“Clean, Efficient & Resilient Energy”

A Study in Industrial Insulation

 “Clean, Efficient & Resilient Energy”

Topics:
•Function of an Insulation
•Selection of an Insulation
•Performance of an Insulation
•Protective Coverings
•Custom Soft Insulation Covers
Function of an Insulation

Understanding why insulation is necessary on the

system is the first step in selecting the appropriate
insulation.

Why am I insulating this system?

Function of an Insulation
Insulations are defined as those materials or combinations of materials
which retard the flow of heat energy by performing one or more of the
following functions:
• Energy Conservation
• Process Control
• Personnel Protection
• Condensation Control
• Freeze Protection
• Noise Reduction
• Fire Protection
• Reduce Environmental Pollution

Why Am I Insulating?
Function of an Insulation

Not all properties of insulation are significant for all materials or

applications.

In some applications certain properties may assume extreme

importance (i.e. when insulations must be compatible with chemically
corrosive atmospheres.)

Therefore we must understand which properties are most important

when insulating a particular system.

When selecting an insulation for our systems we have to consider the

following:

Why Am I Insulating?
Selection of an Insulation

• System Dependent
– Operating Temperature
– Vibration
– Physical Abuse
– Fire Protection
– Location/Space Weight
– Service/Maintenance
– Water Ingress

How Do I Choose?
Selection of an Insulation

• Material Dependent
– Available Forms
– Ease of Installation
– Compliance with Code and
Industry Standards
– Compatibility of materials and
systems
– Life Cycle Costs
Installed Costs
Maintenance Costs
Lost Energy Costs

How Do I Choose?
Selection of an Insulation

• Temperature Range
– Low Temperature Range
- Cryogenic (-450°F to -101°F)
- Refrigeration (-100°F to 31°F)
- Cold and Chilled Water(32°F to 60°F)

– Intermediate Temperature Range

(- 61°F to 600°F)

– High Temperature Range

(- 601°F to 1500°F)

How Do I Choose?
Selection of an Insulation

So Which Insulation?
Selection of an Insulation

Fibrous Insulation:
composed of small diameter fibers which finely divide the air
space. The fibers may be perpendicular or parallel to the surface
being insulated, and they may or may not be bonded together.
Silica, rock wool, slag wool and alumina silica fibers are used. The
most widely used insulations of this type are glass fiber and
mineral wool. Glass fiber and mineral wool products usually have
their fibers bonded together with organic binders that supply the
limited structural integrity of the products.

How Do I Choose?
Selection of an Insulation

Cellular Insulation:
composed of small individual cells separated from each other.
The cellular material may be glass or foamed plastic such as
polystyrene (closed cell), polyisocyanurate and elastomeric.

How Do I Choose?
Selection of an Insulation

Granular Insulation:
composed of small nodules which may contain voids or hollow
spaces. It is not considered a true cellular material since gas can
be transferred between the individual spaces.
This type may be produced as a loose or pourable material, or
combined with a binder and fibers or undergo a chemical
reaction to make a rigid insulation. Examples of these
insulations are calcium silicate, expanded vermiculite, perlite,
cellulose, diatomaceous earth and expanded polystyrene.

How Do I Choose?
Selection of an Insulation

Insulations are produced in a variety of forms suitable for specific

functions and applications. The combined form and type of insulation
determine its proper method of installation.

The forms most widely used are:

1. Rigid boards, blocks, sheets and pre-formed shapes

2. Flexible sheets and pre-formed shapes
3. Flexible blankets
4. Foams

How Do I Choose?
Selection of an Insulation

MAJOR INSULATION MATERIALS

Selection of an Insulation
CALCIUM SILICATE
• composed principally of hydrous calcium silicate
which usually contains reinforcing fibers; it is
available in molded and rigid forms.
• Service temperature range covered is 125°F to
1200°F.
• Flexural and compressive strength is good.
• Calcium silicate is water absorbent.
However, it can be dried out without deterioration.
• The material is non-combustible and used
primarily on hot piping and surfaces.

How Do I Choose?
Selection of an Insulation
MINERAL FIBER
Glass:
• Available as flexible blanket, rigid board,
pipe covering and other pre-molded
shapes.
• Service temperature range is 0°F to 850°F.
• Fibrous glass is neutral; however, the
binder may have a pH factor.
• The product is non-combustible and has
good sound absorption qualities.

Which insulation?
 Selection of an Insulation
MINERAL FIBER
Rock and Slag:
• Rock and slag fibers are bonded together
with a heat resistant binder to produce mineral
fiber or wool.
• Upper temperature limit can reach 1200°F.
• The same organic binder used in the production
of glass fiber products is also used in the
production of most mineral fiber products.
• Mineral fiber products are non-combustible and
have excellent fire properties.

Which insulation?
Selection of an Insulation
CELLULAR GLASS
• Available in board and block form capable
of being fabricated into pipe covering and
various shapes.
• Service temperature range is -450°F to
900°F in composite systems (requires a
coating).
• Good structural strength, poor impact
resistance. Material is non-combustible,
non-absorptive and resistant to many
chemicals.

Which insulation?
Selection of an Insulation
EXPANDED SILICA, OR PERLITE
• Insulation material composed of natural or
expanded perlite ore to form a cellular
structure.
• Temp range 125°F to 1200°F
• Material has a low shrinkage coefficient
and is corrosion resistant; non-
combustible.
• It is used in high and intermediate
temperature ranges. Available in pre-
formed sections and blocks.

Which insulation?
Selection of an Insulation

ELASTOMERIC FOAM
• Foamed resins combined with elastomers to
produce a flexible cellular material.
• Available in pre- formed sections or sheets,
Elastomeric insulation offer water and
moisture resistance.
• Temperature is -40°F to 220°F. Product is
resilient.
• Fire resistance should be taken in
consideration.

Which insulation?
Selection of an Insulation

FOAMED PLASTIC (PIR)

• Insulations produced from foaming plastic resins create
predominately closed cellular rigid materials.
• "K" values decline after initial use as the gas trapped within the
cellular structure is eventually replaced by air.
• Foamed plastics are light weight with excellent cutting
characteristics.
• Available in pre-formed shapes and boards, foamed plastics are
generally used in the lower intermediate and the entire low
temperature ranges. -40°F to 225°F
• Consideration should be made for fire retardancy of the material.

Which insulation?
Selection of an Insulation

REFRACTORY FIBER
• Refractory Fiber insulations are mineral or
ceramic fibers, including alumina and silica,
bonded with extremely high temperature
inorganic binders, or a mechanical
interlocking of fibers eliminates the need
for any binder.
• The material is manufactured in blanket or
rigid form. Thermal shock resistance is
high. Temperature limits reach 2300°F. The
material is non-combustible

Which insulation?
Selection of an Insulation
Aerogel Insulation
• Aerogel insulation blanket is formed of
silica aerogel and reinforced with a
non-woven, glass-fiber batting
• Aerogel insulation comes in 3 forms:
Pyrogel XTE for hot work, Cryogel Z
for cold work and Pyrogel XTF for
passive fire-protection
• The material is manufactured in blanket form.
Thermal shock resistance is high.
• High compressive strength and hydrophobic
• Temperature limits range from -400°F to 1200°F

Which insulation?
Performance of an Insulation
Temp. Mean
Type Form K Notes
Range Temp.
Rigid Pipe 125 to 1200F .35 100F High compression strength, water absorbent,
Covering non-combustible. High flexural strength.
Calcium
and Block Resistant to abrasion. No binder oxidization.
Silicate
Brittle not available in large bore. Heavy. Labour
intensive
Rigid Pipe 0 to 850F .24 100F Good workability, non-combustible, water
Mineral Fiber Covering, absorbent. Light weight. Low compression
Glass Block and resistance. Binder oxidization
Blanket
Rigid Pipe 0 to 1200F .24 100F Good workability, non-combustible.
Mineral Fiber Covering, Water repellent, Low compression resistance.
Rock Slag Block and Light weight. Binder oxidization
Blanket
Rigid Pipe -450 to 900F .35 100F Good strength, water and vapour resistant, non-
Covering combustible, labour intensive.
Cellular Glass and Block poor abrasion resistance. Subject to thermal
shock. Light weight

Which insulation?
Performance of an Insulation
Temp. Mean
Type Form K Notes
Range Temp.
Rigid Pipe 125- .5 200F High compression strength. Wide temperature
Covering and 1200F range. Non-combustible. Corrosion inhibitor.
Perlite
Block Poor abrasion resistance. Brittle. Labour
intensive
Flexible Pipe -40 to .28 90F Closed cell, finish not required, good
Elastomeric
Covering and 220F workability. May require UV protection. Flame
Foam
Sheets spread/smoke limited
Rigid Pipe -40 to .2 110F Lightweight, good workability. K Values
Foamed
Covering and 225F may change with age. Flame spread/smoke
Plastic
Sheet limited
Blanket 125 to .62 600 Good workability, non-combustible.
Refractory 2300F Water absorbent. Low compression resistance.
Fiber Light weight

Blanket -400 to .23 100F Good workability, non-combustible.

1200F Hydrophobic. High compression resistance.
Aerogel
Reusable

Which insulation?
Protective Coverings

The Big Finish:

Insulation Jacketing and Protective Coatings
Protective Coverings

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.

The Big Finish

Protective Coverings

Protective coverings are divided into six functional types:

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

The Big Finish

Protective Coverings

Weather Retarders
The basic function of the weather-barrier is to prevent the entry of
water, ice, snow or atmospheric residue into the insulation.

Vapour Retarders
Vapour retarders are designed to slow down the passage of moisture
vapour from one side of its surface to the other.

Mechanical Abuse Coverings

Rigid jacketing provides the strongest protection against mechanical
abuse from personnel, equipment, machinery, etc.

The Big Finish

Protective Coverings
Corrosion and Fire Resistant Coverings
The corrosive atmosphere must be determined and a compatible
material selected. Fire resistant materials are determined by flame
spread, smoke developed and combustibility.

Appearance Coverings and Finishes

Various coatings, finishing cements, fitting covers and jackets are
chosen primarily for their cosmetic value in exposed areas.

Hygienic Coverings
Coverings must present a smooth surface which resists fungal or
bacterial growth. High temperature steam or high pressure water wash
down conditions require jackets with high mechanical strength and
temperature ranges.

The Big Finish

Protective Coverings
Corrosion and Fire Resistant Coverings
The corrosive atmosphere must be determined and a compatible
material selected. Fire resistant materials are determined by flame
spread, smoke developed and combustibility.

Appearance Coverings and Finishes

Various coatings, finishing cements, fitting covers and jackets are
chosen primarily for their cosmetic value in exposed areas.

Hygienic Coverings
Coverings must present a smooth surface which resists fungal or
bacterial growth. High temperature steam or high pressure water wash
down conditions require jackets with high mechanical strength and
temperature ranges.

The Big Finish

Removable/Reusable Soft Insulation Covers

Sometimes conventional insulations prove time-consuming and

cumbersome to work around during periods of maintenance and repair.

Removable/Reusable Soft Insulation Covers provide a viable alternative

to the typical insulation application.

Fully customized covers for applications from piping and fittings to

turbines and exhaust systems to equipment and acoustics.

Removable/Reusable Soft Insulation Covers are your thermal insulation

and protective covering all in one easily install component.
Removable/Reusable Soft Insulation Covers
• Fast & easy installation (no trades
people necessary)
• Eliminates heat loss, reducing
energy costs
• Can be manufactured to handle
temperatures from 40°F to 1200°F
• Easy removal & replacement for
maintenance access
• Protects workers from burns
& chemical exposure
• Protects equipment & machinery
from harsh environmental exposure
• Work well in humid and wet
environments
“Clean, Efficient & Resilient Energy”

Questions?

Thank You