Note: Descriptions are shown in the official language in which they were submitted.
CA 02784649 2012-08-03
Insulation System and Method of Application Thereof
Field of the Invention
The present invention relates to a method of insulating and jacketing a pipe
or
vessel and to a resulting system of insulation and jacketing for a pipe or
vessel.
Background
In almost all chemical and industrial applications, vessels and piping
carrying
process materials need to be insulated or otherwise protected against outside
environment. Safety and environmental regulations are also stringent in their
requirements that industrial fluids, petrochemicals and waste fluids be stored
and
transported in complete isolation from the surrounding ecosystems.
The problem of oil or other fluid leakage into surrounding soil, water tables
or
rivers and lakes is a significant one that results in loss of product,
ecosystem damage,
loss of reputation in the public eye, fines and even criminal charges.
Vessel jacketing and piping insulation have been used for years for the
purposes
of insulation and containment.
Such insulation typically involves either a spray or fibre-based insulation
applied
to a vessel or pipe, optionally with some form of cladding applied overtop.
Very often
however, insulation materials are necessarily rough with many air pockets and
an
uneven surface. Such texture is advantageous for trapping air and insulating,
but does
not allow for satisfactory adhesion of the cladding. Cladding is required to
ensure
containment against leaks and must be applied evenly and securely.
The use of spray foam insulations produces a less uneven surface than fibre-
based insulation, however it is not suitable for all applications. Conversely,
fibre-based
insulation result in a very uneven surface and results in poor adhesion for
cladding or
jacketing or the like.
A need and interest therefore exists in the art to develop improved methods of
insulating and jacketing vessels and pipes and for improved systems of
insulation and
E1397694 DOC,1 1
CA 02784649 2014-02-24
jacketing.
Summary
A system of insulation and jacketing of industrial equipment is provided. The
system
comprises an insulation layer comprising one or more layers of fiber based
insulation applied to
an outer surface of the equipment,; an intermediate layer applied to an outer
surface of the
insulation layer, said intermediate layer selected from the group consisting
of a polymer plastic
film, a polymer layer and webbing material and a jacketing layer applied and
adhered to an outer
surface of the intermediate layer. The intermediate layer forms a smooth outer
surface and
promotes adhesion of the jacketing layer to the insulation layer.
A method of insulating and jacketing industrial equipment is also provided.
The method
comprises the steps of applying an insulation layer comprising one or more
layers of fiber based
insulation to an outer surface of the equipmentõ applying an intermediate
layer to an outer
surface of the insulation layer; said intermediate layer selected from the
group consisting of a
polymer plastic film, a polymer layer and webbing material and applying and
adhering a jacketing
layer to an outer surface of the intermediate layer. Application of the
intermediate layer serves
to smoothen the outer surface of the insulation layer and promote adhesion of
the jacketing
layer to the insulation layer.
Brief Description of the Drawings
The present invention will now be described in greater detail, with reference
to the following
drawings, in which:
Figure 1 is perspective view of one embodiment of the present system;
Figure 2 is cross sectional view of one example of the present system;
Figure 3 is a cross-sectional view of one example of an insulated pipe of the
present system;
Figure 4 is a cross sectional view of another example of an insulated pipe of
the present system;
and
E1938842 DOCX,1 E1918704 DOCX,1 2
CA 02784649 2012-08-03
Figure 5 is schematic diagram of one embodiment of a method of the present
invention.
Description of the Invention
The present invention relates to a method of insulating and cladding
industrial
equipment, such as piping and vessels and to an insulation and cladding system
for such
industrial equipment. More specifically, the present invention relates to a
method of
cladding or jacketing over fiber-based insulation on industrial equipment such
as pipes
and vessels. The present method and system provide improved leak resistance
and
sealing of the industrial equipment body.
For the purposes of the present invention, piping can be any process piping
found in industrial facilities, as well as pipelines for transporting process
fluids,
petroleum and other materials across great distances. Vessels can include
storage
vessels, reactors, heating and cooling vessels and the like.
Figures Ito 4 have been illustrated with a pipe as one example of the present
system, however it would be understood by a skilled person in the art that any
type of
industrial equipment, including but not limited to pipes and vessels, can be
insulated
and clad using the systems and methods of the present invention. The insulated
and
clad system of the invention is generally indicated as 2 in Figure 1. The
method of the
present invention is generally depicted in Figure 5.
Insulation associated with the present invention can be spray foam
insulations,
fiber-based insulations and chemical insulations such, for example calcium
silicate
insulations.
More preferably the present invention relates to methods of jacketing a pipe
or
vessels covered with a fiber-based insulation. Such fiber-based insulations
can include
those made with wood fiber, glass fiber, mineral fiber and fibers composed of
recycled
materials.
Further preferably, the insulating material can be an aerogel. Aerogels are
porous solid material made by removing the liquid component of a gel in such a
way as
to preserve the framework's pore structure. Aerogels can be made from a number
of
E1397694 DOC,1 3
CA 02784649 2012-08-03
substances including but not limited to gels of silica, metal oxides, metals,
carbon and
metal chalcogenide. Most preferably, the insulating material is a silica
aerogel.
It is also possible to use pyrogel based insulations, which are high-
temperature
insulation blankets formed of silica aerogel and reinforced with a fiber
batting.
With reference to Figure 3, in a preferred first step of the present method, a
pipe
or vessel 4 is covered with one or more layers of insulation 6. The layers of
insulation 6
may be of the same thickness or of varying thicknesses. The layers of
insulation 6 can
be sealed along their longitudinal seam 14 using any well-known adhesive in
the art,
including but not limited to adhesives like Nashua 357 TM adhesive tape. In
the case of
more than one layer of insulation 6 being applied to the pipe or vessel,
sections of
insulation bats or blankets are preferably applied in a brickwork pattern,
such that the
longitudinal seam 14 of inner layers are in misalignment with the longitudinal
seams 14
of subsequent layers. Most preferably the seam14 of inner layers is directly
opposite to
the seams 14 of subsequent layers of insulation.
In an alternate application depicted in Figure 4, insulation 6 can be applied
to a
pipe or vessel that comprises one or more heat traced lines 16 thereupon. In
such
cases, the insulation 6 tends to form a void 18 next to the heat trace lines
16. It is
preferred in such applications to apply the one or more layers of insulation 6
in such an
orientation that the seam 14 of an innermost layer, adjacent the pipe, does
not align
with the heat trace line 16.
In a most preferred embodiment using aerogel insulation 6, the pipe or vessel
4
can first be coated with a protective seal (not shown) prior to application of
the one or
more insulation layers 6. As indicated above, any combination of insulation
layer
thicknesses may be applied in any order to achieve a final desired insulation
thickness.
For example, in the case of aerogel or of pyrogel insulation 6 applications,
the insulation
6 is applied as a 15 mm layer comprising an innermost insulation layer of 5 mm
thickness, covered by an outer insulation layer of 10 mm thickness.
Alternatively, a total
20 mm layer of insulation 6 can be applied by applying two 10 mm thick
insulation
layers. Further alternatively, a total 30 mm layer of insulation 6 can be
applied by
E1397694 DOC,1 4
CA 02784649 2014-02-24
applying three 10 mm layers to the pipe or vessel.
In all cases of applying more than one layer of insulation 6, the longitudinal
seam 14 of
an inner layer of insulation is preferably misaligned with the longitudinal
seam 14 of a
subsequent outer layer of insulation. Most preferably the seam 14 of a
subsequent outer layer
lies diametrically opposite to the longitudinal seam 14 of an inner layer of
insulation, to thereby
follow a 'brickwork' pattern of application.
Once the one or more layers of insulation 6 have been applied, an outer
surface of the
outermost insulating layer is treated, coated or otherwise conditioned to
provide a smooth
surface upon which cladding or jacketing can be applied and adhered.
In one preferred embodiment, an intermediate layer 8 is applied overtop the
outermost
insulation layer 6. The intermediate layer 8 provides a smooth surface and
serves to even out
and eliminate surface irregularities 12 typically found in the insulation
layer, such as fabric
nests. The intermediate layer 8 is preferably in the form of a high
temperature tolerant
polymer plastic film including but not limited to cross-linked or non-cross-
linked polyolefin,
cross-linked or non-cross-linked PVC. Such polymer plastic films are often
commercially called
shrink wrap. More preferably such polymer plastic film can be applied in a
thickness ranging
from about 0.05 millimeters to about 0.10 millimeters and is most preferably
0.08 millimeters
in thickness.
Alternatively, a layer of polymer layer can be applied as the intermediate
layer 8 to the
outermost insulation layer 6 to smoothen the insulation surface. The polymer
layer can be
glued or applied and affixed by any suitable means known in the art. Such
polymer layer is
more preferably similar to those used in the construction industries as vapour
barriers and the
like. Polymer layer is preferred in cases where pipes or vessels 4 are not
easily accessible, for
example in cases when lower surfaces of the pipes or vessels are close to the
ground or other
equipment.
In another embodiment, a webbing material or tape can be applied and then
El 938842 DOCX,1 El 91 8704 DOCX,1
5
CA 02784649 2012-08-03
sprayed with a suitable polymer spray to form the intermediate layer 8. Such
webbing
material, can be, for example a fiberglass cross-linked tape or web sprayed
with a
polymer-based spray. In a most preferred example, such a webbing material is
drywall
tape.
In a further alternate embodiment, particularly in the case of the use of
spray
foam insulation as the insulation layer 6, the outermost layer of insulation 6
can be re-
surfaced, treated, trimmed or otherwise conditioned to smoothen its outer
surface. In
one preferred embodiment, the outer surface of the insulation is run through a
lathe to
produce a smooth outer surface and even insulation thickness along the length
of pipe
The surface smoothening provided by the intermediate layer 8 allows for a
cladding or jacketing 10 to be applied to the insulated pipe or vessel 4, to
protect the
insulation layer 6 and to provide containment in the case of leaks. The
intermediate
layer 8 advantageously provides a smooth surface for better adhesion of a
jacketing or
Alternatively, a blanket comprising polyurea with a fabric backing can also be
applied over the intermediate layer 8 and sealed in place by any suitable
adhesive
known in the art and most preferable by a spray adhesive into a longitudinal
seam 14 of
lower surface of the pipes or vessels are close to the ground or other
equipment.
The thickness of the jacket 10 is preferably in the range of about 60 to about
250
mm, and is most preferably about 120 mm in thickness for piping and vessels.
E1397694 DOC,1 6
CA 02784649 2012-08-03
The thickness of the jacket 10 can be verified by any known means in the art.
Commonly, thickness is tested by a destructive test of cutting the jacket 10
at varying
locations along the pipe or vessel 4 and use of a thickness gauge, such as for
example a
dry film thickness or ultrasound gauge, to measure thickness of the jacketing
layer 10. A
visual or other suitable inspection technique can also be used to inspect for
pinholes or
undercuts in the jacketing layer. Should imperfections exist or if the jacket
does not
meet a minimum desired thickness, further layers of jacketing material can be
sprayed
or otherwise applied to the existing jacketing layer.
Preferably, the insulated, wrapped and jacketed equipment is cured for between
1 to 2 hours without disturbance.
In the foregoing specification, the invention has been described with a
specific
embodiment thereof; however, it will be evident that various modifications and
changes
may be made thereto without departing from the broader spirit and scope of the
invention.
E1397694 DOC,1 7
