Steam Pipe Insulation 101: Materials and Supports - Buckaroos, Inc.

Insulating steam pipes is a critical task for optimizing energy efficiency, ensuring safety, and enhancing the longevity of industrial and commercial systems.

This article will discuss steam pipe insulation and explore various insulation materials as well as the best practices to protect the insulation that surrounds steam pipes.

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Understanding Steam Pipes and Their Insulation

Steam pipe systems, also known as steam distribution systems, are meticulously designed configurations of pipes. They move steam from a boiler or a steam generator to several application areas. Numerous industries, including manufacturing, power generation, and heating systems, extensively utilize steam because of its remarkable ability to efficiently transfer heat at elevated temperatures and pressures.

The temperature range during operation is between 215°F and 350°F or higher. This helps to decrease the thermal shock that may occur on the downstream preheating equipment and the boiler. In a typical system, the boiler generates steam by applying heat to water. The steam then travels through the network of insulated pipes to deliver heat where it’s needed.

According to the US Department of Energy: “Insulation can typically reduce energy losses by 90% and help ensure proper steam pressure at plant equipment. Any surface over 120 °F should be insulated, including boiler surfaces, steam and condensate return piping, and fittings.”

The pipes must be properly insulated to minimize heat loss and to protect workers from hot surfaces. The best insulation for steam pipes should have high-temperature resistance, excellent thermal performance, and durability under industrial conditions.

Various factors, such as the operating temperature of the system, ambient environmental conditions, and the desired energy efficiency, will dictate the choice of insulation material.

Options for Steam Pipe Insulation Material

There are several types of steam pipe insulation available, with calcium silicate and mineral fibers being the most common types of insulation. They can handle high temperatures and provide a good insulation value.

Calcium Silicate

Calcium silicate stands out for its durability and high-temperature resistance, which makes it particularly effective at reducing heat loss in piping systems that operate at high temperatures. It has considerable strength, which enables it to endure physical impacts without compromising its insulating attributes. Its non-flammable quality makes it a good choice for applications where fire safety is a critical concern.

Although calcium silicate might command a higher price than other types of insulation, its robust features and long-lasting nature make it a financially sound investment for steam pipe systems that operate at high temperatures.

Fiberglass (Cellular Glass)

Fiberglass, crafted from thin threads of glass intertwined to form a heat-withstanding material, is a favored option for insulating steam pipes. It offers superior thermal insulation that diminishes heat loss and subsequently boosts the total efficiency of the system.

Polyurethane

Polyurethane is a versatile insulation material that is commonly used in a variety of applications, including steam pipe insulation. It provides excellent thermal resistance for effective control of heat loss or gain in steam pipe systems. Furthermore, its structural strength and durability make it suitable for challenging industrial environments.

However, its temperature limit is lower compared to some other insulation materials, so it may not be the best choice for high-temperature steam pipe systems.

Polystyrene

Polystyrene is a lightweight and cost-effective insulation material often used in various insulation applications. However, it’s important to note that while it has good insulating properties, its relatively low melting point makes it less suitable for high-temperature applications such as steam pipe insulation.

Mineral Wool

Mineral wood and “mineral fibers” refer to the same insulation material used for steam pipes. It is made by spinning or drawing molten minerals or synthetic minerals like ceramics and slag into thin fibers. It can tolerate high temperatures, which makes it ideal for steam pipe insulation and it is valued for its fire resistance and ability to absorb sounds.

Polyisocyanurate

Polyisocyanurate, also known as PIR, is a type of thermoset plastic recognized for its exceptional thermal characteristics. While it may carry a comparatively higher price tag, its superior heat resistance and dimensional constancy make it a justifiable expenditure for rigorous applications. In its inflexible state, it can withstand temperature ranges from -297 degrees Fahrenheit to 300 degrees Fahrenheit.

Investing time and resources in proper steam pipe insulation can lead to significant long-term energy savings, enhanced safety, and improved system longevity. Whether you’re choosing fiberglass, mineral wool, or polyisocyanurate insulation, the quality of the installation is as critical as the material itself.

Buckaroos® Products That Enhance Insulation Effectiveness

For enhanced insulation protection, Buckaroos® offers an array of products, such as insulation shields and saddle supports. These products are designed to protect the insulation from compression under the hanger, maintain its integrity, and prolong its lifespan, thereby optimizing the performance of your steam pipe insulation.

Tru-Balance™ E Insulated Pipe Supports

The Tru-Balance™ Model E Insulated Pipe Supports is a top-quality pre-insulated saddle system for commercial piping systems with temperatures up to 300º F. It comes with rigid polyisocyanurate insulation, which is 3 PCF for sizes up to 12″ IPS and 4 PCF for sizes 13″ and larger. The Tru-Balance™ E features a vapor-retardant facing that doesn’t promote mold or fungus growth.

Sliding Saddles

A sliding saddle is a type of pipe support designed to manage both the weight of the pipe, and any movement from thermal expansion and contraction. It consists of two main parts: the saddle and a base that it can slide on. The saddle is shaped to fit the contour of the pipe, and distributes its weight over a larger area to reduce the pressure on any single point.

The sliding base underneath the saddle is typically constructed of two plates of material, often metal, with low friction between them. One plate is fixed, and the other is connected to the saddle, and can slide on the fixed plate. Buckaroos® suggests using Sliding Saddles along with a stiff insulation material instead of using wooden blocks.

CoolDry™ Heavy Duty Pipe Supports

The CoolDry™ Heavy Duty Pipe Supports is designed particularly for NPS pipe sizes starting at 3 inches, and is recommended for installation on roller hangers, or struts. It is ideal for cold water solutions, but it can also be applied to hot piping intended for domestic hot water and low-pressure steam lines up to a temperature of 250°F. With this product in place, thermal performance efficiency is assured across all hangers and support points to secure the entire system.

Secure Your Steam Pipe System with Buckaroos® Support Products

By selecting Buckaroos® products to improve your insulation effectiveness, you are opting for quality and reliability. With our insulation shields and saddle supports, you can be confident in the long-term performance and protection of your steam pipe insulation.

In the past, simple wood block or dowel inserts were normally used with pipe insulation protection shields to support insulation at hanger locations, but things have changed.

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With increasing environmental concerns, like mold and mildew problems, and a greater emphasis on green building, engineers are taking a closer look at their support systems to choose the most efficient. In addition, newer specifications call for colder piping systems for chilled water and other cold lines, which has created the need for a wider array of pipe insulation support systems than currently offered by manufacturers.

What Are Pipe Insulation Support Systems?

Pipe insulation supports are various forms of rigid block and pipe insulation materials used in combination with protection shields to prevent low-density pipe insulation from getting crushed at hanger locations. Proper pipe insulation supports and shields are critical for maintaining thermal performance and system integrity where the pipe insulation passes through a clevis hanger, roller, anchor, guide or strut system.

The compressive strength of the support resting on the shield must be sufficient to support the pipe insulation, and it must keep the vapor-retardant jacketing intact. The ideal pipe insulation support prevents direct transfer of moisture or heat from the shield to the actual iron pipe.

Support and Shield Materials

Rigid pipe insulation support products are typically made from the following materials:

• Wood blocks (soft and hard woods) with shields
• High-temperature, rigid fiberglass blocks with shields
• Rigid (6 PSI) polyisocyanurate blocks with shields
• Heavy density urethane blocks with shields
• Heavy density phenolic foam blocks with shields
• Wood dowel/PVC disc combination support with shields
• Wood dowels with shields
• Extruded polystyrene pipe insulation with shields
• Rigid polyisocyanurate pipe insulation with shields
• Rigid urethane pipe insulation with shields
• Rigid phenolic foam pipe insulation with shields
• Calcium silicate (12 PSI) pipe insulation with shields
• Perlite (12 PSI) pipe insulation with shields
• Cellular glass pipe insulation with shields

Pipe insulation protection shields are generally fabricated from galvanized carbon steel and are available in various gauges and lengths. Stainless steel shields are also popular, especially in food process and clean room environments where sanitation of the entire building’s pipe insulation system is critical. Also, mold, mildew, bacteria and rust are less likely to develop on the surface of stainless steel protection shields. For this reason, although stainless steel shields are more expensive than carbon steel shields, many engineers prefer the benefits of stainless steel. Another advantage to stainless steel is the ease of cleaning the shield with a damp cloth.

Protection shields are usually available in a 180-degree form and are designed to give a perfect fit to the bottom side of the pipe insulation. Typically, the smaller the copper or iron pipe, the lighter the gauge of carbon steel shields applied and the shorter the length of the shields. The gauges and lengths increase as the iron pipe size and insulation thickness increase. The normal range of carbon steel gauge offerings are 22- to 12-gauge, with lengths normally at 8 inches, 12 inches, 18 inches and 24 inches for iron pipe sizes ranging from one-half–inch to 36 inches in diameter.

Pipe insulation shield quality has improved during the past few years. Flared edge shields were designed to protect the vapor-retardant jacket facing from being punctured, and center-ribbed shields have been made available by the major clevis hanger and shield manufacturers for several years. These ribbed shields give the perfect fit inside the clevis hanger and help prevent the shield from sliding out of the clevis hanger during pipe movement.

Plated shields are used with applications that require roller hangers. The additional plate is centered on the underside of the shield, which gives extra structure and stability to the pipe insulation support system. The plate is generally made of 1/4–inch thick hardened steel and is spot-welded to the adjoining, lighter carbon steel shield.

In recent years, pre-insulated shields have become more popular, featuring a combination of rigid insulation, vapor-retardant jacketing and a self-seal tape to ensure a tight vapor-retardant closure system and a protection shield. Some specifications call for a 360-degree over/under shield to give complete protection around the entire area of the pipe insulation support.

The advantage to pre-insulated shields is that they are simple and ready to install versus field-fabricated blocks and dowels, which have to be inserted into the pipe insulation before the actual installation.

Who Installs Support Systems?

Either the insulation contractor or the mechanical contractor installs pipe insulation supports, but this depends on the requirements of the mechanical engineer writing the specification and/or the normal trend set by the region of the country.

In Midwest and Southern states, the insulation contractor usually carries the responsibility for installing the pipe insulation support systems, but in Western and East Coast states the mechanical contractor provides the supports and shields. In Canada, the mechanical contractor is usually responsible for the pipe insulation support system.

Many insulation contractors prefer to supply the shields themselves because it gives them better control of their project. By supplying the supports and protection shields they are guaranteed that the products will be onsite and ready when it is time to install the support system at the hanger or support area.

It is very important that good communication take place between the insulator and mechanical contractor when the former is supplying the shields. They have to make sure the supports and protection shields are on the job site when it is time to install the insulation to the hanger locations.

Importance of the Proper Supports and Shields

Most pipe insulation failures occur at hanger locations, so it is vital for the pipe insulation support system to be correctly engineered. It must provide proper compressive strength and maintain the vapor retardant jacket, especially for cold piping systems. Because of potential pipe movement at hanger locations, engineers must be sure that the pipe insulation support system is correctly designed to prevent any chance of damage to the jacketing, which can result in serious condensation problems if it is punctured.

Normally, cold and chilled water applications require extruded rigid polystyrene, polyisocyanurate, urethene, phenolic foam, cellular glass or Perlite pipe insulation. Due to their strong moisture- and water-resistant properties, these insulations are superior in maintaining system integrity in the sealed piping system. Calcium silicate is recommended for hot piping systems over 300 F.

The ideal pipe insulation support system features are:

• Outstanding thermal values
• Excellent compressive strength
• Clean appearance, matching the adjoining pipe insulation
• Long-lasting performance
• Low perm-rated, vapor-retardant properties
• Strong water-retardant properties
• Stability inside the clevis hanger, with low friction properties
• Resistance to mold or mildew
• Noise reduction properties during piping operation
• Vapor-retarder continuity to adjoining insulation

Where Pipe Insulation Supports Are Used

Pipe insulation support systems are used on all insulated pipe that travels through a clevis hanger system. These systems include, but are not limited to, plumbing, hot water heating, chilled water, refrigeration, ammonia, liquid nitrogen, brine, steam and condensate lines.

Pipe roller and shoe supports are generally used on hot piping systems, or in cases where the project has large-diameter pipe, a high weight factor, or a high expansion or contraction variable. These products are designed to endure pipe movement while still maintaining the integrity of the actual pipe and surrounding pipe insulation.

Pipe Insulation Shield Specifications

Even though most of the protection shields used are made from 22- and 20-gauge carbon steel, certain projects must meet the Manufacturers Standardization Society (MSS) of the Valve and Fittings Industry Inc. Standard Practice Number MSS–SP 58, Table 5, for Type 40 shields. This specification usually applies to projects by the Corps of Engineers or other governmental organizations. This specification calls for the following guidelines.

Hanger spans are governed by MSS Standard SP-69 and ASTM B31.1 and are determined by the measurement of the outer diameter of bare pipe. The span loads are based on schedule 80 pipe filled with water, with 3-inch–thick, 12 PCF pipe insulation covered with metal jacketing. Concentrated loads such as valves and fittings must be added when applicable. The mechanical engineer must account for all of these design responsibilities.

Summary

Support systems play a crucial role in the long-term success of a pipe insulation project. Choosing the correct support/shield combination will ensure a quality installation that should last for the lifetime of the pipe insulation system.

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