Insulation Jackets-The

War on Pipe Insulation

Meghan Reilly

Account Manager

Mreilly@thermaxxjackets.com

Pipe insulation is not the low hanging

fruit…..It’s the fruit starting to Rot on the

ground!

Insulation Story

Was Insulated & Removed

Removed for Maintenance or inspection

Never Insulated

Valve was never insulated during construction phase

Removable Insulation

Removable insulation is installed

Mechanical Insulation =

Comfort & Appearance

Safety

Energy Efficiency

Start with steam:

The 200psi Gorilla

*Efficiency gains available from insulation and steam trap monitoring

**Using fuel cost of $22 per million BTU

*** Total U.S Consumption approximately 95 Quadrillion BTU’s annually

5

Opportunity

District Steam Industrial Steam

U.S. Facilities 5,800 43,000

Steam usage 1.1 Quads 12.7 Quads

Efficiency Gain* 8% 5%

Annual Savings** $2 Billion $14 Billion

• Over 10% of total annual U.S. energy consumption***

• $16 Billion/year in available savings

• Common systems

• Concentrated market ($300K annual savings per facility)

• Opportunity to provide compelling ROI

Why are we missing insulation?

No Budget

Might be Asbestos

in the area?

We will do it later

Did not know how much was missing

Phase 1 Battle Plan

Building by Building

Buildings not scheduled for major renovation in next 24 months

Perform a detailed insulation survey

Steam and Condensate Focus

Incentive investigation- Local Gas Company, Facility

Document and Notify- Environmental & Safety Concerns

(asbestos, lighting, leaks)

ROI Presentation and Sortable Reports

Mechanical Information, Accurate Locations, Photo’s,

Temperatures…all in the Cloud

Insulation Audit-iOS App

Energy Efficiency…Calculate

3E Plus BTU Loss Calculations (ASTM C680)

Typical Project Payback

< 18months

Item Location Description

Flange

Class

Nominal

Pipe Size

Operating

Temp ⁰F

SF/

component

Wind

speed

Hrs in

service/yr.

Insulation

Thickness

Bare

BTU/hr/sf

lost

Insulated

BTU/hr/sf

lost

Insulated

Touch

Temp ⁰F

Dollars LOST

per yr. if

Uninsulated

Insulation

cover Cost

Each

Payback

in

Months QTY

Total yearly

savings if

insulated

1

Steam

Tunnel

6" 250lb. Gate

Valve Bonnet 250 6.00 300 5.2 0 8760 1" 608 56 107 $342.59 $343.00 13.23 1 $311.04

2

Steam

Tunnel

10" 250lb. Gate

Valve Bonnet 250 10.00 300 8.25 0 8760 1" 608 56 109 $543.54 $50.00 1.22 1 $493.48

3

Steam

Tunnel

4" 125lb. Spence

Type E Main Va. 125 4.00 300 6.42 0 8760 1" 621 51 103 $432.02 $456.00 13.80 1 $396.54

4

Steam

Tunnel

3/4" Sarco B1H

Inverted Bucket

Steam Trap n/a 0.75 216 1.62 0 8760 10mm 285.36 51 95 $50.09 $115.00 33.54 1 $41.14

5

Steam

Tunnel

3/4" Armstrong

2011 Inverted

Bucket Steam Trap n/a 0.75 230 1.42 0 8760 10mm 320 35 97 $49.24 $115.00 31.47 1 $43.85

Customer Name

Ambient Temp 75 ⁰F

Cost per

MMBTU$12.37

REPORT SUMMARY:

$1,286.05

$1,079.00

10.07

Sample Results

YEARLY SAVINGS IF INSULATED:

Total Insulation Jacket Cost:

Average Payback in Months:

DOLLARS LOST EACH YEAR IF COMPONENTS REMAIN UN-INSULATED $1,417.48

Heat-Loss & ROI

Item #

1

Location

Steam Tunnel

Description

6’ 250lb. Gate

Valve Bonnet Flange Class

250 Nominal Pipe

Size

6.00

Operating Temp ⁰F

300

SF/component

5.2

Wind Speed

0

Hrs in service /yr.

8760

Insulation Thickness

1”

Bare BTU/hr/sf lost

603

Insulated BTU/hr/sf lost

56

Insulated Touch Temp ⁰F

107

Dollars LOST per yr. if

uninsulated

$342.59

Insulation cover

Cost Each

$343.00

Payback in

Months

13.23

QTY

1

Total yearly savings if

insulated

$311.04

REPORT SUMMARY:

YEARLY SAVINGS IF INSULATED $1,286.05

Total Insulation Jacket Cost $1,079.00

Average Payback in Months 10.07

DOLLARS LOST EACH YEAR IF COMPONENTS REMAIN UN-INSULATED $1,417.48

Phase 2 Execution

Abatement if required

Install Pipe Insulation & Removable Jackets

Unique QR Codes for Scanning

Proper Labeling- Facility assistance

Perform Post Inspection with gas company

Install Ambient Temperature Monitoring Sensors

Collecting data 24/7

Web Portal

Live temperatures

Image overlays

Savings to-date per component

Monthly Report

Shows total savings, providing justification for current

and future projects

Summary of monthly results

Constant improvement and refinement of analysis

capabilities using proprietary information from entire

client-base

Alerts

Defaults based on component type

Fully customizable

Email/SMS alerts to client upon device malfunction

Documenting Savings

Phase 3 Occupation (Maintaining) Monitor and set up alerts on Ambient temperature spikes

Company Receives a Notification when temperature rises

Insulation removed or steam leaks

Install App on Facilities IPads/IPhones

Allow Facilities to view asset numbers and jacket photo’s

Allow facility to price and request heat loss cost

Yearly maintenance inspections

Use the app to photograph insulation work yearly for a 5 year

period

Reinstall removed insulation jackets or document insulation that

has disappeared

Monthly reports showing BTU savings and Temperatures

All information is archived and can be viewed with APP

Photo Album

Condensate Pump After

Photo Album

Expansion Joint Before and After

Steam Vault Before and After

Steam Vault Before and After

Before and After Steam Trap Station

Before and After

WeatherMaXX

Strainer and Spool Before and After

Photo Album

Photo Album

Photo Album

Thank You

Energy Efficiency…Calculate

Sample

Project Highlights Job Name Acme

Opp Number 6831

Date 4/8/14

Total Project Cost $39,723.00

Total Jacket Savings $8,836.31

Total Steam Trap Failure Prevention $10,749.44

Total Yearly Savings $19,585.75

Incentive $15,889.20

Months- ROI2 14.60

Payback in Months 24.34

5 Years of Savings $97,928.77

Monthly Cost of waiting $1,632.15

CO2 Greenhouse Reduction (Metric Tons/yr)

40.69