Mechanical Insulation for the Manufacturing Industry

Elizabeth Ruiz, Editor, Maintenance World

Posted 6/5/2024

Introduction

A recent study shows that using mechanical insulation on mechanical systems in your plant can result in huge energy savings (reducing cost) and helps reduce GHG and carbon emissions. See the charts below to see details on emission reduction and cost savings. (1)

Chart showing the magnitude of mechanical insulation’s savings.

Image courtesy Business & Industry Connection

The study aimed to determine how much energy could be saved and GHG emissions reduced by using insulation on systems operating at high temperatures. The results of the study were surprising due to the restricted scope of the study. It only examined some types of ready-to-use mechanical insulation used on popes and equipment operating between 150ºF and 800ºF. (1) Read more about the study.

So, what is mechanical insulation and how is it used? What are the best ways to use it in the manufacturing industry? Why should companies consider using insulation in their plants?

What is Mechanical Insulation and How is it Used?

We all know about building insulation within walls and roofs of buildings. It insulates equipment or processes. It is used on both hot and cold mechanical piping equipment, HVAV applications, and refrigeration/other low-temperature piping and equipment. It is also used for furnaces and boilers, storage tank, and loud equipment. It is used in many places, including manufacturing facilities, power plants, refineries, hospitals, schools, and government buildings. (2) (3)

Insulation is used to reduce heat or cooling loss, minimize expansion and contraction, lower noise levels, prevent burns or limit exposure to heat/cold, and prevent/suppress fires. The moisture control it provides can help with mold prevention. It can be used to maintain the temperature of a substance being held in pipes or equipment, preventing the use of more energy to reheat or cool it when it reaches its destination. It is used to protect workers from burns or hot surfaces as well. (3) (6) (2)

Insulation can be made from a number of different materials that are:

Cellular: e.g. expanded plastics and closed-cell foams; polyethylene, elastomeric “rubber”, polystyrene, polyisocyanurate
Fibrous: e.g. mineral wool or fiberglass
Flaked: e.g. processed minerals; vermiculite
Granular: e.g. perlite or calcium silicate
Reflective: e.g. silver-painted insulation panels

(2) (4)

Types of cellular materials:

cellular materials used to manufacture mechanical insulation — *Image courtesy Armacell*

Types of fibrous materials:

fibrous materials used to manufacture mechanical insulation — *Image courtesy Armacell*

Insulation products are made in different forms for different purposes. Rolls of woven or expanded material are used to wrap pipes or ducts in tight spaces. Panels and tiles are good to install around equipment. Sprayable expanding foam insulates inaccessible places. Loose or granular products are used to fill up irregular spaces. (2)

Best Ways to Use Insulation for the Manufacturing Industry

In the manufacturing or industrial sector, insulation should be applied to:

Hot Water Plumbing Lines
Circulating/Service Hot Water Lines
HVAC Systems-Liquid Lines (Chilled Water)
HVAC Systems-Air Ducts
Rain Water Leaders
Cold Process Piping
Hot Process Piping
Food Process Piping

(5)

Properly insulating the equipment and processes in your facility immediately reduces the carbon footprint and energy costs. Regular inspection and good reliability and maintenance of mechanical insulation is key to experiencing the potential benefits it can provide. (3) (2)

mechanical insulation on piping in boiler room

Benefits of Mechanical Insulation

Applying mechanical insulation to equipment and components prolongs equipment life. It protects equipment from rust and helps it run more efficiently. The reduction of moisture buildup mechanical insulation provides protects workers from mold exposure and other bacterial diseases. The reduction of energy usage immediately helps reduce operating costs. (6)

More overall benefits of installing insulation:

Condensation control
Water conservation
Freeze protection
Improved fire safety
Energy savings
Reduced overall energy costs
Emission reduction
Equipment and system performance
Extended equipment life
Better heating and cooling performance and efficiency
Worker protection
Acoustics; noise reduction

(3) (5)

Conclusion

Mechanical insulation is referred to some in the industry as the “forgotten technology” or the “best kept secret.” Why is it so often overlooked? Because it is hidden inside walls, it is easy to forget about insulation in favor of more visible technologies like electric vehicles or wind and solar power generation. (3) (2)

The recent study highlighted the substantial energy savings and reduction in greenhouse gas emissions achievable through the use of insulation on high-temperature systems in industrial plants. The results underscore the critical role of insulation in enhancing efficiency, lowering operational costs, promoting environmental sustainability, and increasing safety of personnel.

By properly insulating equipment and maintaining these systems, many types of organizations can significantly reduce their carbon footprint and energy expenses, while also benefiting from improved equipment performance and worker safety. The adoption of mechanical insulation is a practical, cost-effective measure that supports both economic and environmental objectives in the manufacturing industry.

Sources:

1) “Study Confirms Insulation Reduces Energy Usage, Emissions.” Jack Bittner, NIA President, Senior Product Manager, Johns Manville Industrial. June 3, 2024. Published by Business & Industry Connection Magazine.

3) “What is Mechanical Insulation & Why It Matters (Beginner’s Guide)” Multiservice Industrial online blog post. December 23, 2022.

4) “A Comparison of Mechanical Insulation Materials.” Armacell blog. January 12, 2022.

5) “Mechanical Insulation: Where and Why.” Armacell blog. January 19, 2022.

6) “Industrial/Commercial Mechanical Insulation.” LMCT Mechanical Insulators blog.

Cardinal Manufacturing, Helping to Bridge the Manufacturing Skills Gap

The manufacturing industry is a crucial contributor to the economy, accounting for over 11% of the total output in the United States. However, many manufacturing companies are currently facing a skills gap, with more open job positions than there are workers ready to fill them. A study conducted by Deloitte and the Manufacturing Institute predicts that 2.1 million manufacturing positions will go unfilled by 2030, potentially leading to a loss of $1 trillion in GDP for the United States.

South Carolina Ranked as the #1 State for Manufacturing

Manufacturing has been a key component to the South Carolina economy in the last 10 years and the state's efforts to improve infrastructure and educate a highly skilled workforce are paying off. The state has been making headlines lately for its attractiveness to corporations around the world.

The Decade of American Reshoring

The COVID-19 pandemic and recent world events have pushed manufacturing companies to shift their production to the United States in 2023, with 1,8000 companies in the US alone planning to reshore production to the states. While reshoring efforts are ramping up, manufacturers must be wary of the skills gap.

Lost Radioactive Capsule Proves Preventive Maintenance is as Important as Ever">

Lost Radioactive Capsule Proves Preventive Maintenance is as Important as Ever

Preventive Maintenance is as important as ever and this is extremely evident considering a radioactive capsule was lost in the vast landscape of Western Australia for nearly 2 weeks. Emergency services had been scanning the truck’s route for the last seven days and finally found the capsule on Wednesday, February 1st. A team driving down the road used radiation detection equipment to locate the capsule on the side of the road, outside of Newman.

HBD Condition Monitoring Devices at the center of Ohio Derailment

It appears the three rail workers on board the train took the appropriate measure when the sensor alerted them a bearing/axel was too hot. However, upon conducting further research it appears the system of HBDs in North America are largely ineffective.

Failure Analysis Uncovers the Cause of the Keystone Oil Spill

After nearly 2 months of investigations and a root cause analysis, TC Energy Corp revealed the cause of the oil spill was likely a combination of a welding flaw and bending stress fatigue which resulted in a crack forming and eventually lead to the rupture. The cause of the bending stress is still unclear and remains a focal point of the root cause failure analysis a third-party is conducting.

Ohio Foundry Explosion

On February 20th around 2pm an explosion erupted at the I. Schumann & Co. Foundry in Bedford, Ohio. The foundry recycles scrap metal into bronze and brass ingots and pellets. Fire officials say the cause of the explosion is under investigation by state and federal authorities but it appears the blast originated near a kettle-like piece of equipment which holds molten metals before being poured into molds.

Mechanical Insulation for the Manufacturing Industry