Pump Insulation: Heat Loss & Savings

Removable insulation for hot-service pumps reduces heat loss from the casing while allowing access for maintenance. When comparing pump insulation jackets or blankets, check clearances around seals, bearings, couplings and motor cooling paths. Inzonex supplies fitted modular insulation for boiler-feed, hot-oil, condensate and process-pump applications.

Direct answer: In this simplified reference model, bare surface heat-loss flux is roughly 1,000 W/m² at 120 °C and 1,800 W/m² at 200 °C, with 20 °C ambient air. The tables compare bare and insulated scenarios; they are not measured results or a guarantee for every installation. Confirm geometry, coverage and the required surface-temperature target for the project.

Heat loss vs insulated — by surface temperature

Surface temp	Bare loss	Insulated	Outer surface	Reduction
100 °C	800 W/m²	74 W/m²	27 °C	90.7%
120 °C	1,000 W/m²	97 W/m²	30 °C	90.3%
160 °C	1,400 W/m²	147 W/m²	35 °C	89.5%
200 °C	1,800 W/m²	204 W/m²	40 °C	88.7%

Calculated per-m² flat-surface screening reference: combined external h = 10 W/m²·K, 50 mm Lamella (≤220 °C) or 100 mm Wired mat (>220 °C), 20 °C ambient. Multiply by the bare area. See the calculation method, a measured boiler installation and the Inzonex survey-to-manufacture process. The boiler case documents a different application, not measured performance for this equipment.

Worked examples (per year, 8,000 h, natural gas)

Item	Heat saved	Energy/yr	CO₂/yr	€ saved/yr
A feed-water pump casing (2.5 m², 160 °C)	3.1 kW	29 MWh	6.0 t	€1,710
A hot-oil pump body (1.2 m², 200 °C)	1.9 kW	18 MWh	3.6 t	€1,046

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FAQ

How much heat does a bare pump lose?

Multiply the bare-loss flux in the reference table by the hot pump-casing area. The worked examples report heat saved after insulation, not bare heat loss: about 3.1 kW for the illustrated feed-water pump casing and 1.9 kW for the hot-oil pump body. Annual results use 8,000 operating hours and the stated calculation assumptions.

Can you insulate boiler-feed and similar?

The pump casing is insulated while bearings, mechanical seals, couplings and motor cooling paths remain accessible and are checked against the equipment manufacturer's requirements. Inzonex modules open with snap-button fasteners and magnets where applicable. The separate functional zipper provides access to the insulation core for cleaning or replacement.

How much does pump insulation save?

Inzonex projects can achieve up to 96% heat-loss reduction, depending on equipment, coverage and operating conditions. The worked example on this page uses its stated assumptions; it is not a quoted saving for every installation. Enter your own operating hours, energy price and installed cost to estimate annual savings and payback.

What insulation thickness is used?

The reference calculations use 50 mm mineral-wool Lamella up to 220 °C and 100 mm Wired mat above 220 °C. These are calculation scenarios, not a universal specification. Select the complete assembly for the equipment temperature, ambient conditions and the required outer-surface temperature. Inzonex projects target ≤45 °C; some duties require a different thickness or material to meet that target.