Clean, Efficient & Resilient Energy. A Study in Industrial Insulation

Transcription

1 Clean, Efficient & Resilient Energy A Study in Industrial Insulation

2 Clean, Efficient & Resilient Energy Topics: Function of an Insulation Selection of an Insulation Performance of an Insulation Protective Coverings Custom Soft Insulation Covers

3 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?

4 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?

5 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?

6 System Dependent Operating Temperature Vibration Physical Abuse Fire Protection Location/Space Weight Service/Maintenance Water Ingress How Do I Choose?

7 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?

8 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?

9 So Which Insulation?

10 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?

11 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?

12 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?

13 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?

14 MAJOR INSULATION MATERIALS

15 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?

16 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?

17 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?

18 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?

19 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; noncombustible. It is used in high and intermediate temperature ranges. Available in preformed sections and blocks. Which insulation?

20 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?

21 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?

22 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?

23 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?

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

25 Performance of an Insulation Type Form Temp. Range K Mean Temp. Notes Perlite Rigid Pipe Covering and Block F.5 200F High compression strength. Wide temperature range. Non-combustible. Corrosion inhibitor. Poor abrasion resistance. Brittle. Labour intensive Elastomeric Foam Flexible Pipe Covering and Sheets -40 to 220F.28 90F Closed cell, finish not required, good workability. May require UV protection. Flame spread/smoke limited Foamed Plastic Rigid Pipe Covering and Sheet -40 to 225F.2 110F Lightweight, good workability. K Values may change with age. Flame spread/smoke limited Refractory Fiber Blanket 125 to 2300F Good workability, non-combustible. Water absorbent. Low compression resistance. Light weight Aerogel Blanket -400 to 1200F F Good workability, non-combustible. Hydrophobic. High compression resistance. Reusable Which insulation?

26 Protective Coverings The Big Finish: Insulation Jacketing and Protective Coatings

27 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

28 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

29 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

30 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

31 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

32 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.

33 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

34 Clean, Efficient & Resilient Energy Questions? Thank You