In the vast and intricate world of industrial facilities, the significance of maintaining the temperature of liquids flowing through pipes is paramount. Pipe insulation serves as a protective cloak that helps to ensure optimal temperature regulation and energy efficiency. Understanding the different types of pipe insulation is crucial to selecting the right one for specific applications.
Goto Huichen to know more.
Pipe insulation materials are as varied as they are essential. Here, we uncover the diverse types available, each serving a unique purpose in the industrial landscape.
Recognized for its remarkable flexibility and lightweight structure, polyethylene is extensively utilized in cooling applications and widely favored in both residential and commercial sectors.
Also known as PIR, polyisocyanurate is an advanced form of polyurethane foam insulation. It excels in high-temperature applications due to its excellent fire resistance and thermal efficiency. With the ability to withstand continuous exposure to temperatures up to 300 degrees Fahrenheit without rapid degradation, PIR insulation is a reliable choice for demanding industrial purposes.
Polystyrene is a popular material known for its exceptional insulation properties. It is widely used in low-temperature applications to provide consistent and reliable thermal insulation.
Polyurethane insulation is highly esteemed for its exceptional insulating properties and impressive durability. It retains its shape and insulation effectiveness across a wide range of temperatures, which makes it the preferred choice for insulating refrigeration systems and chilled water pipes. Its remarkable resistance to moisture absorption enhances its lifespan which means it is a cost-effective solution in the long run.
Phenolic foam insulation is widely recognized for its exceptional fire resistance and low smoke emission. It is a great choice for environments that demand high fire safety standards. Check out this link for more information: Phenolic foam insulation.
It has a low thermal conductivity for superior insulation performance and energy efficiency.
Fiberglass insulation is known for its exceptional thermal insulation, cost-effectiveness, and fire resistance. Made of fine glass fibers that effectively trap pockets of air, it offers excellent thermal insulation properties. It is also non-combustible, which makes it a safer choice in environments prone to fire hazards.
The use of a vapor barrier is necessary with fiberglass insulation to prevent moisture absorption.
Mineral wool, also known as rock wool, is widely acclaimed in industrial settings due to its exceptional thermal and acoustic insulation properties. It is a versatile material that is produced by spinning molten rock or industrial waste into fibers, to effectively impede heat transfer and minimize noise.
With an impressive temperature tolerance of up to 1,000 degrees Fahrenheit, mineral wool is particularly suitable for high-temperature applications. It exhibits fire-resistant characteristics, repels water, and mitigates the risk of mold and corrosion. Similar to fiberglass, the use of a vapor barrier is necessary to prevent moisture infiltration.
Nitrile rubber, highly regarded for its moisture and flame resistance, is the optimal choice for refrigeration lines and air-conditioning systems. It is renowned for its exceptional durability and flexibility, and easy installation in various configurations. With impressive oil and chemical resistance, nitrile rubber insulation guarantees long-lasting and reliable performance even in systems exposed to such substances.
EPDM rubber insulation is highly durable and resistant to UV radiation, so it is an excellent choice for outdoor applications. It can withstand diverse weather conditions without significant degradation. Its elasticity and flexibility make installation easy and help to ensure a precise fit around pipes. However, EPDM, like other rubber insulations, is not suitable for high-temperature environments.
Understanding where and why each type of pipe insulation is used is key to selecting the best pipe insulation material for any given scenario.
The primary objective of insulation is to minimize heat loss or gain in pipework, thereby enhancing energy efficiency. Opting for insulation materials with low thermal conductivity is recommended, as they exhibit superior resistance to heat transfer.
Want more information on Cellular Glass Pipe Insulation? Feel free to contact us.
To ensure suitable insulation selection, it is crucial to thoroughly comprehend the thermal requirements of the system.
Fluctuations in temperature can trigger the formation of condensation, which in turn leads to corrosion, insulation deterioration, and the unwelcome presence of moisture. To combat this, it is common practice to employ waterproof insulation materials equipped with vapor barriers such as rubber, fiberglass, and mineral wool.
Ensuring proper installation guarantees a watertight seal, to effectively prevent the ingress of moisture and thereby preserve the system’s efficiency and lifespan. The application of insulation in HVAC systems and refrigeration lines proves instrumental in regulating condensation, staving off corrosion, and extending the overall longevity of the system.
Ensuring proper freeze protection is critical when choosing pipe insulation. Exposed pipes in freezing temperatures can lead to substantial expenses and disruptions. Effective insulation reduces heat loss and mitigates potential risks. High R-value materials, such as polyurethane foam, are commonly used for this purpose.
Noise reduction is crucial, especially in residential or commercial buildings where pipe noise can disrupt. Insulation acts as a sound barrier that can help to minimize noise from water, gas, or other fluids in pipes. Materials like fiberglass, mineral wool, and polyurethane foam are helpful due to their excellent sound absorption. These types of insulating materials can create a peaceful and comfortable environment by reducing pipe noise.
Rubber insulation, in particular, acts as a sound barrier, to help minimize noise from vibrating pipes in residential and commercial buildings.
Beyond the insulation itself, the role of insulated pipe supports cannot be overstated. They secure the insulated pipes, to help ensure alignment and structural integrity.
Insulated pipe supports, like those offered by Buckaroos®, are crucial in safeguarding the insulation material and maintaining the efficacy of the entire insulation system. They provide:
Buckaroos® stands out as a leader in providing high-quality pipe insulation types and insulated pipe supports. Whether you’re looking for Phenolic supports for their fire performance or Polyisocyanurate for high-temperature applications, Buckaroos® has a solution tailored to your needs.
Our Polyphen™ rigid phenolic foam insulation provides top-notch thermal performance and durability, and when it comes to resisting moisture intrusion, CoolDry™ Insulated Pipe Supports are the ultimate solution, especially in condensation-prone situations. Trust us to keep your pipes in top shape!
Introducing our CoolDry™ Sliding Pipe Supports, a 360° insulated pipe support system for chilled water applications! It’s designed to handle controlled linear expansion and contraction up to 4″ in one direction. Our system is manufactured with Polyphen™ rigid phenolic foam insulation, which has been tested and passed the ASTM E-87 Class A requirements for flame spread and smoke development (25/50 rating).
CoolDry™ Heavy Duty Pipe Supports are specially designed for chilled water and cold piping systems that experience significant movement caused by expansion and contraction. It is recommended for roller hanger applications as well as trapeze and strut systems. If you need to use it outdoors, make sure to protect it from the weather. These saddles meet the MSS SP-58/69, Type 40 Shield requirements, for top-quality performance and durability.
E Insulated Polyisocyanurate Pipe Support
Our E Insulated Polyisocyanurate Pipe Support is a 360° insulated pipe support system that is perfect for cold piping systems operating below ambient temperatures. Crafted with rigid polyisocyanurate insulation, it ensures optimal performance and efficiency.
Don’t compromise on the performance and durability of your industrial piping. Make the right choice for your pipe insulation and support needs with Buckaroos®.
Our diverse range of industrial piping solutions caters to various requirements, in order to provide high structural integrity and thermal efficiency. Explore our products and find the perfect fit for your application.
When it comes to insulating LNG pipe, polyisocyanurate (PIR) and cellular glass are the two most commonly used materials. Both types are excellent insulation options when they are part of a well-designed, properly installed system. However, PIR’s many benefits can make it a preferred choice as it is cost effective and easier to work with.
While PIR and cellular glass are very different, both are successfully used in LNG applications and have long service lives. Cellular glass is exactly what it sounds like – glass, an inorganic material, that contains a myriad of closed cells. PIR is an organic material that is blown to create a foam, also containing closed cells. While both products are insulating materials, they differ in many of their properties.
The main advantages of cellular glass as LNG pipe insulation are its water resistance (zero permeability), its low flammability and a broader service temperature range. And since cellular glass is made entirely of closed glass cells, it offers very good resistance to both liquid water and water vapor infiltration.
The operating temperature range of cellular glass is -450°F to 900°F, whereas PIR is rated for -450°F to 300°F. Being inorganic, cellular glass is non-combustible, whereas Johns Manville’s PIR product Trymer® has an ASTM E84 rating of 25/295 (25/50 option available). The accessory products used with cellular glass, including joint sealants and vapor retarders, are organic. This means that the completed cellular glass insulation system does not have the same combustibility performance as the cellular glass insulation alone.
The biggest advantages of PIR insulation are its lower (better) thermal conductivity, lower density resulting in lower total system weight, ease of fabrication and its significantly lower total installed cost. When compared to cellular glass, PIR has a thermal conductivity that is 35-75% lower (and therefore superior). This difference in thermal conductivity directly translates into less insulation thickness needed when using PIR to prevent condensation control and/or limit the heat gain.
This means that PIR insulation systems have a smaller outer circumference than cellular glass systems by approximately 10-20%. As a result, PIR systems need less of the expensive accessory products like vapor retarders, joint sealant, and metal jacketing than cellular glass systems. As an example, a 6” NPS -260F° LNG line with 90F° ambient temperature, 85% relative humidity and 0 mph wind speed with jacketing emittance of 0.9 needs 5.5” thickness of Trymer PIR to prevent condensation. With the same calculations, changing the insulation to cellular glass will require 7” to prevent condensation.
Additionally, the total system using PIR insulation can cost less than cellular glass and has lower installation costs. PIR is easier to fabricate and install, while cellular glass is fragile and requires more expertise for installation. While some manufacturers might offer 3-foot segment lengths for cellular glass, the standard is 2-feet. Standard length for PIR is 3 feet for pipe shells/segments, which means there are 50% fewer circumferential joints. Fewer joints when installing PIR results in a faster installation, reducing the opportunity for water or water vapor to enter the system during construction/installation.
The main disadvantage of PIR is that while it is closed cell, it is not as water resistant as cellular glass. However, any concern with the water and water vapor resistance of PIR is eliminated by properly designing and installing the full insulation system, which is required for both PIR and cellular glass. A full insulation system includes dual vapor retarders, fully sealed joints between insulation pieces, vapor stops at key locations, and a properly installed outer protective jacket system.
At JM, we know there is no single best pipe insulation material; every material has advantages and disadvantages. When selecting an insulation material, specifiers should weigh the advantages and disadvantages against their relative importance for the specific project along with the history of successful use of the material in similar applications.
Overall, PIR insulation systems make a strong case for themselves. They require less insulation thickness, use less accessory material, and are easier to fabricate and install. As a result, the total installed cost savings of using PIR over cellular glass can be substantial.
Visit our page Insulation for Cryogenic and LNG Systems for additional resources, and check out our newly revised systems guide for PIR in LNG applications.
Contact us to discuss your requirements of aluminum foil faced insulation. Our experienced sales team can help you identify the options that best suit your needs.