Insulation Guidance

FUEL EFFICIENCY
BOOKLET
The economic thickness of

insulation for hot pipes
BEST PRACTICE
PROGRAMME
The views and judgements expressed in this Fuel Efficiency Booklet are not necessarily
those of the Department of the Environment, ETSU or BRECSU.
Cover photograph courtesy of Courtaulds Fibres
THE ECONOMIC THICKNESS OF INSULATION FOR HOT PIPES
CONTENTS
INTRODUCTION
THE EFFECT OF INSULATION
THE ECONOMIC THICKNESS OF INSULATION
Basic requirements to estimate economic thickness
TYPES OF INSULATION
THE ESTIMATION OF ECONOMIC THICKNESS
Use of specially prepared tables
By customised tabulation
ADAPTING TO AMBIENT CONDITIONS
12
ACKNOWLEDGEMENT
13
SOURCES OF FURTHER INFORMATION
13
APPENDIX 1
Some useful conversion factors
15
APPENDIX 2
Tables reproduced from BS 5422: 1990
16
APPENDIX 3
Heat loss graphs for various materials and surface temperatures
25
Preformed rigid fibrous sections
26
Preformed rigid calcium silicate or 85% magnesia sections
36
Preformed rigid polyisocyanurate or polyurethane sections
46
Preformed expanded nitrile rubber and polyethylene foam sections
49
APPENDIX 4
Some basic heat transfer formulae
51
INTRODUCTION
dominant; the greater the temperature and area,
INTRODUCTION
This booklet is concerned with the economic
the greater the loss. Adding an insulating layer
thickness of insulation for hot pipes.
to a hot surface reduces the external surface
Considerable amounts of data and practical
temperature. Although the surface area may be
advice is given, intended for use both by
increased if insulation is added to a circular pipe,
experienced personnel and as training material.
the relative effect of the temperature reduction is
The cost of installing the insulation is offset
much greater and a reduction in heat loss is
by the large savings in fuel bills which can be
achieved.
achieved through insulating pipes. This booklet
Consider for example, a 15 mm bore pipe
explains how to determine the thickness of
running through still air (at 20C) carrying a hot
insulation which will result in the optimum
fluid raising its external temperature to 75C.
installation.
The heat loss is about 60 W per metre of pipe
This booklet is concerned only with hot
run. The addition of a 25 mm thick layer of
pipes, although the insulation of pipes operating
standard pipe insulation would increase the
below ambient temperature is also important. In
surface area by a factor of approximately 3.5,
particular, pipes forming part of domestic and
but the external surface temperature would fall
non-domestic heating and hot water systems,
from 75C to around 23C. The overall effect
and process pipework are covered. The
would be to reduce the heat loss from 60 W to
information and techniques for determining the
12 W per metre run of pipe.
most economic thickness of insulation is

Unwanted heat loss costs money. The loss of
consistent with BS 5422:1990.
heat from a 100 m run of bare 50 mm bore
This booklet is intended as a brief guide to
pipe carrying process steam at 100C, would
the economic thickness of insulation for hot
cost around 3,000 per annum if the steam
pipes, and therefore references are made
was supplied by a gas boiler with a gas cost of
throughout to the extensive documentation
1p/kWh (approximately 30p/therm). This cost
available from the insulation industry and the
would be reduced to 250 per annum if a 50
British Standards Institution (BSI).
mm thick layer of appropriate insulation was
Fuel Efficiency Booklet 19 - Process Plant
applied. Thus, an annual saving of 2,750
Insulation and Fuel Efficiency - gives a broad
would be achieved.
picture of the use of insulation for process plant

and should be read in conjunction with this
booklet.
The avoidable cost increases dramatically as the

temperature of the process fluid increases. If the
hot fluid was at 200C, the bare pipe cost
Any surface which is hotter than its
would be around 10,000 per annum. This level
surroundings will lose heat. The rate at which
of heat loss is equivalent to running a 1 kW
heat is lost depends on many factors, but the
electric fire night and day for more than 25
temperature and area of the surface are often
years. It could be reduced to 560 per annum if
a 75 mm thick layer of insulation were used (the
Fig 1 Heat loss through unlagged flanges
insulation thickness must be increased as the

pipe temperature increases, to ensure a suitable
Unlagged
flanges
,,,,,,,,
,,,,,,,,
,,,,,,,,
,,,,,,,,
,,,,,,,,
,,,,,,,,
,,,,,,,,
external surface temperature). In this case, there

is an avoidable cost of 9,440 per annum.
The use of insulation on pipes carrying high
temperature streams is a normal and accepted
,,,,,,,,
,,,,,,,,
,,,,,,,,
,,,,,,,,
,,,,,,,,
,,,,,,,,
,,,,,,,,
,,,,
,,,,
,,,,,,,,
,,,,,,,,,
,,,,,,,,,,,,
,,,,,,,,,
,,,,,,,,,,,,,
,,,,,,,,,
,,,,,,,,,
,,,,,,,,,
,,,,,,,,,,,,,
,,,,,,,,,,,,,
practice. It should not be assumed that any

existing insulation provides the most effective
Lagged
flanges
arrangement for avoidable cost reduction. In

many cases, thicker insulating layers would be
well justified. All hot surfaces lose heat and, as
shown in Fig 1, attention should be given to
valves, flanges, etc., which are often left
uninsulated for maintenance reasons. An
uninsulated valve loses about the same amount
of heat as 1 m of uninsulated pipe of the same
diameter. Uninsulated flanges, which have a
temperature induced stresses in the pipework
smaller surface area, lose about half this amount.
system, which can be a cause of leakage at joints.

Although some form of insulation is
Thus, a 50 mm valve carrying process steam at

200C would cost about 100 per annum
normally found on high temperature pipework,
without insulation, but only about 6 per
low temperature small bore pipes, or pipes which
annum with appropriate insulation. The
are used only intermittently, are often
operation of valves need not be affected by
completely neglected. However, as with valves
insulation and it can be applied in easily
and flanges, there is a considerable potential for
removable sections to ease maintenance. An
avoidable cost savings. For example, the
additional benefit is a more uniform metal
payback periods for 25 mm thick insulation on
temperature with a consequent reduction in
15 mm pipe in a gas fired domestic heating
Table 1 The Payback Period for Insulation on Domestic Central Heating Pipework
Number of Operating Hours
Payback Period (Years)
1000
2000
3000
0.7
4000
0.5
(Payback period assumes that the total cost for the installation of the insulation is 2 per metre)
installation, for which the operating temperature
Manufacturers of insulation normally
would be typically 60 - 70C, are as shown in
provide information on thermal performance
Table 1. The payback period is the time taken to
which avoids the need for complex heat transfer
recoup the initial cost of an investment from the
calculations. The data, which are normally
savings it produces.
referred to as U values, give the heat loss per

unit length of pipe for a range of pipe diameters,
THE ECONOMIC THICKNESS OF
process stream temperatures and insulation
INSULATION
thicknesses. Whilst such data are useful for
The examples presented in the previous Section
estimation purposes, it is important to note that
give an indication of the cost savings which can
the values are based on specified external
be achieved by the use of insulation to prevent
conditions (often quiescent air at 20C). Some
the unwanted dissipation of heat from pipework.
caution must be exercised if the actual
For a given pipe and process conditions, the rate
application conditions vary considerably from
of dissipation is dependent on the thickness of
those used to establish the U values.

It would be possible to reduce dissipative
the insulating layer and its thermal performance.
losses from pipework systems to effectively zero
In most cases, the most important aspect of

the insulations thermal performance is thermal
by an appropriate choice of material and
conductivity, a physical property which relates
thickness. The cost of operating a hot pipe is
the rate at which heat is conducted through a
the cost of the heat loss, plus the cost of any
material to the temperature difference across the
insulation. In general terms, there is a cost
conduction path. For the same thickness of
penalty associated with increased thickness and
insulation, heat losses are reduced as the thermal
improved thermal performance. Although
conductivity reduces. The effective thermal
higher expenditure results in greater cost
conductivity of an insulating layer may depend
savings, there is a point at which increased
on the application procedure since this may
expenditure to improve the level of insulation
influence, for example, the extent of voids or
cannot be justified by the additional savings
binder material. Operating temperature also
which would arise.

The combined effect of increased
affects the value of many insulating materials

thermal conductivity (see Section 4 Types of
expenditure due to increasing the thickness of
insulation).
the insulating layer, and increased cost saving,

for a specific set of operating conditions, is
Other factors influencing thermal

performance include surface properties which
illustrated in Fig 2. The minimum cost shown is
affect losses due to radiation. For example,
the lowest combined cost of insulation and heat
radiation losses can be reduced by the addition
loss over a given period of time (the evaluation
of a shiny metallic skin to the insulating layer.
period). The minimum cost occurs at a
The benefits of such an addition depend on
particular thickness of insulation, referred to as
actual conditions, but a 10% reduction in overall
the Economic Thickness of Insulation. In
heat loss would not be untypical.
practice, the curves are less smooth because
i.e. it is the product of the annual operating hours
Fig 2 Economic thickness of insulation
and the life of the investment in years. Annual

costs tend to be more meaningful than evaluation
period costs. Consequently, in any analysis of
economic thickness, the determination of annual
costs is recommended, the evaluation period costs
Total cost
are easily established from the annual data.

Ideally, the life of the investment would be based
Cost ()
on the useful life of the insulation, but often

company policies regarding investment criteria
Lost heat
cost
require a much shorter period to be used. The

data required for the complete analysis of
economic thickness can be summarised:
1
To determine the annual cost of heat loss per

metre run of pipe
Insulation
cost
Data requirements:
Minimum
cost
The cost of fuel (In the normal units of

purchase, e.g. pence/therm)
The boiler efficiency (%)

Annual operating period (hours)
many types of insulation are available only in
Heat loss per metre run of pipe

(Watts/metre) which depends on:
certain thicknesses. Nonetheless, the principle
Pipe size
still applies.
Operating temperature
Type and thickness of insulation
Basic requirements to estimate economic
Ambient conditions
thickness
(Methods to estimate the heat loss from
Most of the information which is needed to
these data are given in Section 5)
estimate the economic thickness of insulation
follows from Fig 2. In particular, data are required
To determine the cost of insulation
Data requirements:
which allows the cost of heat loss from the

pipework system over the evaluation period, and
Cost of material ( per metre of pipe)
Cost of ancillary materials ( per metre of
the cost of installing insulation to be determined.
pipe)
Both these items need to be established for a

range of insulation thicknesses. In BS 5422:1990,
the main reference for this booklet, evaluation
Labour costs ( per metre of pipe)
To determine the evaluation period
Data requirements:
period is defined as the total number of operating

hours over which the investment is to be assessed,
The investment life (years)
Annual operating period (hours)
TYPES OF INSULATION
The analysis to determine the economic
siliceous/aluminous/calcium materials
thickness of insulation can be carried out from

first principles using basic data. This procedure
Organic - based on hydrocarbon polymers in

the form of thermosetting/thermoplastic
can incorporate both the exact detail of any
resins or rubbers.
particular application and the standard company
The insulation material can be either flexible or
method for assessing potential investment. For
rigid, both types of which are available in
example, Discounted Cash Flow (DCF)
preformed pipe sections. Table 2 lists the
techniques are employed by some organisations.
common types along with relevant details.
At the other extreme, tables of economic
Certain types of insulation can be applied by
thicknesses based on typical values of costs, etc.,
spraying and this might be appropriate for large
have been prepared. The use of such tables may
pipes. Of the insulating materials listed in
not provide the optimum solution for a
Table 2, mineral wool and polyurethane rigid
particular case, but they would normally provide
foam can be applied in this way. Other
a better answer than an arbitrary choice of
insulating materials with a spray application
thickness.
option are vermiculite (maximum temperature
Before the methods of achieving a value for
1,100C) and alumino silicate (maximum
economic thickness are considered, it is useful to
temperature 1,260C). A binder may be
consider briefly the types of available insulation.
required.
Thermal performance and installation costs are
The thermal conductivity of insulating
affected by this choice.
materials varies considerably according to the

type of material, its density and operating
temperature. Table 3 gives a representative
TYPES OF INSULATION
Insulation material is classed as:
selection.
Inorganic - based on crystalline or amorphous

Table 2 Insulating materials available in preformed pipe sections
Approximate Maximum
Temperature C
Normal Bulk Density kg/m3
Mineral Wool (Glass)
230
15 - 100
Mineral Wool (Rock)
850
80 - 150
Magnesia
315
180 - 220
Calcium Silicate
800
190 - 260
Polyurethane Rigid Foam
110
30 - 160
Polyisocyanurate Rigid Foam
140
30 - 60
Phenolic Rigid Foam
120
35 - 200
Material
Polythene
80
30 - 40
Synthetic Rubber
116
60 - 100
Table 3 Thermal conductivities of insulating materials

Material
Density
Thermal Conductivity W/(m.K)
kg/m3
Temperature C
50
Calcium Silicate
100
300
0.083
210
0.055
0.058
65 - 90
0.039
Mineral Wool (Glass)
16
0.047
0.065
48
0.035
0.044
Mineral Wool (Rock)
100
0.037
0.043
0.088
Magnesia
190
0.055
0.058
0.082
Polyisocyanurate Foam
50
0.023
0.026
Expanded Nitrile Rubber
Service temperature is an obvious criterion
for the selection of an appropriate material, but
THE ESTIMATION OF ECONOMIC

THICKNESS
other factors relating to the operating
There are three different methods of estimating
environment must also be taken into account.
economic thickness. The first uses specially
These include internal or external use, required
prepared tables based on assumptions about
surface finish, structural strength constraints and
every item of data required to estimate economic
accessibility. Although materials exist to satisfy
thickness. The assumptions are reasonable for a
all common requirements, it is important to
wide range of applications and the tables are
note that the economic thickness varies
easy to use. However, there is a margin of error
according to type because of differences in
with this method, because specific details cannot
properties and costs.
be included. The second and more accurate
Further details about insulation materials
method is the formulation of customised tables
can be found in the TIMSA Handbook (available
which do take account of specific details and
from The Thermal Insulation Manufacturers and
which therefore provide a greater degree of
Suppliers Association, PO Box 111, Aldershot,
confidence. These two methods will be described
Hampshire, GU11 1YW) and BS 5970: 1992.
in detail in this Section
Insulation for pipework is also discussed in Fuel
The third method of estimating economic
Efficiency Booklet 19 - Process plant insulation and
thickness is an algebraic solution. This requires
fuel efficiency - which gives general information
mathematical manipulation skills, but it has the
on insulating a range of process plant and more
least number of assumptions and is the most
details of surface finishes and general good
flexible of the three methods. It should only be
practice.
attempted if a very precise value of thickness is

needed, and often this is not a requirement
because many types of insulation are available
application data, but if data are available, they
only in certain specific sizes. For this reason, the
should be checked for consistency with the
algebraic method will not be described in this
assumptions. Unless otherwise stated in Tables 8
booklet. For a more detailed explanation of the
to 16, ambient conditions are still air at 20C.
technique, reference can be made to Energy
Table 4 shows the fuel costs and evaluation
Efficiency for Technologists & Engineers; Eastop &
period used to derive the tabulated values for the
Croft, published by Longman Scientific &
three application categories, non-domestic
Technical; ISBN 0-582-03184-2.
central heating and hot water services, domestic

central heating and hot water services and
Use of specially prepared tables
process pipework. Fuel costs are expressed in
Tables of the economic thickness of insulation
pence per useful MJ. This is the cost of the fuel
for various types of application are included in
in pence per MJ divided by the efficiency of the
BS 5422:1990. Values of the economic
boiler.
thicknesses have been tabulated for appropriate
Table 17 gives the useful cost of heat for
ranges of pipe sizes, pipe surface temperatures,
common fuels over a range of fuel prices,
(normally the process stream temperature), and
expressed in the normal purchase units, based
insulation thermal conductivities. These tables
on typical boiler efficiencies. For a particular
have been reproduced in this booklet in
purchase price, the useful cost of heat can be
Appendix 2 as follows:
obtained directly from Table 17. Insulation costs
are expressed in a particular way which is
Non-Domestic heating and hot water
described below. In general terms, the economic
services
Heating
- gas-fired boiler
Table 9
- oil-fired boiler
Table 10
Hot water services
thicknesses have been derived for estimates of
- solid fuel boiler Table 8
fuel, insulation and installation costs which will

apply in 1995.
Table 11
By customised tabulation
Domestic heating and hot water services

Heating
- heated areas
If the data relating to a particular application are
Table 12
significantly different from those forming the
- unheated areas Table 13

Hot water services - heated areas
assumptions used to derive the tabulated values
Table 14
of economic thickness (Tables 8-16) a calculation
- unheated areas Table 15
Process pipework
specific to the application must be performed.
Table 16
The most straightforward method of calculation
These tables provide the easiest method of
is to create a table which shows the total cost,
determining the required value of economic
i.e. the cost of the heat loss plus the insulation
thickness, but the conditions of the application
costs over the evaluation period, for a range of
under consideration should reasonably satisfy
insulation thicknesses. The thickness which
the assumptions used to derive the tabulated
results in the minimum total cost can then be
values. Use the tables in the absence of any
selected.
Table 4 Fuel costs and evaluation period used to derive the economic thickness Tables 8 - 16
Fuel Cost
pence per useful MJ
Evaluation Period
hours
Non-domestic central heating and hot water services

Fuel:
Solid Fuel
Gas
Oil
Application:
0.38
0.57
0.67
Central Heating
Hot water services
20,000
40,000
Domestic central heating and hot water services

Fuel:
Gas
Application:
0.76
Central Heating
Hot water services
17,000
9,000
Process pipework
Notes:
(1)
(2)
0.6 (2)
40,000
Each evaluation period is based on a typical intermittent operation for the number of
hours shown over a five year period (e.g. continuous non-domestic operation for five years =
40,000 hours)
Deduced from data in BS 5422:1990
Fig 3 Example of table needed for customised tabulation

Thickness of
insulation
(mm)
Heat loss
Cost factor
(W/m)
(/W)
Cost of heat lost over

evaluation period
(/linear m)
Installed cost
of insulation
(/linear m)
Total cost
(/linear m)
A table of the type shown in Fig 3 is
example, that a 50 mm bore pipe with 50 mm of
required. Information described in Section 3,
insulation would lose heat at 20 W/m; the same
The economic thickness of insulation, must be
pipe without insulation would lose heat at 240
available to complete the table. The meaning of
W/m. In a similar way, the value of heat loss
the headings and the method of calculating the
can be determined for any combination of pipe
relevant values are as follows. Each heading has
bore and insulation thickness. If conditions are
been assigned a step number, used to clarify the
windy, refer to Section 6.
worked example given on Page 9.

Cost factor (Step 3)
Thickness of insulation (Step 1)
The cost factor is the cost in pounds of one
The table is completed for a range of
watt of heat loss per metre of pipe over the
possible insulation thicknesses. If necessary, the
evaluation period. It depends on the evaluation
first entry can be bare pipe, i.e. insulation
period and the cost of useful heat. The stages in
thickness equals 0 mm, and successive entries
determining the cost factor are:
made for each of the available thicknesses of the
i) Determine the number of MJ of heat which
selected insulation. Alternatively, the tabulated
are lost per metre of pipe over the evaluation
values of economic thickness can be used as a
period if the rate of loss is one watt/metre.
guide to the approximate value and a range of
A watt is a joule per second. Therefore, if
thicknesses around this value used in the table.
the evaluation period is expressed in hours,
Heat loss (Step 2)
the number of joules which are lost with a

one watt heat loss is:
This is the rate of heat loss, in watts, per

metre of pipe. It depends on the process stream
evaluation period x 3,600
temperature, the pipe diameter, the insulation

thickness and ambient conditions. The heat loss
A megajoule (MJ) is 1,000,000 joules
can be determined conveniently from pre-
(106 joules), therefore the number of MJ lost
prepared graphs (Graphs 1 - 25) which give the
with a one watt heat loss is:
heat loss for a range of insulation types and
evaluation period x 3,600 / 106
thicknesses, pipe diameters and temperatures.

ii) Determine the cost factor which is the
For presentational convenience, these graphs are

reproduced in Appendix 3. Table 5 summarises
product of the cost of useful heat in pence
conveniently the content of each of the graphs.
per MJ and the number of MJ lost, i.e.,

cost x evaluation period x 3,600 / 106
Use Table 5 to select the appropriate graph for
The result should be divided by 100 so that
the particular insulation type and pipe
the cost factor is expressed in /W
temperature relevant to the application under

consideration. The use of these graphs is
The two stages can be combined into a single
illustrated in Graph 3 which is based on a pipe
formula:
temperature of 100C insulated with performed
Cost factor = pence x evaluation period x 36

MJ
106
rigid fibrous sections. The dotted lines show, for
Cost of heat lost over evaluation period
Installed cost of insulation (Step 5)

This is the total cost of the insulation per
(Step 4)
This is simply the total value of the heat lost
metre of pipe inclusive of the cost of the
per metre of pipe, for the particular thickness of
insulating materials, the installation cost, surface
insulation, over the evaluation period. The heat
finish, fixing materials etc. This cost must be
loss column gives the loss in watts per metre and
determined for every thickness of insulation
the cost factor gives the cost in /W for the
considered.
evaluation period. Therefore, the cost of heat
Total cost (Step 6)
loss is given by:
This is the sum of the cost of heat loss over
Heat loss x Cost factor
the evaluation period and the installed cost of

insulation.
Table 5 Summary of heat loss graphs (Appendix 3)

Pipe Surface
Graph Number
Temperature (C)
Insulation Type
A
50
11
70
D
24
21
75
12
100
13
150
14
200
15
300
16
400
17
500
18
600
19
700
10
20
145
25
22
23
Insulation Types A: Preformed rigid fibrous sections

B: Preformed rigid calcium silicate or 85% magnesia sections (magnesia sections up to
300C only)
C: Preformed rigid polyisocyanurate or polyurethane sections (polyurethane sections up to
100C only)
D: Preformed expanded nitrile rubber and polyethylene foam sections
10
Example:
The following example shows the use of the
customised tabulation method for estimating
economic thickness.
A non-domestic heating system uses steam at
slightly over 100C supplied though 50 mm bore
pipes. The steam is supplied by a gas boiler which
is 70% efficient and the cost of gas is 28 pence per
therm. Preformed fibrous insulation material
(thermal conductivity - 0.055 W/(m.K) ) is to be
used. The total cost of installed insulation for the
various thicknesses available from the
manufacturer is as follows:
19 mm thickness
1.40/m
25 mm
2.00/m
32 mm
2.30/m
38 mm
2.90/m
50 mm
8.40/m
The evaluation period is 22,000 hours (5 year
investment life with 4,400 hours of operation per
annum) and the pipework can be assumed to run
through still air at 20C.
Step 3 Cost Factor

Table 17 indicates that the useful cost of heat for a
gas boiler with 70% efficiency and a fuel cost of
22.16 p/therm is 0.30 p/MJ and for a fuel cost of
29.54 p/therm the useful cost is 0.40 p/MJ. In this
particular application the gas cost is 28 p/therm and
the useful cost of heat must be estimated. Simple
proportionality can be used; for this application, the
useful cost is given by:
0.30
Useful Cost = 22.16 = 0.38 p/MJ
The evaluation period is 22,000 hours and,
therefore, the cost factor is given by:
Cost Factor = 0.38 x 22,000 x 36 = 0.30 /W
106
Note that the cost factor is the same for all
insulation thicknesses.
( )
Step 4 Cost of heat lost over evaluation

period
The product of the cost factor and the heat lost.
Therefore:
Cost of heat = 30 x 0.30 = 9.00/m
Step 1 Thickness of insulation

For this application, Table 9 indicates that the
economic thickness is 37 mm (tabulated results for
a pipe with an outside diameter of 60.3 mm are
the closest to the proposed application).
Consequently estimates around this thickness are
likely to be required and the first estimate of
economic thickness should be 25 mm. The values
for each of the columns of the estimating table
can now be evaluated.
Step 5 Installed cost of insulation

Given as 2.00/m
Step 6 Total cost
The sum of the cost of heat and the installed cost of
insulation (Step 4 + Step 5), i.e.:
Total Cost = 9.00 + 2.00= 11.00/m
Similar calculations are used for all the other
thickness values and the results have been tabulated
in Table 6. This shows that the minimum cost
occurs with an insulation thickness of 38 mm and
this should be the thickness selected. Note that in
this example the tabulation method gives
approximately the same value of economic
thickness as given in the pre-prepared tables. THIS
WILL NOT BE TRUE FOR EVERY APPLICATION. It
must also be remembered that the values for Total
Cost are heavily dependent on the investment
criteria of the organisation.
Step 2 Heat Loss

Graph 3 is the appropriate heat loss graph for this
application. This shows that a 50 mm bore pipe
with 25 mm of preformed fibrous insulation
would lose heat at the rate of 30 W/m.
11
ADAPTING TO AMBIENT CONDITIONS
Table 6 Example of economic thickness determination by tabulation

Thickness of
insulation
mm
Heat Loss
Cost Factor
W/m
/W
Cost of Heat
Loss
/m
Installed Cost
of Insulation
/m
Total Cost
/m
25
30
0.30
9.00
2.00
11.00
32
26
0.30
7.80
2.30
10.10
38
23
0.30
6.90
2.90
9.80
50
20
0.30
6.00
8.40
14.40
surface would normally have a high emissivity,
6 ADAPTING TO AMBIENT CONDITIONS

All the procedures indicated above have been
based on ambient conditions of still air at 20C.
Air motion, which in most practical applications
will be due to wind, and a different ambient
temperature, can have a significant effect on the
rate of heat loss and, consequently, the
economic thickness of insulation.
oxidised steel a medium emissivity and polished

aluminium a low emissivity.
If there is no data on typical wind speeds,
the following values are recommended:
Wind speed can have a large effect on the

heat loss from bare pipes as shown in Table 7.
Sheltered situations
1 m/s
Normal situations
3 m/s
Exposed situations
10 m/s
Fortunately, for insulated pipes the effect of
This gives multiplying factors for bare pipe heat
exposure to wind speed alone will not normally
losses compared with those in still air conditions
increase the heat loss from a well insulated pipe
shown in Graphs 1 - 25.
by more than 10% even in exposed conditions.
The factors for high, medium and low
This is because the thermal resistance of the
emissivity surfaces refer to the nature of the
insulation is the dominant factor in determining
outer surface of the pipe. As a guide, a painted
the rate of heat loss.
Table 7 Wind speed correction factors for heat losses from bare pipes only
Wind Speed (m/s)
Multiplying Factors
High Emissivity
Medium Emissivity
Low Emissivity
Surface
Surface
Surface
Still Air
1.00
1.00
1.00
1.35
1.44
1.58
1.65
1.81
2.11
2.00
2.25
2.72
2.60
3.00
3.86
10
4.00
4.75
6.32
12
Variations in ambient temperature also affect the
Copies of these British Standards are available
rate of heat loss, which in general is proportional
from:
to the difference between the pipe (fluid)
British Standards Institution
temperature and the ambient temperature. For
Sales Department
example, if the average ambient temperature is
Linford Wood
10C as opposed to 20C, and the pipe
Milton Keynes
temperature is 150C, the rate of heat loss will be
MK14 6LE
7.7% (10 130) greater.
For outdoor insulated piping in the UK, a
Insulation Suppliers:
rough guide would be to increase the still air,
TIMSA Handbook: The Specifiers Insulation Guide
20C ambient, heat loss rate by 15% - 20% to
1992
take account of the lower air temperature and
Copies of this publication are available from:
exposure to winds.
Thermal Insulation Manufacturers and Suppliers
It is necessary to emphasise the importance
Association
of cladding or sealing outdoor insulation to
PO Box 111
make it waterproof as far as possible. The heat
Aldershot
losses from wet insulation will far exceed the
Hampshire
heat losses through dry material.
GU11 1YW
Tel: 01252 336318
ACKNOWLEDGEMENT
The Department of the Environment is grateful

to the British Standards Institution for
Energy Efficiency Best Practice programme

publications:
permission to reproduce material from BS5970:
Copies of literature applicable to insulation and
1992 and BS 5442: 1990.
to energy efficiency in industry in general are

available from:
Energy Efficiency Enquiries Bureau
British Standards:
ETSU
The following British Standards contain further
Harwell
information on thermal insulation, its
Didcot
specification and sources of supply:
Oxon
BS 5422:1990 - Method for specifying thermal
OX11 0RA
insulating materials on pipes, ductwork and
Tel: 01235 436747
equipment (in the temperature range -40C to
Fax: 01235 433066
+700C)
BS 5970:1992 - Code of practice for thermal
insulation of pipework and equipment (in the
Energy Management is a free journal issued on
temperature range -100C to +870C)
behalf of the DOE which contains information
13
The latest news in energy efficiency technology
on the latest developments in energy efficiency,

and details of forthcoming events designed to
promote their implementation.
Copies of Energy Management can be
obtained through:
Emap Maclaren Limited
Maclaren House
19 Scarbrook Road
Croydon
Surrey
CR9 1QH
14
APPENDIX 1
SOME USEFUL CONVERSION FACTORS
Conversion factors for units used in this booklet

SI
Imperial
Temperature
1.8
Length
mm
+ 32
0.0394
in
ft
3.2808
Volume
litres
0.2200
gal
Weight
tonne
0.9842
ton
Energy
GJ
9.4782
therm
Heat flow rate
W/linear m
1.0400
Btu/ft h
Thermal conductivity
W/m K
6.9335
Btu in/ft2h F
Thermal conductance
W/m2K
0.176
Btu/ft2h F
For heavy fuel oil the number of litres in tonne = 1,020

Medium fuel oil the number of litres in a tonne = 1,040
Gas oil the number of litres in a tonne = 1,180
15
APPENDIX 2 TABLES REPRODUCED FROM BS 5422: 1990
TABLES REPRODUCED FROM BS 5422: 1990
Table 8 Economic thickness of insulation for non-domestic heating installations

served by solid fuel-fired boiler plant
Hot face temperature (in C) (with ambient still air at +20C)
Outside diameter
+ 75
+100
+150
of steel pipe on
which insulation Thermal conductivity at mean temperature (in W/(m.K))
thickness has
0.025
0.04 0.055 0.07 0.025 0.04 0.055 0.07 0.025 0.04 0.055 0.07
been based
(in mm) 1
Thickness of insulation (in mm)
17.2
14
17
20
23
17
21
24
26
22
25
28
32
21.3
15
18
22
24
17
22
25
27
23
26
30
34
26.9
17
20
23
25
20
24
26
28
24
28
32
35
33.7
17
21
24
26
20
25
27
31
25
29
34
37
42.4
18
22
25
27
21
25
28
32
25
31
35
39
48.3
18
23
25
28
22
26
29
33
26
32
36
41
60.3
19
24
26
29
23
27
31
35
27
33
38
43
76.1
20
24
27
31
23
28
33
36
28
35
40
45
88.9
20
24
28
32
24
28
33
37
29
36
42
46
114.3
21
25
29
33
25
30
35
39
31
37
44
48
139.7
22
26
30
34
25
31
36
41
31
38
45
50
168.3
22
26
31
35
25
32
37
42
32
40
46
52
219.1
22
27
32
36
26
33
38
43
33
42
48
54
273.0
23
27
33
36
26
34
39
44
34
43
49
55
Above 323.9
23
28
34
38
27
35
42
47
35
45
53
60
and
including
flat surfaces
1
Outside diameters are as in BS 3600. The same thickness of insulation would be used for copper pipework of
approximately similar outside diameters.
16
Table 9 Economic thickness of insulation for non-domestic heating installations served by

gas boiler plant
Outside diameter
+ 75
+100
+150
of steel pipe on
which insulation
Thermal conductivity at mean temperature (in W/(m.K))
thickness has
0.025
0.04 0.055 0.07 0.025 0.04 0.055 0.07 0.025 0.04 0.055 0.07
been based
(in mm) 1
17.2
17
22
24
26
20
24
27
31
24
29
34
37
21.3
18
23
25
27
22
25
29
33
26
32
36
39
26.9
20
24
26
29
23
27
31
34
27
33
38
42
33.7
21
25
27
31
24
28
33
36
28
35
40
44
42.4
22
25
29
32
25
30
34
38
30
37
42
47
48.3
22
26
30
33
25
31
35
39
31
38
44
48
60.3
23
27
32
35
26
32
37
41
33
39
46
50
76.1
24
28
33
36
27
34
39
43
34
42
48
52
88.9
24
29
34
37
28
35
40
45
35
43
49
53
114.3
25
31
35
39
29
36
42
47
36
45
51
56
139.7
25
32
36
41
30
37
43
48
37
47
53
59
168.3
25
32
37
42
31
38
45
50
38
48
56
61
219.1
26
33
38
44
32
40
46
52
40
51
58
65
273.0
27
34
40
45
33
41
47
53
41
52
59
68
Above 323.9
27
36
42
47
34
43
51
58
42
54
63
72
and
including
flat surfaces
1
17
Table 10 Economic thickness of insulation for non-domestic heating installations served by

oil-fired plant
Outside diameter
of steel pipe on
which insulation
thickness has
been based
(in mm) 1

+ 75
+100
+150

0.025
0.04
0.055 0.07
0.025
0.04 0.055 0.07 0.025 0.04 0.055 0.07
17.2
18
23
25
28
22
26
29
33
26
32
36
40
21.3
19
24
27
29
23
27
32
35
27
34
38
43
26.9
21
25
28
32
24
29
33
36
29
35
41
45
33.7
22
26
29
33
26
31
35
38
31
37
43
47
42.4
23
27
32
35
26
32
37
41
32
39
45
50
48.3
24
28
33
36
27
33
38
42
33
41
46
51
60.3
25
29
34
37
28
35
39
44
35
43
49
52
76.1
25
31
35
39
29
36
42
46
36
45
50
55
88.9
25
32
36
41
30
37
43
48
37
46
51
57
114.3
26
33
38
43
31
38
44
49
39
48
54
60
139.7
27
34
39
44
33
41
47
51
41
50
57
63
168.3
27
35
41
45
33
42
48
54
42
52
59
66
219.1
28
36
42
47
34
43
51
56
43
54
62
69
273.0
29
37
43
48
35
44
52
57
45
55
64
71
Above 323.9
31
38
45
52
37
47
55
62
47
60
69
77
and
including
flat surfaces
1
18
Table 11 Economic thickness of insulation for non-domestic hot water services
Outside diameter
of steel pipe on
which insulation
thickness has
been based
(in mm) 1
Water temperature +60C)

Solid Fuel
Gas
Oil

0.025
0.04
0.055 0.07
0.025
0.04 0.055 0.07 0.025 0.04 0.055 0.07
17.2
17
21
24
27
20
24
28
32
22
27
31
34
21.3
18
22
25
28
22
26
30
34
23
28
32
36
26.9
20
23
27
29
23
28
32
35
24
29
34
38
33.7
20
24
28
31
24
29
33
37
26
31
36
40
42.4
21
26
30
33
25
31
34
39
28
33
38
42
48.3
22
27
31
34
26
32
36
40
29
34
39
43
60.3
23
28
32
36
27
33
38
42
30
36
41
45
76.1
23
29
34
37
28
35
40
44
31
37
42
47
88.9
24
30
35
38
29
36
41
45
32
38
44
48
114.3
25
31
36
40
30
37
43
47
33
40
46
51
139.7
25
32
37
41
31
38
44
50
34
41
47
54
168.3
26
33
38
42
32
39
45
52
34
42
51
56
219.1
26
34
39
44
33
41
47
55
35
44
53
59
273.0
27
35
40
45
34
42
51
57
36
45
55
61
Above 323.9
29
36
42
50
35
44
54
61
40
51
59
65
and
including
flat surfaces
1
19
Table 12 Economic thickness of insulation for domestic central heating installations

in heated areas
Outside diameter Water temperature of +75C with ambient still air temperature of + 20C
of copper pipe
(in mm)
Thermal conductivity at +40C (in W/(m.K))
0.025
0.030
0.035
0.040
0.045

10
17
18
19
20
27
12
18
19
20
21
29
15
18
19
21
29
31
22
20
29
30
32
33
28
21
30
32
34
35
35
22
32
34
35
37
42
22
33
35
37
39
54
23
35
37
39
40
Flat surfaces
29
31
34
36
38
Table 13 Economic thickness of insulation for domestic central heating installations

in unheated areas
Water temperature of +75C with ambient still air temperature of -1C
Outside diameter
of copper pipe
(in mm)

0.025
0.030
0.035
0.040
0.045

10
19
20
21
32
34
12
20
21
22
32
34
15
21
22
32
33
35
22
22
32
34
35
36
28
23
34
36
36
36
35
24
35
37
38
39
42
25
37
38
39
40
54
26
37
38
39
40
Flat surfaces
34
37
40
43
45
20
Table 14 Economic thickness of insulation for domestic hot water systems in heated areas
Water temperature of +60C with ambient still air temperature of + 20C
Outside diameter
of copper pipe
(in mm)

0.025
0.030
0.035
0.040
0.045

10
13
14
14
14
15
12
13
14
14
15
16
15
13
14
14
16
17
22
14
15
16
17
18
28
14
15
16
18
19
35
15
17
17
19
19
42
15
17
18
19
20
54
16
18
19
20
21
Flat surfaces
20
22
24
24
25
Table 15 Economic thickness of insulation for domestic hot water systems in unheated areas
Water temperature of +60C with ambient still air temperature of -1C
Outside diameter
of copper pipe
(in mm)

0.025
0.030
0.035
0.040
0.045

10
14
15
16
17
18
12
15
16
17
18
19
15
15
17
17
19
19
22
16
18
20
20
21
28
17
19
20
21
30
35
18
20
21
22
31
42
19
20
22
23
32
54
20
21
23
33
34
Flat surfaces
23
25
25
29
31
21
Table 16 Economic thickness of insulation for process pipework and equipment

Hot face temperature at mean temperature (in C) (with ambient still air at +20C)
Outside diameter
of steel pipe
(in mm)
+100
+200
+300

0.02 0.03 0.04 0.05 0.06 0.03 0.04
0.05 0.06 0.07 0.03 0.04 0.05
0.06 0.07

17.2
28
31
35
38
41
45
49
52
56
59
52
57
61
66
70
21.3
29
33
37
40
43
46
50
54
58
62
55
60
65
70
74
26.9
31
35
39
43
46
50
54
59
63
67
59
64
69
74
78
33.7
33
36
40
44
48
52
56
61
65
69
61
66
72
77
82
42.4
36
40
45
49
53
56
61
67
72
77
67
73
79
84
90
48.3
38
42
47
51
55
59
64
70
75
80
70
77
82
88
95
60.3
41
45
50
55
59
63
69
75
81
86
76
82
89
96 102
76.1
42
47
52
57
62
67
73
79
85
90
78
86
94
101 107
88.9
44
49
54
59
64
70
76
82
89
94
83
90
98
105 112
101.6
45
50
56
62
66
73
79
85
91
97
85
93
101 109 116
114.3
46
52
57
63
68
76
80
87
93
99
87
95
103 111 118
139.7
49
54
60
66
71
78
84
92
99
105
94
102
110 118 125
168.3
52
58
64
70
76
83
90
98
105 111 101 107
117 126 134
219.1
54
60
67
74
80
87
95
104 112 119 105 114
124 133 142
244.5
55
62
69
76
82
89
98
106 115 122 108 117
127 137 146
273
56
64
71
78
84
94
100 110 118 126 113 120
132 142 151
323.9
58
66
73
80
86
94
104 114 123 132 115 123
135 145 154
355.6
59
67
74
81
88
97
107 116 125 134 116 125
137 147 156
406.4
62
69
76
83
90
100 109 118 127 136 118 128
140 150 159
457
63
70
77
84
91
102 111 120 129 138 121 132
144 154 163
508
65
72
79
86
93
105 114 123 132 141 124 134
146 156 165
Over 508
72
78
87
98
105 113 124 133 142 151 127 137
151 161 170
and incl. flat

surfaces
22
Table 16 Economic thickness of insulation for process pipework and equipment cont...
Hot face temperature at mean temperature (in C) (with ambient still air at +20C)
Outside
+400
+500
+600
diameter
of steel
pipe
0.04 0.05 0.06 0.07 0.08 0.05 0.06 0.07 0.08 0.09 0.06 0.07 0.08
(in mm)
95
89
93
+700
0.09 0.10 0.07 0.08 0.09 0.10
0.11
17.2
64
69
74
79
83
76
81
86
91
21.3
68
73
78
83
88
81
86
91
96 101 93
98 103 107 99 104 109 114 119
26.9
73
78
83
89
94
87
92
98 103 107 100 105 110 115 120 113 118 123 128 133
33.7
76
81
87
92
97
89
95 100 106 111 103 108 114 119 124 116 121 127 132 137
42.4
83
89
96 102 107
48.3
87
93
100 106 112 103 109 116 122 128 119 125 132 138 143 134 140 146 152 158
60.3
94 101 108 115 121 111 118 125 132 138 128 135 142 149 156 144 151 158 165 172
98 103 108 113 105 110 115 120 125
99 105 111 117 123 114 120 126 132 137 128 134 140 146 152
76.1
99 106 114 121 127 117 124 132 139 146 135 142 149 156 163 152 159 166 173 180
88.9
103 110 118 126 133 123 130 138 145 152 141 148 156 163 170 159 166 174 181 189
101.6
106 114 123 130 138 126 134 142 150 157 145 153 161 169 177 164 172 180 187 195
114.3
109 116 125 133 140 129 137 145 153 160 149 157 165 173 181 167 175 183 191 198
139.7
116 124 133 141 149 138 146 155 163 171 158 167 175 184 190 179 187 195 204 211
168.3
124 132 142 151 159 147 156 165 174 182 170 178 188 196 205 191 200 209 218 227
219.1
130 140 151 161 171 156 166 176 186 195 180 190 200 210 220 203 213 223 233 243
244.5
135 145 156 165 175 161 171 182 192 201 186 196 206 216 226 210 220 230 240 250
273
139 149 160 170 180 166 176 188 198 207 191 202 213 224 235 217 227 238 248 258
323.9
142 153 164 174 184 171 181 193 202 212 196 207 218 229 240 223 233 244 254 264
355.6
146 157 168 178 188 177 185 197 206 216 201 212 224 235 245 230 240 251 261 271
406.4
149 160 171 181 192 181 189 202 213 223 207 218 230 241 252 234 245 257 269 279
457
153 165 176 187 198 187 196 209 220 231 213 225 238 250 261 242 254 266 278 289
508
155 168 179 191 202 191 200 213 226 237 218 231 244 256 267 248 260 273 285 296
Over 508
158 171 182 195 205 194 207 218 230 239 228 240 250 261 270 257 271 279 293 304
and incl.
flat
surfaces
Note: For thicknesses in bold type, the outside surface temperature is likely to exceed 50C if a low emissivity
surface is used, i.e. bright metal
23
Table 17 Fuel cost comparisons: cost of heat related to fuel price

Cost of heat
pence/useful
MJ
Fuel oil at
Natural gas at
Solid fuel at
70% efficiency 70% efficiency 55% efficiency
pence/l
pence/therm
/t
Solid fuel at
70% efficiency
/t
Electricity at
100% efficiency
pence/kWh
0.30
7.89
22.16
38.4
58.61
1.08
0.40
10.52
29.54
51.2
78.15
1.44
0.50
13.15
36.93
64.0
97.68
1.80
0.56
14.73
41.36
71.7
109.40
2.02
0.60
15.78
44.31
76.8
117.22
2.16
0.64
16.83
47.27
81.9
125.03
2.30
0.68
17.88
50.22
87.0
132.85
2.49
0.72
18.94
53.18
92.1
140.66
2.59
0.76
19.99
56.13
97.2
148.48
2.74
0.80
21.04
59.08
102.4
156.29
2.88
0.84
22.09
62.04
107.5
164.11
3.02
0.88
23.14
65.00
112.6
171.92
3.17
0.92
24.20
67.96
117.7
174.74
3.31
0.96
25.25
70.91
122.8
187.55
3.46
1.00
26.30
73.87
128.0
195.37
3.60
1.04
27.35
76.82
133.1
203.18
3.74
1.08
28.40
79.77
133.2
203.66
3.89
1.12
29.46
82.73
143.3
218.81
4.03
1.16
30.51
85.68
148.4
226.67
4.18
1.20
31.56
88.64
153.5
234.44
4.32
NOTE 1: The first column shows the basic costs required for economic thickness calculations. The range
covers both past prices and possible future price increases.
NOTE 2: The efficiencies given in the column headings indicate the values assumed in the calculations; they
do not represent the actual operating efficiency. In practice the system efficiency for a particular
application may be considerably lower than the values given.
This Table is based on Table 36 in BS 5422: 1990. The column headed Fuel oil at 70% efficiency has
been recalculated and is not taken from the British Standard. Copies of the original document can be
obtained by post from British Standards Institution, Sales Department, Linford Wood, Milton Keynes,
MK14 6LE.
24
APPENDIX 3
HEAT LOSS GRAPHS FOR VARIOUS MATERIALS AND SURFACE TEMPERATURES

A wide variety of pipe insulation products is
available from many different companies. The
heat loss graphs are based on four common
product types, which are given below.
Preformed rigid fibrous sections (including

rock and glass fibres) (Graphs 1-10)
Preformed rigid calcium silicate or (up to

300C) 85% magnesia sections.
(Graphs 11 - 20)
Preformed rigid polyisocyanurate or (up to

100C) polyurethane sections
(Graphs 21 - 23)
Preformed expanded nitrile rubber and

polyethylene foam sections (Graphs 24 - 25)
25
Nominal bore (mm)
26
6 7 8 910
20
30
40 50 60 70 80 90 100
200
300
Btu/ft h
7 8 9 10
20
30
40 50 60 70 80 100
Heat loss
200
300
400 500 600 800 1000
400 500 600 800 1000
3/
10
1/
15
W/m
1
3/
11/2
11/4
40
32
20
50
25
3
21/2
80
65
125
100
150
20
18
16
14
12
Bare pipe
10
100 88 75 63 50 38 32 25 19
200
Insulation thickness (mm)
250
500
450
400
350
300
Graph 1 Heat loss for pipes with surface temperature of 50C with varying insulation thicknesses
PREFORMED RIGID FIBROUS SECTIONS
Nominal bore (inches)
Nominal bore (mm)
27
6 7 8 910
20
30
40 50 60 70 80 90 100
200
300
Btu/ft h
7 8 9 10
20
30
40 50 60 70 80 100
Heat loss
200
300
400 500 600 800 1000
400 500 600 800 1000
3/
10
1/
15
W/m
1
3/
11/2
11/4
40
32
20
50
25
3
21/2
80
65
125
4
150
100
10
200
Bare pipe
250
19
20
18
16
14
12
100 88 75 63 50 38 32 25
500
450
400
350
300
Nominal bore (mm)
28
6 7 8 910
20
30
40 50 60 70 80 90 100
200
300
400 500 600 800 1000
Btu/ft h
7 8 9 10
20
40 50 60 70 80 100
Heat loss
30
200
300
400 500 600 800 1000
3/
10
1/
15
W/m
1
3/
11/2
11/4
40
32
20
50
25
3
21/2
80
65
125
150
100
10
200
Bare pipe
250
19
20
18
16
14
12
100 88 75 63 50 38 32 25
500
450
400
350
300
Nominal bore (mm)
29
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
3/
8
10
300 400 500 600 8001000
1/
2
15
200
3/
4
20
50 60 70 80 100
25
20
11/2
11/4
40
32
W/m
50
10
3
21/2
80
65
40
125
30
150
200
100
10
250
Bare pipe
20
18
16
14
12
100 88 75 63 50 38 32 25 19
500
450
400
350
300
Nominal bore (mm)
30
20
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
3/
8
10
W/m
1/
2
15
10
1
3/
4
11/2
11/4
40
32
20
50
25
3
21/2
80
65
40
125
30
150
200
100
10
250
Bare pipe
20
18
16
14
12
100 88 75 63 50 38 32 25 19
500
450
400
350
300
Nominal bore (mm)
31
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
Heat loss
300 400 500 600 800 1000
2000
4000
6000 8000 10000
6000 8000 10000
10
20
3/
8
15
W/m
1/
2
20
10
1
3/
4
25
11/2
11/4
50
40
32
3
21/2
80
65
40
125
30
150
200
100
10
250
Bare pipe
20
18
16
14
12
150 125 100 88 75 63 50 38 32 25 19
500
450
400
350
300
Nominal bore (mm)
32
20
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
3/
8
10
W/m
1/
2
15
10
1
3/
4
11/2
11/4
40
32
20
50
25
3
21/2
80
65
40
125
30
150
200
100
10
250
Bare pipe
20
18
16
14
12
150 125 100 88 75 63 50 38 32 25 19
500
450
400
350
300
Nominal bore (mm)
33
20
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
3/
8
10
W/m
1/
2
15
10
1
3/
4
11/2
11/4
40
32
20
50
25
3
21/2
80
65
40
125
30
150
200
100
10
250
Bare pipe
20
18
16
14
12
150 125 100 88 75 63 50 38 32 25 19
500
450
400
350
300
Nominal bore (mm)
34
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
Heat loss
300 400 500 600 800 1000
2000
4000
3/
8
10
6000 8000 10000
6000 8000 10000
1/
2
15
20
3/
4
20
W/m
25
10
11/2
11/4
50
40
32
3
21/2
80
65
40
125
30
150
200
100
10
250
Bare pipe
20
18
16
14
12
150 125 100 88 75 63 50 38 32 25 19
500
450
400
350
300
Nominal bore (mm)
50 60 70 80 100
200
300 400 500 600 8001000
35
20
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
3/
10
W/m
1/
15
10
1
3/
11/2
11/4
40
32
20
50
25
3
21/2
80
65
2000
125
40
150
30
200
10
250
100
20
18
16
14
12
150 125 100 88 75 63 50 3832 25 19 Bare pipe
500
450
400
350
300
Nominal bore (mm)
36
6 7 8 910
20
200
300
Btu/ft h
7 8 9 10
20
40 50 60 70 80 100
Heat loss
30
200
300
3/
8
10
400 500 600 800 1000
400 500 600 800 1000
1/
2
15
40 50 60 70 80 90 100
3/
4
20
30
25
11/2
11/4
40
32
50
W/m
3
21/2
80
65
125
150
100
10
200
Bare pipe
250
25
20
18
16
14
12
100 88 75 63 50 38
500
450
400
350
300
PREFORMED RIGID CALCIUM SILICATE OR 85% MAGNESIA

SECTIONS
Nominal bore (mm)
37
6 7 8 910
20
30
40 50 60 70 80 90 100
200
300
Btu/ft h
7 8 9 10
20
30
40 50 60 70 80 100
Heat loss
200
300
400 500 600 800 1000
400 500 600 800 1000
3/
8
10
1/
2
15
W/m
1
3/
4
11/2
11/4
40
32
20
50
25
3
21/2
80
65
125
4
150
100
10
Bare pipe
200
25
250
38
20
18
16
14
12
100 88 75 63 50
500
450
400
350
300

SECTIONS
Nominal bore (mm)
38
6 7 8 910
20
30
40 50 60 70 80 90 100
200
300
400 500 600 800 1000
Btu/ft h
7 8 9 10
20
40 50 60 70 80 100
Heat loss
30
200
300
400 500 600 800 1000
3/
8
10
1/
2
15
W/m
1
3/
4
11/2
11/4
40
32
20
50
25
3
21/2
80
65
125
150
100
10
200
Bare pipe
250
25
20
18
16
14
12
100 88 75 63 50 38
500
450
400
350
300

SECTIONS
Nominal bore (mm)
39
20
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
3/
10
W/m
1/
15
10
1
3/
11/2
11/4
40
32
20
50
25
3
21/2
80
65
40
125
30
150
100
10
Bare pipe
200
25
250
38
20
18
16
14
12
100 88 75 63 50
500
450
400
350
300

SECTIONS
Nominal bore (mm)
40
20
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
3/
10
W/m
1/
15
10
1
3/
11/2
11/4
40
32
20
50
25
3
21/2
80
65
40
30
125
150
100
10
200
Bare pipe
250
25
20
18
16
14
12
100 88 75 63 50 38
500
450
400
350
300

SECTIONS
Nominal bore (mm)
41
50 60 70 80 100
200
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
Heat loss
300 400 500 600 800 1000
2000
4000
3/
8
10
6000 8000 10000
6000 8000 10000
1/
2
15
2000
3/
4
20
300 400 500 600 8001000
25
20
11/2
11/4
40
32
W/m
50
10
3
21/2
80
65
40
30
125
4
150
100
10
200
Bare pipe
250
25
20
18
16
14
12
150 125 100 88 75 63 50 38
500
450
400
350
300

SECTIONS
Nominal bore (mm)
42
20
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
3/
10
W/m
1/
15
10
1
3/
11/2
11/4
40
32
20
50
25
3
21/2
80
65
40
125
30
150
100
10
200
Bare pipe
250
25
20
18
16
14
12
150 125 100 88 75 63 50 38
500
450
400
350
300

SECTIONS
Nominal bore (mm)
43
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
10
20
3/
15
W/m
1/
20
10
1
3/
25
11/2
11/4
50
40
32
3
21/2
80
65
40
30
125
150
100
10
200
Bare pipe
250
25
20
18
16
14
12
100
200 175 150 125 88 75 63 50 38
500
450
400
350
300

SECTIONS
Nominal bore (mm)
44
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
10
20
3/
15
W/m
1/
20
10
1
3/
25
11/2
11/4
50
40
32
3
21/2
80
65
40
125
30
150
100
10
200
Bare pipe
250
25
20
18
16
14
12
100
200 175 150 125 88 75 63 50 38
500
450
400
350
300

SECTIONS
Nominal bore (mm)
45
20
50 60 70 80 100
200
300 400 500 600 8001000
2000
4000
20
Btu/ft h
30
40 50 60 70 80 100
200
300 400 500 600 800 1000
Heat loss
2000
4000
6000 8000 10000
6000 8000 10000
3/
8
10
W/m
1/
2
15
10
1
3/
4
11/2
11/4
40
32
20
50
25
3
21/2
80
65
40
125
30
150
100
10
200
Bare pipe
250
25
20
18
16
14
12
100
200 175 150 125 88 75 63 50 38
500
450
400
350
300

SECTIONS
Nominal bore (mm)
46
6 7 8 910
20
30
40 50 60 70 80 90 100
200
300
Btu/ft h
7 8 9 10
20
40 50 60 70 80 100
Heat loss
30
200
300
400 500 600 800 1000
400 500 600 800 1000
3/
10
1/
15
W/m
1
3/
11/2
11/4
40
32
20
50
25
3
21/2
80
65
5
4
125
100
150
Bare pipe
10
19
200
25
250
38
20
18
16
14
12
100 88 75 63 50
500
450
400
350
300
PREFORMED RIGID POLYISOCYANURATE OR POLYURETHANE

SECTIONS
Nominal bore (mm)
47
6 7 8 910
20
30
40 50 60 70 80 90 100
200
300
400 500 600 800 1000
Btu/ft h
7 8 9 10
20
40 50 60 70 80 100
Heat loss
30
200
300
400 500 600 800 1000
3/
8
10
1/
2
15
W/m
1
3/
4
11/2
11/4
40
32
20
50
25
3
21/2
80
65
125
150
100
10
Bare pipe
200
25 19
250
38
20
18
16
14
12
100 88 75 63 50
500
450
400
350
300

SECTIONS
Nominal bore (mm)
48
6 7 8 910
20
30
40 50 60 70 80 90 100
200
300
400 500 600 800 1000
Btu/ft h
7 8 9 10
20
40 50 60 70 80 100
Heat loss
30
200
300
400 500 600 800 1000
3/
10
1/
15
W/m
1
3/
11/2
11/4
40
32
20
50
25
3
21/2
80
65
125
150
100
10
Bare pipe
200
25 19
250
38
20
18
16
14
12
100 88 75 63 50
500
450
400
350
300

SECTIONS
Nominal bore (mm)
49
6 7 8 910
20
200
300
Btu/ft h
7 8 9 10
20
30
40 50 60 70 80 100
Heat loss
200
300
400 500 600 800 1000
400 500 600 800 1000
3/
8
10
40 50 60 70 80 90 100
1/
2
15
30
3/
4
20
25
11/2
11/4
40
32
50
W/m
3
21/2
80
65
5
4
125
100
150
Bare pipe
10
200
13
250
19
20
18
16
14
12
50 38 32 25
500
450
400
350
300
PREFORMED EXPANDED NITRILE RUBBER AND POLYETHYLENE

FOAM SECTIONS
Nominal bore (mm)
50
6 7 8 910
20
30
40 50 60 70 80 90 100
200
300
Btu/ft h
7 8 9 10
20
30
40 50 60 70 80 100
Heat loss
200
300
400 500 600 800 1000
400 500 600 800 1000
3/
8
10
1/
2
15
W/m
1
3/
4
11/2
11/4
40
32
20
50
25
3
21/2
80
65
125
150
100
10
Bare pipe
200
250
13
20
18
16
14
12
50 38 32 25 19
500
450
400
350
300
PREFORMED EXPANDED NITRILE RUBBER AND POLYETHYLENE

FOAM SECTIONS
APPENDIX 4 SOME BASIC HEAT TRANSFER FORMULAE
SOME BASIC HEAT TRANSFER FORMULAE
approximately equal to process stream
The various methods of estimating the economic
temperature
thickness of insulation have made reasonable
t2
assumptions about the ambient conditions.
tm = ambient temperature (C)
Since these can have a significant effect on the
ri
= radius of outer surface of insulation (m)
rate of heat loss, any serious divergence from the
r0
= outer radius of pipe (m)
assumed conditions should be analysed as an
di
= diameter of outer surface of insulation (m)
individual case. This requires the use of basic
= surface heat transfer coefficient (W/m2K)
heat transfer equations. There are many
= thermal conductivity of insulation
standard texts on heat transfer which give
= outside temperature of insulation
(W/m.k)
These equations are used to find the heat loss
Q = U (t1 - tm)
per metre length of pipe. The overall heat
. . . A1
transfer coefficient, U, is determined first by

complete details but the basic equations are:
1 =
1
3.142dih
U
ln (ri/ro)
6.284 k
solving equation A2. Equation A1 then gives the

required value. The problem is determining a
. . . A2
suitable value for h, the surface heat transfer

coefficient. This can be done from first
and
principles (see any standard text on the subject)
Where:
or Table 22 can be used to give an approximate
Q = heat loss per metre length of pipe (W/m)
value.
U = Overall heat transfer coefficient (W/m2)

t1 = pipe surface temperature (C) -
Table 22 Variation of outer surface coefficient with temperature difference between surface and air
for various outer dimensions of insulation
High emissivity surface
Outer diameter
insulation (in mm)
Low emissivity surface
Temperature difference (t2 - tm) (in K)

1
10
10
Outer surface coefficient, h (in W/(m2.K))

40
8.0
8.4
9.1
9.7
3.4
3.9
4.7
5.4
60
7.6
8.0
8.7
9.3
3.1
3.5
4.2
4.9
100
7.3
7.7
8.3
8.8
2.7
3.1
3.8
4.4
200
7.0
7.4
7.9
8.4
2.4
2.8
3.4
4.0
Vertical flat surface
6.6
7.0
7.5
8.0
2.0
2.4
3.0
3.6
NOTE: The above figures refer to the outer surface of the insulation
51
Titles in the Fuel Efficiency Booklet series are:
17
Economic use of coal-fired boiler plant
Energy audits for industry
19
Process plant insulation and fuel efficiency
1B
Energy audits for buildings
20
Energy efficiency in road transport
Steam
Economic use of fired space heaters for industry
Fuel Efficiency booklets are part of the Energy
and commerce
Efficiency Best Practice programme, an initiative
Compressed air and energy use
aimed at advancing and promoting ways of
Degree days
improving the efficiency with which energy is
The economic thickness of insulation for
used in the UK.
hot pipes
For copies of Fuel Efficiency booklets or
Economic use of electricity in industry
further information please contact the addresses
9B
Economic use of electricity in buildings
below.
10
Controls and energy savings
11
The economic use of refrigeration plant
(minimum of 6) to the ETSU or BRECSU
12
Energy management and good lighting practices
address with order to cover cost of packaging
13
Waste avoidance methods
and posting. Please make cheques, drafts or
14
Economic use of oil-fired boiler plant
money orders payable to ETSU or BRECSU, as
15
Economic use of gas-fired boiler plant
appropriate.
16
Economic thickness of insulation for existing
Overseas customers please remit 3 per copy
industrial buildings
The Governments Energy Efficiency Best Practice Programme provides

impartial, authoritative information on energy efficiency techniques and
technologies in industry, transport and buildings. This information is
disseminated through publications, videos and software, together with
seminars, workshops and other events. Publications within the Best
Practice Programme are shown opposite.
Energy Consumption Guides: compare energy use in

specific processes, operations, plant and building types.
Further information
Future Practice: reports on joint R & D ventures into new

energy efficiency measures.
For buildings-related publications

please contact:
Enquiries Bureau
BRECSU
Building Research Establishment
Garston, Watford, WD2 7JR
Tel 01923 664258
Fax 01923 664787
E-mail brecsuenq@bre.co.uk
For industrial and transport

publications please contact:
Energy Efficiency Enquiries Bureau
ETSU
Harwell, Didcot, Oxfordshire,
OX11 0RA
Fax01235 433066
Helpline Tel 0800 585794
Helpline E-mail etbppenvhelp@aeat.co.uk
Good Practice: promotes proven energy efficient

techniques through Guides and Case Studies.
New Practice: monitors first commercial applications of new
energy efficiency measures.
General Information: describes concepts and approaches

yet to be fully established as good practice.
Fuel Efficiency Booklets: give detailed information on
specific technologies and techniques.
Energy Efficiency in Buildings: helps new energy managers
understand the use and costs of heating, lighting etc.
CROWN COPYRIGHT REVISED 1993 REPRINTED 1996

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FUEL EFFICIENCY

The economic thickness of

THE ECONOMIC THICKNESS OF INSULATION FOR HOT PIPES

THE EFFECT OF INSULATION

THE ECONOMIC THICKNESS OF INSULATION

Basic requirements to estimate economic thickness

THE ESTIMATION OF ECONOMIC THICKNESS

Use of specially prepared tables

ADAPTING TO AMBIENT CONDITIONS

SOURCES OF FURTHER INFORMATION

Preformed rigid fibrous sections

Preformed rigid calcium silicate or 85% magnesia sections

Preformed rigid polyisocyanurate or polyurethane sections

Preformed expanded nitrile rubber and polyethylene foam sections

THE ECONOMIC THICKNESS OF INSULATION FOR HOT PIPES

dominant; the greater the temperature and area,

This booklet is concerned with the economic

the greater the loss. Adding an insulating layer

thickness of insulation for hot pipes.

to a hot surface reduces the external surface

Considerable amounts of data and practical

temperature. Although the surface area may be

advice is given, intended for use both by

increased if insulation is added to a circular pipe,

experienced personnel and as training material.

the relative effect of the temperature reduction is

The cost of installing the insulation is offset

much greater and a reduction in heat loss is

by the large savings in fuel bills which can be

achieved through insulating pipes. This booklet

Consider for example, a 15 mm bore pipe

explains how to determine the thickness of

running through still air (at 20C) carrying a hot

insulation which will result in the optimum

fluid raising its external temperature to 75C.

The heat loss is about 60 W per metre of pipe

This booklet is concerned only with hot

run. The addition of a 25 mm thick layer of

pipes, although the insulation of pipes operating

standard pipe insulation would increase the

below ambient temperature is also important. In

surface area by a factor of approximately 3.5,

particular, pipes forming part of domestic and

but the external surface temperature would fall

non-domestic heating and hot water systems,

from 75C to around 23C. The overall effect

and process pipework are covered. The

would be to reduce the heat loss from 60 W to

information and techniques for determining the

12 W per metre run of pipe.

most economic thickness of insulation is

consistent with BS 5422:1990.

heat from a 100 m run of bare 50 mm bore

This booklet is intended as a brief guide to

pipe carrying process steam at 100C, would

the economic thickness of insulation for hot

cost around 3,000 per annum if the steam

pipes, and therefore references are made

was supplied by a gas boiler with a gas cost of

throughout to the extensive documentation