Are Insulation Blankets Safe for Outdoor Applications?

There are two possible problems when considering using removable insulation blankets for outdoor applications:

•    The potential for water to get underneath the blanket and stay, which could in turn lead to pipe corrosion under certain circumstances.
•    The possibility of poor insulation performance when exposed to the elements.

Because insulation blankets, by nature, are not sealed, they are not impervious to water. Brett Herman, Firwin’s VP of sales and customer services, says the first question you should ask yourself when considering using insulation for an outdoor application is, “Can I afford any water getting under the blanket?” If the answer is no, then insulation blankets are not likely candidates for you application. However, if the problem isn’t a question of water getting under the blanket, but rather a fear of the water lingering, removable insulation remains a viable solution.

In many applications, high temperatures from typical engine exhaust cylinders (provided they are non-cyclical) will burn off excess water that remains under an insulation blanket—thus eliminating the risk of corrosion. In terms of ability to perform in outdoor conditions, insulation blankets’ standard outer layer (silicone impregnated fiberglass) can withstand temperatures as low was -67° F before cracking—and some even feature a UV resistant coating. When it comes to responding to water, some kinds of insulation are more water-resistant than others.

To accommodate outdoor applications, Firwin incorporates design modifications into blankets, such as extra flaps to reduce the amount of water that gets beneath a blanket. If corrosion is an issue, Firwin may also recommend consulting with an outside corrosion engineer.

For more information, continue reading about insulation blankets for outdoor applications here.

Appropriate Insulation for Marine Applications

Marine applications differ from land-based applications in three main areas: Firstly, a ship engine is typically used for prime power, so it is running all the time and generating a lot of continuous heat, unlike a back-up power generator. Secondly, and perhaps even more importantly, are the additional safety concerns that arise from being a sea-borne vessel—out on the water is not a place for heat-related issues. Thirdly, the engine room is often in tight quarters, increasing the likelihood that someone brushes up against a hot exhaust component.

For these reasons, Firwin typically recommends a thicker level of insulation than would suffice in standard non-marine power applications – usually 2-inch thick insulation blankets, as long as space allows. Extra care is also taken in designing the blankets to ensure that small gaps between components are covered. Firwin Hard Coat is also an excellent alternative to removable insulation blankets for marine applications, especially in cases where space constraints do not allow for thicker insulation. 

For more information about insulation for marine applications, please contact us today.

Alternative Fastening Techniques for Insulation Blankets

Over the years, Firwin has developed more than a few ways of building fasteners for its removable insulation blankets, but its traditional modus operandi has always been with stainless steel lacing wire. “We find that stainless steel lacing wire works best,” says Paul Herman, Firwin’s president. “But for certain applications, where speedy installation is key, or where the client will be removing the [insulation] blankets frequently to do maintenance, we will recommend alternatives.”

So what are some of the alternatives? Thus far, Firwin has developed and produced insulation blankets that can be fastened by way of straps, snaps, springs, even Velcro. All of these options provide lighter, cheaper, and more accessible means of opening and closing insulation blankets.

 A recent challenge: Firwin was tasked to develop a new spring system for one of its clients. But first there were a few slight problems that required solving. As Brett Herman, Firwin’s V.P. of Sales & Customer Service, sums it up, “We have made spring fasteners available to our customers in the past… However, we used to find that the spring fasteners available ‘off the shelf’ just did not provide the proper fit that insulation blankets require. We knew that if we were to provide spring fasteners as a legitimate option, we would have to design one ourselves.” 

That’s just what Firwin did. Working with a local spring manufacturer, Firwin retrofitted their fasteners so that they would snap off with ease, all the while maintaining their sturdiness over time and at high temperatures. Insulation blankets fitted with these new and customized spring fasteners (as well as all other fastening alternatives) are currently available from Firwin upon request.

Insulation Outer Fabric: What are the Options?

An insulation blanket is composed of three main layers: An inner face, the insulation media itself, and the outer fabric. The inner face, known as the hot face, comes in direct contact with the hot component. Typically a stainless steel mesh, it holds the insulation in place. The outer fabric, known as the cold face, covers the insulation.

Outer fabric can be fluid-resistant or non-fluid resistant. Silicone or Teflon™ lamination endows the fabric with fluid-resistant properties, greater abrasion resistance, and the ability to withstand greater amounts of mechanical stress. Additionally, these types of fabrics are well suited to surviving the elements.

However, once temperatures reach above 500° F, the adhesives and coatings begin to break down, causing the material to lose integrity and become brittle. Some fabrics can continue to perform up to 600° F, at which point laminated fabrics maintain integrity while losing lamination. For extremely high-temperature applications, non-fluid resistant, woven, non-coated fabrics fare well. For applications that require fluid-resistance as well as high-temperature resistance, other materials must be considered.

Curious about what kind of outer fabric is right for your particular application? Read more to find out what other options are available.

How to Install Firwin Removable Insulation Blankets

Last week, we discussed fastening techniques for insulation blankets. But what about proper installation? Combined with the right fastener, proper insulation installation is crucial in maximizing heat reduction. An improperly installed blanket can result in uncovered parts, heat leakage, or damage to the blanket—all of which can cost you time and money.

To help our customers get the most from our insulation, we’ve put together a basic guide to Firwin insulation blanket installation. This step-by-step guide, complete with pictures and diagrams, shows you exactly what do to and how to do it.

Firwin’s removable insulation blankets are available for many different applications, including manifolds, turbos, elbows, flanges, and flex joints, among others. Please contact Firwin directly if you require further instruction on installation for these or other components.

Energy Savings with Removable Valve Insulation

Getting the most out of your pipeline applications requires attention to heat—and sources of heat loss. The more heat you lose the higher the cost, so identifying key areas for insulation can go a long way towards increasing efficiency. Valves, flanges, expansion joints, and other irregular surfaces are common culprits of heat leakage, and maintenance often damages existing insulation. To circumvent these issues, many industrial professionals turn to removable insulation to maximize heat retention and increase pipe performance.

The U.S. Department of Energy recommends insulating any surface that reaches temperatures greater than 120° F, in order to protect personnel. The use of reusable insulation pads is pivotal in maintaining a safe environment: because the pads can be periodically removed for inspection and replaced as needed, they are an effective way to resolve current heat loss issues and prevent problems down the road.

Depending on valve size and operating temperatures, insulating valve covers can achieve impressive energy savings: the difference in heat loss between the un-insulated valve and the insulated valve operating at the same temperature. To get an idea of how much you can save, take a look at this helpful table from the U.S. Department of Energy.

Interested in removable valve insulation? Contact Firwin today to learn more about our hands-on service.

An Inside Look: Are Insulation Surface Temperatures Safe?

How hot does the outer surface of an insulation blanket get? When thinking about insulation temperatures, it’s important to remember that fabrics do not conduct heat; metals do. As a result, the relative temperature of a fabric surface can be higher, and still be safe to touch. However, it wasn’t until 1998 that a formal differentiation was made between metal and other surface types. For both, 140° F (60° C) had been the accepted standard temperature.

The UL220 Specification for Stationary Engine Generator Assemblies, issued in September of 1998, was the first standard to quantify acceptable temperatures. Based on this specification, fabric surfaces, such as insulation blankets, can reach temperatures up to 203° F (95° C), and still be safe enough for casual contact.

For more information about safe contact temperatures for insulation materials and more, please see our Firwin Insulation Insights FAQ.

Insulation Thickness: What’s Right for You?

Determining the right insulation blanket thickness for your application depends on a range of factors—ambient temperature, air flow velocity, material, emissivity, and more—and it’s not always obvious what level of thickness you need. While 1-inch blanket thickness typically suffices for most insulation applications, blankets can vary in thickness from ½ of an inch to 4 inches. Within that range, how do you know what’s right for you?

"It really comes down to the customer's concern,” says Brett Herman, Firwin's vice-president of engineering and customer service. "1-inch thick insulation is standard, and more than sufficient for most applications. If a customer has a particular need, be it keeping in as much heat as possible, or minimizing outer touch temperature or the heat in a room to a point below what a standard 1-inch blanket would accomplish, then we would look into thicker insulation.”

Thicker insulation, such as a 2-inch thick blanket, is more appropriate for power generation in prime power applications, where the engine is running constantly. With backup power applications, which only run periodically, 1-inch insulation is the norm.

Because each application must be evaluated on an individual basis, always seek professional advice. To learn more about insulation thickness levels and how to select what’s right for you, check our FAQ (see below) or contact Firwin today.

Insulation Blanket Thickness Tips: http://www.firwin.com/pdf/firwin-faq-insulation-thickness.pdf

Insulation Insights: 6 Tips for Proper Insulation Blanket Care

We’ve talked a lot about selecting the right insulation combination for a given project, but effective insulation depends on much more than materials: it depends on consistent and proper maintenance. Here are six easy tips to help you ensure proper insulation blanket performance and longevity.

1. The fastening system is more than suitable to hold the blankets in place. Care must be taken not to use brute strength when installing blankets.
2. For the best service, blankets should be kept clean.
3. Any chemicals that will cause aluminum or silicone coatings to deteriorate should be removed and cleaned off.
4. Should the blanket or insulation mat become saturated with oil, its natural "non-combustible" characteristics will no longer be effective and the blanket should be replaced.
5. Like all engine parts, blankets should be regularly inspected.
6. Care must be taken not to cut or damage the outer protective cover fabrics with sharp instruments.

For further information and care tips, please visit www.firwin.com or contact us directly.

Green Insulation Spotlight: CMS Materials

As a result of legislation in Europe, developed in response to increasing awareness for health and safety regulations, a new group of fibers has been developed for temperature ranges higher than 1100⁰F (590⁰C). Produced in much the same way as mineral wool, these new fibers are made from calcium, magnesium, and silica, and are referred to as CMS fibers. CMS fibers are low bio-persistent (similar to glass), and form body-fluid soluble, non-ceramic, fiber blanket insulation. CMS fibers have been exonerated from all carcinogenic classification under Nota Q of directive 97/69 EC European Union. Because of this clearance, CMS fibers have replaced refractory ceramic fiber (RCF) for use within insulation across Europe. CMS insulation also exhibits better thermal conductivity characteristics than many RCF fibers, and is unaffected by incidental spills of oil or water. Thermal and physical properties are restored  after drying. A greener, safer asbestos-alternative, CMS materials are widely used in a range of insulation applications.

To learn more about CMS fiber insulation and its applications, please contact Firwin or visit our site today.
   

4 Asbestos Alternatives: Making the Right Choice

Although it’s common knowledge that asbestos poses numerous health risks, it has been difficult to find one fiber that covers the same temperature ranges and offers the same level of chemical resistance. These inherent characteristics established asbestos as the insulation of choice for engines, boilers, and piping, from the 1800s through the 1980s. As serious health risks were uncovered, asbestos was banned and the search for risk-free alternatives began.

Because no one single material adequately covers the full range of temperatures, from Arctic lows to the high temperatures experienced in engines of all types, it was necessary to develop a variety of materials to cover requirements for insulation purposes. Firwin has never used asbestos, and we’re dedicated to manufacturing the right material combination for a given project.

Below, we offer descriptions of several common alternative materials, and the appropriate applications for each.

1. Cellular glass. Impermeable to moisture, cellular glass is non-combustible and can’t burn. This material is often used in cryogenic insulation and some industrial applications.

2. Polystyrene and polyurethane. For low temperatures through 250 degrees F, foams, polystyrene, and polyurethane can often provide the solution. Environmental disposal must be taken into consideration.

3. Cellulose insulation. Often used in house insulation, cellulose insulation must be treated with fire retardants before use. When wet, it takes considerably longer to dry than fiberglass, and is not suitable for high temperature insulation.

4. Fiber insulation. Fiber insulation is made from melted minerals, which are then extruded to form fibers. These fibers can be processed into batts, blankets, boards, and preforms, as required by a particular application. Fibers used by reputable manufacturers feature a fiber diameter and length well in excess of ACGIH requirements. Because fibrous, non-organic materials can cause temporary discomfort and irritation, protective clothing should be worn. Types of fiber insulation include:

• Fiberglass. Fiberglass is the preferred insulation for temperatures up to 1100 degrees F. In accordance with ACGIH requirements, the fibers are long and they dissolve in body fluids. House and building applications, boilers, and engine exhausts all benefit from various forms of fiberglass insulation.

• Mineral wool and basalt wool. Made from melted volcanic rock and extruded into fiber, spun mineral wool is then chopped into separate fiber lengths and manufactured into blankets and boards. With a thermosetting resin to bind the fibers, these materials cover temperatures up to 1100 degrees F, much like fiberglass.

• Ceramic wool. Ceramic wool insulation is suitable for insulating equipment at temperatures up to 2400 degrees F. Ceramic wool materials also exhibit better thermal conductivity characteristics than fiberglass.

As will all insulation materials, care must be taken in both selecting and using the above materials. Additional materials for higher temperature applications are also available—as is green insulation. Please check in next week to learn about the distinct advantages of going green.

Meet Our New Distributor: Evapar

Firwin is proud to announce a new partnership with Evapar, a distributor located in Evansville, Indiana. Evapar will service coal mines in Western Virginia and Kentucky, where our products play an essential part in keeping mine workers safe. Because the requirements for insulation within a mine are much different than other applications, we specially design insulation that can withstand the environmental hazards that coal miners and mining equipment face. Evapar shares our philosophy that exceptional service and outstanding products go hand-in-hand: together, we’re making sure our clients receive the support they need.

With a special training center located at Evapar’s headquarters, in Evansville, Indiana, Evapar features hands-on instruction and training for new service personnel. Courses centered on areas such as electrical, generator, fuel system, governor and transfer switch fundamentals equip new personnel with the skills they need to perform in the field, and provide an excellent opportunity for experienced personnel to expand their knowledge. We’re confident Evapar’s expertise and dedication to quality service will greatly benefit our clients, and we look forward to working with them.

For more information about Evapar, please visit their website here: http://www.evapar.com/service.htm

Questions or comments? We love hearing from you. Be in touch with us at: http://www.firwin.com/contact.html

Putting Custom Extrusion and Injection Moulding Insulation to Work

Firwin manufactures custom extrusion and injection moulding removable insulation blankets appropriate for injection moulder barrel heaters, pre-heat covers, and service throw insulation covers. Designed specifically for electrical connections and thermocouples, all of our insulation blankets are made from non-combustible, high-temperature materials. When used properly, these types of insulation blankets help our customers realize significant cost-savings by reducing energy input and minimizing heat loss.

A recent customer was using touch-safe perforated heatshields on an Italtech machine, which was located beside a shipping door. The heatshields were losing energy, resulting in poor temperature uniformity and ultimately causing quality issues. To solve the problem, the client installed Firwin insulation blankets— the insulation set quality back on track with a 7 month ROI.

For other stories on how extrusion and injection moulding custom insulation has helped our customers, or to request more information, please visit our site today.

http://removable-insulation-blankets.firwin.com/item/insulation-solutions-by-industry/plastics-extrusion-injection-moulding/item-3792?

Sound Attenuation Solutions

Although diesel-powered equipment offers countless advantages, the noise associated with these machines is less than ideal. Sound levels can reach deafening levels, posing a threat to operators, employees in the vicinity, and other nearby machining processes. As a result of our commitment to manufacturing the highest quality removable insulation blankets, many clients turn to us for sound attenuation solutions. While insulation blankets can help dampen sound, most sound attenuation solutions involve a combination of materials that are specially selected to suit a given application.

Material selection for sound attenuation is dependent on the frequency of the sound the material must block. Fiberglass and mineral wool are particularly well-suited to absorbing higher frequency sound, in the 1,000 to 4,000 Hz range. Lower frequency sounds are harder to absorb because of their long wavelengths, but typically the thicker the material or barrier, the more effective the absorption. To guide you in your material selection for sound absorption, please see our convenient guide to sound absorption materials and factors to consider.

http://firwin.com/pdf/sound-attenuation-diesel-powered-equipment.pdf

Tapes vs. Blankets: Which One is Right for You?

It’s not always clear which type of insulation is best for your engine and exhaust components: with many different types of tapes, sleeves, and blankets available, finding what you’re looking for can be a headache. To be certain, each insulation variant has distinct advantages when used appropriately. With these benefits in mind, we’ve put together a few quick tips to make the selection process a little easier—so you can get the most from your insulation.

Tapes and sleeves are off-the-shelf, stocked items, and their flexibility makes them a good choice for many applications. In instances where you’re looking to insulate a variety of parts quickly, sleeves and tapes can work quite well. But when it comes to larger, thicker parts, it becomes less economical and more labor intensive. Wrapping tape around a large exhaust pipe, for example, would be difficult and time consuming. For these kinds of applications, insulation blankets are often the better choice. Because they can be manufactured in many different thicknesses and are easy to install, they work very well for engine and exhaust components. While tapes and sleeves are a great quick-fix, they don’t provide the same long-term coverage as insulation blankets.

Still not sure? Check out our useful chart for more pros and cons of tapes, sleeves, and blankets: http://www.firwin.com/pdf/tapes-blankets-application.pdf

Underground Mine Safety: The Role of Insulation

With diesel accounting for 72 percent of the energy used by the mining sector, it’s no surprise that miners are seeking the most reliable, safe, and cost-effective diesel-powered equipment. As developing economies continue to drive demand and contribute to record-high prices for precious metals and other natural resources, miners increasingly require diesel-powered equipment to work within the mine and beyond—from extraction through transportation, diesel-powered vehicles play a quintessential role.

The underground mining process comes with its own unique set of challenges, and working safely and efficiently with diesel-powered mining equipment is no exception. Miners must consider exposed exhaust and engine components, which can run extremely hot, as well as diesel particulate matter and high, ambient heat. In addition to the risks posed to workers, surrounding equipment can also suffer as a result of uncontrolled temperatures and exhaust.

Standard insulation blankets feature a fiberglass material underside, which can become a fire hazard if it encounters oil or an engine leak: a very dangerous situation within a mine. Additionally, standard insulation features a silicone impregnated fiberglass outer cover—in a mining environment, this type of insulation is prone to tears and rips.

To ensure a safe working environment in the mine, Firwin has developed a unique insulation blanket: MineWrap™. Featuring a stainless steel liner to seal off the insulation material and prevent oil from seeping in, MineWrap™ also offers a stainless steel foil exterior to reinforce its outer cover. The steel foil exterior is also covered with wire mesh. Both rugged and fire-resistant, MineWrap™ has been keeping miners safe across the industry. To learn more, please visit www.firwin.com today.

Oil and Gas Insulation Coverage

To match the continual expansion of the oil and gas sector in Alberta and Western Canada, we’ve opened a new Western Canada Sales office to better serve our clients. Each division of the oil and gas industry, from upstream and midstream upgrading facilities to downstream refineries and product development, comes with unique challenges and requirements for managing heat-related issues. Be it for protecting equipment from external environmental conditions, safe-guarding personnel from hot process piping, or providing heat retention to increase a plant's energy efficiency, removable insulation blankets are an important component in ensuring the safe and efficient operation of a petrochemical facility.

Firwin removable insulation blankets are custom designed using the latest technology and quality materials. Removable thermal blankets are only effective when properly designed and fitted to the equipment they are meant to insulate: Our blankets are designed to wrap snugly around even the most complicated upstream equipment, including those with multiple penetrations for fittings and electric, steam, or glycol tracing.

Appropriate for many applications, Firwin removable insulation blankets are used to cover valves, flanges, instrumentation panels and sending units, level indicators, and other types of equipment. Visit us at www.firwin.com today to learn more.

Insulation Key in Meeting Diesel Emission Standards

Over the years, we’ve seen engine manufacturers take a turn toward keeping diesel engine emissions down. With new engines being designed with emissions reduction in mind, complete with catalytic filters to treat harmful exhausts, we’ve done our part to help keep engines clean and green. An important part of emissions reduction rides on the maintenance of high exhaust temperatures: to maintain these temperatures and adhere to emission standards, an engine must be properly insulated.

By 2015, all off-highway and stationary diesel engines will be subject to the EPA’s highest Tier 4 level of emission control. Engine and catalyst manufacturers have responded with several approaches. Engine modification aims to reduce emissions where they start, within the engine, through better design and control. After-treatment treats the exhaust after it leaves the engine, with catalytic filers, fuel modifications, and other methods. Often, these approaches are used together to achieve the required emissions reduction.

As a key component in emissions reduction, engine insulation works to maintain high engine exhaust temperatures. Some technologies require a heat exhaust level in excess of 800°F in order to fully function, and to maintain internal heat and maximum burn-off. As a primary insulation provider for a range of diesel engine manufacturers, we’re proud our removable insulation is helping our clients achieve their emission reduction goals. Engine users and catalyst manufacturers alike recommend removable insulation blankets as an important aspect of their emission reduction strategy: Contact Firwin to find out how our insulation can work for you.

Permanent Hard Coat Insulation

Although removable insulation blankets are the perfect solution for many industries and applications, we understand that there are times when a thinner, permanent insulation is more appropriate. Our specially designed Permanent Composite Hard Coat™ provides a unique insulation solution for limited space applications, with the ability to withstand extremely high temperatures.

Often used on elbows, exhaust manifolds, exhaust tubing, and turbochargers, our clients in the aerospace, defense, marine, and mining industries turn to our hard-coat insulation to ensure both safety and performance. Conforming tightly to the part, hard-coat insulation prevents fluids from igniting on hot engine and exhaust parts and protects personnel from burns. And, because of its high-temperature performance, the composite is ideal for engine compartments and components requiring long-term exposure to high temperatures. By lowering ambient temperatures, the composite reduces heat stress for both the application and the operator.

A more durable, longer-lasting choice than removable insulation, our Permanent Composite Hard Coat™ can be installed within three short weeks: Once a part arrives at our plant, we apply insulation and return the component to you as needed. To learn about this product and more, please contact us.

http://removable-insulation-blankets.firwin.com/item/hard-coat-composite-insulation/hard-coat-insulation-overview/item-1043?

Firwin Expands U.S. Distribution Network

As a custom manufacturer of a variety of insulation products, we’re dedicated to providing our clients with individual insulation solutions. To help us reach a broader client base, we’ve enlisted three new U.S. distributors: The Edward D. Newell Company, Onsite Power Inc., and Renosa.

In business for 48 years, the Edward D. Newell Company is located in Bristol, Wisconsin. As a former Firwin customer since 2006, they recognized the value of adding a Firwin insulation product line: they now represent Firwin in Illinois, Michigan, Ohio, and Wisonsin. For our clients looking for custom insulation blankets for power generation applications in this region, Edward D. Newell’s unparalleled expertise and customer service is sure to surpass our clients’ expectations. As a family-owned company, they strive to make each customer feel like their only customer: a value mirrored by our own commitment to quality and service.

Specializing in representing suppliers in the onsite power/distributed generation industries in the Rocky Mountains, Onsite Power Inc. distributes our products to clients in Colorado, Utah, Montana, Idaho, and New Mexico. With a dedication to independent sales representation, Onsite Power successfully navigates the energy products and services markets, and understands the challenges specific to the Rocky Mountain region. With their support, Firwin’s power and engine insulation products are now reaching a wide range of clients throughout the area.

A client of Firwin’s since 2007, Renosa Corp. is located in Dayton, Ohio. After experiencing first-hand the quality of our removable insulation blankets, Renosa decided they would be a natural addition to their product line. Now representing Firwin in Oregon, Washington, and Alaska, Renosa’s commitment to representing superior manufacturers of quality products and delivering the best in customer service sets them apart from other power generation industry product distributors.

The Edward D. Newell Company’s contact is Mike Kime: mkime@ednewell.com / 262.857. 6871.

Onsite Power’s contact person is Dennis Roundtree: dennis@onsitepowerinc.com / 303. 690. 8486.

Renosa’s contact person is David Hammond: dhammond@renosa.com / 503. 864. 3952.

Firwin Corp. Makes Custom Insulation Products

Firwin Corp is a leading manufacturer of custom insulation products for diesel and gas engines & exhaust systems, and industrial applications. Our 2 main product lines are removable insulation blankets and permanent Hard Coat™ composite insulation. We also stock a wide selection of high temperature tapes and sleeves. We service a diverse range of industries, providing insulation solutions for applications such as diesel and gas powered generating stations, gensets, on-road and off-road vehicles, as well as industrial applications such as process and steam line valves, flanges, and piping.

To learn more, visit us at: http://www.firwin.com/