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Insulation Kits

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U.S. and Foreign Patents Pending

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Insulation Kits
Todays Presentation:

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Background on AMI What led AMI to the Insulation Kit Concept Preview of the Product and Benefits Energy & Environmental Savings Demonstration Project Data

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Insulation Kits
About Auburn Manufacturing (AMI):

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Founded in 1979 Developer, manufacturer & marketer of textile products Extreme temperature industrial applications
Welding protection Industrial insulation Safety apparel Gaskets and seals MROP and OEM applications

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Insulation Kits
About AMI Textiles:

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Extremely high heat resistant low thermal conductivity Aramid fibers, fiberglass, silica Coated fabrics for resistance to oil, moisture, heat

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Insulation Kits
AMI Industrial Insulation Products:

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Textiles & other components for the fabrication of custom-made removable/reusable insulation covers High temp applications
Petrochemical Paper Power generation

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Insulation Kits
AMI Industrial Insulation Products:

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Active member of the National Insulation Association Saw a need for innovation Looked for a new approach to insulation pads and covers Low temperature steam distribution systems prime candidate

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Insulation Kits
Steam distribution systems have many components

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Why Steam Distribution Systems?

Temperatures typically below 500F Lots of piping system components
Areas with high incidences of unintended heat loss, or gain

Generally not optimally designed for low temperature steam dist. systems
Custom-made covers are expensive Covers are designed for higher-temp industrial steam systems

Many times they do not get replaced

Too cumbersome
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Insulation Kits
These bare steam pipe components represent low hanging fruit for energy saving opportunities!

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Insulation Kits
Steam & Hot Water Distribution Systems

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New Concept
Use modularized insulation kits Insulate ALL of these difficult, convoluted surfaces, leaving no surfaces bare (except valve handles) Types of components:
Valves Valve bonnets & stems Flanges Pressure regulators Strainers
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Insulation Kits
What are modularized insulation kits?

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All-in-One Modularized Insulation Kits

Removable/reusable insulation blanket 4x8 blanket can typically insulate up to five 3 components Material is easily cut with utility knife Attachment and installation requires minimum tools

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Insulation Kits
Basic concepts of modularized insulation kits
Fast On-site fabrication!

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Basic Concept Standardized materials are brought to the job site (insulation sheets and rolls of hook and loop fastener) Modules provide a basis for cutting insulation sheets into required smaller size sheets or pieces Minimum tools (only tape measure, scissors, utility knife, and pliers stapler)
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Insulation Kits
Basic concepts of modularized insulation kits

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Basic Concept Stapler with hook and loop fasteners allow for flexibility of attachments On-site measuring, cutting & fabrication by the installers Surfaces of any shapes can be insulated

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Insulation Kits
Basic concepts of modularized insulation kits

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Basic Concept
Finished blankets can later be removed & reinstalled without use of tools Damaged or missing materials can be replaced by facility personnel

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Insulation Kits
Must meet temperature and performance requirements

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Requirements
Continuous exposure to 500F Coated fabric on both sides that is water and oil repellent Meets Flame Spread/Smoke Developed Index of 25/50 per ASTM E-84

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Insulation Kits
Must meet temperature and performance requirements

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Why these are effective

The first layer of insulation reduces heat loss by at least 85% Valves, pressure regulators, PRVs, strainers, etc. have very large surface areas (more than they appear) Covering these surfaces with only one layer of insulation Can significantly reduce heat load in room Reduce space air temperature Remove hot surfaces that pose burn potential
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CASE STUDIES
Institutional Settings
Conducted In 2009-2010
Colleges Universities
Bates College New York University MIT Harvard University of Maine

Government Building
Lewiston Armory

Hospital
Central Maine Medical Center

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CASE STUDY
Bates College
Situation:
230F Steam 1 Mech. Room 65 Components 97F Air Temp

Installation took several days Air temp dropped 17 48,500 Btu/hr heat load reduction $4000/yr in energy savings 20 tons/yr in CO2 reduction Payback < 1 year

Before

After
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CASE STUDY
Lewiston Armory
Situation:
Boiler Room 230F Steam 21 Bare Pipe Components

20,000 Btu/hr heat load reduction $1,363/yr in energy savings 7 tons/yr in CO2 reduction Payback < 1 year

Before

After
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CASE STUDY
Central Maine Medical Center
Situation:
Centralized steam 230F Bare components in mechanical room that was mechanically cooled.

10 components insulated 33,390 Btu/hr heat load reduction $3900/yr in energy savings 23 tons/yr in CO2 reduction Payback < 1 year

Before

After
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CASE STUDY
New York University
Situation:
Purchase Steam 430F Insulation contractor concerned about high room temp in mechanical room

12 butterfly valves insulated Installation Time: 15 minutes/valve 110,000 Btu/hr head load reduction $13,000/yr in energy savings 75 tons/yr in CO2 reduction Payback < 6 months

Before

After
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CASE STUDY Massachusetts Institute of Technology

Situation:
Central steam 430F 3 Mech. rooms High room temps

Insulation contractor performed work 74 components 2 insulators 2 days Less than man-hour per component $21,000/yr in energy savings 122 tons/yr in CO2 reduction Payback < 6 months Safe room temperature

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After

CASE STUDY
Massachusetts Institute of Technology
Situation:
Conventional Removables & Modular Insulation Kits

CASE STUDY
Harvard University
Situation:
Bare gate valves bonnets & stems High temps in steam tunnels Insulation needed to be easy to remove/reinstall

Insulated gate valve bonnets and stems 51,000 Btu/hr in heat load reduction $6,000/yr in energy savings 35 tons/yr in CO2 reduction Payback < 3.6 months

Before

After

CASE STUDY
University of Maine
Situation:
Boiler Replacement Project 180F water 27 components Valves/Fittings left bare

Operates only 8 months/yr Previously left valves/fittings bare too hard to insulate and maintain 20 minutes per fitting to install $2,280/yr in energy savings 7.3 tons/yr in CO2 reduction

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SUMMARY OF DEMONSTRATION PROJECTS

Energy Savings Short Payback

$51,300 value of energy saved Payback averaged 8 months 307 tons/yr reduction greenhouse gasses
Equivalent to 2700 barrels of oil saved Equivalent to 115,000 gallons of fuel oil saved

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SUMMARY OF DEMONSTRATION PROJECTS

Save Energy
Reduce Emissions Reduce Room Temp Improve Safety

Case studies demonstrate ease and speed of on-site fitting, cutting, fabrication & installation Bare components = opportunities for
Energy savings Reduced CO2 emissions Room air temp reduction Improved safety

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WANT TO KNOW HOW BIG THE NEED IS?

Institutional Market
Untapped Opportunity Opportunity knocks at this door 3,000 Hospitals 4,000 Colleges/Universities 88,000 Municipalities Federal & State Facilities
Military Bases Veterans Hospitals Correctional Facilities Schools Knock, knock, knock..

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INSULATING BARE PIPING COMPONENTS

Indoor Steam And Hot Water Distribution Systems
Thank you. Got Questions? Got Projects?

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