Whenever we have a surface at a temperature different from that of the ambient which surrounds it, we can have energy loss due to the temperature differential. This can be most significant when the differentials are large- as in Furnaces, Power Stations, Refineries or in low temperature storage for Liquefied Gases (Natural gas, Ethylene, Propane, Butane or Ammonia). Insulation is necessary to reduce energy consumption, sound pollution and improve the comfort and quality of life in new or existing installations and buildings, regardless of the construction method. Insulation is also provided to provide safety against possible burns to persons who may come in contact with a hot surface.
Insulation is an integral part of every home, office and public building. It is in the cars we drive and the appliances we use to keep and cook our food, and to keep us warm in the winter or cool in the summer. By increasing the efficiency with which we use our energy it helps to safeguard our stocks of fossil fuels, and it reduces the amount of CO2 we release into the atmosphere as a result of our daily activities, helping to ensure that we leave behind a healthy world for future generations.

Environmental quality Insulation helps to fight global warming as it reduces the amount of fossil fuels, such as oil and gas that we burn for energy and thereby reduces the volumes of greenhouse gases we release into the atmosphere. Reduction of greenhouse gas emissions is an ecological function of insulation..

Energy savings Thermal insulation reduces heat wastage, which in turn means we need less energy for our heating and cooling systems. Effective insulation can therefore reduce our energy bills, energy consumption, and related pollution, by up to 80%.

Comfort in summer and winter Comfort in our homes and workplaces rely on us maintaining a good inside temperature regardless of the season. To maintain comfortable temperatures by conditioning the air within by the use of HVAC equipment, either in winter or in summer, we need a combination of effective thermal insulation throughout the building (including windows); ventilation system adapted to the season; tight fitting doors, shutters etc and an airtight building envelope to keep out draughts.

Acoustic comfort Over last few years, noise has become an increasing problem, as traffic, running of equipment and processes are getting noisier and the need quite condition is increasing. Man is incapable physiologically of blocking out unwanted noise, unlike blocking out wanted light which is done by simply closing the eyes. Prevention of stress and even more serious health problems that can result from excessive noise, require external Noise control measures through effective acoustic insulation in buildings along highways and around noisy equipment.

Where to install insulation will depend on the type and design of the equipment or process to be insulated.

The more insulation you deploy, the more you will save in energy costs and increased efficiency. However, where to put the insulation will depend on the equipment or process involved, and how it has been designed. The primary consideration must always be safety, and therefore hot pipes and equipment within a working area must be insulated, especially if they are operating at above 60°C. The same applies to chilled pipes and equipment operating at more than 10°C below ambient. Insulating hot or cold processes and plant will make them more economical and environment-friendly to run, as they will require less energy, and therefore be responsible for less atmospheric emissions. However, efficient insulation will also make a process more thermally stable and thus help to reduce breakdowns and maintenance costs. In addition to providing excellent thermal and fire performance, insulation products from Lloyds possess excellent acoustical properties, which help to reduce noise transmission from noisy equipment, such as Diesel Generating sets, compressors, Gas turbines and stacks, pipe and ductwork systems. It has become a statutory requirement to ensure quiet conditions in work places and in areas close to residential spaces.

• Select the most appropriate insulation product for your application, bearing in mind temperature of operation, shape and size of item to be insulated, performance requirements including acoustical duty etc.
• Having selected the correct material, ensure that the application is carried out scientifically by applicators having sufficient knowledge and experience.
• Remember to consider various factors such as condensation risk avoidance to prevent corrosion on steelwork, and incorporate an effective vapour barrier at the right place.
• Do not leave sections Un-Insulated and do not leave gaps between adjacent sections of insulation – if necessary fill difficult spaces with small off-cuts or with loose wool.
• Be aware of local and national legislation and standards that may affect the type, design and thickness of the insulation products you use.
• Always follow the manufacturers’ instructions when fitting insulation products and systems.
• If in doubt, refer to Lloyds technical help line for advice before drawing up the insulation Remember, it is always easier and more cost-efficient to install higher levels of insulation at the project construction stage, than to have to retrofit additional layers at a later date.

When piping and equipment operate at temperatures lower than the ambient air, moisture in the air will condense if the exposed temperature is below “Dew point” or freeze if the temperature is below “Freezing Point” – or on the cold pipe surface. It can occur on exterior surface of the insulation when we use insufficient thickness. If we do not provide Good “Vapour Retarder” or “Vapour Barrier”, such condensation or freezing can occur on the pipe /vessel surface causing the insulation to soak and the condensed water to freeze. This is a total breakdown situation water on the pipe/ vessel surface also causes corrosion which is providing sufficient insulation thickness couples with an effective vapor retarder system is those essential in all cold insulation work.

Moisture in any form is cause for first deterioration of insulation moreover, if can cause mould growth and create slippery and unsafe floors in our work place.

High temperatures are encountered in high pressure steam lines, process lines, exhaust systems, or ovens generally operating at 300°c to 800°c range. Protection of metal casting itself, reduces of heat loss and protecting personnel from burns are the main objects for installing insulation on heated systems in this temperature zones.

There are insulations specially designed for high temperature systems – and selecting the right one should be based on the unique requirements of the system you are insulating. Be sure to examine the insulation for its thermal values likes its maximum service temperature and its thermal conductivity profile and other performance values carefully. In addition, you may want to ask the following questions before providing an insulation recommendation:

1. What is the process?
2. What are the process temperatures?
3. What’s in the process and in the exterior environment?
4. Is the piping & equipment located where people can come in contact with them?
5. Is fire an issue?

As thermal conductivity decreases, therefore, a lesser thickness of insulation is required to achieve the same thermal insulation performance. This is particularly important with higher temperatures where very high thickness may be required with a typical commercial insulation like low density glass fibre. An efficient insulation allows effective levels of thermal insulation to be achieved using lower thickness products, which are easier to install, protect and encapsulate.

Thermal performance of an insulating material is affected by two factors, thickness of the material (t) and its thermal conductivity (‘k’ value). The thermal performance of a material at a particular thickness is known as its thermal resistance.

K-Factor (Thermal Conductivity Factor) – The measure of energy in Watts that pass through one square metre of a homogeneous substance, 1 metre thick, for each degree K temperature difference. The lower the K-value, the higher the insulating value. Textbook definition: The time rate of steady heat flow through a unit area of a homogeneous material induced by a unit temperature gradient in a direction perpendicular to that unit area.

Insulation materials usually have K-Factors less than one and are reported at what is called Mean Temperature. To determine the mean temperature, measure the surface temperatures on both sides of the insulation, add them together and divide by two.

When comparing the insulating value of different types of insulations, it’s important to look at K-Factor and the mean temperature. As mean temperatures rise, so does the K-Factor.

C-Factor (Thermal Conductance Factor) – C-Factor is the number of Watts which will pass through 1 square metre of material with 1°K temperature difference for a specified thickness. The C-Factor is the K-Factor divided by the thickness of the insulation. The formula is the reciprocal of the R-Factor formula. The lower the C, the better the insulator.

R-Value (Thermal Resistance Value) – R-Value is a measure of the ability to retard heat flow rather than to transmit heat. “R” is the numerical reciprocal of C, thus R=1/C. Thermal resistance designates thermal resistance values: We commonly come across R values demanded in BTU ft – lb (British) units for instance; R-11 equals 11 resistance units in that unit. It works to 0.52 m2°K/W in metric system. The higher the “R”, the higher (better) the insulating value.

Temperature is a property unto itself. It is not a measure of the amount of heat present. For example, if you pour two cups of coffee, one to the brim, and the other only halfway, the temperature will be the same in both cups, but the partially filled cup will only contain half the quantity of heat of the full one.

Mean Temperature is the average of the sum of a hot surface temperature and a cold surface temperature. Insulation conductivity (K-Factor) is tested at a number of mean temperatures to develop conductivity curves that simulate actual service conditions under which insulation systems are used. All conductivity figures (K, C, R) must be qualified by a mean temperature.

Ambient Temperature is the average temperature of the medium, usually air, surrounding the object under consideration.

No. R-value is the measurement of only one type of heat loss (conduction), which is the transfer of heat through a solid material. R-value does NOT account for radiant heat loss or convective heat loss, which is the transfer of heat by physical air and moisture leakage and may along with latent heat associated with condensation of vapour, may account for up to 60% of HVAC effort.

Use of closed cell insulation like polyurethane / Polyisocyanurate, used with correct position of vapour barrier, drastically reduces HVAC loads due to all such paths of loss in a building.

LII manufactures PUF/PIR, Rockwool & Ceramic Fiber Insulation products in a variety of forms for different applications.

Which product type to choose for which application will depend on a number of criteria:

Nature of the application – Pipework, for instance, can be insulated with either roll material or special preformed pipe sections – the latter are engineered to suit specific pipe diameters and are quicker to install sometimes provided covering having sealing flaps for reduced cold bridging, however, roll material can be more economical in certain cases. For higher diameter pipes and vessels. Lamella products offer higher compression resistance for walk-on applications.

Operating temperature – Rockwool is light, flexible and economic, making it the preferred choice for many industrial thermal and acoustic insulation applications where operating temperatures are between 250°C and 500°C. For higher temperatures, Ceramic fiber products are available to provide efficiency performance.

Operating criteria – For areas subject to fluctuating temperature and vibration, for instance, such as chimneys and exhaust systems, wired mats offer flexibility combined with mechanical strength.

Finding the ‘right’ insulation begins with asking some basic questions such as:
What is the operating or line temperature of the system your customer needs to insulate?

In general, systems needing insulation can be divided into three temperature ranges: Low Temperature Range (-160°c to 65°c) cryogenic Refrigeration, cold/chilled water and commercial heating and cooling systems.

Medium Temperature Range (65°c to 350°c) Hot water and steam, power/process piping, ovens and stacks.

High Temperature Range (350°c to 850°c) Power generation, turbines, kilns, smelters, exhaust systems and power piping.

Low temperature systems such as those needed for cryogenic storage of Liquefied Natural Gas (LNG), Ethylene, Propylene, Propane, Butane, Ammonia are typical Industries applications refrigeration or chilled water range from -160°c to 0°c.Refrigeration, warehouse, cold stores, Supermarkets and food processing are typical of low temperature commercial applications. Chilled water systems such as those used in HVAC systems generally range from 0°c to 20°c.

Chilled water systems require special attention because one must design for protection against external condensation at all costs and hence take due case to consider the effect of moisture or water vapor transmission (WVT) on the insulation system condensation and drips in such systems can cause expensive damage to buildings interiors.

WVT tells you how much water will be transmitted through an insulation system under certain conditions. Different insulation systems, vapor retarders and installation methods will affect the WVT of the system. Condensation control and process control are two major reasons for insulating low temperature systems. When equipment or piping operates at temperatures lower than the ambient air, moisture in the air will condense or freeze on, or within, the insulation surface – or on the cold pipe surface. Unless the system is protected by sufficient insulation thickness and by adequate vapor retarders, the insulation may become wet, causing corrosion, and causing it to become ineffective.

This will help you determine which part of the system is outdoors and the insulation needs protection from weather and which are other from corrosive atmospheres, water or chemical washdowns, abuse or other conditions.

The facing material is generally a vapor retarder and is usually applied toward the “warm-side” of any insulation provided over a cold system in buildings; it must be positioned to help resist the movement of warm moist vapor towards cold surfaces where it can condense. In hot, humid climates, a vapor retarder may not be needed. Since building construction practice incorporates dense fairly impermeable elements like concrete or however, winter conditions demand very careful examination of where to locate the vapour barrier.

The efficiency and service of insulation is directly dependent upon its protection from moisture entry and mechanical and chemical damage. Choices of jacketing and finish materials are based upon the mechanical, chemical, thermal and moisture conditions of the installation, as well as cost and appearance requirements. Protective coverings are divided into six functional types:

Weather Barriers
Vapor Retarders
Mechanical Abuse Coverings
Corrosion and Fire Resistant Coverings
Appearance Coverings and Finishes
Hygienic Coverings

Understanding specifications is an important part of the job. LII provides users with a guideline on the optimum insulation specifications best suited to the situated and needs of a specific user.

Important testing, codes and standards setting organizations critical to ensuring the performance of insulation procedures and systems include:

BIS – Bureau of Indian Standards.
ASTM—American Society for Testing Materials
ASHRAE—American Society of Heating, Refrigerating, and Air Conditioning Engineers.
BEE- Bureau of Energy efficiency.

Some of the performance specifications that you will need to become familiar with on the job include water vapor transmission, compressive strength, and fire hazard classifications.

While checking the manufacturers’ specification sheets for specification compliance, examine if he is a single material vendor. Such a source of information could be one sided and misleading. It is mos appropriate to go strictly by the data from the standards, covering a particular material / family of materials rather than from a sales promotion material.

To reduce the transfer of heat, most commonly from the outside of a building to the inside in summer, and the reverse in winter. In addition, in hot water plumbing insulation is applied so that water in them cools down more slowly, to save energy required for heating air and also to ensure we get hot water whenever we open the faucet.. Similarly, insulation is required when we have cold air ducts in air conditioning.

Our commonly used heat and cold household appliances are insulated. For example, our refrigerator is able to maintain the cold with least amount of compressor running time thanks to insulation provided to its walls. Similarly our insulated oven retains heat for cooking.

Air does not conduct much heat as long as it stays still. Most forms of insulation make use of this fact by creating a matrix of fibers or cells to provide a barrier to heat. Insulation materials always consist of air or some other gas trapped within bubbles or between fibers of a non conducting material. These are called mass type insulation materials. The best materials are those that are light in weight, resistant to air movement, water resistant, long-lasting, fireproof and cause no danger to health. Rockloyd and Supercera / Isoloyd Nil Flame are the major players in this field.

Another effective barrier to heat is a reflective surface or a cascade of reflective surfaces, which resist heat transfer by radiation because shiny surfaces are bad at both radiating and absorbing heat. Hence reflective foil layers can be used as insulation provided there is air film next to it. Resistance to heat flow offered by these foils is limited, however, and hence it cannot normally be used widely to provide good and effective insulation. Mass type insulation is more widely used.

The temperature difference; between one side of the insulation and the other; determines the rate at which heat passes through the insulation, or the overall construction incorporating it. Thus during warmest ambient temperature periods, our air conditioned space receives maximum heat and needs the air conditioner to run for longer periods. Any increase in the temperature difference between outside and inside increases the energy consumption.

It slows down the ingress of heat from the outside into the house so that less air conditioning Effort is needed to keep it as cool.. Unless the supply of energy is controlled, however, the house will simply get colder and colder. So, to achieve optimum energy saving, it is important for the cooling to be adjusted with a thermostat, along with well designed insulation in place. Overall, in a house, lowering of temperature by only 1 degree C, increases energy consumption by 15 to 20 percent and hence steals back much of the possible savings from insulation. Hence, in any discussion on energy consumption, we need to study how much insulation we must provide and also fix the temperature setting of the thermostat.

Insulation cuts down the heat that would otherwise have flowed in and heated up our rooms. Cooking, electric lighting, and other appliances also account for additional heat loads in buildings. These are the reasons why we need air conditioning to remove all such heat and keep our interiors at comfortable levels.

When we insulate, the inner surfaces of rooms remain cooler, reducing the “radiator” effect to occupants and objects within. In such cases, those rooms will be comfortable even at a slightly warmer air temperature. With no insulation, even with air conditioning, the inner surfaces of the room tend to get very warm on a hot summer day. Even if the air is cooled down, radiation from a warm roof or wall surface could make us feel uncomfortable.

This depends on where we place the insulation within the construction of a roof or a wall.

A building with solid brick or concrete walls stores a lot of heat and takes time to cool down. As long as the walls are hot, we will feel uncomfortable. Once the air conditioner stops, the air will obviously tend to get warmer. Whenever, we have insulation, this gain in heat is much slower.

It is a converse process in winter. Brick and concrete ‘retain’ the cold from low outside temperatures, and can stay cold for considerable lengths of time. We are all familiar with the problem of un-insulated concrete and brick housing. ‘Hot in summer – Cold in winter!’

The factors to be considered here are:

If insulation is to be provided externally, the need for a very credible external finishing system which is totally proof against water and damp
When insulation is to be applied as the inner surfaces, we need to consider disruption and inconvenience to occupants and acceptability of the finished inner surface to the needs and preferences of the occupant. Fire safety is also an important factor.
The relative cost-effectiveness of possible measures.
The actual finished cost of such measures – if we are working to a budget.
The principle of optimizing insulation to the running cost of the HVAC system.
The possible need to solve a specific problem e.g. west or south facing walls which get heated up in a particular room.

The pros are speed and convenience. Blown rockwool (a mineral-fibre material), Rockwool slab, Polyurethane slabs or in-situ poured Rigid Polyurethane are insulants which can be suitable in this concept. Foam insulation for a cavity of about 70 mm, when applied well, provides excellent thermal insulation value coupled with very good moisture /damp resistance. Polystyrene based products are attacked by vermin and rodents and hence are to be avoided. Besides this they are easily flammable.

Normally there is little or no disruption and no loss of space from the interior; and in most cases the thermal performance of the house is improved in more ways than just heat loss. Temperatures of the structure itself are stabilized while comfort levels are improved very effectively. On the debit side, the exterior appearance of the house is altered, and this one factor may stand in the way in many cases. This choice tends to be somewhat expensive because it involves external thermal insulation covering to form a new weatherproof layer calling for careful detail at eaves, openings, rainwater pipes all the way to ground level which should be protected against damp.

The cost, technical soundness and finished appearance of the operation all depend on careful detailing. It takes some design skill to achieve these to give an aesthetic and acceptable finish.

External insulation is worth doing since it can result in appreciable improvement to the insulation of our buildings. Added thickness poses challenges during detailing, and failure to solve them can cause cold bridges, condensation, pattern staining, etc., or an inadequately weather-resistant building.

If external insulation involves a separately fitted facade panel, a variety of materials like Rigid Polyurethane, high density water repellant Rockwool would qualify for selection. If the application involves a screed coursing i.e., Insulation materials for external surfaces must have sufficient rigidity, good resistance to water ingress and must form a good bond with the external finish. The basic method involves fixing of the required layer of insulation, covered by a layer of weatherproof cladding. The insulation has to be a board or rigid block fixed to substitute using a good fixing technique. Conversely, in situ spray applied rigid polyurethane is a very good choice, since it provides a monolithic joint-free insulating envelope reinforcing the external weather barrier. Where a board is used, cold bridges arc avoided, but the weight of cladding must be carried by the adhesive applied to board or through carefully selected fastener arrangement.

Insulation is performed by a large number of ancillary materials apart from the insulation material itself. Detailing involves correct arrangement of building components and these materials. Care is particularly needed at a junctions – e.g. at a window reveal – to ensure durability and correct performance of the insulation and the whole building. For the base of the wall, the commonest insulating detail at present is to stop the insulation at damp-proof course: DPC) level. This is invariably ugly, and also does not insulate the wall below DPC. If insulation is to be provided over an existing external surface – into reveals, under heads, over sills, etc. Remember that all these places really need more, not less, insulation than the rest of the wall, because they offer a “Thermal bridge” for heat to escape through. We need to provide as much as possible, and never none. Some areas require an especially robust surface (e.g. adjacent to a path or drive;. It is no solution simply to avoid insulating them.

Since externally insulated systems are evoking a lot of interest, a detailed analysis of the concept is provided.

The external cladding, whether in the form of a panel or in the form of plaster or rendering, needs to be tough – resistant to children, ladders and general wear and tear apart from being able to face weather. The success or failure of such work depends greatly on how the details are dealt with; good building construction experience is essential and, above all, every single detail must be worked out on paper before starting.

Overhead costs are relatively low, since scaffolding requirement is minimal. Weather does not affect progress. The house can be tackled room by room (at the time of decoration for instance, this minimizes both cost and disruption, and the cost can be spread over a long period. There is a fairly wide choice as to how much insulation can be added. One should also be prepared to accept reduced inner dimensions of rooms. There are many issues related to our lifestyle habits e.g., we like to drive a nail to hang pictures. The technique is not compatible with wall mounted furniture or fittings, and similarly it normally misses insulating the wall within the depth of floors. In theory there is possibility of thermal buildings at these places. In practice, it does not appear to matter in most houses.
How is ‘internal’ insulation to walls carried out?

By covering the inside with a new surface or lining, insulated from the existing wall. Usually the lining is plaster of Paris. Cement boards insulation needs to be in slab form, which can be fitted with a simple metal or wooden batten system.
What does cost effectiveness mean?

There is always a saving in energy cost which can be expected whenever we insulate. Such saving is weighed in relation to the cost of providing insulation. If the expected saving is marginal, we may be able to justify a small outlay. Although calculation of cost effectiveness is an involved exercise at the best of times, it can be appreciated that today’s ever increasing cost of energy would justify every unit of energy saved. Moreover, apart from cost effectiveness, significant benefits of insulation should also be taken into account such as reduction in compressor size that can do the same duty.
What order of priorities do we see in today’s context?

We need to convince architects, consultants and owners to appreciate the role played by insulation. In this, we must take full advantage of the present energy consciousness (e.g. Green movement, LEED Certificate) work to incorporate hot water plumbing insulation, particularly in solar homes. Second, ventilation control (i.e. sealing gaps and crevices) through which warm air and humidity infiltrates. Third cavity wall insulation. Fourth, double glazing in living rooms.

However, good our present air conditioning systems may be, with an ever increasing rise in the cost of energy, retrofitting such as double glazing or providing wall insulation or ceiling insulation, will become more cost-effective.

If good LEED ratings are to be sought the following principles are recommended in building construction:

Use durable products and materials: Because manufacturing is very energy-intensive, a product that lasts longer or requires less maintenance usually saves energy. Durable products also contribute less to our solid waste problems.
Choose low-maintenance building materials: Where possible, select building materials that require little maintenance (painting, re-treatment, waterproofing, etc.), or whose maintenance will have minimal environmental impact.
Choose building materials with low embodied energy: Heavily processed or manufactured products and materials are usually more energy intensive. As long as durability and performance will not be sacrificed, choose low-embodied-energy materials.
Buy locally produced building materials: Transportation is costly in both energy use and pollution generation. Look for locally produced materials. Local hardwoods, for example, are preferable to tropical woods.
Use building products made from recycled materials: Building products made from recycled materials reduce solid waste problems, cut energy consumption in manufacturing, and save on natural resource use.
Use salvaged building materials when possible : Reduce landfill pressure and save natural resources by using salvaged materials. Make sure these materials are safe (test for lead paint and asbestos), and don’t sacrifice energy efficiency or water efficiency just to reuse old materials.
Seek responsible wood supplies: Use lumber from independently certified well-managed forests. Avoid lumber products produced from old-growth timber unless they are certified. Don’t buy tropical hardwoods unless the seller can document that the wood comes from well-managed forests.
Avoid materials that will generate pollutants: Solvent-based finishes, adhesives, carpeting, particleboard, and many other building products release formaldehyde and volatile organic compounds (VOCs) into the air; these chemicals can affect workers and occupants health as well as contribute to smog and ground-level ozone pollution outside. Avoid materials that give off HCFCs, such as extruded polystyrene.
Minimize use of pressure-treated lumber: Use detailing that will prevent soil contact and rot. Where possible, use alternatives such as recycled plastic lumber. Take measures to protect workers when cutting and handling pressure treated woods. Scraps should never be incinerated.

What is green building?

Green building is the act of reducing the amount of impact, or carbon footprint, that a building has upon the environment, during its lifespan. When implementing green building practices, the focus is in three specific resources: energy, water, and materials. The health of the people occupying the building and the surrounding community are also carefully considered. Superior design, construction, and maintenance are three factors that contribute extensively to the streamlining, or efficient usage, of the above mentioned resources.

A green building is a structure that is environmentally responsible and resource-efficient throughout its life-cycle. These objectives expand and complement the classical building design concerns of economy, utility, durability, and comfort.

Green buildings are designed to reduce the overall impact of the built environment on human health and the natural environment by:

Efficiently using energy, water, and other resources
Protecting occupant health and improving employee productivity
Reducing waste, pollution and environment degradation

For example, green buildings may incorporate sustainable materials in their construction (e.g., reused, recycled-content, or made from renewable resources); create healthy indoor environments with minimal pollutants (e.g., reduced product emissions); and/or feature landscaping that reduces water usage (e.g., by using native plants that survive without extra watering).

What are the benefits of green building?

Buildings have an enormous impact on the environment, human health, and the economy. The successful adoption of green building strategies can maximize both the economic and environmental performance of buildings. Specific environmental, economic and social benefits are listed in Why Build Green?

Research continues to identify and clarify all of these benefits and costs of green building, and of how to achieve the greatest benefits at the lowest costs.
How do buildings affect climate change?

The energy used to heat and power our buildings leads to the consumption of large amounts of energy, mainly from burning fossil fuels – oil, natural gas and coal – which generate significant amounts of carbon dioxide (CO2), the most widespread greenhouse gas

Reducing the energy use and greenhouse gas emissions produced by buildings is therefore fundamental to the effort to slow the pace of global climate change. Buildings may be associated with the release of greenhouse gases in other ways, for example, construction and demolition debris that degrades in landfills may generate methane, and the extraction and manufacturing of building materials may also generate greenhouse gas emissions.
Is green building or sustainable design more expensive than traditional building practices?

No, this is a popular misconception. Green building can reduce your overall construction costs by more than 25%, and that is just the beginning! After implementing green building practices, you will likely find many monetary benefits, including lowered maintenance costs.
What makes your buildings green?

We work very hard to make a positive impact on our environment. We focus on energy efficiency and utilizing reusable and/or recyclable materials. Our design and building systems minimize both material usage and waste.
What part do reused and recycled building materials play in green building?

Purchasing materials that contain recycled content helps to support recycling efforts in the community, state, region, and nation. These products also reduce solid waste problems, cut energy consumption in manufacturing, and save natural resources. Some examples include materials with recycle content include cellulose insulation, Homosote, Thermo-ply, floor tile made from ground glass, and recycled plastic lumber. Salvaged building materials which are incorporated should be safe (test for lead paint and asbestos) and should not sacrifice energy or water efficiency.
Will you assist me in getting my LEED certification?

Obviously, we cannot promise LEED certification as there are many factors outside of our parameters or control. We are able, however, to focus on many specific requirements of LEED certification to aid you in achieving your certification.

Our areas of expertise are:

Environment friendly Insulation system and ability to recycle/reuse in the future.
Energy Efficiency
Cool Roofing & wall cladding system.

What is Fire protection?

Fire protection is a provision we makes crucial for the safety of personnel and physical property.

The aim of fire protection in buildings and technical installations is first of all to reduce the possibility of fire breaking out and, thereafter, in the event of a fire, to hold back or prevent the spread of flame and toxic gases. The object is to preserve the stability of the structure from the impact of the fire and allow time for people to be evacuated. Whilst important, the objective of preserving property is secondary to that of saving of lives.
How to choose fire insulation?

The choice of solution for fire insulation depends on specific application and regulations.

To identify the purpose of the insulation is the major activity in any solution. They are:
A) Is it to prevent fire breakout at the start of a fire?
B) Is it also to prevent spread of fire once it has developed?

Answer to A (i.e; to prevent fire breakout), one should choose materials – the main insulant and ancillaries with non-combustible rating. Codes would normally specify the minimum requirements for different types of spaces.

If the object is also to prevent fire spread, then the solution will be dependent on the application – HVAC ducts, pipes, walls, steel structures etc which differ in the path traversed by the effect of fire. Requirement will normally be given in the codes as a fire resistance period (e.g. 15min, 30 min or 1 hour).

An insulation with high service temperature rating is normally featured as fire barrier insulation. The specific choice depends on the application and on other codal provisions.
For an optimum solution, three basic questions must be answered, viz;
1) Service temperature of the high temperature insulation,
2) Thermal performance requirements at fire temperatures and
3) The ability of the system to resist any dislodgement so that the treatment stays in place for the entire duration of fire exposure.
What are Firestops?

Firestops are systems specifically designed to stop smoke, toxic fumes, super-heated gases, and fire from migrating from one room to another, or from one floor to another. Firestops are provided at cable / pipe/ duct penetration to ensure that the opening around them are as resistive to fire / smoke propagating as the wall through which such penetration exists. Fire stops are specially engineered assemblies and are to be installed by experienced and qualified companies. They should be provided as per local and international fire codes in line with National Fire Protection Association (NFPA) guidelines. Material should be installed according to manufacturers’ specifications by qualified craftsmen.
What is fire rating?

It’s a rating of the length of time it takes a fire to penetrate a barrier. Designates the ability of a material to contain a fire in a carefully controlled test setting for a specified period of time. A material tested in a laboratory that adequately contains a fire for two hours and meets other requirements during the laboratory fire test, is given a two-hour fire resistance rating. Fire-resistance ratings are based on full-scale tests under simulated fire conditions and are generally recognized by building code authorities (like National Building code of India ) and fire insurance rating bureaus (like FM approvals, Under writers Laboratories (UL), Insurance Association of India). Requirements for fire-resistance ratings are usually set by designers and local building code officials based on the expected occupancy of the building, speed of access of fire fighting team etc.

What is a pre-insulated sandwich Panel (PSP)?

Sandwich panels are a remarkable product since they can act as strong as a solid material, but possess excellent insulation value and weigh significantly less. The trend for “stronger-lighter” become increasingly important in the transportation and aerospace industries, and sandwich panels filled this need admirably. Today’s modular construction of facilities like cold stores and similar temperature controlled warehouse feature pre-insulated sandwich panels in very large measure.

The common composite sandwich structure is made up of two major elements, the skin and the core. Sandwich panel skins are the outer layers and are constructed out of a variety of materials metals like coated steel, aluminium, plastic composites and plywood in certain cases are commonly used.

The core materials provide many of the panels’ desirable properties and are often composed of rigid foam, and where insulation duty is not desired various types of structural honeycomb.
Are the panels structural?

Yes. By virtue of composite construction where the two metal faces are integrally bonded through the matrix of rigid foam, these panels have extraordinary capability to span wide lengths and also withstand external wind loading with minimum girt deployment. Panels are subjected to tests by reputed classification bodies (like Factory Mutual Approvals) revealing their potential as load bearing and fire resistive elements in building construction.
Do PSP need a vapor barrier?

Metal facings on PSP’s provide a zero perm barrier against vapour migration. All joints between panels need proper installation practice to render them impermeable. So that the system is vapour tight.
What are the advantages of using Polyurethane Foam as Insulation as core in PSP as compared to other materials like Expanded polystyrene (EPS)?

PSP choose to use closed cell polyurethane foam (PUF) insulation instead of expanded polystyrene (EPS) for several reasons. First, polyurethane is a far better insulator than EPS & other insulation cores commercially available. Which means that a thinner panel is capable of giving higher thermal efficiency since Polyurethane foam has a nominal R-value much higher than EPS. Rigid Polyurethane foam is formed when liquid components are injected between metal / flexible faces Natural adhesive property of polyurethane during curing period is helps in strong adhersion with the metal faces without any adhesives. Panels so formed are structurally much stronger than EPS panels. While the EPS is simply glued onto the substrates (with either water, polyurethane or formaldehyde based glues), injected polyurethane foam adheres and bonds to every small area of surface (substrates, top-plates, splines, cam-locks, electrical boxes, etc.), before becoming rigid.

Polyurethane has better fire, flame, and smoke characteristics. Much more on fire and safety issues later but suffice it to say that PU foam is significantly safer in fire situation and our polyurethane foam does not melt at any temperature. Polyurethane is also a very strong matrix which allows the use of cam-locks embedded into the foam. This saves labour in the field and makes strong panel connections quickly and easily.
What about PSP in fires?

Fire requires three components: ignition, oxygen, and fuel. PSP have no air gaps within the solid core of the insulation so the fire cannot “run up the wall” cavity as is the case with traditional stud construction. Polyurethane foam is a “thermoset” product and does not melt at any temperature.

PSPs insulation core are tested to the American Society for Testing and Materials (ASTM) E84 “Standard Test Method for Surface Burning Characteristics of Building Materials” with Aluminium foil facing for smoke spread and flame spread. The PIR insulation core has a Class 1 foam core. & class “P” ignitibility (As per BS 476 – Part 5) not easily ignitable.

The ultimate test for fire safety is “Proof of the pudding” tests as in the US corner Test and simulated tests as carried out at the laboratories of FM Approvals, USA.
How and Why is Insulation Used to Control Noise?

Noise Control to achieve quiet condition when adjoining areas are noisy requires suitably insulated barriers. They feature acoustical materials, some of which may also perform thermal insulation duty concurrently.

Quiet condition are required to ensure productivity in work place and comfort in living areas. The degree of “quietness” required is determined by the nature of activity in the quieter area. In work places, there are special laws and codes which govern the “Noise levels” that are permitted.
How can I control the noise in my workplace?

Noise in the workplace can be highly distracting, limit communication, affect safety as well as reduce work performance and productivity.

Noise can be a problem in factories, vehicles, open plan office environments or building and construction sites. Because of excess noise, instructions can sometimes be misheard or announcements not heard at all which may compromise both productivity and safety.

Open plan office environments where multiple distractions and conversations occur can reduce concentration levels, alter train of thought or reduce the ability to focus attention, again potentially impacting negatively on work performance and productivity. Properly designed partial height barriers and absorption ceiling and wall surfaces help reduce built up noise in open plan offices.

In Industry, when workplace noise is identified the following should be considered:

Removing or replacing the source of noise with plant or equipment with lower noise emissions. Specifying maximum noise emission as part of purchase documentation is highly recommended.
Ensuring all plant and equipment is installed correctly to ensure low noise emissions
Treating vibration sources within a machine or engine with correctly designed isolators.
Using noise damping products to reduce metal to metal contact
Providing effective maintenance procedures to eliminate noise arising from insufficient lubrication, abrading machine parts, faulty seals or worn bearings
Analysing each element of a machine rather than the whole machine, for instance using strategically located anti-vibration mountings, mufflers or silencers depending on the noise potential of each component.
Whether work undertaken or equipment used can be modified without impacting the process to reduce noise emissions
Using sound absorbing materials on floors, walls and ceilings to limit reverberation and thereby to achieve noise reduction by internal absorption.
Placing sound barriers or enclosures around noisy equipment to minimise emissions to other areas which are relatively quicker.
Scientific acoustical design featuring Absorptive / barrier panels.

What is thermal equilibrium?

This is a common term as it relates to thermodynamics and heat transfer calculations. It is a state of thermal dynamics where the equilibrium temperature is attained as a result of the heat input becoming equated to the heat loss.
Can nonmetallic pipes and vessels be traced in the same way as we trace metallic surface?

When we design heat tracing for non-metallic pipes and vessels, it is important to cross check on the maximum temperature rating of the non-metallic pipe or vessel material. The heater cable operating temperature (sheath temperature) must be safely lower than the temperature rating of the pipe or vessel. The maximum operating temperature is calculated considering “runaway” conditions. Runaway conditions typically occur at the highest possible ambient, with temperature controller failure due to closure of contacts resulting in a continuously energized heater. Power cables with lower outputs will have lower equilibrium operating temperatures and are therefore the best choice for non-metallic heating applications.

Designs must also take into consideration that heat from the tracer does not transfer as easily into a non-metallic material as it does through a metal wall.” Constant watt” heaters will therefore operate at higher temperatures on non-metallic surfaces. Self-regulating (SR) cables will also tend to operate at higher temperatures resulting in a reduction in power output. Heat transfer aids can help reduce these effects. For example, a good design practice is to cover the cable with a parallel pass of 2″ wide aluminum tape. With a larger Heat transfer area, this will help reduce sheath temperatures on constant watt cables and improve power output of SR cables.
What are Self-Regulating Heating Cables?

These cables provide a power output which increases as temperatures fall and decreases as temperatures rise. Self-regulating heating cables feature a polymer / carbon matrix as the conductor which is engineered to possess self limiting property – rises, the resistance increases as the temperature increases finally reaching “open circuit” at the rated temperature.

The self-regulating heating cable has the feature of adjusting its power output for local condition along its length (Such as local heat sinks) to a certain extent.
Heat loss.

Heat loss is the rate at which heat from a liotter process equipment flows to a cooler ambient, stated in watts. The purpose of heat tracing is to make good such heat lost through the thermal insulation so as to maintain a desired temperature difference. This is the first step in heat tracing system design. Heat loss calculations involve following factors:

Difference between maintenance temperature and ambient.
Pipe Size or Vessel area.
Types and Thickness of Thermal Insulation.
Presences of heat sinks (like metal pipe supports).

What is the function of thermal insulation for heat traced pipes?

Prevents excessive heat loss and there by limits the out put necessary from an Electric Heat tracing system.
Provides personnel protection (not hot surfaces)
It allows the pipe temperature to increase a to maintenance temperature required in a shorter time.
Conserves Energy dissipation from the whole system.

By covering the inside with a new surface or lining, insulated from the existing wall. Usually the lining is plaster of Paris. Cement boards insulation needs to be in slab form, which can be fitted with a simple metal or wooden batten system.

There is always a saving in energy cost which can be expected whenever we insulate. Such saving is weighed in relation to the cost of providing insulation. If the expected saving is marginal, we may be able to justify a small outlay. Although calculation of cost effectiveness is an involved exercise at the best of times, it can be appreciated that today’s ever increasing cost of energy would justify every unit of energy saved. Moreover, apart from cost effectiveness, significant benefits of insulation should also be taken into account such as reduction in compressor size that can do the same duty.

We need to convince architects, consultants and owners to appreciate the role played by insulation. In this, we must take full advantage of the present energy consciousness (e.g. Green movement, LEED Certificate) work to incorporate hot water plumbing insulation, particularly in solar homes. Second, ventilation control (i.e. sealing gaps and crevices) through which warm air and humidity infiltrates. Third cavity wall insulation. Fourth, double glazing in living rooms.

However, good our present air conditioning systems may be, with an ever increasing rise in the cost of energy, retrofitting such as double glazing or providing wall insulation or ceiling insulation, will become more cost-effective.

If good LEED ratings are to be sought the following principles are recommended in building construction:

Use durable products and materials: Because manufacturing is very energy-intensive, a product that lasts longer or requires less maintenance usually saves energy. Durable products also contribute less to our solid waste problems.
Choose low-maintenance building materials: Where possible, select building materials that require little maintenance (painting, re-treatment, waterproofing, etc.), or whose maintenance will have minimal environmental impact.
Choose building materials with low embodied energy: Heavily processed or manufactured products and materials are usually more energy intensive. As long as durability and performance will not be sacrificed, choose low-embodied-energy materials.
Buy locally produced building materials: Transportation is costly in both energy use and pollution generation. Look for locally produced materials. Local hardwoods, for example, are preferable to tropical woods.
Use building products made from recycled materials: Building products made from recycled materials reduce solid waste problems, cut energy consumption in manufacturing, and save on natural resource use.
Use salvaged building materials when possible : Reduce landfill pressure and save natural resources by using salvaged materials. Make sure these materials are safe (test for lead paint and asbestos), and don’t sacrifice energy efficiency or water efficiency just to reuse old materials.
Seek responsible wood supplies: Use lumber from independently certified well-managed forests. Avoid lumber products produced from old-growth timber unless they are certified. Don’t buy tropical hardwoods unless the seller can document that the wood comes from well-managed forests.
Avoid materials that will generate pollutants: Solvent-based finishes, adhesives, carpeting, particleboard, and many other building products release formaldehyde and volatile organic compounds (VOCs) into the air; these chemicals can affect workers and occupants health as well as contribute to smog and ground-level ozone pollution outside. Avoid materials that give off HCFCs, such as extruded polystyrene.
Minimize use of pressure-treated lumber: Use detailing that will prevent soil contact and rot. Where possible, use alternatives such as recycled plastic lumber. Take measures to protect workers when cutting and handling pressure treated woods. Scraps should never be incinerated.

Green building is the act of reducing the amount of impact, or carbon footprint, that a building has upon the environment, during its lifespan. When implementing green building practices, the focus is in three specific resources: energy, water, and materials. The health of the people occupying the building and the surrounding community are also carefully considered. Superior design, construction, and maintenance are three factors that contribute extensively to the streamlining, or efficient usage, of the above mentioned resources.

A green building is a structure that is environmentally responsible and resource-efficient throughout its life-cycle. These objectives expand and complement the classical building design concerns of economy, utility, durability, and comfort.

Green buildings are designed to reduce the overall impact of the built environment on human health and the natural environment by:

Efficiently using energy, water, and other resources
Protecting occupant health and improving employee productivity
Reducing waste, pollution and environment degradation

For example, green buildings may incorporate sustainable materials in their construction (e.g., reused, recycled-content, or made from renewable resources); create healthy indoor environments with minimal pollutants (e.g., reduced product emissions); and/or feature landscaping that reduces water usage (e.g., by using native plants that survive without extra watering).

Buildings have an enormous impact on the environment, human health, and the economy. The successful adoption of green building strategies can maximize both the economic and environmental performance of buildings. Specific environmental, economic and social benefits are listed in Why Build Green?

Research continues to identify and clarify all of these benefits and costs of green building, and of how to achieve the greatest benefits at the lowest costs.

The energy used to heat and power our buildings leads to the consumption of large amounts of energy, mainly from burning fossil fuels – oil, natural gas and coal – which generate significant amounts of carbon dioxide (CO2), the most widespread greenhouse gas

Reducing the energy use and greenhouse gas emissions produced by buildings is therefore fundamental to the effort to slow the pace of global climate change. Buildings may be associated with the release of greenhouse gases in other ways, for example, construction and demolition debris that degrades in landfills may generate methane, and the extraction and manufacturing of building materials may also generate greenhouse gas emissions.

No, this is a popular misconception. Green building can reduce your overall construction costs by more than 25%, and that is just the beginning! After implementing green building practices, you will likely find many monetary benefits, including lowered maintenance costs.

We work very hard to make a positive impact on our environment. We focus on energy efficiency and utilizing reusable and/or recyclable materials. Our design and building systems minimize both material usage and waste.

Purchasing materials that contain recycled content helps to support recycling efforts in the community, state, region, and nation. These products also reduce solid waste problems, cut energy consumption in manufacturing, and save natural resources. Some examples include materials with recycle content include cellulose insulation, Homosote, Thermo-ply, floor tile made from ground glass, and recycled plastic lumber. Salvaged building materials which are incorporated should be safe (test for lead paint and asbestos) and should not sacrifice energy or water efficiency.

Obviously, we cannot promise LEED certification as there are many factors outside of our parameters or control. We are able, however, to focus on many specific requirements of LEED certification to aid you in achieving your certification.

Our areas of expertise are:

Environment friendly Insulation system and ability to recycle/reuse in the future.
Energy Efficiency
Cool Roofing & wall cladding system.

Fire protection is a provision we makes crucial for the safety of personnel and physical property.

The aim of fire protection in buildings and technical installations is first of all to reduce the possibility of fire breaking out and, thereafter, in the event of a fire, to hold back or prevent the spread of flame and toxic gases. The object is to preserve the stability of the structure from the impact of the fire and allow time for people to be evacuated. Whilst important, the objective of preserving property is secondary to that of saving of lives.

The choice of solution for fire insulation depends on specific application and regulations.

To identify the purpose of the insulation is the major activity in any solution. They are:
A) Is it to prevent fire breakout at the start of a fire?
B) Is it also to prevent spread of fire once it has developed?

Answer to A (i.e; to prevent fire breakout), one should choose materials – the main insulant and ancillaries with non-combustible rating. Codes would normally specify the minimum requirements for different types of spaces.

If the object is also to prevent fire spread, then the solution will be dependent on the application – HVAC ducts, pipes, walls, steel structures etc which differ in the path traversed by the effect of fire. Requirement will normally be given in the codes as a fire resistance period (e.g. 15min, 30 min or 1 hour).

An insulation with high service temperature rating is normally featured as fire barrier insulation. The specific choice depends on the application and on other codal provisions.
For an optimum solution, three basic questions must be answered, viz;
1) Service temperature of the high temperature insulation,
2) Thermal performance requirements at fire temperatures and
3) The ability of the system to resist any dislodgement so that the treatment stays in place for the entire duration of fire exposure.

Firestops are systems specifically designed to stop smoke, toxic fumes, super-heated gases, and fire from migrating from one room to another, or from one floor to another. Firestops are provided at cable / pipe/ duct penetration to ensure that the opening around them are as resistive to fire / smoke propagating as the wall through which such penetration exists. Fire stops are specially engineered assemblies and are to be installed by experienced and qualified companies. They should be provided as per local and international fire codes in line with National Fire Protection Association (NFPA) guidelines. Material should be installed according to manufacturers’ specifications by qualified craftsmen.

It’s a rating of the length of time it takes a fire to penetrate a barrier. Designates the ability of a material to contain a fire in a carefully controlled test setting for a specified period of time. A material tested in a laboratory that adequately contains a fire for two hours and meets other requirements during the laboratory fire test, is given a two-hour fire resistance rating. Fire-resistance ratings are based on full-scale tests under simulated fire conditions and are generally recognized by building code authorities (like National Building code of India ) and fire insurance rating bureaus (like FM approvals, Under writers Laboratories (UL), Insurance Association of India). Requirements for fire-resistance ratings are usually set by designers and local building code officials based on the expected occupancy of the building, speed of access of fire fighting team etc.

Sandwich panels are a remarkable product since they can act as strong as a solid material, but possess excellent insulation value and weigh significantly less. The trend for “stronger-lighter” become increasingly important in the transportation and aerospace industries, and sandwich panels filled this need admirably. Today’s modular construction of facilities like cold stores and similar temperature controlled warehouse feature pre-insulated sandwich panels in very large measure.

The common composite sandwich structure is made up of two major elements, the skin and the core. Sandwich panel skins are the outer layers and are constructed out of a variety of materials metals like coated steel, aluminium, plastic composites and plywood in certain cases are commonly used.

The core materials provide many of the panels’ desirable properties and are often composed of rigid foam, and where insulation duty is not desired various types of structural honeycomb.

Yes. By virtue of composite construction where the two metal faces are integrally bonded through the matrix of rigid foam, these panels have extraordinary capability to span wide lengths and also withstand external wind loading with minimum girt deployment. Panels are subjected to tests by reputed classification bodies (like Factory Mutual Approvals) revealing their potential as load bearing and fire resistive elements in building construction.
Do PSP need a vapor barrier?

Metal facings on PSP’s provide a zero perm barrier against vapour migration. All joints between panels need proper installation practice to render them impermeable. So that the system is vapour tight.
What are the advantages of using Polyurethane Foam as Insulation as core in PSP as compared to other materials like Expanded polystyrene (EPS)?

PSP choose to use closed cell polyurethane foam (PUF) insulation instead of expanded polystyrene (EPS) for several reasons. First, polyurethane is a far better insulator than EPS & other insulation cores commercially available. Which means that a thinner panel is capable of giving higher thermal efficiency since Polyurethane foam has a nominal R-value much higher than EPS. Rigid Polyurethane foam is formed when liquid components are injected between metal / flexible faces Natural adhesive property of polyurethane during curing period is helps in strong adhersion with the metal faces without any adhesives. Panels so formed are structurally much stronger than EPS panels. While the EPS is simply glued onto the substrates (with either water, polyurethane or formaldehyde based glues), injected polyurethane foam adheres and bonds to every small area of surface (substrates, top-plates, splines, cam-locks, electrical boxes, etc.), before becoming rigid.

Polyurethane has better fire, flame, and smoke characteristics. Much more on fire and safety issues later but suffice it to say that PU foam is significantly safer in fire situation and our polyurethane foam does not melt at any temperature. Polyurethane is also a very strong matrix which allows the use of cam-locks embedded into the foam. This saves labour in the field and makes strong panel connections quickly and easily.
What about PSP in fires?

Fire requires three components: ignition, oxygen, and fuel. PSP have no air gaps within the solid core of the insulation so the fire cannot “run up the wall” cavity as is the case with traditional stud construction. Polyurethane foam is a “thermoset” product and does not melt at any temperature.

PSPs insulation core are tested to the American Society for Testing and Materials (ASTM) E84 “Standard Test Method for Surface Burning Characteristics of Building Materials” with Aluminium foil facing for smoke spread and flame spread. The PIR insulation core has a Class 1 foam core. & class “P” ignitibility (As per BS 476 – Part 5) not easily ignitable.

The ultimate test for fire safety is “Proof of the pudding” tests as in the US corner Test and simulated tests as carried out at the laboratories of FM Approvals, USA.
How and Why is Insulation Used to Control Noise?

Noise Control to achieve quiet condition when adjoining areas are noisy requires suitably insulated barriers. They feature acoustical materials, some of which may also perform thermal insulation duty concurrently.

Quiet condition are required to ensure productivity in work place and comfort in living areas. The degree of “quietness” required is determined by the nature of activity in the quieter area. In work places, there are special laws and codes which govern the “Noise levels” that are permitted.
How can I control the noise in my workplace?

Noise in the workplace can be highly distracting, limit communication, affect safety as well as reduce work performance and productivity.

Noise can be a problem in factories, vehicles, open plan office environments or building and construction sites. Because of excess noise, instructions can sometimes be misheard or announcements not heard at all which may compromise both productivity and safety.

Open plan office environments where multiple distractions and conversations occur can reduce concentration levels, alter train of thought or reduce the ability to focus attention, again potentially impacting negatively on work performance and productivity. Properly designed partial height barriers and absorption ceiling and wall surfaces help reduce built up noise in open plan offices.

In Industry, when workplace noise is identified the following should be considered:

Removing or replacing the source of noise with plant or equipment with lower noise emissions. Specifying maximum noise emission as part of purchase documentation is highly recommended.
Ensuring all plant and equipment is installed correctly to ensure low noise emissions
Treating vibration sources within a machine or engine with correctly designed isolators.
Using noise damping products to reduce metal to metal contact
Providing effective maintenance procedures to eliminate noise arising from insufficient lubrication, abrading machine parts, faulty seals or worn bearings
Analysing each element of a machine rather than the whole machine, for instance using strategically located anti-vibration mountings, mufflers or silencers depending on the noise potential of each component.
Whether work undertaken or equipment used can be modified without impacting the process to reduce noise emissions
Using sound absorbing materials on floors, walls and ceilings to limit reverberation and thereby to achieve noise reduction by internal absorption.
Placing sound barriers or enclosures around noisy equipment to minimise emissions to other areas which are relatively quicker.
Scientific acoustical design featuring Absorptive / barrier panels.

What is thermal equilibrium?

This is a common term as it relates to thermodynamics and heat transfer calculations. It is a state of thermal dynamics where the equilibrium temperature is attained as a result of the heat input becoming equated to the heat loss.
Can nonmetallic pipes and vessels be traced in the same way as we trace metallic surface?

When we design heat tracing for non-metallic pipes and vessels, it is important to cross check on the maximum temperature rating of the non-metallic pipe or vessel material. The heater cable operating temperature (sheath temperature) must be safely lower than the temperature rating of the pipe or vessel. The maximum operating temperature is calculated considering “runaway” conditions. Runaway conditions typically occur at the highest possible ambient, with temperature controller failure due to closure of contacts resulting in a continuously energized heater. Power cables with lower outputs will have lower equilibrium operating temperatures and are therefore the best choice for non-metallic heating applications.

Designs must also take into consideration that heat from the tracer does not transfer as easily into a non-metallic material as it does through a metal wall.” Constant watt” heaters will therefore operate at higher temperatures on non-metallic surfaces. Self-regulating (SR) cables will also tend to operate at higher temperatures resulting in a reduction in power output. Heat transfer aids can help reduce these effects. For example, a good design practice is to cover the cable with a parallel pass of 2″ wide aluminum tape. With a larger Heat transfer area, this will help reduce sheath temperatures on constant watt cables and improve power output of SR cables.
What are Self-Regulating Heating Cables?

These cables provide a power output which increases as temperatures fall and decreases as temperatures rise. Self-regulating heating cables feature a polymer / carbon matrix as the conductor which is engineered to possess self limiting property – rises, the resistance increases as the temperature increases finally reaching “open circuit” at the rated temperature.

The self-regulating heating cable has the feature of adjusting its power output for local condition along its length (Such as local heat sinks) to a certain extent.
Heat loss.

Heat loss is the rate at which heat from a liotter process equipment flows to a cooler ambient, stated in watts. The purpose of heat tracing is to make good such heat lost through the thermal insulation so as to maintain a desired temperature difference. This is the first step in heat tracing system design. Heat loss calculations involve following factors:

Difference between maintenance temperature and ambient.
Pipe Size or Vessel area.
Types and Thickness of Thermal Insulation.
Presences of heat sinks (like metal pipe supports).

What is the function of thermal insulation for heat traced pipes?

Prevents excessive heat loss and there by limits the out put necessary from an Electric Heat tracing system.
Provides personnel protection (not hot surfaces)
It allows the pipe temperature to increase a to maintenance temperature required in a shorter time.
Conserves Energy dissipation from the whole system.

Metal facings on PSP’s provide a zero perm barrier against vapour migration. All joints between panels need proper installation practice to render them impermeable. So that the system is vapour tight.

PSP choose to use closed cell polyurethane foam (PUF) insulation instead of expanded polystyrene (EPS) for several reasons. First, polyurethane is a far better insulator than EPS & other insulation cores commercially available. Which means that a thinner panel is capable of giving higher thermal efficiency since Polyurethane foam has a nominal R-value much higher than EPS. Rigid Polyurethane foam is formed when liquid components are injected between metal / flexible faces Natural adhesive property of polyurethane during curing period is helps in strong adhersion with the metal faces without any adhesives. Panels so formed are structurally much stronger than EPS panels. While the EPS is simply glued onto the substrates (with either water, polyurethane or formaldehyde based glues), injected polyurethane foam adheres and bonds to every small area of surface (substrates, top-plates, splines, cam-locks, electrical boxes, etc.), before becoming rigid.

Polyurethane has better fire, flame, and smoke characteristics. Much more on fire and safety issues later but suffice it to say that PU foam is significantly safer in fire situation and our polyurethane foam does not melt at any temperature. Polyurethane is also a very strong matrix which allows the use of cam-locks embedded into the foam. This saves labour in the field and makes strong panel connections quickly and easily.

Fire requires three components: ignition, oxygen, and fuel. PSP have no air gaps within the solid core of the insulation so the fire cannot “run up the wall” cavity as is the case with traditional stud construction. Polyurethane foam is a “thermoset” product and does not melt at any temperature.

PSPs insulation core are tested to the American Society for Testing and Materials (ASTM) E84 “Standard Test Method for Surface Burning Characteristics of Building Materials” with Aluminium foil facing for smoke spread and flame spread. The PIR insulation core has a Class 1 foam core. & class “P” ignitibility (As per BS 476 – Part 5) not easily ignitable.

The ultimate test for fire safety is “Proof of the pudding” tests as in the US corner Test and simulated tests as carried out at the laboratories of FM Approvals, USA.

Noise Control to achieve quiet condition when adjoining areas are noisy requires suitably insulated barriers. They feature acoustical materials, some of which may also perform thermal insulation duty concurrently.

Quiet condition are required to ensure productivity in work place and comfort in living areas. The degree of “quietness” required is determined by the nature of activity in the quieter area. In work places, there are special laws and codes which govern the “Noise levels” that are permitted.

Noise in the workplace can be highly distracting, limit communication, affect safety as well as reduce work performance and productivity.

Noise can be a problem in factories, vehicles, open plan office environments or building and construction sites. Because of excess noise, instructions can sometimes be misheard or announcements not heard at all which may compromise both productivity and safety.

Open plan office environments where multiple distractions and conversations occur can reduce concentration levels, alter train of thought or reduce the ability to focus attention, again potentially impacting negatively on work performance and productivity. Properly designed partial height barriers and absorption ceiling and wall surfaces help reduce built up noise in open plan offices.

In Industry, when workplace noise is identified the following should be considered:

Removing or replacing the source of noise with plant or equipment with lower noise emissions. Specifying maximum noise emission as part of purchase documentation is highly recommended.
Ensuring all plant and equipment is installed correctly to ensure low noise emissions
Treating vibration sources within a machine or engine with correctly designed isolators.
Using noise damping products to reduce metal to metal contact
Providing effective maintenance procedures to eliminate noise arising from insufficient lubrication, abrading machine parts, faulty seals or worn bearings
Analysing each element of a machine rather than the whole machine, for instance using strategically located anti-vibration mountings, mufflers or silencers depending on the noise potential of each component.
Whether work undertaken or equipment used can be modified without impacting the process to reduce noise emissions
Using sound absorbing materials on floors, walls and ceilings to limit reverberation and thereby to achieve noise reduction by internal absorption.
Placing sound barriers or enclosures around noisy equipment to minimise emissions to other areas which are relatively quicker.
Scientific acoustical design featuring Absorptive / barrier panels.

This is a common term as it relates to thermodynamics and heat transfer calculations. It is a state of thermal dynamics where the equilibrium temperature is attained as a result of the heat input becoming equated to the heat loss.

When we design heat tracing for non-metallic pipes and vessels, it is important to cross check on the maximum temperature rating of the non-metallic pipe or vessel material. The heater cable operating temperature (sheath temperature) must be safely lower than the temperature rating of the pipe or vessel. The maximum operating temperature is calculated considering “runaway” conditions. Runaway conditions typically occur at the highest possible ambient, with temperature controller failure due to closure of contacts resulting in a continuously energized heater. Power cables with lower outputs will have lower equilibrium operating temperatures and are therefore the best choice for non-metallic heating applications.

Designs must also take into consideration that heat from the tracer does not transfer as easily into a non-metallic material as it does through a metal wall.” Constant watt” heaters will therefore operate at higher temperatures on non-metallic surfaces. Self-regulating (SR) cables will also tend to operate at higher temperatures resulting in a reduction in power output. Heat transfer aids can help reduce these effects. For example, a good design practice is to cover the cable with a parallel pass of 2″ wide aluminum tape. With a larger Heat transfer area, this will help reduce sheath temperatures on constant watt cables and improve power output of SR cables.

These cables provide a power output which increases as temperatures fall and decreases as temperatures rise. Self-regulating heating cables feature a polymer / carbon matrix as the conductor which is engineered to possess self limiting property – rises, the resistance increases as the temperature increases finally reaching “open circuit” at the rated temperature.

The self-regulating heating cable has the feature of adjusting its power output for local condition along its length (Such as local heat sinks) to a certain extent.

Heat loss is the rate at which heat from a liotter process equipment flows to a cooler ambient, stated in watts. The purpose of heat tracing is to make good such heat lost through the thermal insulation so as to maintain a desired temperature difference. This is the first step in heat tracing system design. Heat loss calculations involve following factors:

Difference between maintenance temperature and ambient.
Pipe Size or Vessel area.
Types and Thickness of Thermal Insulation.
Presences of heat sinks (like metal pipe supports).

What is the function of thermal insulation for heat traced pipes?

Prevents excessive heat loss and there by limits the out put necessary from an Electric Heat tracing system.
Provides personnel protection (not hot surfaces)
It allows the pipe temperature to increase a to maintenance temperature required in a shorter time.
Conserves Energy dissipation from the whole system.

Prevents excessive heat loss and there by limits the out put necessary from an Electric Heat tracing system.
Provides personnel protection (not hot surfaces)
It allows the pipe temperature to increase a to maintenance temperature required in a shorter time.
Conserves Energy dissipation from the whole system.