Insulation systems, like all mechanical systems, require periodic inspection and maintenance. While inspection and maintenance are the responsibility of the owner, the fact is that many insulation systems are frequently ignored. With time, insulation systems can be damaged, and the entire system can become ineffective if the damaged areas are not repaired or replaced. Train your employees to perform regular maintenance, and hire insulation contractors for regular inspection and maintenance to prevent this outcome.

Failure to perform inspections and implement a timely maintenance plan carries several risks. On hot systems, missing insulation will result in increased heat loss, which may translate to significant economic losses over time. On cold systems, damaged vapor retarders will lead to increased water vapor intrusion, which can reduce insulation effectiveness, increase the possibility of corrosion, and increase the potential for mold growth. For outdoor systems, damaged or missing weather barriers can allow rainwater entry, which can compromise the effectiveness of the insulation system. Rain and moisture intrusion through open or damaged areas can lead to corrosion under insulation (CUI) for outdoor, hot systems. If an inspection reveals missing or damaged insulation, repairs should be scheduled as soon as possible. Rapid repair is needed for cold systems, where water vapor intrusion can quickly spread.

At a minimum, insulated areas should be inspected annually. Critical systems could require more frequent inspections to ensure continuous operation. Inspection of the external surface should include checking for signs of cracking, distortion, damage, or corrosion; evidence of hot spots on high-temperature systems; and condensation and ice buildup on low temperature systems. When necessary, the external weather barrier should be removed to enable inspection of the insulation and attachments. Infrared video cameras are useful for inspection and should be considered for use after the startup inspection and for ongoing insulation maintenance. Infrared inspection can reduce the need to remove the weather barrier to inspect the insulation.

When removal and replacement of part or all of the insulation system is indicated, re-insulation should be performed in the same manner as specified for the initial installation, unless the nature of the damage suggests that the system was improperly insulated or the materials originally used are now outdated. When determining how much insulation to remove, cut and remove it until you reach undamaged insulation, if that is possible. Care should be taken in removing existing insulation to minimize damage. Temporary protection for adjacent insulation may be required to prevent damage while repairs are underway.

The following sections, “Risk Assessment Discussion” and “Maintenance Checklist,” were created by the National Insulation Association and the National Institute of Building Sciences, and are excerpted from the Mechanical Insulation Design Guide.

FAILING TO INSULATE CAN RESULT IN:

1. Increase in energy costs
2. Increase in greenhouse gas emissions
3. Loss of process/production quality and increase in costs
4. Occurrence of CUI
5. Development of condensation or ice, depending upon the service temperature
6. Development of mold or mildew
7. Decrease in personnel safety
8. Decrease in personnel productivity
9. Loss of time spent on other projects
10. Decline in facility appearance
11. Decrease in the life and operational efficiency of equipment in the area
12. Increase in life-cycle cost
13. Failure to obtain sustainability objectives
14. Failure to realize return on investment (ROI) estimates

Risk Assessment Discussion

Not maintaining a mechanical insulation system promptly and effectively is associated with risks. Those risks, and the severity of potential consequences, will vary depending upon the service temperature of the operating system on which the insulation is installed, the surrounding environment, ambient conditions, the extent of any damage to the insulation system, the insulation system design, the quality of the installation, the timeline of correcting any damage, and other conditions that may be unique to the area in question. The risks of failing to implement a timely and effective mechanical insulation maintenance plan can be serious.

Each company and individual has their own level of risk tolerance; however, the risk of failing to establish a timely and proper mechanical insulation maintenance plan is real and should not be overlooked or underestimated.

Maintenance Checklist

Upon observing any of the following conditions, a maintenance request/action plan should be implemented to assess the degree of damage, and the damaged area of the insulation system should be repaired or replaced to prevent further damage and avoid additional risk. This list is not presented in order of importance or priority. The list is provided as a guide for individuals evaluating the condition of an installed mechanical insulation system. It is not intended to be all inclusive or to provide sufficient information to act as a stand-alone document that would allow anyone, experienced or inexperienced, to function as an inspector of mechanical insulation systems.

Checking for all of the following occurrences is a good start for a maintenance plan.

• Damage to or wearing of the outer jacketing/finish of the insulation system (damage could be caused by mechanical abuse, negligence, or weather; or it could simply occur over time)
• Unsealed penetrations in the insulation system
• Missing insulation
• Insulation that has been removed and not yet replaced
• Insulation supports that are failing or appear not to be working correctly
• Ice, mold, and mildew on/in the insulation system
• Condensation
• Discoloration of the insulation system (other than by dirt)
• Discoloration of adjacent materials
• “Fish mouthing” of the outer jacketing seams
• Missing or loosening of insulation system securements
• Sagging or pulling away of the insulation system
• “Hot spots” in the insulation system
• Appearance of moisture on the insulation system
• Joints in the insulation that appear to be opening
• Expansion or contraction joints that appear to be functioning incorrectly
• Indication of moisture due to condensation on adjacent surfaces—stained ceiling tiles, drips, wet floors, water staining, etc.
• Insulation system being used in a different environment or service than the original design for the insulation system

With proper attention and maintenance, insulation systems can save a company considerable energy and money, improving process efficiency and equipment life. Mechanical engineers and insulation contractors can play a key role in facilitating regular inspection and maintenance programs to achieve this outcome. Owners/operators should also train all plant operations and maintenance personnel on the importance of looking for and reporting any signs of damage to the insulation system.

If you want your employees to learn more about insulation or become a Certified Thermal Insulation Inspector, visit www.insulation.org/training-tools or www.niaeducationcenter.org.