Category Archive: hard coat insulation

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:

Marine

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.

Underground Mining

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. 

Oil & Gas

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.

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

Standard insulation blankets have 2 features which can make them less than ideal for an underground mining environment:

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 blankets

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

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

Hardcoat insulationSome 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.”

Heat Shield on Engine

Mining exhaust with both MineWrap™ and Hard Coat

Turbo and Manifold with Firwin Hard Coat insulation

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.

Introduction to Engine Component Insulation

engine component insulation

Engines play a vital role in a wide range of industrial applications. However, they also introduce a variety of hazards and risks to the work environment if the proper precautions are not implemented. For example, they can generate a significant amount of heat, which can negatively impact nearby equipment performance and integrity, and employee health and safety in the absence of a proper insulation solution. Insulation is key to protecting nearby employees and equipment while optimizing engine performance.

The Importance of Engine Component Insulation

If an engine does not have proper insulation, the heat it produces during use can lead to a significant rise in temperatures. Elevated temperatures can cause a number of problems for equipment and employees, such as:

  • Increased employee discomfort. The heat generated by engines can raise ambient temperatures within the work environment to uncomfortable levels, which makes it difficult—if not impossible—for workers to complete their tasks safely. Insulation keeps heat contained within the engine or exhaust so it will not influence conditions in the surrounding area.
  • Higher risk of employee injury/illness. Increased temperatures inside and outside the engine can also lead to employee injury or illness; for example, hot exterior surfaces can cause severe burns, while hot ambient temperatures can trigger heat exhaustion. Engine insulation protects employees from exposure to overly hot surfaces and temperatures.
  • Greater chance of equipment damage. High engine temperatures can cause overheating in some systems. Additionally, they put any nearby thermally sensitive components (e.g., hoses and wires) at a higher risk of suffering thermal damage. Insulation shields components and equipment around the engine from potentially damaging heat.
  • Decreased equipment performance. The performance of an engine is significantly affected by its ability to achieve and maintain proper internal temperatures. While high heat is detrimental to nearby components, systems, and people, it is critical to efficient operation. Insulation enables an engine to keep the heat it generates contained inside of it and its exhaust system so it can operate at optimal capacity. As a result, it helps reduce energy usage and emission levels.

Engine Component Insulation Solutions at Firwin

Firwin is an industry-leading supplier of insulation solutions. After nearly 40 years in the industry, we’ve garnered the knowledge and skills needed to create insulation products for a range of industrial applications. Our engine component insulation offerings include:

Removable Insulation Blankets

Our flagship product, removable insulation blankets are typically composed of the following 3 layers: an inner steel mesh layer, a middle insulation medium layer, and an outer silicone-coated fiberglass layer. Fastened in place with stainless steel lacing wire, they are perfect for engine components that require regular maintenance since they can be easily removed and replaced as needed. Additionally, they can be customized for fit and application-specific characteristics, such as alternative materials and fastening systems.

MineWrap™ Removable Blankets

Our MineWrap insulation blankets are engineered to meet the specific needs of the underground mining industry. The flagship MineWrap Mark II has a flame-resistant foil inner liner lined with stainless steel mesh, which protects it from oil and hydraulic fluid intrusion and, consequently, eliminates the risk of fire. The MineWrap Mark III has a reinforced stainless steel foil exterior covered by a layer of stainless steel mesh, which makes it better suited for more demanding mining applications.

Permanent Hard Coat Composite Insulation

Permanent Composite Hard Coat Insulation
Our hard coat composite insulation coatings are an ideal insulation option for components that do not need regular repair and maintenance. After the composite coating is thinly applied to the target material, it forms a permanent high temperature insulation layer,  that also protects the insulation material from combustion in the event of an engine leak or malfunction. It is rated for temperatures up to 900° F.

Stainless Steel Foil Insulation

metal foil insulationOur metal foil insulation (MFI) is another permanent insulation option for exhaust components (e.g., tubes, piping, and elbows). The insulation material is encapsulated by an outer foil layer that is permanently welded to the engine component, which results in a durable, leak-free, and highly customizable solution.

Contact Firwin for Engine Component Insulation Needs

Firwin’s highly customizable range of engine component insulation solutions makes it easy to prevent even the most powerful engines from harming your employees and equipment. Whether you need a removable or permanent product, we can help you protect your people, products, and processes. To learn more about our engine component insulation solutions and how they can benefit you, contact us today.

Hard Coat Insulation vs. Removable Insulation

They may sound like the same thing, but insulation coating and insulation blankets are actually quite different. When you face choosing between these two, equally high-quality products, you need to know some key facts to make the right decision.

Essentially, it comes down to some key factors including the need for removability, your space constraints, the importance of fireproofing, and finally, cost.

Type of Insulation:

An important factor is the type of insulation needed, including the desired strength. Considering that Firwin HC™ is in fact hard and more durable, it is more suited for extremely rugged conditions. Our blankets, although also tough, are not as impenetrable as our hard coatings. The hard coat is more applicable where there is a possibility of sharp objects coming into contact with the insulation and the possibility where insulation can be torn.

Removability:

Firwin HC™ Hard Coat is permanently applied and cannot be removed, while our insulation blankets can in fact be removed and even reused. This is important if you need to do periodic maintenance on whatever you are insulating. In that case, the blankets will better serve your needs. Additionally, since the hard coating is applied directly onto parts, you need to disassemble you components and send them to Firwin for coating. If the components are difficult to access and disassemble, then we recommend using our insulation blankets.

Space Constraints and Fireproofing:

Because Firwin HC™ is applied directly to the component, it conforms tightly to the part and is ideal for applications that offer limited space. The thinness and flexibility of the hard coating makes it more of a viable option when the blankets are too bulky to fit.

Firwin HC™ is non-flammable and proves to be a valuable safety and fireproof option. As for the insulation blankets, they are fire retardant. For those applications requiring a further measure of safety, Firwin offers our MineWrap™ blankets which completely enclose and prevent any oils or fluids from lodging in the insulation and igniting fire.

Cost:

While both insulations take about 2-3 weeks in lead time from order to delivery, hard coating will last longer but are also more than removable insulation.

Therefore, whether you need hard coat or removable insulation, there is one thing you can count on, and that’s the experts at Firwin. If you have any doubts about which is right for you, just contact a rep at Firwin today and we can help you make the perfect insulation decision.

insulation blankets
Firwin insulation blankets
Hard Coat
Firwin HC™ Hard Coat