Advantages and disadvantages of jacketing

What is jacketing?

Jackets are insulators that cover processing components, including pipes, valves and filters, accessories and pumps. The valve cover is wrapped around the valve and the hooks are firmly joined together with the help of the rope. Jackets are used for thermal insulation.

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A range of thermal-jacketed products is available for organic and inorganic chemical processors. pharmaceutical plants, polymer producers. petrochemical plants and food processors.

Generally, jacketing that has been specifically fabricated falls into one of three broad categories: standard, swaged and hybrid systems.

Standard jacketing:

Typically, this system provides uniform application of heat by covering the pipe or valve (core) from the flange. The jacket is welded to the back of the flange so oversize valves must be used to accommodate bolts.

Swaged jacketing:

This system is often used where protection against cross-contamination is required and where temperature discontinuities at flanges can be tolerated. Swaged jacketing can be less expensive than standard jacketing because small in-line flanges can be used, also referred to as capped or partial jacketing.

Hybrid jacketing:

This method utilises a combination of both swaged and standard jacketing systems as well as removal and special jacketing. Straight-line piping may use swaged jacketing while valves and fittings employ standard or removable jacketing to eliminate temperature discontinuities at critical flow areas.

Jacketed valves:

All types of valves can be fully jacketed by fabricating techniques, including many valves not available with integrally-cast jackets.

Standard fabrication includes modifying the valve to accept oversize flanges. extending the body as necessary to ANSI standard. then adding the full jacket ensuring that the interior tolerances remain the same as the original unjacketed valve.

Advantages of jacketing:

• Unit construction

• High rates of heat transfer from the heating medium to the process

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• Ability to maintain processing temperatures within close tolerances

Disadvantages of jacketing:

Choosing between removable thermal insulation blankets and Hard CoatTM permanent insulation depends on the application.

Insulating hot surfaces on engines and exhaust systems remains a key operating and safety issue for engine-powered vehicles and equipment. Among the benefits of applying thermal insulation covering to engine manifolds, turbochargers, and other hot exhaust components are:

• shielding hoses, wiring, and electronic components from malfunctioning due to excess heat
• protecting personnel from burns
• maintaining exhaust heat at level required for optimal catalyst performance
• sound attenuation

While removable thermal insulation blankets have typically been the insulation of choice, recent advances in rigid insulation have given equipment designers and packagers more variety as to what medium to use when insulating their engine and exhaust components.

Firwin Corp’s Hard CoatTM insulation is one such example of the new generation of rigid insulation. The product 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 CoatTM 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.

Among the industries that have taken to Hard CoatTM type insulation over removable insulation blankets are marine, defense, and especially underground mining, where shielding the insulation material from leaked engine oil or hydraulic fluid is a top priority.

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 an insulation product is required, Hard CoatTM insulation is a definite option, and may be more economical in the long run.”

Each of the technologies has its own particular advantages and drawbacks. The rigid outer surface of Hard CoatTM insulation makes it less prone to tears or punctures than standard silicone-impregnated insulation blankets, and more resistant to damage from fluid leaks. It also makes Hard CoatTM insulation more durable than blankets. In addition, Hard CoatTM insulation is typically more compact than insulation blankets, as the insulation is formed directly on the component to be insulated. The disassembled, non-insulated part is shipped to Firwin, where the Hard CoatTM insulation is applied via a proprietary process. The insulated part is then shipped back to the customer. The resulting compactness can be critically important in engine compartments where space is often at a premium.

“While permanent insulation such as Firwin Hard CoatTM has its advantages, 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.”

Removable insulation blankets do have significant advantages for a number of applications. They are designed to be easily installed, requiring no special tools or training for installation. Importantly, they can also be easily removed, a key benefit where equipment may require periodic maintenance and inspection. Unlike Hard CoatTM which requires parts to be shipped to a factory, removable insulation blankets are typically designed remotely using measurements, drawings, and digital photos. The resultant blanket design is saved as a pattern, which can be referenced at a later date should the same part need an insulation blanket. Firwin Corp maintains an extensive library of patterns covering a wide range of engines and exhaust system components. Thus redesign is minimized, and replacement sections can be easily manufactured should any part of the insulation blanket become damaged.

Although removable insulation blankets can be susceptible to absorption of leaked flammable fluids into the insulation material, careful design and material selection can minimize this issue – Firwin’s MineWrapTM blankets designed for underground mining are a case in point. Finally, insulation blankets typically offer greater sound absorption than Hard CoatTM materials, and also tend to be more vibration resistant.

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