice

Jacket (e) Metal Fabric

Insulation Thickness, Inches Pipe Sizes, Inches 0.5*2 2.5*4 5*8 10*30

a = Jacket required on outdoor piping. b = Polyvinyl chloride (PVC) jacket required. c = For use with direct buried piping (not with conduit type systems). d = Insulate where the piping is accessible (e.g., up to 8 feet above the finished floor). e= Protective jackets consisting of 0.016 inches 316 stainless steel shall be used for exposed (exterior) insulation systems and where exposed in interior mechani cal equipment rooms, or other high traffic areas (up to 10 feet above finished floor). As an alternative, PVC jacket and fitting covers may be used in these inte rior spaces. INSULATION SPECIFICATION: Flexible Cellular: ASTM C 534, 5 pcf density, k = 0.27 Btu in/h ft at 75 F
2

Cellular Glass: ASTM C 552, 8.5 pcf density, k = 0.35 Btu in/h ft at 75 F
2

Calcium Silicate: ASTM C 533, 13 pcf density, k = 0.38 Btu in/h ft at 100 F
2

Mineral Fiber: ASTM C 547, 4 pcf density, k = 0.23 Btu in/h ft at 75 F

2

INSULATION SYSTEMS

SECTION 230700 * PAGE 7

UNIVERSITY OF PENNSYLVANIA

Design Guide DRAFT July 27, 2012

MECHANICAL EQUIPMENT INSULATION SCHEDULE

EQUIPMENT LOCATION EQUIPMENT TYPE SURFACE METAL TEMP (DEGREES F) INSULATION TYPE IN DOOR OUT DOOR

INSULATION DENSITY (PCF) THICKNESS (INCHES) JACKET

Cooling Coil Sections and Cooling Coil Condensate Pump Tanks Supply Fan, Dehumidifier, Air Blender, and Heating Coil Casings/ Sec tions Pumps Serving Cold Water Systems

55

Mineral Fiber Board

All Service

55 to 140

Mineral Fiber Board

2 All Service

40 to 180

Mineral Fiber Board or Cus tom Removable Covers

See Para graph 9.0.J

Sidestream Filters, Air Purg ers and Air Sep arators Serving the Chilled Wa ter and Hot Wa ter Heating Systems Water to Water Heat Exchang ers Chiller Evapora tor and Conden ser Marine Wa ter Boxes, Con denser Water Strainer and Water Storage Tanks

40 to 180

Mineral Fiber Board

See Article 9.0.J

50 to 180 40

Mineral Fiber Board or Custom Removable Covers Mineral Fiber Board

1.5

See Para graph 9.0.J

See Para graph 9.0.J

INSULATION SYSTEMS

SECTION 230700 PAGE 8

UNIVERSITY OF PENNSYLVANIA

Design Guide DRAFT July 27, 2012

MECHANICAL EQUIPMENT INSULATION SCHEDULE

EQUIPMENT LOCATION EQUIPMENT TYPE Steam to Water Heat Exchang ers Steam Conden sate Pumps, Condensate Receivers, Con densate Coolers and Flash Tanks Water Treat ment Chemical Mixing/ Storage Tanks Expansion Tanks and Hu midifier Separa tors Duct Mounted Sound Attenua tors in Supply Air Ducts SURFACE METAL TEMP (DEGREES F) 250 INSULATION TYPE Calcium Silicate or Custom Re movable Covers Calcium Silicate IN DOOR X OUT DOOR

INSULATION DENSITY (PCF) 13 THICKNESS (INCHES) 3 JACKET

Cement Finish Cement Finish

250

13

170

Mineral Fiber Board

1.5

18 Gauge Metal Jack et See Para graph 9.0.J

40 to 180 75

Mineral Fiber Board

Mineral Fiber Board

All Service

INSULATION SPECIFICATION: Flexible Cellular: ASTM C 534, k = 0.27 Btu in/h ft at 75 F

2

Cellular Glass Block: ASTM C 552, k = 0.35 Btu in/h ft at 75 F

2

Calcium Silicate: ASTM C 533, k = 0.38 Btu in/h ft at 100 F

2

Mineral Fiber Board (w/ vapor barrier): ASTM C 612, k = 0.23 Btu in/h ft at 75 F
2

Mineral Wool Felt (block or blanket): ASTM C 533, k = 0.50 to 0.58 Btu in/h ft at 600 F
2

INSULATION SYSTEMS

SECTION 230700 PAGE 9

UNIVERSITY OF PENNSYLVANIA

Design Guide DRAFT July 27, 2012

SHEET METAL DUCTWORK INSULATION SCHEDULE PLENUM OR DUCT LOCATION PLENUM OR DUCTWORK TYPE Rectangular Supply and Return Ductwork in Mechanical Rooms, All Exposed Areas and Duct Shafts Rectangular Supply and Return Duct work in Concealed Areas Note: Return duct work in plenum return spaces and /or condi tioned areas is not required. Outside Air Intake, Relief and Exhaust Plenums Louver Blank Off Panels INSULATION TYPE Rigid Mineral Fiber Board INSULATION DENSITY (PCF) 3 X 6 THICKNESS (INCHES) 1.5 2 All Service + JACKET

INDOOR X

OUTDOOR

Rigid Mineral Fiber Board

X X

3 6

1.5 2

All Service +

OR Mineral Fiber Wrap 1 X 1 X Rigid Mineral Fiber Board Rigid Mineral Fiber Board X X X 6 6 6 2 2 2 All Service + Galvanized Sheet Metal (Two Sides) X X 1 1 2 2 All Service + 2 + 2 All Service

Round and Flat Oval Supply and Outside Air Ductwork, and Return Ductwork in Mechanical Rooms Kitchen Hood Ex haust Ductwork

Mineral Fiber Wrap

Calcium Silicate OR Ceramic Fiber Blanket OR Fire Rated Ductwrap System

13

None

X X

1 or 3 (two 1.5 inch layers)

None

INSULATION SYSTEMS

SECTION 230700 PAGE 10

UNIVERSITY OF PENNSYLVANIA

Design Guide DRAFT July 27, 2012

SHEET METAL DUCTWORK INSULATION SCHEDULE PLENUM OR DUCT LOCATION PLENUM OR DUCTWORK TYPE Emergency or Standby Power Generator Air Intake Plenum, Intake Ductwork and Intake Attenuator INSULATION TYPE Rigid Mineral Fiber Board INSULATION DENSITY (PCF) 6 THICKNESS (INCHES) 1.5 All Purpose Jacket with Vapor Barrier JACKET

INDOOR X

OUTDOOR

Ductwork Requiring Noise Transmission Control (as indicated on the Drawings)

Rigid Mineral Fiber Board

Noise Barrier Jacket

+ = For rectangular ducts and plenums exposed to weather, pitch ductwork or insulation board minimum 1/4 inch per foot to prevent rainwater from accumulating on top of duct or plenum. Cover insulation board with corrugated rolled aluminum jacketing installed in strict accord ance with manufacturer's recommendations. ++ = Use double layer application of two 2 inch thick panels to ensure overlapping of all seams and joints to minimize heat loss and hot spots. INSULATION SPECIFICATION: Rigid and Semi Rigid Mineral Fiber Board (w/ vapor barrier): ASTM C 612, k = 0.23 Btu in/h ft at 75 F
2

Mineral Fiber Wrap (w/ vapor barrier): ASTM C 553, k = 0.27 Btu in/h ft at 75 F
2

Calcium Silicate: ASTM C 533, k = 0.38 Btu in/h ft at 100 F

2

Ceramic Fiber Blanket: k = 0.27 Btu in/h ft with a melting point of 3200 F and a 3 hour fire rating for 5 inch thickness when tested in accordance with ASTM E119
2

Thermal Insulating Wool: k = 0.22 Btu in/h ft at 100 F 2 Flexible Cellular: ASTM C 534, k = 0.27 Btu in/h ft at 75 F
2

INSULATION SYSTEMS

SECTION 230700 PAGE 11