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Insulatedouter face 39.0 °C
Barepeak 180 °C
Peak 180 °C · 6.2 kW bare ·
0.3 kW insulated · 39.0 °C outer face
Details · heat · surface · sections · calculate
Peak surface temperature 180 °C and the 6.2 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 180 °C bare, and the 6 element group(s) in it lose 6.2 kW. The largest single item in it is the feed pump at 1.7 kW.
With Inzonex Modular Insulation over the same area the calculated loss is 0.3 kW, which is 95.0 % lower. The reduction this survey publishes is 95 %. At 6,000 operating hours a year that is 35.3 MWh of heat retained.
Visible in this view: feed pump, globe valve, return lines, strainer and blowdown flanges — ~100 °C.
| This view | Bare | Insulated |
|---|---|---|
| Surface heat loss | 6.2 kW | 0.3 kW |
| Surface temperature | 180 °C | 39.0 °C |
| Heat retained / yr | — | 35.3 MWh |
| Fuel equivalent / yr | — | 37.6 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 39.0 °C. The design target for surfaces people work next to is 45 °C. The bare steel measures 180 °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 180 °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 180 °C bare, 6,000 operating hours a year. The retained heat is valued at £1,879 a year at £50/MWh of fuel and avoids 7.0 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 | £1,879 |
| Heat retained | 35.3 MWh |
| Fuel equivalent | 37.6 MWh |
| Emissions avoided | 7.0 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.
The pump casing/volute can be insulated with a removable cover at ~100 °C, while the seal, bearings and coupling stay accessible. It removes a standing loss and a hot-touch hazard.
On the surveyed Cochran the feed pump, valves, returns, strainer and blowdown ran near 100 °C.
Individually no, collectively yes — a feed set of a dozen warm bodies is a continuous multi-hundred-watt loss, cut ~95% with removable sleeves and covers.