Industrial insulation design often takes into consideration many factors, including carbon reduction, value, fire safety, resistance to corrosion and length of service. Another key factor to consider for insulation systems is the potential for damage – from weather conditions, caused by humans or machinery, or temperature and situational considerations.
In this blog we explore some of the most common types of damage, the issues that arise from damage, plus how to select the right industrial insulation for a project. All of these factors can collectively make a big difference in long-term performance and maintenance needs.
Moisture and Corrosion Under Insulation
Corrosion Under Insulation (CUI) is likely the first thing that comes to mind when thinking about industrial insulation damage. After all, it’s unfortunately a common occurrence, and one that can be very expensive to remedy.
CUI refers to the corrosion of piping, pressure vessels and structural components resulting from water being trapped between these substrates and layers of surrounding insulation. Even though insulation systems are designed to deter water ingress, and JM’s industrial products are water resistant or hydrophobic, impurities present in water that enters the system can chemically interact with metal piping and accelerate corrosion. Because CUI is difficult to detect, it can lead to catastrophic consequences such as explosions or fires.
Physical damage
There are various, common scenarios in which insulation systems can be physically damaged. Improper installation techniques can immediately damage insulation or metal jacketing. Examples including fish mouthing between the closure of a metal jacket or applying metal banding too tightly on the exterior of metal jacketing, causing immediate kinks in the metal jacket, impacting the insulation beneath. Maintenance workers walking on insulated pipes or leaning items like ladders against insulation can also cause damage. Damage often happens during the construction process because other trades who come after insulators may accidentally damage it while they are completing their portion of a project. Insulation can also be damaged by machinery like forklifts or tools hitting or being dropped on insulated pipes. Additionally, weather events such as floods, hurricanes or hail have the potential to damage insulation systems.
High or low temperatures and chemical exposure
High-temperature gases or liquids can damage insulation if the insulation isn’t properly rated for high-temperature conditions. The inability of the insulation to cope with these consistently high temperatures can cause cracks, excessive shrinkage, ruptures or thermal shock. Conversely, failure to use appropriately rated insulation for Liquid Natural Gas (LNG) or cryogenic applications can also cause cold-temperature issues. Moisture in an insulation system can freeze, expand and ultimately degrade the insulation.
Once damage has occurred
Damaged insulation can cause a myriad of issues. From reduced energy efficiency, burn injury risks, and loss of process control to increased maintenance costs and environmental impacts, damage to insulation is undesirable across the board.
Damaged insulation allows for accelerated heat gain or loss, which then leads to increased energy consumption, increased carbon emissions and higher energy costs. Damaged insulation can also disrupt processes that require precise temperature control.
And, of course, damaged insulation means an increase in maintenance needs and costs. Even necessary, planned downtime on process equipment to replace or repair damaged insulation can be significantly costly. If large sections of insulation need to be replaced, the material and labor costs can be quite high. These costs don’t take into account catastrophic failures that result when damaged insulation is left untreated. For example, if cryogenic pipes are not well enough insulated, they can develop ice buildup on the outside, sometimes several feet thick. Or if hot piping gets too hot, it can catch fire and potentially cause deadly explosions at locations like oil refineries.
Choosing and installing the right products
By making the proper selections for industrial insulation systems during the design phase of a project, many potential causes of damage to insulation can be avoided. The right insulation can make a difference between long-term performance or the need for replacement. Insulation materials must be properly engineered for the specific application and must be installed properly.
For example, to protect a system from CUI, there are several preventative methods to consider, including the use of products imbued with corrosion-inhibiting chemistry such as JM’s Thermo-1200® Calcium Silicate and Sproule WR-1200® Expanded Perlite which both contain our XOX Corrosion Inhibitor®. Another great Johns Manville product is our new Cross-Flo® metal jacketing, which helps moisture escape from an insulation system via the embossed pattern of the jacketing and the presence of weep holes at low points of the insulation system.
Considering process temperature ranges for a system is important in choosing the correct insulation. Things like compressive strength, ease of installation, material cost, acoustical performance and more can also factor into picking the right product.
Proper installation is also key. It is in the owner’s best long-term interest to have certified inspectors on any insulation project, especially large ones. The National Insulation Association (NIA) has a certified insulation inspector program that has certified more than 130 inspectors nationwide.
JM has several industrial insulation solutions, and our handy material selection matrix can help narrow down the best option for an application. You can also check out our product selection guide for industrial insulation and metal jacketing for more details, as well as our industrial insulation page.
