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Insulatedouter face 34.0 °C
Barepeak 120 °C
Peak 120 °C · 8.0 kW bare ·
0.4 kW insulated · 34.0 °C outer face
Details · heat · surface · sections · calculate
Peak surface temperature 120 °C and the 8.0 kW of this view are FLIR readings taken on a working cochran shell boiler, with areas from the CAD model of the same equipment uplifted ×1.4 for bolts and irregular geometry. The area field opens on the value that reproduces that loss at that temperature, so the bare tile starts on the surveyed figure; where a view holds elements at different temperatures this comes out below the geometric area. Surface heat loss only, ISO 12241 steady state. Emissivity 0.90 bare and 0.85 on the insulated face; fuel at 94 % heat-supply efficiency and 185 kg CO₂e per MWh of fuel. Operating hours and energy price are example inputs for one boiler — put your own in. Figures are for one boiler.
On the surveyed cochran shell boiler the hottest point of this view measures 120 °C bare, and the 1 element group(s) in it lose 8.0 kW. The largest single item in it is the front (burner) door at 8 kW.
With Inzonex Modular Insulation over the same area the calculated loss is 0.4 kW, which is 94.8 % lower. The reduction this survey publishes is 95 %. At 6,000 operating hours a year that is 45.5 MWh of heat retained.
Visible in this view: front (burner) door at ~120 °C, with the burner mounting.
| This view | Bare | Insulated |
|---|---|---|
| Surface heat loss | 8.0 kW | 0.4 kW |
| Surface temperature | 120 °C | 34.0 °C |
| Heat retained / yr | — | 45.5 MWh |
| Fuel equivalent / yr | — | 48.4 MWh |
q = h(Ts − Ta) + εσ[(Ts+273.15)⁴ − (Ta+273.15)⁴], with h = 5.7 + 3.8v W/m²K. Conductivity is taken as λ = 0.031 + 0.000188 × mean layer temperature, W/mK, evaluated at the solved mean layer temperature. Certified λ curves differ between products.
With a 50 mm core the calculated outer surface is 34.0 °C. The design target for surfaces people work next to is 45 °C. The bare steel measures 120 °C over the same area on the FLIR survey.
Inputs: 50 mm core, air 28 °C at 0.5 m/s, emissivity 0.90 bare and 0.85 on the insulated face, bare surface 120 °C. Area, temperature and hours are editable in the calculator above.
| Calculation input | Value |
|---|---|
| Insulation thickness | 50 mm |
| Ambient air | 28 °C |
| Air speed | 0.5 m/s |
| Emissivity, bare / insulated | 0.90 / 0.85 |
| Area uplift for bolts | ×1.4 |
The insulation is made in separate sections around the hinged doors, the valves and the mountings. Each section can be removed separately for burner service or inspection and refitted afterwards. Safety devices and required clearances stay unobstructed.
No access-time saving is included in this calculation.
| Stays accessible | How |
|---|---|
| Hinged doors | own section |
| Valves and mountings | own section |
| Instruments | own section |
| Safety devices | left clear |
Reference case: one boiler, this view at 120 °C bare, 6,000 operating hours a year. The retained heat is valued at £2,420 a year at £50/MWh of fuel and avoids 9.0 t CO₂e.
Natural gas at £50/MWh, 94 % heat-supply efficiency and 185 kg CO₂e per MWh of fuel. Operating hours and fuel price are example inputs for one boiler; enter your own to recalculate the results.
| Per year | Reference case |
|---|---|
| Estimated energy cost saving | £2,420 |
| Heat retained | 45.5 MWh |
| Fuel equivalent | 48.4 MWh |
| Emissions avoided | 9.0 t CO₂e |
Figures are for one boiler and for this view only. The surface is treated as flat area: thermal bridges and fixings are not resolved separately.
On the surveyed Cochran the front (burner) door measured ~120 °C over a 5.3 m² face, bare — roughly 8 kW of standing loss.
Yes — a removable panel is shaped to the door and hinges with it, insulated when closed and clear of the burner mounting and sight port when open.
About 34 °C — below the 45 °C touch-safe threshold — a ~95% cut in loss.