Insulation reduces the rate at which heat flows from hot to cold.
Fremont, CA: In industrial environments, it reduces energy costs, enables more precise process control, and helps keep workers and others close by from harm. If the insulation is defective, it won’t perform these functions to the level required, which can mean unexpected shutdowns and repair bills.
Industrial insulation problems take many forms. They range from seemingly insignificant to undeniable failures.
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Wrong insulation for the application
Insulation comes in many forms, and a complete installation usually incorporates several components. Materials must be appropriate to the application.
Industrial insulation contractors lacking industry-specific experience may pick the wrong insulating material, vapor barrier, or sheathing by accident or choice. They may appreciate only some application details or choose inexpensive materials because they bid low to win the job.
Too little or too much insulation
A common mistake is thinking more insulation is better. After a certain thickness diminishing returns set in, the additional cost exceeds the benefits. However, insufficient insulation, perhaps as a cost-saving measure, leads to increased heat loss and all the problems.
Faulty installation
Insulation almost always requires a vapor barrier and an outer sheath. These prevent heat transfer and moisture penetration. Joints in the insulation must be sealed with care to avoid this latter problem, preferably with pressure-sensitive adhesive tape rather than staples. It’s essential to limit the use of staples as these provide openings for moisture and corrosion. Joints in sheathing should be caulked.
Moisture
When insulation gets wet, it loses virtually all its ability to prevent heat flow. It can also cause corrosion under the insulation around pipes and storage vessels, even those fabricated from stainless steel. If the moisture subsequently freezes, it can cause extensive damage.
Contamination/corrosion
“Contamination” in this context refers to pollutants that could attack the sheathing or insulating material. Chemical leaks and airborne gases are possible culprits, as are other materials used in industrial processing operations, such as lime.
Damage
Damaged sheathing lets moisture in and allows heat to flow. Damage often results from pipework on ducting being climbed to reach parts of a process plant or other equipment. It can also result from an accident, such as a fork truck being driven into or scraping alongside pipes or storage tanks.
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