New Mechanical Insulation Measures and Reports Temperatures and Savings

Smart Jacket from Thermaxx Jackets & EET Adds Digital Insight to Industry

April 16, 2013 – West Haven, CT – Most industrial insulation is a single-function device. It keeps steam components hot or refrigeration units cold and provides little insight about the process. Smart Jackets change that by reporting insightful data.

The new digital insulation cover monitors temperatures, evaluates health status and notifies upon deviation from the norm. The automated insulation product is the result of collaboration between sensor specialist Embedded Energy Technology and insulation fabricator Thermaxx Jackets.

Large scale steam distribution and heating systems represent over 10 percent of our nation’s annual energy consumption, and nearly all of them suffer from radiant heat loss and steam leakage. Each facility can recover tens of thousands of dollars annually by installing removable Smart Jackets to prevent heat loss and quickly detect failing components.

Smart Jackets record internal and ambient room temperatures with a wireless sensor. Every data point is reported to an online dashboard, allowing plant technicians to monitor efficiency from anywhere. But who wants to constantly watch a temperature gauge? Custom email and text message alerts can be set to notify maintenance staff in the event of fluctuation or critical levels. By the time steam system failures are typically visible, thousands of dollars can be lost. Smart Jackets catch potential failures before they become costly problems, increasing responsiveness and decreasing energy consumption. The Utility Distribution Superintendent at the University of Georgia, Robert White, expressed his enthusiasm for Smart Jackets.

“We have been waiting for this technology for a while,” White said. “We currently have more than 170 buried steam vaults, some of which require road or lane closures to access. Being able to open my computer and see the real time temperatures gives me total piece of mind. We have previously tested other standalone monitoring systems that were more difficult to install and service and also did not provide the added insulation benefit we get from the Smart Jackets. Thermaxx Smart Jackets are now in 80% of our steam pits and will be in the remainder as soon as funding allows.”

About Thermaxx:
Thermaxx LLC is located in West Haven, CT and provides removable insulation covers for steam components. Staff engineers and designers with cross-disciplinary experience can tailor custom solutions to almost any insulation challenge.

About Embedded Energy Technology:
Embedded Energy Technology (EET) specializes in harnessing technology such as non-invasive sensors, wireless, and remote monitoring, to help industrial facilities realize energy savings.  EET provides Smart Jacket electronics and support exclusively to Thermaxx Jackets. You can visit the website at eetinside.com.

To learn more about Thermaxx Jackets’ Smart Jackets, contact Brian Bannon at (203) 931-2122 or bbannon@thermaxxjackets.com. You can also visit the website at http://www.thermaxxjackets.com.

Brian Bannon
Thermaxx Jackets
(203) 931-2122

Project Background
Duke University is home of the Blue Devils, boasting a population of 13,000 undergraduate and graduate students and world-class faculty. Duke has an unyielding commitment to spreading and applying knowledge in service of society, both near the North Carolina-based campus and beyond. In 2009, Duke launched its Climate Action Plan which has enabled the university to reduce emissions by 16% as of 2012.

In November of 2012, Duke University enlisted the services of Thermaxx LLC to improve energy efficiency by providing removable insulation jackets and removable insulation covers in its Levine Science Research Center mechanical room.

The mechanical room was mostly well-insulated, with the notable exception that of most of the steam components that require routine inspection. As it stood, Duke’s use of inferior insulating pads and not insulating some of these steam components at all resulted in greater energy consumption. With concern for both energy efficiency and ambient temperature, which started at 110 degrees Fahrenheit, Thermaxx and Duke determined all components in need of insulation jackets, including pressure-reducing valves, flanges, control valves, pneumatic metering valves, and wye strainers. Thermaxx manufactured removable, replaceable insulation jackets tailored to each component. In addition, Thermaxx fabricated sound attenuation insulation jackets to insulate and silence the pressure reducing valves.

Spirax pressure reducing valve in Duke mechanical room prior to insulation.

Pressure reducing valve with Thermaxx Jacket

 
Project Impact
Duke’s staff had positive comments in regards to the design and fit of the insulation jackets. Additionally, various concern areas were improved:

• Safety: The project improved safety by properly insulating steam components. The ambient temperature in the mechanical room was also reduced from 110 to 75 degrees, making the environment more comfortable.
• Energy: Duke University realized a 967.75 reduction in therms, or 96,775,000 BTUs, which is expected to hold true in future years.
• Costs: Cost reduction from energy reduction will be nearly $1,500.00. The payback period (time required for Duke to recover net costs of the project) on energy reduction savings alone is approximately 22 months.

For more information on this project, please contact:

Bill Tyree
Regional Sales Manager
Thermaxx LLC
16 Hamilton Street
West Haven CT 06516
203 932 9639
Email: btyree@thermaxxjackets.com

For steam-using plants and facilities, calculating steam costs, like calculating steam pipe heat loss, is an important step towards revealing energy and cost savings opportunities.

Loaded vs. Unloaded Cost of Steam

The cost of steam production throughout the course of various projects is twofold: loaded and unloaded cost.  The unloaded cost takes into account only the cost of fuel necessary to produce steam with consideration towards total steam used.  Loaded cost, however, combines each and every cost associated with steam production.

Rough Estimated Steam Costs

The below formula has been used by some[i] as a rough estimate of total steam cost:
Total Steam Cost ($/MMBtu) = Fuel Cost ($/MMBtu) x 130%

Calculating Unloaded Steam Costs

For boilers, we’ve found this boiler steam cost calculator (Internet Explorer compatible only).

Alternatively, unloaded steam costs are calculated in the manner specified below:

SC = (a_{F *} (H_g ^_ h_f) ) / (1,000 • ηB)[ii]

Where:
SC  = steam cost, unloaded
aF  = fuel cost in $/Million Metric British Thermal Units (MMBtu)
Hg  = enthalpy of steam, in Btu/lb.
hf  = enthalpy of boiler feedwater in Btu/lb.
ηB = true boiler efficiency (per ASME PTC 4.1 method)
1,000 = cost measured in units of 1,000 lbs. per hour

In this simplified calculation method, the formula assumes that one boiler is being used, one fuel and a single steam pressure.

True Boiler Efficiency (ηB)

The ηB figure representing boiler efficiency comprises these aspects, along with their subcategories:

• fuel moisture content
• combustion air temperature
• radiation losses
• flue gas losses
• blowdown losses

Given that one boiler is used here, only one boiler efficiency is taken into account.

Calculating the Enthalpy of boiler feedwater (hf)

Condensate Return may be incorporated into the calculation in conjunction with feedwater to present a clearer idea of cost, as the amount of condensate returned greatly impacts steam cost.

hf = % (GR) + %(LP) + %(MP) + %(HP) + %(MW)

Several Condensate Return Systems are used, and are categorized thusly:

1. GR: Gravity or atmospheric — condensate returned at or close to 0 psig
2. LP: Low pressure — condensate returned from 1 to 15 psig
3. MP: Medium pressure — condensate returned from 16 to 99 psig
4. HP: High pressure — condensate returned at 100+ psig
5. MW: Make-up water — water added to steam to compensate for condensate which is not returned to boiler

Necessary to adjusting the Unloaded Cost calculation is to also change the enthalpy of boiler feedwater.  Calculate it in the following manner, using whichever condensate information applies in your case.  If only a few of the above systems are used, leave the other percentages at 0.

Apply this new information to the original formula of SC = (a_{F *} (H_g ^_ h_f) ) / 1,000 • ηB to achieve the Unloaded Steam Cost (SC).

Calculating Loaded Steam Costs

As indicated, Loaded Cost of Steam incorporates additional several factors.  The following costs make up the total:

• Unloaded Cost of Steam
• Electrical power
• Chemical
• Water and sewer
• Emission payments
• Labor (management, operations, and maintenance)
• Waste disposal
• Maintenance
• New projects

The Loaded Cost, or true cost of steam, is the sum of the above items.  The cost may at times be one and a half to two times the cost as compared to the Unloaded Cost. 

Steam System Definitions

Million Metric British Thermal Units (MMBtu): A Btu is how much heat is required to raise the temperature of 1 pound of liquid water by 1 °F.  MMBtu’s measure one million BTUs.

Enthalpy: The total heat content of a system. Internal energy + Pressure x Volume.

Fuel Moisture Content: Amount of moisture (water) in a fuel, which affects how readily it will burn.  Usually shown as a percentage of the oven-dry weight of fuel.

Radiation Losses: A number that describes the amount of heat lost from a boiler to the air through conduction, radiation and convection.

Flue Gas Losses: This gas is produced when combustion occurs in the flue.  It is lost, however, due to: high gas temperature, unfinished combustion, lack of air supply, moisture or a high rate of combustion.

Blowdown Losses: When water is removed from a boiler, it is called the “blowdown.”  Blowdown is removed to maintain the levels of suspended and dissolved solids and to remove sludge.  This is typically shown as a percentage.

Feedwater:  Water added to a boiler while it’s in use. This combines both make-up and return condensate.

Make-up Water: Water added to a boiler feed to “make up” for water lost due to blowdown, leaks, etc.

Return Condensate: When steam transfers heat, it turns into a liquid called condensate. Condensate returned to the boiler can save energy by requiring less make-up water.

Steam Cost Resources

[i] http://www.erc.uic.edu/iof/docs/Steam/IL_IOF_Steam_Presentation.ppt
[ii] http://www.swagelok.com/Chicago/Services/Energy-Services/~/media/Distributor%20Media/C-G/Chicago/Services/ES%20-%20Knowing%20Cost%20of%20Steam_BP_31.ashx
http://www.energystar.gov/ia/business/industry/bnch_cost.pdf
http://www1.eere.energy.gov/manufacturing/tech_deployment/pdfs/tech_brief_true_cost.pdf

credit: nyc.gov

On December 28, 2009, New York City enacted a new law requiring energy audits and retro-commissioning of many buildings — local law 87. Local law 87 requires many large buildings to “undergo an energy audit every ten years, along with retro-commissioning, to “tune up” the building’s existing systems and ensure efficient operation.”

LL 87 Compliance Summary

Large buildings that are not already LEED-certified, Energy-Star approved, or meet other exception criteria, must take three steps to comply.

1. Energy Audit
Building owners must undertake energy audits to identify energy savings opportunities. The audit covers all base building systems such as HVAC and electrical and must “identify reasonable measures and capital improvements that would result in energy use or cost reductions, the associated savings, cost of implementation, and simple payback period.” The audit must be at least a SHRAE Level 2 Energy Audit and must be performed or supervised by an approved and properly certified energy auditor.

 2. Retro-commissioning
Building owners must also undertake retro-commissioning to correct deficiencies identified in the energy audit. Retro-commissioning must ensure that the building systems meet the criteria identified in section 28-308.3 of local law 87. The criteria include, but are not limited to:

• HVAC calibration and sequencing of hot water and lighting settings
• Cleaning and repair of pipes, HVAC equipment, boiler room components
• Training of maintenance staff and documentation of  manuals and permits for HVAC, electrical, and plumbing equipment

The retro-commissioning team must include certain approved and properly certified professionals.

3. Energy Efficiency Report
To complete compliance, the building owner must file an energy efficiency report documenting the energy audit and retro-commission. The due date depends on the last digit of the tax block number; the first emergency efficiency reports (for tax blocks ending in ‘3’) are due in 2013.

Where Insulation Jackets Fit In

Criteria 2.8
Criterion 2.8 in section 28-308.3 of LL87 specifically requires insulation for certain components. Criteria 2.8 states, “Exposed hot and chilled water and steam pipes three (3) inches or greater in diameter with associated control valves are insulated in accordance with the standards of the New York city energy conservation code as in effect for new systems installed on or after July 1, 2010.”

Stay-in-place pipe insulation and pipe wraps may meet the requirements for some simple pipes. However, removable insulation jackets can be the superior choice for pipes and components that require regular maintenance. In addition, many valves and components of highly irregular shape cannot be insulated practically with stay-in-place insulation. Thermaxx provides hot pipe insulation jackets, chilled pipe insulation jackets, and a large variety of valve insulation jackets that can be produced to the exact requirements of those undertaking retro-commissioning efforts for LL87 compliance.

Steam Traps
Criterion 2.5 in section 28-308.3 of LL87 requires that, “Steam traps have been replaced as required to maintain efficient operation, if applicable.” We’ve written previously about the importance of properly monitoring steam traps in manufacturing plants. Large buildings reliant on steam heating also stand to benefit greatly from paying attention to steam traps and it seems as though NYC has recognized this in LL87.

–Local Law 87 is a significant piece of legislation to help New York City realize its Greener, Greater Buildings Plan, an aggressive sustainability program targeting the existing large city buildings projected to “reduce greenhouse gas emissions by almost 5 percent, have a net savings of $7 billion, and create roughly 17,800 construction-related jobs over 10 years.”

New 3-D Scanner Takes Perfect Measurements for Insulation Jackets

October 23, 2012 – West Haven, CT – Thermaxx Jackets introduces 3-D scanning to the removable insulation design process, replacing the industry standard of manual measurements that can be cumbersome, incomplete and error-prone.

Tailormaxx Scanner records millions of measurements in only seconds.

Imagine insulating the component pictured above. Any error or forgotten measurement could result in the scrapping or reworking of one or more interlocking insulation components at the expense of thousands of dollars and weeks of lost time. It is also common for complex jackets to be installed during a scheduled annual shutdown, which might only last a few days. If the jacket does not fit, there will be no time for a second try. No pressure, right? That is the reality for most removable insulation manufacturers, who measure each pipe, valve and component by hand.

Thermaxx is proud to advance the removable insulation industry with the new Tailormaxx Scanner. The Tailormaxx is a 3-D scanner that records coordinates for everything in its path, resulting in a completely measurable 3-D computer model. Each scan contains millions of measurements, and can be accessed throughout the manufacturing process to ensure an accurate fit. Thermaxx managers, now nicknamed tailors, can carry the scanner into the field so every client benefits from the new technology.

“The rule our field technicians lived by was to measure three times and cut once,” says Brian Bannon, founder and CEO of Thermaxx. “To my disbelief, we would sometimes measure three times, cut once, re-measure five times, cut twice, and the jacket still would not fit. I quickly learned that the problem was not the carpenter, but the tools in the tool bag. A tape measure, note pad and camera were just not getting the job done. For 18 months, Thermaxx engineers worked tirelessly to create a devise that was accurate, rugged and affordable. The Tailormaxx was born.”

The Tailormaxx Scanner relies on a non-contact emission that triangulates distances between everything within its field of view. That information is relayed back to the computer where a database records a complex series of measurements. Tailors still measure by hand, giving Thermaxx engineers two points of reference. Any discrepancies are examined more closely. That means that by the time the first cut is made, every dimension has been verified two or three times, eliminating the potential for error.

Without Thermaxx’s 3-D scanner, inaccurate removable insulation measurements were a challenge. The Tailormaxx Scanner changed that when it passed initial field trials and several client projects with 100% accuracy. Thermaxx sales managers, tailors and engineers are all available to comment on how 3-D imaging is revolutionizing their field and the way that industrial problems are solved.

Thermaxx LLC is located in West Haven, CT and provides removable insulation covers for steam components. Staff engineers and designers with cross-disciplinary experience can tailor custom solutions to almost any related challenge.

To learn more about Thermaxx Jackets, please contact Brian Bannon at (203) 931-2122 or bbannon@thermaxxjackets.com. You can also visit the website at http://www.thermaxxjackets.com/

All employers have the duty to exercise diligence in creating a work environment that is safe and healthy.  The Occupational Safety & Health Administration (OSHA) helps employers meet this duty by setting forth regulations and standards designed to improve safety and well-being at work.

We have scoured the lengthy list of OSHA regulations to find those that relate to insulation covers. Below are 5 ways that insulation covers may improve compliance with OSHA regulations.

1.     Hot Pipe Coverage

OSHA does not actually have a specific regulation in its general industry standards (regulations which pertain to all workplaces subject to OSHA regulations) that specifically regulates when hot pipes need to be covered. However, OSHA has stated (see this letter of interpretation) that “OSHA does consider exposed heated surfaces, if there is a potential for injury, to be a hazard and will issue citations if employees can come into contact with such surfaces.”  

In that interpretation, OSHA also referenced two standards, applicable to special industries: textiles and pulp, paper, and paperboard mills.

1910.262(c)(9) governs the textile industry and states “Steam pipes. All pipes carrying steam or hot water for process or servicing machinery, when exposed to contact and located within seven feet of the floor or working platform shall be covered with a heat-insulating material, or otherwise properly guarded.”

1910.261(k)(11) governs pulp, paper, and paperboard mills and states, “Steam and hot-water pipes. All exposed steam and hot-water pipes within 7 feet of the floor or working platform or within 15 inches measured horizontally from stairways, ramps, or fixed ladders shall be covered with an insulating material, or guarded in such manner as to prevent contact.”

A third regulation specifically requiring insulation for hot pipes is 1910.265(f)(5), which applies to the sawmill industry, and states, “Steam mains. All high-pressure steam mains located in or adjacent to an operating pit shall be covered with heat-insulating material.”

2.     Wet Floors from Condensation

OSHA standards require that floors be kept dry in most workplaces. Standard 1910.22(a)(2), which is part of OSHA’s general requirements, states, “The floor of every workroom shall be maintained in a clean and, so far as possible, a dry condition. Where wet processes are used, drainage shall be maintained, and false floors, platforms, mats, or other dry standing places should be provided where practicable.”

A common cause of wet floors is condensation that drips from pipes and components. For example, when there is a difference between cold water pipe temperature and air temperature, condensation forms and may drip on the floor. Insulation jackets for cold pipes and components eliminates condensation to keep things dry.

3.     Reducing Occupational Noise

OSHA Standard Number 1910.95 pertains to most workplaces and has a number of rules pertaining to high workplace noise levels. When noise exposure exceeds certain levels, employers are required to provide protective equipment and possibly administer a hearing conservation program.

Whenever feasible, OSHA recommends reducing noise at the source, and this is the practical first thing to investigate in regards to addressing workplace noise. When noise originates from equipment — such as compressors or motors, for example — it may be possible to reduce noise with removable acoustic insulation.

4.     Replacing Potentially Harmful Insulation

Two insulation materials that are subject to OSHA regulations are asbestos and synthetic mineral fibers.

Asbestos
It is widely known that OSHA limits exposure to asbestos. Standard number 1910.1001 covers most OSHA rules regarding asbestos. Two areas that OSHA says may often have asbestos are “pipe and boiler insulation materials.” If your facility contains component insulation made of asbestos-containing materials, it may be necessary to replace the insulation with a safe insulation cover.

Synthetic Mineral Fibers
Two common synthetic mineral fibers used as insulation materials are fiberglass and mineral wool fiber (like rockwool). Both are considered by OSHA to be inert or nuisance dusts, and are subject to permissible exposure limits. See http://www.osha.gov/SLTC/syntheticmineralfibers/index.html for more information.

Worker exposure to synthetic mineral fibers may be increased if workers must make insulation from raw materials; one solution to this is to purchase complete insulation covers when possible. Workers may also be exposed to synthetic mineral fibers if insulation is left uncovered; insulation jackets may resolve this issue.

 5.     Reducing Confined Space Entry

Closely confined spaces can be very dangerous, and are therefore heavily subject to many OSHA regulations, most of which can be found here. It is generally wise for employers to reduce the need to enter confined spaces —confined spaces can be dangerous and ensuring safety (especially in permit-confined spaces) can be quite costly and time-consuming.

Often, confined space entry is required to access steam traps and valves in steam systems in order to perform regular manual inspection of valves and components. However, manual inspection can often be limited by augmenting manual inspection with temperature sensors. In some applications, insulation covers with built-in temperature sensors can be used to kill two birds with one stone.

Let’s examine the three biggest reasons an insulation jacket might not fit.

3.  Poor Design

A tailor could meticulously measure a groom for a tuxedo, and produce a jacket accurate in every dimension that still looks ridiculous if the buttons are 6 inches off the mark. Likewise, an insulation jacket with poorly designed closures will not fit right. Another design aspect critical to fit is making the proper allowance for the internal material in design of the exterior jacketing. The design of seams also affects jacketing fit. An insulation fabricator’s design capabilities will have a major impact on fit.

2.  Imprecise production

Precision is a given in mass manufacturing. Six sigma and total quality management principals have become so entrenched in modern operational practices that deviation from production specs is very rare in the mass production of goods. However, perfectly precise adherence to design specifications is simply less frequent in custom manufacturing. Without large runs, there is less ability to rely on process automation, statistical process control, and experience curves. Thus, the perfect fit of custom insulation products is often compromised during production. Excellent operational practices are required for custom insulation manufacturers to overcome these issues.

1.     Inaccurate Measurements

Failure to take perfectly precise measurements of the components to be insulated is the leading cause of poorly fitting jackets. Measuring components for insulation can get complicated and invites a multitude of issues.

First, the technician must measure the right things. Not every curve and bolt may need measured (this could be unfeasibly time-consuming), but every facet that will determine jacket dimensions and seam placement does need measured. This generally requires a technician with an understanding of jacketing design. If the technician fails to measure a needed dimension, re-measurement can be time-consuming and cost-prohibitive. However, most technicians are under some pressure to ensure a speedy measurement process.

In addition, the human eye is only so precise. Human measurement generally involves some level of estimation and rounding to the nearest unit of measurement.

Measuring hot components can be challenging. The technician may need to avoid direct contact or use cumbersome protective gear. Alternatively, the technician could shut off equipment, but this often inconvenient and sometimes costly. These challenges increase the likelihood of human error.

Indeed, most shortcomings for measuring components for mechanical insulation are due to human error.

Technology is being developed to help solve this dilemma. 3-D scanning technology eliminates the need for human measurements. Thermaxx Jackets has recently developed the use of advanced portable scanning technology that measures every facet and aspect of components down to extremely small units of measurement. TailorMaxx Scanning technology enables us to spend more time designing the perfect jacket to fit measurements that are always accurate. The result? A more perfect fitting insulation jacket.

TailorMaxx Scanner 3D Rendering

Manholes and pits are usually strategically placed to allow for access to buried vaults. These vaults, or concrete structures, vary in size but are normally 10’ x 10’. This is where the shut off and maintenance valves are located. These shut off valves give the utility staff the ability to shut off the steam to facilitate replacement or maintenance operations in the buildings.

Steam vault with insulation jackets

Steam Vault Insulation Issues

When insulating components within the steam vault, three special issues must be considered: moisture, heat, and location.

Moisture: Most vaults are damp due to rain water runoff or ground water. Moisture and insulation are normally not used in the same sentence; thus, specifying the correct insulation is very important.

Heat: The ambient temperature in a vault is directly related to the steam pressure and existing pipe-component insulation in place. Ambient temperatures greater than 150°F are not uncommon. Steam vaults often suffer from “Out of sight: out of mind” syndrome.

Location: Steam tunnel access is usually located at intersections or on sidewalks. Costly confined space entry and traffic control usually makes vault entry a process that should be limited as much as is possible.

How do I specify the right Removable Jacketing Material?

You must keep the above mentioned conditions in mind when picking the proper jacketing material. First, understand the steam pressure. Knowing the maximum pressure and temperature will determine the thickness of the insulation. Most projects are designed by picking an appropriate touch temperature. This is the temperature of the outside of the insulation cover. Second, look at potential water. If the vault or pit is subject to moisture, choose a hydrophobic insulation material. In addition to hydrophobic insulation, jackets should have a 1/8” grommet on the low point of the jacket for drainage. In the event of water filling the jacket, the grommet will allow the water to evacuate and the steam will help dry. Third, understand the age of the system. If the system is older, you may want to choose a Teflon product for the hot-side of the jacket to help protect the jacket against periodic steam leaks.

Example: What is the perfect insulation jacket for a 325°F steam gate valve, located in a potentially wet vault?

Hot-Side of Jacket: Teflon coated fiberglass

Insulation: 10 to 15mm Pyrogel Insulation. It is very important that the insulation be sewn into the jacketing material allowing it to be an integral part of the jacket. This will allow the insulation to stay in place during the wetting and drying process.

Cold-Side of Jacket: Silicone coated fiberglass

Thread: Teflon

A quality-made insulation jacket constructed of these materials will keep things dry and keep heat where it belongs — in the steam system.

It’s difficult to make the decision between purchasing hot or cold removable insulation materials without truly knowing both sides of the story. Both forms of insulation materials are going to save you money in the end, but it is vital to determine which is the most practical and cost effective for your piping system.

There are questions that need to be asked when choosing insulation. At the top of this decision tree is the most important: is the equipment or piping that we are insulating hot or cold? Once this question is answered the next question is: interior or exterior? The answer to these two questions will jump start the decision process when choosing an insulation

Hot Insulation Materials

Removable insulation is specifically designed to insulate piping systems transporting gas and substances at high temperatures. The materials used to construct the insulation work to prevent your pipes from overheating, while keeping the warmth inside the pipe. This helps to cut down on energy bills for your facility, saving you money in the long run.

So, what materials are used during circumstances that require hot insulation? Well, that depends on the intended purpose of the pipe being insulated. There is a laundry list of materials to choose from all with different purposes. Below are 3 common materials:

The most important part about picking a hot insulation material is understanding the maximum temperature the insulation will be covering. Components less than 350°F can be covered with off the shelf pre-molded fiberglass. When components are near or above temperatures of 1000°F, silica or ceramic insulation is usually required. It is very important to adhere to manufactures suggestions when picking and installing insulation for hot components.

Cold Insulation Materials

Just like hot insulation materials, some of the materials used to produce cold insulation vary dependent upon the system of pipes they are insulating. Therefore, the materials used in either hot or cold insulation are dependent on the customization of the particular piping system. Two common materials used in cold insulation are:

With chilled insulation, keeping the cold in is as important as keeping the heat out. There are many types of insulation used on chilled water pipes. The two most popular are foam glass and rubber insulation or Armaflex. Although a little more difficult to work with than pre molded fiberglass, when installed correctly, these materials do a great job of stopping condensation and preventing energy loss.

What Is the Difference?

The difference between hot and cold insulation materials comes down to a few things. Firstly, the materials used in hot insulation covers doesn’t require a water vapor barrier that a cold insulation system needs to properly function. The water vapor barrier helps prevent metal degradation that can occur overtime.

Buildups of condensation occur within cold systems, which require bendable or flexible insulation to deal with this issue. Therefore, the types of metal, fiberglass, foam and other materials used for thermal bridging in cold insulation are much more flexible and moldable than those found in hot insulation materials.

Lastly, closed cell structure is needed in cold insulation to help avoid wicking. The material in high temperature insulations allows water to enter because the heat will cause the moisture to evaporate. However, in a cold insulation system the water will not evaporate. Closed cell structure of the cold insulation material helps prevent this problem.

Wrapping Up

Once the insulation has been chosen, an exterior jacketing must be picked. When the insulation is installed properly and to manufactures suggestions, the covering is usually chosen for the environment it will be exposed to rather than the hot or cold type it is insulating. For interior components, that will not be walked on or subjected to frequent damage, PVC or silicone is normally used. For pipes that may be subjected to frequent damage, metal or thicker PVC can be used.

If you are considering insulating your steam system, remember to never insulate the diaphragm chamber of the pressure reducing valve. Indeed, the diaphragm chamber of any pressure regulator should never get insulated.

About PRVs in Steam Systems

A pressure regulator is a type of valve whose primary mission is to adjust the pressure of a medium (like steam) to meet the need of particular application, regardless of fluctuations in pressure of the substance that flows in the valve.

In a steam-using plant, steam is often generated at high pressures and reduced locally to provide heat for each steam user. The typical component used to accomplish this is a pressure reducing valve (PRV), which is, to be specific, a type of pressure regulator — though these terms are often used interchangeably. To maintain the proper outgoing system pressure, the prv must be able to respond to changes in pressure of incoming flow: if load pressure increases by 50 psi, the valve must reduce the pressure by an additional 50 psi.

The Role of the Diaphragm in PRVs

While some pressure regulators may use only a spring as the loading element, most pressure regulators — especially steam system prvs — utilize a diaphragm or comibination diaphragm/spring. The diaphragm is a flexible membrane that responds to changes in pressure and restricts/seals flow appropriately. The diaphragm chamber is often housed underneath the valve, but can be located in different areas and positions.

Why You Don’t Insulate the Diaphragm Chamber of the PRV

In a steam system, the area below the diaphragm becomes filled with condensate as the steam in that area condenses.  If the diaphragm is insulated, the temperature at the diaphragm area increases, because the insulation traps heat in that area. If the temperature increases, the pressure is artificially adjusted, and the valve may not operate as it should. If insulated, there is a chance that the condensate under the diaphragm reaches a temperature that will cause flash steam. The flash steam now requires more space than is available and will cause erratic operation of the valve at the very least, and can even rupture the diaphragm.

What is Flash Steam?
We’re glad you asked. When water has more energy than can exist as liquid at a given temperature, the water “flashes off” as a burst of steam. This can be particularly dangerous because steam occupies much more space than water. Water at 15 psig (pounds/square inch) has a specific volume of 0.017004 Cubic feet/lb.; steam at 15 psig has a specific volume of 13.75 Cubic feet/lb. The steam occupies 808.63 times the space as the water.

When the liquid flashes to steam it is like a mini explosion — the steam expands in a small, liquid filled space causing the diaphragm to flex, if the diaphragm cannot flex enough to accommodate the flash steams requirement for “space”, it will rupture.

PRV insulation can help save your facility a good bit of money; making sure you do not insulate the diaphragm will save you a lot of trouble.