Critical Thickness of Insulation – Critical Radius

In a plane wall the area perpendicular to the direction of heat

flow adding more insulation to a wall always decreases heat
transfer. The thicker the insulation, the lower the heat
transfer rate. This is due to the fact the outer surface have
always the same area.

But in cylindrical and spherical coordinates, the addition of

insulation also increases the outer surface, which decreases
the convection resistance at the outer surface. Moreover, in
some cases, a decrease in the convection resistance due to the
increase in surface area can be more important than an increase
in conduction resistance due to thicker insulation. As a result
the total resistance may actually decrease resulting in increased
heat flow.
The thickness upto which heat flow increases and after which
heat flow decreases is termed as critical thickness. In the case
of cylinders and spheres it is called critical radius. It can be
derived the critical radius of insulation depends on the thermal
conductivity of the insulation k and the external convection heat
transfer coefficient h.

Term “Critical” itself is not complete by itself it is subjective term.

Insulation Thickness which is acceptable on one circumstance and

applications is not acceptable on the other case. There are many
factors which need to be considered while deciding critical insulation
thickness.

I am explaining it giving thermal Insulation some cases are

applicable for electrical insulation also.
CASE 1: As per IS 14164

Recommended surface temperature is Ambient + 20 deg C

Recommended surface heat loss is 125 W/Sq mtr-hr

Recommended surface temperature for human safety is 65 deg C

Most of the above factors need to be considered while deciding on

critical insulation thickness.

Let me explain this with an example.

If we consider surface temperature as factor (usually considered for

steam line or boiler wall) allowed maximum surface temperature is
Ambient + 20 deg C. This could be wrong insulation thickness in
some cases if we compare it with surface heat loss factor 125W/Sq
mtr-hr.

If we consider personnel safety factor (usually considered for steam

condensate line or steam trap outlet) allowed maximum surface
temperature is 65 deg C. This could be wrong insulation thickness in
some cases if we compare it with surface heat loss factor 125W/Sq
mtr-hr or Ambient + 20 deg C.

CASE 2: Method of Insulation( Application Practice)

If insulation is loosely warped then it allows air ingress into the hot
surface as hot air is lighter it moves out creating suction of fresh cold
air under the insulation causing continuous heat loss. Same
insulation thickness with same insulation material will give different
result.
CASE 3: Role of Density of Insulation ( Same is applicable in case of
electrical insulation also

Heat absorbed = M x Cp x dT

M- Mass

Cp - Specific heat or thermal conductivity

dT - temperature difference

If density is higher, heavier is the mass. more is the heat absorbed.

For example in case of thermal insulation as per IS 8183 (Bonded

Mineral wool specification)

It is categorized into groups based on density range and application

temperature.

Group 1 Bulk Density Between 12- 50 Kg/m3 maximum

recommended hot face temperature is 250 deg C

Group 2 Bulk Density Between 51- 80 Kg/m3 maximum

recommended hot face temperature is 400 deg C
Group 3 Bulk Density Between 81- 120 Kg/m3 maximum
recommended hot face temperature is 550 deg C

Group 4 Bulk Density Between 121- 160 Kg/m3 maximum

recommended hot face temperature is 750 deg C

Mean temperature (deg C) = (Th + Tc)/2

For Group 2, 3 & 4 at 50 deg C Mean temperature ( Example, Th

=80 Tc = 20 ) Thermal Conductivity 0.43 mW/cm deg C

For Group 2, 3 & 4 at 100 deg C Mean temperature ( Example, Th

=180 Tc = 20 ) Thermal Conductivity 0.52 mW/cm deg C

For Group 3 & 4 at 150 deg C Mean temperature ( Example, Th

=280 Tc = 20 ) Thermal Conductivity 0.62 mW/cm deg C

Lets say

If for 250 deg C Hot face temperature higher Group 4( 150 Kg/m3
Density commercially available) insulation is considered instead of
Group 3(80 Kg/m3 Density commercially available). Thermal
conductivity is same for same insulation thickness. ( Higher the
density, Higher the mass)

System heat loss will be higher if longer is the transfer/traveling

distance.
CASE 4: Reflective effect(Combination factor

If two or more lines are passing in closed by proximity then it creates

combination effect.

Hot steam line passing near the another hot steam line will create
reflective effect on each surface resulting in more surface heat loss.

Hot steam line passing near the another chilled water or cold water
line will create reflective effect on each surface resulting in more
surface heat loss from hot surface and heat gain by cold line.

CASE 5: Cost of ownership Factor

Most of the time organizations also considers commercial impact of

insulation. The cost impact of allowable heat loss over the life time
effective insulation cost is also major factor in decision making.

Life time effective insulation cost include cost of procurement, cost of

application, effective insulation life, maintenance criticallity(Plant
Shut required or not resulting production loss) and maintenance
cost.

If cost impact of allowable heat loss over the additional thickness of

effective insulation is lower then additional thickness is not
considered by organization. While, if cost impact of allowable heat
loss over the additional thickness of effective insulation is higher then
additional thickness is considered by organization.
Hope above explanations have give some brief idea how critical
insulation thickness is practically decided as best practice.