Hard Coat vs. Removable Insulation Blankets – which one is right for my application?
Although Firwin is one of North America’s leading manufacturers of removable insulation blankets, we see ourselves as an insulation solution provider, offering our customers the most appropriate insulation solution that meets their needs. That is why we offer tapes and sleeves and is why we introduced our Firwin HCTM “Hard Coat” product last summer. As opposed to insulation blankets, which are designed to be removable and reusable, Firwin HCTM is an insulation coating that is affixed to the product. Both removable insulation blankets and Firwin HCTM have their advantages and disadvantages. What variables need to be considered in order to determine which insulation is right for a given application?
“There are a number of factors to consider,” said Bret Herman, Firwin’s vice president of engineering and customer service. “Does the customer require removable insulation? Are there space constraints? Is the application such that there is the potential of fluid seeping into the insulation material, thereby posing a fire hazard?. These are just some of the factors that need to be taken into account when deciding between Hard Coat and standard removable insulation blankets,” added Brett.
The chart below outlines the various advantages and disadvantages of Firwin HC vs. Removable Insulation Blankets. As always, it is best to let one of Firwin’s customer service representatives help you in choosing the best system for your particular application.
Firwin HCTM Hard Coat vs. Removable Insulation Blankets
Permanently applied to the component – cannot be removed
Blankets can be removed and reused – ideal for equipment that requires periodic maintenance
Solid outer surface – not prone to tearing, ideal for applications under rugged conditions
Standard removable insulation blankets have silicone impregnated outer surface – may tear or puncture under rugged conditions.
The component must be disassembled and shipped to Firwin for HC coating to be applied
Removable insulation blankets are designed remotely from measurements, drawings, and photos. The component remains with the customer, attached to the equipment.
Conforms tightly to part – ideal for limited space applications
Limited space applications can pose a challenge to blanket installation and proper fastening.
Completely encapsulates the part – preventing fluids from igniting on hot engine and exhaust parts
Blankets can act as a shield to prevent fluids for reaching engine and exhaust components, but some seepage under the blanket can occur.
No risk of fluid reaching insulation material and igniting
Can be designed with stainless steel inner liner to prevent fluids from seeping into the insulation material
Non-flammable
Fire retardant
Lead time of 3 weeks
Typical lead time of 2 to 3 weeks; can usually be expedited if necessary
Higher cost (6 to 12 times) than standard removable insulation blankets, but longer life span.
Cost can vary according to material make-up of blanket, but more economical than Hard Coat. Blanket life depends on application, and frequency of removable.
Removable Insulation Blankets vs. Permanent Composite Insulation
Comments Off on Insulation Blanket Installation – Hard to Identify Parts
Firwin insulation blankets provide critical protection for engines, generators, exhaust systems, and more. Since they are used in such a wide range of applications, insulation blankets come in a variety of shapes, sizes, and materials. Each blanket style has unique installation instructions. While most blankets are straightforward to install, some can be more challenging due to the shape of the blanket out of the box which doesn’t correspond with the shape of the part.
How Installation Works
Firwin’s insulation blankets are engineered to ensure accurate fits around exhaust and engine components. We understand that a clean fit is critical and time is of the essence, which is why our blankets can be immediately installed right out of the box. For complicated or unique blanket installations, we also provide a numbered diagram to simplify the process.
How to Install Insulation Blankets
Some insulation blanket installation methods for hard-to-identify parts we see at Firwin include:
Segmented Elbows
When installing an insulation blanket on segmented elbows, it is important to cover the full surface area. You can do this by curving the edges of the blanket to create the elbow’s shape. Secure the blanket to the elbow with lacing wire and avoid gaps or voids.
Flanges
Wrap the blanket around the flange and secure it temporarily with a piece of wire or lacing. Carefully pull on the blanket’s drawcords at the top and bottom until the blanket begins to tighten around the flange. When you can see the shape of the flange, you can remove the wire you used to secure the blanket and then use the wiring on the draw cords to fasten them around the rivets.
MineWrap™ Mark II Butterfly Elbows
Open the blanket and pull it over the elbow by curving the edges. Once the elbow is covered, secure the blanket to the joint with lace wire.
Purifiers with Cones
Firwin’s blankets for purifiers with cones are specifically designed to fit snugly. Simply open the blanket and curve it around the cone until the edges meet. The shape of the blanket will conform to the purifier and cone. Then, wrap the blanket with wire to secure it to the equipment.
Manifolds
Due to their complexity, manifolds require a more complex installation. Follow these steps to ensure that your Firwin insulation blanket is properly installed:
Fold the blanket around the manifold.
Once the blanket is in position, create a loop on one end of the lacing wire by twisting the wire around itself.
Feed the loop under the manifold and pull the loop up to hook on the first capstan rivet.
Pull on the long end of the wire to tighten it around the rivet and then wrap the wire around the blanket and the first rivet under the manifold.
Feed the wire back under the manifold, tighten it, and wrap it around the next rivet.
Feed the wire down to the button on the blanket, tighten the wire, wrap it around the blanket, and snip the wire.
Continue this process until the manifold insulation blanket is fully installed.
It is important to avoid over-twisting the wire during installation, as it could break off.
Working with Firwin
At Firwin, we are pleased to provide excellent service throughout your insulation selection and installation. We take your requests seriously and strive to respond to every inquiry within 24 hours. Our dedicated team of in-house insulation design experts will help you find the ideal insulation solution for your needs. An ISO 9001:2015 certified company, we stand by our products and services, and will always work with you to solve any problems as they arise.
Contact Firwin to Discuss Your Custom Insulation Solution
Comments Off on High Temperature Thermal Insulation Product
Making sure you select a material that can withstand the parameters of your application is a central requirement when choosing a high-temperature thermal insulation product. There are a variety of materials that can be used for insulation, and your selected material must be able to tolerate the specific demands of your equipment and operational environment.
High-Temperature Applications
When choosing an insulation solution for high-temperature environments, the tolerances of considered materials should be carefully examined to ensure safe operation and long service life.
Typical applications that experience high temperatures include:
Furnaces and boilers
Ovens and kilns
Expansion joints
Flanges
Heat exchangers
Compressors
Turbines
Chillers
Incinerators
Catalytic converters
Engine & Exhaust Components
Welding
Dryers
High-pressure steam piping
High-Temperature Insulation Materials
There is a range of insulation materials suitable for high-temperature usages, such as:
Fiberglass
Fiberglass offers superb flexibility and dimensional stability for temperatures up to 1200º F. User-friendly with little odor or smoke, fiberglass will not corrode the metals it protects. One of the most common insulation materials, fiberglass is used in a wide array of everyday applications.
CMS Wool
Even though CMS wool is marginally more expensive than fiberglass, it is odorless and can withstand temperatures up to 2192º F. CMS wool is used in a broad range of common applications.
Super Wool
Super wool features a distinct low biopersistance and therefore requires fewer safety and health requirements when managing the material. Super wool exhibits low heat storage capacity and low thermal conductivity, as well as exceptional thermal shock resistance. Able to withstand a temperature range of 500º to 2000º F, common applications for super wool include domestic appliances, furnaces, kilns, laboratory ovens, boiler lining, reformers, fire protection, high-temperature gaskets, turbine insulations, expansion joints, and industrial equipment.
Ceramic fiber
This material is inorganic, smoke-free and features above-average insulation properties, low heat storage capacity, low thermal conductivity, and dependable thermal shock resistance. It is suggested for use in applications exceeding 2000º F. Typical applications of ceramic fiber include furnaces and kilns, high-temperature gaskets, expansion joints, boiler lining, laboratory ovens, reformers, and fire protection.
Polycrystalline Fiber
Made primarily of aluminum and silicon, polycrystalline fiber is created by using sol-gel technology. Double-needled fibers make polycrystalline fibers particularly strong and flexible. They can endure temperatures up to 2912º F and are tolerant of chemically destructive, oxidizing, or atmospherically reduced environments. Common applications include ceramic kilns and furnace linings.
Comments Off on Types of Fastening Systems for Insulation Blankets
Fastening systems are an important part of any insulation system. They secure the insulation, which is essential for preventing air leakage and maintaining thermal performance. Let’s look at the different fastening features and benefits.
Fastening Options
There are various ways to fasten removable insulation blankets, but the most common fastener is stainless steel lacing wire and rivets. This type of fastening is also often used for heavier blankets because it’s strong and durable. Other common fastening options include snaps, straps, Velcro, and springs. The best option will largely be influenced by your application type and budget, as each choice comes with its own set of benefits and disadvantages.
Fastening Features & Benefits
Rivets & Stainless Steel Lacing Wire
Rivets and stainless steel lacing wire provide extra-secure fastening capabilities due to their durability and flexibility. The material is corrosion-resistant and less likely to snap under tension, so it can be shaped and tied into any complex configuration.
Straps
Our straps are made of Teflon or silicone and facilitate quick, easy installation. Their benefits include:
Easy tightening
Weather resistance
Abrasion resistance
High strength
Low stretch
Fits in a variety of locations
Springs
Our patented springs were specifically developed to fasten insulation blankets. Their advantages include:
Snaps are an easy-to-install alternative for simple geometry insulation blankets. They may not be the best solution for blankets with complicated geometries. The benefits of snaps include:
Good shear strength
Easy installation and removal
Durable and long-lasting
Velcro
Velcro can be made of various materials, including nylon, stainless steel, and polyester. The best type of Velcro depends on the application. This fastener is best for securing blankets quickly. Other benefits include:
Easy removal and installation
Suitable for low-temperature applications
Affordable (note: some Velcro types like stainless steel or Nomex are higher-priced)
Working With Firwin
Working with Firwin is more than just purchasing fastening systems for insulation blankets. We take the time to get to know our customers and their specific needs so that we arrive at the best-individualized solutions. We also build supportive professional relationships with our customers, so they can always count on us for sound advice. Whether you’re looking for a one-time purchase or a long-term solution, Firwin is your trusted partner for all insulation needs.
If you’re still undecided on which fastening system is best for your application, contact us and we can help you choose the right one for your needs.
Comments Off on Heat Shields: Materials, Types, and Industrial Applications
Industrial equipment is prone to producing high heat levels when in operation, which can impact the surrounding areas. This can lead to uncomfortable, or even dangerous, working environments for personnel, and it can negatively impact the performance of surrounding machinery. Heat shields are used to reduce the effect of high temperatures in areas around equipment that generate heat. They are specifically designed to protect equipment and personnel from high heat levels. There are several types of heat shields available, and selecting the right heat shield for your application depends on several factors, including the end-use, the surrounding environment, and the industry.
What is a Heat Shield?
A heat shield refers to any material that can be used as an obstacle to prevent heat from entering the surrounding area. A heat shield can be removable, like an insulation blanket, to allow for easy service access, or it can be permanent, like a hard coating material that is used to insulate surrounding components.
Some of the most common heat shield types include:
Firwin Hard Coat™ Insulation: Hard Coat™ is a composite material composed of ceramic fiber insulation with a high alumina content. This is covered by a heat-resistant and highly durable composite. Hard Coat™ insulation forms a permanent, hard, and rugged exterior, making it ideal for applications with low maintenance requirements. Hard Coat™ insulation is non-flammable and resistant to water and oil, making it ideal for applications that are exposed to high temperatures for long periods.
Removable Insulation Blankets: This type of heat shield is composed of three primary layers. The outer protective cover shields the insulation from the environment. The insulation mat is composed of insulation material and contains heat, preventing it from escaping into the surrounding environment. The inner liner secures the insulation blanket in place. Removable insulation blankets can be reused and are ideal for equipment that requires periodic maintenance. Insulation blankets can also be constructed to act as shields for preventing fluids from reaching exhaust and engine components.
Firwin Metal Foil Insulation (MFI™): MFI™ is made of either aluminized polyester or aluminum foil that is secured to one or both sides of the heat shield. The foil reflects the heat, preventing it from escaping the insulation. This option is ideal for exhaust system components, such as elbows, tubing, and piping, that require pre-installed insulation. It acts as a barrier to fluid seepage. MFI™ offers superior durability, which means that it can withstand steam solvent/washing.
Heat shields mitigate heat damage to sensitive components and can protect against burns. They also allow equipment that requires high operating temperatures to run optimally while protecting the surrounding environment.
Heat Shields in Industry Applications
Heat shields are beneficial in a wide range of applications. Different industries utilize different types of heat shields to fit the needs of their application and the surrounding environment. Some of the most common heat shield applications include:
The tight quarters and constant engine operation in marine applications can quickly create a dangerous environment for those on board. With such limited space, the chances of personnel getting injured from an overheated component raise exponentially. Both removable insulation blankets and permanent hard coat insulation are ideal for different components in marine applications to facilitate safe heat control through dispersion and redirection.
In underground mining, there are significant safety challenges due to high temperatures, exposed engine and exhaust components, and other factors. Both permanent composite Hard Coat™ insulation and MineWrap™ removable insulation blankets are ideal solutions for mining applications. The permanent solution coats equipment in a thin insulation layer that prevents oil and hydraulic fluid from engine leaks or broken hoses from building up on or igniting equipment; while MineWrap™ removable blankets have a mesh reinforced foil interior that shields the insulation material. Both solutions cover the exposed exhaust and engine components, reducing heat and improving the shielding of workers from burns.
The oil and gas industry also faces similar safety challenges, however, heat retention is critical to the optimal functioning of process systems. Firwin’s ThermoWrap™ insulation blankets are designed to contain heat to the oil and gas, petrochemical, and industrial components to improve efficiency and protect employees. Each blanket is custom manufactured to wrap around the component needing insulation.
Why choose Firwin?
Firwin offers heat shields that protect employees from physical harm, prevent flammable fluid ignition, mitigate heat damage in the surrounding environment, and lower temperatures. Firwin is a leading manufacturer of insulation products for diverse industrial applications. To find out more,contact us or if you know what you need already,request a quote.
Firwin Corporation is a premier manufacturer of custom insulation products for gas/diesel engines and exhaust systems as well as industrial applications. We invest heavily in R&D to ensure that Firwin is at the forefront of the latest developments in the insulation industry. Our goal remains to offer our customers the best possible insulation solutions for their unique applications.
Here are some examples of products that have resulted from our R&D efforts over the years.
MineWrap™ Mark I and Mark III
If equipment malfunctions in underground mining sites, it can have disastrous consequences for workers and facilities. In the event of an engine oil leak or a leak from a burst hydraulic line, there is a danger of the oil seeping into the insulation material and catching fire. To prevent these hazards, our R&D team developed MineWrap™—a unique line of insulation blankets for wrapping underground mining equipment.
MineWrap™ Mark I and Mark III feature a foil and mesh inner liner that isolates the insulation material, as well as extra rigidity to withstand wear and tear in harsh environments. On the Mark III, we designed the outer liner with reinforced stainless steel foil and mesh for extra puncture resistance.
Permanent Hard Coat Insulation™
Click to Expand
Our Permanent Composite Hard Coat™ is more durable and compact than most conventional insulation products. It can withstand extremely high temperatures and fit in tight spaces. This product is ideal for heat-prone applications like engines, exhaust systems, elbows, and turbochargers, where space is at a premium and removable insulation is not required. Clients in the automotive, mining, marine, and defense industries currently use the Permanent Composite Hard Coat™ to manage their heat-related issues.
Metal Foil Insulation
Firwin MFI Metal Foil Insulation is ideal for exhaust system parts (tubing, piping, elbows) that require pre-installed installation. The insulation is encased by an outer foil that is permanently welded to the part. It provides a visually appealing insulation cover that offers excellent durability, can withstand steam washing and solvents, and keeps fluids from seeping into the insulation material.
Fire Blankets
Our removable fire blankets are designed to protect heat-sensitive components from chemical fires. The blanket slips over the valve or other part to protect it from fires for up to 30 minutes. This gives the operator enough time to initiate safety procedures by shutting down the line, controlling the fire, and minimizing damage.
Our fire blankets have been applied successfully in the oil and gas and chemical industries.
Remote Scanning
In situations where it is impractical for clients or Firwin to take manual measurements at the client’s facility, we employ remote scanning technology to create digital replicas around which we design our insulation products. Some machines have complex geometries, making it challenging to get accurate, reliable measurements by hand. With remote scanning technology, the customer can scan their machinery and send the 3D models to Firwin. We use these models to develop accurate insulation products that fit the customer’s application and save on travel costs and time.
3D Printing
Firwin’s in-house 3D printing technology allows us to accommodate more complex designs and streamline the production process, ultimately saving our customers time and money. Our ability to 3D print exhaust component prototypes allows us to test fit our blankets in house, which is especially important when developing insulation blankets for new customer applications.
Innovation
Firwin takes pride in innovation and excellence. We encourage our people to embrace an entrepreneurial spirit and provide cutting-edge solutions for demanding applications across diverse industries. Our research and development teams focus on continually improving existing products and adding new ones to benefit our customers.
Working with Firwin Corporation
As a leader in insulation engineering, Firwin Corporation is dedicated to providing high-quality permanent and removable insulation products. For over 40 years, our R&D department has been at the forefront of groundbreaking insulation research. We create solutions for a diverse range of applications, including gas-powered and diesel engines, offroaders, and industrial steam lines and vents. Contact us to learn more about our research and development efforts or to start your custom insulation solution.
Comments Off on Industrial Furnace Insulation Blankets
Insulation is an extremely important consideration for the safe and efficient use of industrial furnaces. Without it, the extreme heat dissipates into the surrounding area, significantly increasing the risk of burns and other injuries. An insulation blanket is a simple, effective, and affordable solution to this problem, and its wide range of benefits are matched by its versatility. Insulation blankets can be made of various types of material, and modern insulation blankets are designed with three layers that provide a combination of different functions to increase protection and efficiency in several ways.
The Importance of Furnace Insulation
The extremely high operating temperatures of industrial furnaces necessitate furnace insulation. Doing so improves its efficiency and boosts safety in the surrounding area. Operators of industrial furnaces in particular need every safety measure possible in place to reduce the risk of burns, and insulation blankets are an effective, reliable, and simple solution.
An insulation blanket covers the outside of a furnace and ductwork, is easily removable, and long-lasting. It can be customized to fit a variety of furnaces and related equipment and constructed with other considerations in mind depending on the nature of the work environment.
Furnace Insulation Materials
There are three main components of a reliable and high-quality insulation blanket:
Protective cover: Also known as the “cold face,” a protective cover shields the insulation from the outer environment and keeps the inner insulation material from escaping. The best protective cover is necessary for the longevity of the blanket and can be made with other considerations in mind (weather-proofing, tear resistance, etc.).
Insulation media: The actual insulation is typically achieved by a 1″ thick sheet of fiberglass, but it can vary in thickness from as thin as .5″ to 4″. The thickness of the insulation medium depends on the level of heat reduction required and the size limitations of the area in which the furnace equipment is located.
Inner liner: Also known as the “hot face,” the inner liner acts as a barrier between the insulation material and the furnace and keeps the blanket in place. It’s most commonly made of steel mesh, but different fabrics or metal foil can also be used.
The exact composition of an insulation blanket depends on its intended application, the level of heat, proximity to other equipment, and other end-use considerations. They are easily wrapped around the part using lacing wire, which is usually preferred for its versatility. Other options for securing the insulation blanket include:
Snaps
Straps
Springs
Velcro
These options have additional benefits such as ease of removal, elasticity, and the ability to fit the blanket around components in adaptive ways.
Benefits of Temperature Insulation
High-temperature furnace insulation vastly improves the efficiency and safety of furnaces. Beyond a furnace’s basic functioning, insulation is one of the most important factors for ensuring that it operates as intended. It not only creates a safer environment while keeping energy costs lower, but it also keeps the furnace running longer because it reduces unnecessary stress on the equipment.
As the chamber heats up, the heat can escape through uninsulated areas on the outer surfaces of the furnace. This renders the furnace’s exterior needlessly hot and dangerous and increases the energy needed for the interior of the furnace to reach the set temperature. Insulation blankets drastically reduce this danger and wasted energy, allowing the furnace to function at lower levels to achieve the desired heating capabilities.
Insulation Blankets from Firwin
Although very simple in principle, the most effective and safe insulation blankets are the result of impeccable design and manufacturing. Firwin takes into account many factors most other insulation blanket manufacturers may overlook, such as:
UV light and weather protection for outdoor uses
Ability to withstand chemicals and other substances
Levels of flame retardance
Durability in harsh environments
Sound absorption
Desired exterior or “touch” temperature
Heat retention and exhaust points
High degrees of customization
For these reasons and more, Firwin’s industrial furnace insulation wraps are among the most maintenance-free product on the market for furnace insulation needs. Contact us today with any questions, custom orders, or to request a quote.
Comments Off on Removable Insulation Blankets ‘Take Charge’
In many of today’s diesel and gas engines, you’ll find two ‘chargers’ that are designed to increase engine efficiency. One runs hot, the other cold, and both use removable insulation blankets. The two ‘chargers’ that we are referring to are turbochargers and charge air coolers.
Turbochargers
The purpose of a turbocharger (commonly referred to as turbo) is to increase the mass of air entering the engine to create more power. Turbochargers make this possible by using an engine’s exhaust gas flow to power a turbine with drives a compressor, which in turn increases the air flow into the engine’s cylinders. The more air present in the engine’s cylinders, the greater the air / fuel mix, and the the greater the resulting horsepower.
Since they use the engine’s own exhaust gas to drive the turbine located inside the turbo’s housing, turbochargers run hot. Combine this with the fact that the internal turbine can spin at speeds in excess of 200,000 rpm, and you have the potential for even more heat. And heat is what you want, as the greater the heat and resultant pressure of the exhaust, the faster the turbine will spin, and the more air gets pushed to the engine’s cylinders by the compressor.
This heat does have ramifications, however, for safety and engine performance. An exposed hot turbocharger can pose a danger to personnel, as well as adversely affecting heat sensitive components that are nearby. As well, increased heat can increase stress on the piston, piston rings, cylinder liner, and cylinder head of the engine.
While the air that leaves the compressor section of the turbo is not as hot as the exhaust, (as the compressor is drawing in ambient air and not exhaust air), the act of compression does causes the temperature of the air to increase (for a typical diesel engine, to around the 200°C / 400°F mark). Since hot air is not as dense as cooler air, less air can be pushed into the engine cylinders, which in turns limits the effectiveness of the turbocharger. This is where Charge Air Coolers come into play.
Charge Air Coolers
The job of the ‘Charge Air Cooler’ also known as an ‘intercooler’ or ‘aftercooler’ is to take the compressed air and cool it down before it enters the engine. The resultant cooler air is more dense, and thus more air can be packed into the engine cylinders than could have been achieved with the hot air coming out of the turbo compressor.
Removable Insulation Blankets ‐ How They Help
Firwin Turbocharger Cover
For turbochargers, a properly designed removable insulation blanket fitted on top of the turbo ‘hot side’, helps to keep the hot side of the turbo hot, and the cool side cool. This allows the turbo to function more efficiently. Nearby components that might be affected by the extremely hot ambient temperatures generated by an exposed turbocharger are also protected. Finally, there is the aspect of personnel safety – a turbocharger with a removable insulation blanket will protect people from accidentally burning themselves on an otherwise hot engine component.
CAT C27 / C32 Charge Air System with insulation blankets. Note the large cooler system (large black fan) in the background.
For charge air coolers, removable insulation blankets are primarily found on the piping that leads from the turbo/compressor into the cooler/radiator. The cooler might be a bit of a distance from the turbo, and the piping, which can be in excess of 400°F for diesel applications (gas would be higher) can pose a hazard to personnel if not properly insulated. Covering these pipes with removable insulation blankets brings the outside touch temperature down to safe levels.
For more information on how Firwin can help you with your engine insulation needs, please visit our website , or call us at 1 877 347 9467.
Comments Off on Diesel Powered Equipment: Underground Mine Safety – The Role of Insulation.
Firwin Industry Series – Underground Mining
From scoops and scalers to pallet handlers and personnel carriers, underground mining relies on diesel-powered equipment to get the job done. Diesel power provides the mine with a rugged, reliable, and cost effective energy source; overall, diesel accounts for 72 percent of the energy used by the mining sector.* With developing economies such as China and India fueling demand and contributing to record high prices for aggregates, precious metals, and other natural resources, mining equipment manufacturers are experiencing an increasingly strong demand for diesel powered vehicles that can extract, load, and transport.
(* Diesel Service and Supply website, Industrial_Industry_Usage)
Diesel Powered Equipment in an Underground Environment: The Challenges
As can be imagined, underground mining poses a number of challenges when it comes to the safe and efficient use of diesel powered mining equipment:
•Exposed exhaust and engine components: Diesel exhaust can get extremely hot. With work in an underground mine often taking place within confined spaces, workers are at risk from severe burns from uncovered exhausts and engine components.
•Diesel particulate matter: Exhaust from diesel powered mining equipment must be properly filtered in order to protect personnel from noxious fumes. Fire Safety: Oil from a burst hydraulic hose, or from an engine leak, can start to smoke upon contacting exposed exhaust components.
•High ambient heat: The heat generated by diesel powered equipment can heat up an already sweltering underground environment. Furthermore, it can cause heat sensitive cables and sensors to malfunction.
Meeting the Challenges: How Insulation Blankets Can Help
Blanketing the exposed engine and exhaust components is an important step in meeting the challenges of operating diesel powered equipment. Once properly insulated, ambient heat is reduced, and workers are shielded from burns. A good ventilation system is of course essential in ensuring that hot air is removed and cooler air is brought in, and to remove noxious fumes from the mine.
As regards the latter, pollution control equipment, such as catalysts and particulate filters, are essential in removing much of the noxious material before it leaves the exhaust. Proper insulation can even help catalysts burn exhaust pollutants more effectively by maintaining an optimal high exhaust temperature as the exhaust travels along the piping and into the catalyst.
Standard Insulation Blankets: Why They Sometimes Fall Short
The underside of a regular-issue insulation blanket is typically fiberglass material, which is non-combustible, held in place by wire mesh. While fine for most applications, in an underground mine, oil from a burst hydraulic hose line, or an engine leak, can seep underneath an insulation blanket and lodge in the insulation material. Separated from the hot component by only a wire mesh, this mixture of oil and insulation material can become a fire hazard, the last thing you want in a underground mine.
Standard Insulation Blanket Construction
The second limitation of standard insulation blankets is the outer cover. Typically a silicone impregnated fiberglass, the outer cover is designed to be durable and withstand normal wear and tear for years. In an underground mine, however, the confined spaces and potential rock falls can lead to sharp objects coming into contact with the insulation blankets. Not designed to withstand this kind of treatment, regular insulation blankets can be prone to tearing or puncture.
MineWrap™ Insulation Blankets: Designed for the Underground Mine
MineWrap Mark II’s Stainless Steel Inner Liner
To meet these concerns, Firwin’s R & D department designed a blanket with the specific needs of underground mining in mind. Known as MineWrap™ Mark II, this blanket features a stainless steel inner liner, which seals off the insulation material and prevents any oil from seeping in.
For those applications that require extra strength and rigidity to reinforce its outer cover, MineWrap™ comes in a Mark III version. The Mark III blanket features a reinforced stainless steel foil exterior, which in turn is covered with a stainless steel mesh. Joint safety seals can be added to further seal off any exposed exhaust between blanket sections.
With its added dimensions of increased fire safety and rugged exterior, MineWrap™ has become the insulation blanket of choice for a number of mines and equipment manufacturers.
Firwin Hard Coat: A Permanent Insulation Solution for Underground Mines
Some underground mines have determined that while they need their hot exhaust components insulated, they do not need to have the insulation be removable. These mines have opted for Firwin Corp’s Hard Coat™ insulation system . Hard Coat™ features a durable, lightweight exterior, and is typically applied to components such as exhaust manifolds, turbochargers, elbows, and exhaust piping. Unlike removable insulation blankets, which are wrapped around an engine or exhaust component and fastened with a fastening system (typically stainless steel lacing wire), Hard Coat™ insulation is a permanent insulation applied directly to the component being insulated. This results in the insulation material being completely enclosed and shielded from exterior elements. As such, the danger of equipment oil and fluid leaks that might otherwise seep into the insulation material and cause a potential fire hazard is eliminated.
According to Firwin President Paul Herman, “For certain high-temperature applications where safeguarding for oil leaks is a priority, space is at a premium, and a removable insulation product is not required, Hard Coat™ insulation is a definite option, and may be more economical in the long run.”
“While permanent insulation such as Firwin Hard Coat™ has its advantages, for instance it compactness and durability, there are drawbacks as well”, notes Paul Herman. “It cannot be removed should a part require servicing. The coating must be applied at our factory. It is also more expensive up front than traditional insulation blankets.”
Mining exhaust with both MineWrap™ and Hard Coat
Turbo and Manifold with Firwin Hard Coat insulation
Conclusion:
While insulating exposed hot exhaust components are essential for underground mines, it is important to choose the correct insulation solution so that the insulation itself does not add any new safety concerns. MineWrap™ Removable Blankets and Hard Coat Composite Insulation have been designed to effectively insulate mining equipment exhaust components in a manner that encompasses the safety concerns of underground mines.
Comments Off on Velcro Fasteners – What You Need to Know
Among the fastening systems we offer for our removable insulation blankets is Velcro. An excellent and easy to use fastener, Velcro is often used in applications which require a simple and quick fastening method. Velcro fastening does, however, come with some limitations, which users need to be aware of in order for it to function as intended.
Background – How It Works
Velcro is actually the trade name for what is generically known as ‘Hook and Loop’ fastening. The hook‐and‐loop fastener was conceived in 1941 by Swiss engineer George de Mestral who lived in Commugny, Switzerland. The idea came to him one day after returning from a hunting trip with his dog in the Alps. He took a close look at the burrs (seeds) of burdock that kept sticking to his clothes and his dog’s fur. He examined them under a microscope, and noted their hundreds of “hooks” that caught on anything with a loop, such as clothing, animal fur, or hair. He saw the possibility of binding two materials reversibly in a simple fashion if he could figure out how to duplicate the hooks and loops. It took de Mestral around 10 years to perfect the process, and Velcro was born.
Velcro Fastening on Removable Insulation Blankets
Velcro fastening systems are supplied on rolls of paired woven tapes. The materials used in making these woven tapes are typically one or more of nylon, polyester, and Nomex (a flame‐resistant meta‐aramid material developed in the early 1960s by DuPont). Each paired tape has a loop tape, with loops made from the same fiber as the woven tape, and a hook tape. The hook tape, regardless of what material the woven tape is made from, typically has nylon or polyester hooks. For example, when ordering a Nomex Velcro, even though the base tape and loops are made with Nomex, the hooks will still be made with Nylon or Polyester.
Velcro can either be used as the prime fastening system where the Velcro keeps the blanket closed, or it can be used as a secondary or complementary fastener, as in the case of ‘D rings’, where the ‘D rings’ fasten the blanket and the Velcro is only used to secure the ‘D ring’ strap in place.
Why Velcro Fastening Sometime Becomes Ineffective
Velcro tapes are temperature rated when ‘closed’ (i.e. when hook and loop are fastened). In fact clothing manufacturers always require the Velcro tape to be closed before ironing/pressing garments ‐ and which is why you should also fasten any Velcro garments before putting them in the washer / dryer! So a Nomex base Velcro with nylon or polyester hooks will have a slightly higher temperature rating (350°F / 177°C) than a polyester‐based Velcro (280°F / 138°C), as the Nomex provides some additional heat protection for the nylon / Straps with Velcro &”D” Ring Fastening System polyester hooks when the tape is in the closed state. For temperatures beyond 350°F / 177°C, stainless steel hooks are available. Depending on the base tape used, stainless steel hooked Velcro tape can be used in applications as high as 450°F / 232°C for Nomex‐based tape, to as high as 800° F / 426° C for Velcro tapes constructed completely from 300 series stainless steel. The higher one goes on the temperature scale, the more expensive the Velcro tape becomes, especially the stainless steel versions. Because of this price premium, Velcro fastening is most commonly found on removable insulation blankets used in temperature ranges which can support nylon or polyester hooks.
As mentioned, both Nylon and Polyester have a temperature tolerance up to 280°F / 138°C , beyond which they tend to break down or melt if brought into contact with a heated surface. In practice, manufacturers like to err on the side of caution, and typically call for a temperature limit of 200°F / 93°C. This means that as long as the outside temperature of the insulation blanket (the ‘cold face’) is below this temperature limit, Nylon and Polyester Velcro should function properly. For example, for a pipe of 3” or 4” diameter, with a room temperature ambient, a typical 1” thick insulation blanket would allow for an internal temperature of up to 800° F / 426° C before the outside face temperature went beyond 200°F / 93°C.
The ‘weak point’ on a Velcro fastener is typically the hooks since they are so fine. Once the hooks are damaged from contact with high temperatures the fastening tape becomes ineffective. This is the most common reason for breakdown of Velcro tapes. Even the accidental brushing of the hook tape against a hot surface is sufficient to damage the hooks. Another common cause of Velcro tape breakdown is when the loops and hooks get clogged up with dust of grime.
Are Velcro Fastened Removable Insulation Blankets Right For You?
As mentioned above, the main benefit of Velcro fastening is the ease in which an insulation blanket can be installed and removed. However, there are situations where Velcro may not be the recommended fastening method. “For low temperature applications, Velcro can be an excellent fastening method”, notes Brett Herman, Firwin’s Vice President of Sales and Customer Service. “This is especially true if the customer requires a fastening method that is easy to install and / or remove.”
“However, there are some drawbacks that customers need to be aware of. Firstly, most Velcro come with polyester or nylon hooks, and if these are exposed to heat approaching 280°F, the hooks can become damaged and the Velcro fastener will no longer be effective. While stainless steel Velcro hooks are an option, they are quite expensive, and even they are limited to 800° F / 426° C – so if the application is very high temperature, these hooks also pose the risk of getting damaged through accidental contact.”
“Secondly, when compared to the ‘standard method’ of fastening blankets via stainless steel lacing wire and rivets, Velcro has an added cost component, mainly from the increased labor needed to produce a Velcro blanket. So for customers looking for a ‘lowest cost’ solution, and for whom ease of installation and removal is not so crucial, an alternative fastening method would be better suited”, added Brett.
Proper Care of Velcro Fastened Removable Insulation Blankets
The recommended use of Velcro when used on insulation blankets, for hot Removable Insulation Blanket with lacing wire & rivet fastening Other blanket fastening methods: Snaps, Straps, Springs equipment and heater bands, is to install and remove blankets when the machine or surface is cold.
Firwin blankets are designed to ensure that Velcro fastenings with nylon / polyester hooks are mounted on the cold side of the blanket insulated from the hot surface by a suitable insulation layer. To be safe, we like to add a buffer to the temperature limit, and call for a temperature below 200⁰F [93 ⁰C] to make sure that the hooks will not be damaged. Care should be taken at all times not to allow the hook side of the blanket to brush up against such a hot surface.
As well, blankets should not be kept in grimy areas, or any place where dirt or molten plastics can get into the Velcro.
