Government Energy Tips

Install Removable Insulation on Uninsulated Valves and Fittings

During maintenance, insulation over pipes, valves, and fittings is often damaged or removed and not replaced. Uninsulated pipes, valves, and fittings can be safety hazards and sources of heat loss. Removable and reusable insulating pads are available to cover almost any surface. The pads are made of a non-combustible inside cove1, insulation material, and a non-combustible outside cover that is tear- and abrasion-resistant. Materials used in the pads are oil- and water-resistant and can be designed for temperatures up to 1600'F. The pads are held in place by wire laced through grommets or by using straps and buckles.

Application

Reusable insulating pads are commonly used in industrial facilities for flanges, valves, expansion joints, heat exchangers/ pumps/ turbines, tanks, and other irregular surfaces. The pads are flexible and vibration resistant and can be used with equipment that is horizontally or vertically mounted or difficult to access. Any high-temperature piping or equipment should be insulated to reduce heat loss, reduce emissions, and improve safety. As a rule of thumb, any surface over 120oF should be insulated for protection of personnel. Insulating pads can be easily removed for periodic inspection or maintenance and replaced as needed. Insulating pads can also contain built-in acoustical barriers for noise control.

Energy Savings

The table below summarizes energy savings due to the use of insulating valve covers for a range of valve sizes and operating temperatures.

a. Based on 2-inches of insulation on 150 pound class flanged valves with an ambient temperature of 65'F. 
b. From a personalc ommunicationa nd with permissionf rom E.J.Bartells Co.

Example

Using the table above, calculate the annual fuel and dollar savings from a 2-inch thick insulating pad installed on an uninsulated 6 inch gate valve in a 250 psig saturated steam line (405'F). Assume continuous operation with natural gas at a boiler efficiency of 80% and a fuel price of $3.00 per million Btu.

Annual Fuel Savings = 11210 Btu/hr x 8760 hours x 1/0.80 = 722.75 MMBtu Annual Dollar Savings= 122.75MM8tu x $ 3.00/MMBgp = g358per6-inch gate valve

About DOE's Office of Industrial Technologies

The Office of Industrial Technologies (OIT), through partnerships with industry government, and non-governmental organizations, develops and delivers advanced energy efficiency renewable energy, and pollution prevention technologies for industrial applications. oIT is part of the U.S. Deparment of Energy's office of Energy Efficiency and Renewable Energy. OIT encourages industry-wide efforts to boost resource productivity through a strategy called Industries of the Future 0OF). IOF focuses on the following nine energy and resource intensive industries:

OIT and its Best Practices program offer a wide variety of resources to industrial partners that cover motor, steam, compressed air and process heating systems. For example, BestPractices software can help you decide whether to replace or rewind motors (MotorMaster+), assess the efficiency of pumping systems (PSAT), or determine optimal insulation thickness for pipes and pressure vessels (3E Plus). Training is available to help you or your staff learn how to use these software programs and learn more a about industrial systems. Workshops are held around the country on topics such as "Capturing the Value of Steam Efficiency," "Fundamentals and Advanced Management of Compressed Air Systems," and Motor System Management." Available technical publications range from case studies and tip sheets to sourcebooks and market assessments. The Energy Matters newsletter, for example, provides timely articles and information on comprehensive energy systems for industry. You can access these resources and more by visiting the BestPracticesW eb site at www.oit.doe.gov/bestpractices or by contacting the OIT Clearinghouse at 800-862-2086 or via email at  This e-mail address is being protected from spambots. You need JavaScript enabled to view it .

Install RemovabIe Insulation Valves and Fittings

During maintenance, the insulation that covers pipes, valves, and fittings is often damaged or removed and not replaced. Pipes, valves, and fittings that are not insulated can be safety hazards and sources of heat loss. Removable and reusable insulating pads are available to cover almost any surface. The pads are made of a noncombustible inside cover, insulation material, and a noncombustible outside cover that resists tears and abrasion. Material used in the pads resists oil and water and has been designed for temperatures up to 1,600oF. Wire laced through grommets or straps with buckles hold the pads in place.

Application

Reusable insulating pads are commonly used in industrial facilities for insulating flanges, valves, expansion joints, heat exchangers, pumps, turbines, tanks, and other irregular surfaces. The pads are flexible and vibration-resistant and can be used with equipment that is horizontally or vertically mounted or that is difficult to access. Any high-temperature piping or equipment should be insulated to reduce heat loss, reduce emissions, and improve safety. As a general rule, any surface that reaches temperature greater than 120 degrees F should be insulated to protect personnelI. Insulating pads can be easily removed for periodic inspection or maintenance, and replaced as needed. Insulating pads can also contain built-in acoustical barriers to help control noise.

Energy Savings

The table below summarizes energy savings due to the use of insulating valve covers for a range of valve s zes and operating temperatures. These values were calculated using a computer program that meets the requirements of ASTM C 680-Heat Loss and Surface Temperature Calculations. Energy savings is defined as the difference in heat loss between the uninsulated valve and the insulated valve operating at the same temperature.

Example

Interpolating from the table above, calculate the annual fuel and dollar savings from installing a 1-inch thick insulating pad on an uninsulated 6-inch gate valve in a 250-pound-per-square-inch-gauge (psig ) saturated steam line (406'F). Assume continuous operation with natural gas at a boiler efficiency of 80% and a fuel price of $8.00 per million Btu ($8.00/MMBtu).

Results:

Annual Fuel Savings: 5,992 Btu/hr x 8,760 hr/yr/ (0.80 x 10 to 6th power Btu/MMBtu) = 65.6 MMBIU

Annual Dollar Savings: 65.6 MMBtu/yr x $8.00/MMBtu = $525 per 6-inch gate valve

Availability

Insulation supply companies are located regionally; this expedites delivery and helps meet site-specific job requirements. Most supply companies can take measurements on-site to ensure the best fit on irregular surfaces. For customized applications, manufacturers can provide instructions regarding the installation and removal of insulating pads.

Noise Control Benefits

Specify insulating pads that contain built-in barriers for noise control.

Insulation or Steam Traps

Effectively insulate inverted bucket traps with removable and reusables nap-on insulation. Thermostatic traps and disk traps should be insulated according to manufacturers' specifications to ensure proper operation.

Before removal of all or any existing insulation material, check for asbestos in accordance with Occupational Safety and Health Administration (OSHA) regulations.

Steam Tip Sheet information adapted from information provided by the Industrial Energy Extension Service of Georgia Tech and reviewed by the DOE Best Practices Steam Technical Subcommittee.