Removable insulation jackets (or insulation blankets) are a leading flexible and effective insulation solution for industrial machinery and piping systems. Understanding their detailed construction and operating principle helps businesses select and apply the product optimally, thereby saving energy and ensuring operational safety.
What is an insulation jacket?
An insulation jacket, also known as a thermal cover or insulation blanket, is a custom-sewn cover designed to wrap around equipment, pipes, valves, fittings, etc., for the purpose of insulating, retaining heat, and providing protection.
Unlike traditional fixed insulation methods (like aluminum or sheet metal cladding), insulation jackets can be easily removed and reinstalled for equipment maintenance or repair without damaging the insulation structure. This flexibility and reusability offer superior long-term economic benefits.
Detailed construction of a removable insulation jacket
A high-quality insulation jacket is typically composed of three specialized material layers, combined with robust fastening accessories to ensure comprehensive insulation performance.
Layer 1: The Outer Cover – The Protective Armor
This is the layer in direct contact with the external environment, acting as a protective armor that shields the inner components from physical, chemical, and weather-related factors.
- Common Material: Double-sided silicone-coated fiberglass fabric is the top choice due to its superior properties. Teflon and Silica fabrics are also used depending on the application requirements.
- Key Features: The silicone coating makes the fabric highly resistant to water, oil, chemicals, and abrasion. This material can withstand high temperatures and is durable, extending the product’s lifespan even in harsh industrial environments.
Layer 2: The Insulation Core – The Heart of the Jacket
This layer directly determines the insulation capability of the jacket. The thickness and type of material are selected based on the equipment’s operating temperature.
- Common Materials: Mineral wool (Rockwool), ceramic fiber, and fiberglass wool. High-density Rockwool such as T50 (80kg/m³) is often preferred for applications requiring high and stable performance. For special cases needing minimal thickness and maximum efficiency, advanced materials like Aerogel may be used.
- Key Features: These materials have an extremely low thermal conductivity coefficient. Their fibrous structure with countless tiny air pockets effectively prevents heat transfer. They are completely non-combustible and also provide good sound insulation.
Layer 3: The Inner Liner – The Direct Contact Layer
This fabric layer is in direct contact with the surface of the equipment being insulated, so it must be able to withstand the system’s maximum temperature.
- Common Materials: Fiberglass fabric, Silica fabric, or heat-resistant stainless steel mesh.
- Key Features: The liner prevents fibers from the central insulation layer from escaping and also protects the equipment’s surface from scratches.
Accessories & Fabrication
To ensure the insulation jacket fits snugly, is well-sealed, and easy to handle, the fabrication details and accessories play a crucial role:
- Sewing Thread: Uses fire-resistant aramid thread or specialized stainless steel thread to ensure strength at high temperatures. Seams are often quilted to secure the insulation wool and prevent it from shifting.
- Straps & Buckles: Aramid fiber or stainless steel 304 straps combined with buckles help secure the insulation jacket firmly and allow for easy removal and installation.
- Fasteners: Heat-resistant Velcro is also used to speed up opening and closing operations.
How insulation jackets work
The insulation principle of the jacket is based on simultaneously blocking all three forms of heat transfer:
- Blocking Conduction: The Rockwool insulation core, with its fibrous structure and millions of interspersed air pockets, makes it very difficult for heat to transfer directly from the hot surface of the equipment to the outer cover.
- Blocking Convection: The insulation jacket is custom-sewn to fit snugly around the equipment, eliminating air gaps and thereby preventing convective air currents from carrying heat away into the environment.
- Blocking Radiation: Some outer cover fabrics have a reflective surface (aluminum-coated) that can reflect thermal radiation, contributing to improved heat retention.
The perfect combination of these three layers creates an effective thermal barrier, keeping thermal energy within the system and reducing the jacket’s outer surface temperature to a safe level.
Key benefits of using insulation jackets
- Energy Savings: Minimizes heat loss, helping the system maintain a stable temperature, reducing the load on boilers and compressors, and significantly saving on fuel and electricity costs.
- Workplace Safety: Lowers the surface temperature of pipes, valves, and equipment to a safe level, completely preventing the risk of burns for operating personnel.
- Equipment Protection: Keeps machinery operating within its ideal temperature range, protects sensitive components from environmental heat effects, and extends equipment lifespan.
- Flexibility and Maintenance Cost Savings: Easily removed and reinstalled in minutes for inspection and maintenance without destroying the insulation. The product can be reused many times, providing long-term economic benefits.
Frequently Asked Questions
What temperature can an insulation jacket withstand?
Depending on the construction materials, an insulation jacket can withstand temperatures from several hundred to over 1000°C. The technical specifications are custom-designed for each specific application.
Why use a removable insulation jacket instead of fixed insulation?
Insulation jackets are superior in flexibility. You can easily remove them for equipment maintenance or repair and then quickly reinstall them, whereas fixed insulation must be destroyed and redone, which is very costly.
What kind of equipment can insulation jackets be used for?
Insulation jackets can be custom-sewn for all types of equipment with complex shapes, such as: valves, fittings, pipe elbows, tanks, turbines, plastic injection machines, engine cylinder heads, etc.
