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PIPE AND EQUIPMENT INSULATIONPreferred Installation Manual

Contents

Safety First 2

Material Handling 2

Preparation and Storage 2

Optimal Work Setup 3-4

Single Wrap Pipe 5

Double Wrap Pipe 6

Multi-Layer Wrap Pipe 7

Preformed Pipe Covering 8

Pipe Fittings 9

Valves and Flanges 10-12

45- and 90-Degree Elbows 13-16

Cryogenic Piping and Equipment 17

Filling Cracks and Voids 17

Cutting Charts 18-22

Equipment Procedures 23-26

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N A N O T E C H N O L O G Y A T W O R KTM

Aspen Aerogels recognizes that performance of our state-of-the-art aerogel insulation materials depends on the total thermal integrity of our system. Therefore, we have developed preferred guidelines for installing aerogel blankets.

All of the procedures described in this manual have been field-proven in conjunction with installation partners.

We are constantly striving to develop new application procedures and insulation systems to make our products stand above our competition with quicker delivery times, simpler logistics, and more reliable installation.

We stand behind our products and are willing to work with you to develop application procedures to suit your project-specific execution plan.

Please feel free to contact us for specialized training or recommendations regarding our application procedures.

Preferred Installation Manual

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N A N O T E C H N O L O G Y A T W O R KTM PIPE AND EQUIPMENT INSULATION

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Material Handling

Aerogel insulations when shipped in full rolls are typically 57” wide weighing approximately �00 lbs per roll. When shipped in orders of two rolls or more, they are packaged in crates containing two rolls (Fig. 1). The use of a pallet jack or forklift will be required in order to move the double roll crates. The crates can also be separated into single roll packaging with the removal of the side braces and the screws located at the bottom of each end once they have been received on site. These rolls can be moved manually with the use of an aluminum tube placed through the center of the roll and picked up from either end.

Safety First

Aerogel materials are engineered with safety and performance as our priorities. Aspen has performed extensive HSE testing and found our materials are safe. For worker comfort when working with aerogel, we recommend dust masks and work gloves to reduce irritation. Standard work gloves and jump suits reduce the “dry feeling” caused by the hydrophobic characteristic of aerogel.

Preparation and Storage

Aerogel insulation materials should be stored in a clean, dry and protected environment. If material has to be stored in an outdoor setting, it should be placed on pallets and thoroughly covered with a waterproof tarp or plastic sheeting. Although the aerogel material is hydrophobic, all necessary measures should be taken to protect it from the weather.

To prepare for installation:

Ensure that pressure testing of piping and fittings has been completed prior to installing insulation. Ensure that all pipe and fitting surfaces over which insulation is to be installed are clean and dry. Ensure that insulation is clean, dry, and in good mechanical condition. Wet, dirty, or damaged insulation is not acceptable for installation. Determine pipe size, pipe length, and number of layers of aerogel blanket required for the application.

•••

•

Fig. 1 MI-P-001

Frequently Asked Questions

But I heard “nanotechnology” is bad?

Aerogel is 95.97% air, so the nanotechnology refers to the pores in the material.

Is aerogel dust safe?

Our material dust is greater than 15 microns and rated only as a “nuisance dust” by OSHA.

Does aerogel silica cause health problems?

Crystalline silica is bad. Aerogel uses amorphous silica, which is not a health hazard beacuse it does not have the shape factor of a crystalline structure.

NOTE: More information on above sections can be found in our Safety & Handling Guidelines manual, which is available on request.


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Optimal Work Setup

To achieve the most productive work environment for use with Aerogel insulations we suggest the following setup.

Bulk Cutting AreA

This area will be used for the cutting of Aerogel materials from the full rolls into lengths required for the application as well as any preformed parts required to ease the installation process. This area should be setup in a covered and protected area. This area should contain several tables to accommodate the roll width and cutting length required for each component being worked. The roll of aerogel material should be situated at the front of the table (Fig. �) where it can be dispensed from the crate or placed on a roller rack with a tube placed though the roll. Please refer to the cutting tools chart below for suggested tools for this application. Once parts are cut in this area, it is suggested that they be placed on pallets (Fig. �) and covered, bagged, or wrapped in plastic before being placed at the work area.

Fig. � MI-P-00� Fig. � MI-P-00� Fig. 4 MI-P-0�0

Fig. 5 MI-P-0�1 Fig. 6 MI-P-0�� Fig. 7 MI-P-0��


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4

Optimal Work Setup

Work AreA

Once material is placed in this area from the bulk cutting area it should be checked that it is covered and protected form weather. Ideally the material should be placed as close to the work area as possible. Remove the materials from the packaging and distribute to the work location. Please refer to the cutting tools chart below for suggested tools for field applications.

Material Cutting Tool

Scissors Box Cutter Tin Snips Heated Knife Pizza Wheel/Electric

Pizza Wheel/Battery

Hand Shear Slitter

Pyrogel √ √ √ √* √ √* √* √*

Cryogel √ √ √* √ √* √*

Spaceloft √ √ √* √ √* √*

Recommended Cutting Tools

√ = field cutting equipment √* = shop cutting equipment


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5

Single Wrap Pipe

1. Cut aerogel blanket to length required for a complete wrap. Cut length may be achieved by either wrapping a piece around the pipe (Fig. 8) or consulting the cutting charts on pages 18-19.

2. Place on pipe and wrap around the circumference of the pipe (Fig. 9). Starting edge of aerogel can be handheld in place while wrapped, or the use of a pin system may be used. Suggested pin is the Durodyne Flipstix.

3. Once wrapped around the pipe, the aerogel may be held in place using tape, wire, or banding (Fig. 10).

4. Completed assembly showing lap joint (Fig. 11).

Fig. 8

MI-D-001 Fig. 9

MI-D-00�

Fig. 10

MI-D-00�

Fig. 11 MI-P-0�4


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6

Double Wrap Pipe

1. Cut aerogel blanket to length required for a complete wrap. Cut length may be achieved by either wrapping a piece around the pipe (Fig. 1�) or consulting the cutting charts on pages 18-19.

2. Place on pipe and wrap around the circumference of the pipe (Fig. 1�).

3. Overlap and continue around circumference to achieve the double layer application (Fig. 14). Starting edge of aerogel can be hand held in place while wrapped, or the use of a pin system may be used (Fig. 15). Suggested pin is the Durodyne Flipstix.

4. Once wrapped around the pipe, the aerogel may be held in place using tape, wire, or banding.

5. Install metal cladding and seal with specification-approved sealant. In some cases the use of attachment can be avoided if the finish point ends just over the top side of the pipe.

Fig. 1�

MI-D-01�

Fig. 14

MI-D-006

Fig. 15

MI-D-005

Fig. 1�

MI-D-001


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7

Multi-Layer Wrap Pipe

1. For applications that require the use of more than two layers of aerogel blanket, the suggested procedure follows the same steps as the double layer application, overlapping the circumferential joint where the first wraps meet (Fig. 16).

2. Once wrapped around the pipe, the aerogel may be held in place using tape, wire, or banding (Fig. 17).

3. Install metal cladding and seal with specification-approved sealant (Fig. 18). In some cases the use of attachment can be avoided if the finish point ends just over the top side of the pipe.

Fig. 16

MI-D-008 Fig. 17

MI-D-009

Fig. 18 MI-P-0�5


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8

Preformed Pipe Covering

Preformed pipe covering is available for pipe sizes from 1/8 inch in up to four plies per section.

This is a single tube type covering that will be shipped uncut at the opening seam to reduce damage during shipping.

The tube should be cut open for installation only after it has been received at the work site and is ready to be installed.

It is suggested that the installer cut open the sections just prior to installation to avoid damage to the material bonding.

Fig. �1 MI-P-0�0

Fig. �0 MI-P-008

Fig. 19 MI-P-0�6


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9

Pipe Fittings

PiPe ends

Install aerogel blanket past the pipe end to the same distance as required for the thickness of the insulation.

Cut plugs from the aerogel to the diameter of the opening and install to match the thickness.

reduCers

Install aerogel blanket to the same thickness as would be required for the piping using the same layout pattern as would be required for the metal cladding less the required overlaps.

Install each layer in a staggered fashion.

tees

Install aerogel blanket using the same techniques as would be used for installing the cladding.

PiPing shoes

Install aerogel blanket around pipe adjacent to the pipe shoe and make a slit the length of the shoe.

Slide aerogel through the shoe area and continue wrapping the aerogel on the other end of the shoe area.

For some shoe types that have a welded section through the center, it may be required to apply the aerogel from both ends.


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10

Valves and Flanges

1. Insulate the pipe as far as the flange, then determine the diameters of the aerogel-insulated pipe and the flange.

2. Wrap strip of aerogel over insulated pipe portion to achieve the same diameter as the flange (Fig. ��). Cut donut to the same size of the bonnet end if insulation is required on the bonnet section.

3. Measure the height between the two outer faces of the aerogel wraps (Fig. ��).

4. Transfer height “B” and circumference “A” to aerogel sheet and mark the cutouts for the bonnet neck “C” (Fig. �4). Move the cutout on each wrap of aerogel to achieve stagger, and slide over handle section to achieve stagger (Fig. �5).

This section gives the general techniques for insulating larger valves and gate valves. Because of the variety in shape and design of flanged valves, some modifications to these instructions may be necessary.

Fig. �4 MI-D-010

Fig. ��

MI-D-01�

Fig. �5 MI-D-011

Fig. ��

MI-D-014


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11

Valves and Flanges

7. The last pieces will insulate the bonnet area if required (Fig. �6). The bonnet insulation of aerogel is cut to the size of C x L1, then marked in quarters (Fig. �7). Next, the scalloped edge of the insulation is determined by swinging an arc from each point marked + in Fig. �7. The radius of the arc is equal to Y. These areas are connected with straight lines to give a smooth scalloped edge (Fig. �8).

6. The aerogel sheet is now wrapped around the valve body followed by any additional layers with joints staggered. Attachment of the aerogel may be done with tape, banding, or wire.

8. Once installation of the aerogel insulation layers is complete, the finished valve should resemble Figs. �9 and �0.

5. Wrap scrap strips of aerogel to build the body of the valve out unit so it is the same dimension as the OD of the flanges.

C Overall length determined by wrapping a strip of aerogel around the bonnet flange and marking where the ends meet

L1 Distance is from the outer surface of the aerogel donut to the approximate middle of the valve body insulation

L2 Distance is from the outer surface of the aerogel donut to the closest surface of the valve body insulation

Y Difference between L1 and L�

Fig. �6 MI-D-015

Fig. �8 MI-D-017

Fig. �7

Fig. �9

MI-D-018

Fig. �0

MI-D-019

MI-D-016


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1�

Valves and Flanges

10. Aerogel-lined removable metal or blanket covers may also be an option for valves and flanges (Figs. �1 and ��).

9. Install metal cladding over aerogel and seal with specification-approved sealant.

Fig. �1 MI-P-009

Fig. �� MI-P-0�1


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1�

45- and 90-Degree Elbows

Pipe Size Elbow Type

Pre-Formed Pre-Cut Gored Stove Pipe1/� – 11/� √

� – 6 √ √ √

6 – 1� √ √

1� – �4 √ √

�5 – �6 √ √

�7 – 48 √

Suggested Elbow Chart

This section covers four types of elbows available for use with aerogel materials and installation suggestions.

Pre-Formed

The pre-formed elbow is fabricated from preformed pipe covering. It is a mitered and glued one-piece elbow. Installation of this elbow will require cutting at the overlapping seam, placing over the elbow, and installing tape or wire to secure. The contractor may also choose to cut these at their own facility with the use of a miter saw and by the measurements shown on page �0.

Fig. �� MI-P-011 Fig. �4 MI-P-01� Fig. �5 MI-P-01�


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14


Pre-Cut

The pre-cut elbow is based on a gore-style pattern attached through the heal area forming a spine through the elbow. This elbow is one piece per layer application for sizes �0” and smaller and two pieces for sizes �1” – �6”. Please refer to the instructions listed below for ease of installation.

1. Remove first course of aerogel from box (on top). Centerline is marked with color-coded stripes: red for inside surface, green for outside surface (Fig. �6).

Fig. �6 MI-D-0�0

2. Apply first finger assembly with red stripe facing the pipe and green stripe on the outside (shortest fingers on the inside layer). Start applying aerogel at three inches before the tangent line of the elbow, and center on the heel section of the elbow (Fig. �8).

Fig. �8MI-D-0�1

Fig. �7 MI-P-0�7

Fig. �9 MI-P-0�8


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3. Repeat steps for second course of aerogel. Start applying aerogel this time at the tangent line of the elbow to achieve stagger, again centering on the heel section of the elbow (Fig. 40).

4. Completed six-ply aerogel assembly showing three-inch tail section on first three layers (Fig. 41).

Fig. 41MI-D-0��

Fig. 40 MI-D-0��

Fig. 4� MI-P-0�9


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16


gored

This style of elbow can be cut by the contractor using the same principles that are used to fabricate the metal gore elbow minus the overlaps required for metal.

Cut the aerogel blanket to the required length and cut as per the gore pattern. Install each layer, staggering the seams where possible. This can be achieved by slitting one of the gored sections down the center to create half a gore. This half section will be used for the starter and finisher of the staggered layer. The gored elbow may also be achieved with the separating of the above listed pre-cut elbows and installed one gore at a time. For larger elbows above �6”, we recommend this type of installation.

stove PiPe

It is suggested that this style of elbow only be used on the small bore piping where the fabrication of the above elbow styles can not be fabricated due to limited elbow throat space. In order to fabricate this elbow, it is suggested that the pre-formed pipe covering be cut at a 45-degree angle with the sections adjoined in the elbow to form the 90-degree elbow

Half gore section

Fig. 4� MI-P-014

Full gore section

Fig. 44 MI-P-015


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17

Cryogenic Piping and Equipment

Follow application procedures in previous sections for piping, fittings, valves and flanges, and elbows while installing specification-approved vapor barrier between installed layers (Fig. 45). Once all required layers have been applied, install metal cladding to specification requirements.

Filling Cracks and Voids

Filling small cracks and voids can be achieved by delaminating the aerogel material to a workable thickness and pushing it into the crack with the use of a knife. For larger cracks and voids, it is recommended that strips or sections be cut from a blanket and added. When delaminating, care must be taken not to shred the material causing it to loosen the aerogel material from the section. It is not recommended that it be shredded into fiber in order to do this, as this will cause the loss of aerogel from the material.

Fig. 45

MI-D-0�4


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18

Cutting Charts

Aerogel 6 mil BlAnket Cut ChArt


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19

Cutting Charts

Aerogel 10 mil BlAnket Cut ChArt


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�0

Cutting Charts

Aerogel insulAtion ClAdding Cut ChArt


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�1

Cutting Charts

Aerogel insulAtion metAl elBoW ChArt


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��

Cutting Charts

Aerogel miter ChArt


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Equipment Procedures

1. Determine area to be insulated. Calculate the circumference of the tank or vessel based on the outside of the insulation.

2. Cut aerogel insulation to desired working length. For smaller tanks or vessels, we suggest a continuous wrap per layer. For larger tanks or vessels, we suggest cutting aerogel insulation to the length that will be workable for the work area.

This section covers the installation of aerogel insulation for tanks and vessels. Because of the variety in shape and design of tanks and vessels, some modifications to these instructions may be necessary. The following application procedures are intended to be used as a guideline and are not intended to act as the only form of installation.

PrePArAtion

Ensure that pressure testing of equipment has been completed prior to installing insulation.

Ensure that all equipment surfaces over which insulation is to be installed are clean and dry.

Ensure that insulation is clean, dry, and in good mechanical condition. Wet, dirty, or damaged insulation shall not be acceptable for installation.

NOTE: When installing multi layers of aerogel insulation, we suggest staggering the edges.

stAndArd insulAtion ProCedures

3. Attach leading edge of aerogel insulation with welded or self-adhesive insulation pins. Apply clips and wrap insulation around the circumference of the tank or vessel. If the use of pins is not possible, the aerogel material can be held in place with bungee-type straps until the wrap is completed and metal banding can be applied.

4. Install welded or self-adhesive pins to the end location adjacent the leading edge, and press over pins and apply clips.

5. For cutouts, we suggest cutting a slit in the aerogel insulation and sliding into position. Then trim to fit the location using a sharp knife or scissors.

6. Apply banding around the circumference of the tank or vessel and tighten.


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�4


vessel heAd instAllAtion

Cut aerogel insulation in a pie shape using one of the methods below. Because of the flexibility of aerogel material, the large edge at the tangent line of the pie section may be much larger then normally applied with other insulation products.

Field Cut Method 1. Measure the distance from the tangent line

to the center of the head. 2. Cut aerogel material to the length as measured from tangent line to head center.

3. Cut aerogel material to the desired width at the tangent line. Mark both edges back to the center line at the other edge of the material, creating a pie shape (Fig. 46).

4. Attach aerogel material at the center point for the head using insulation weld or stick pins. Pull back to the tangent line, and attach with the same method at this location. If the use of pins is not an option, this can be done with the use of a choker system around the tangent line with wire or banding pulled over the installed pie section to hold in place.

5. Continue installing the same size pie sections at each quarter of the head section. Fill in the remaining sections with the same size pie pieces until they will no longer fit. At this point it will require trimming of the pieces to fit in the sections that are now existing (Fig. 47).

Fig. 46 MI-P-016

Fig. 47 MI-P-017


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�5

vessel heAd instAllAtion

Shop Cut Method 1. Measure the distance from the tangent line

to the center of the head. 2. Cut aerogel material to the length as measured from tangent line to head center.

3. Determine circumference on the outside of the aerogel material.

4. Determine the desired working size of the material at the tangent line, and divide by the circumference to determine the required pieces.

5. Determine the center point of the head, and divide by the number of required pieces.

7. Attach aerogel material at the center point for the head using insulation weld or stick pins. Pull back to the tangent line, and attach with the same method at this location. If the use of pins is not an option, this can be done with the use of a choker system around the tangent line with wire or banding pulled over the installed pie section to hold in place.

6. With the determined measurements of tangent line and center section, mark these on the sheet one at each end, and cut the required amount.


Fig. 48 MI-P-018


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�6


1. Determine length of sloped surface. 2. Cut aerogel material to the determined length.

trAnsitions And Cones

3. Determine circumference of vessel or tank. 4. Divide the circumference by the desired work width of aerogel material to determine the required pieces.

5. Determine circumference at the bottom of the cone.

6. Mark each end of cut aerogel material and cut into pie shape.

7. Attach aerogel material at the center point for the cone using insulation weld or stick pins. Pull back to the tangent line, and attach with the same method at this location. If the use of pins is not an option, this can be done with the use of a choker system around the tangent line with wire or banding pulled over the installed pie section to hold in place.

8. Install metal cladding to required specifications and seal with specification approved sealant.

Fig. 49 MI-P-019

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N A N O T E C H N O L O G Y A T W O R KTM

Aspen Aerogels, Inc.�0 Forbes Road, Building BNorthborough, MA 015��www.aerogel.com

phone 508.691.1111fax 508.691.1�00email [email protected]

© �006 Aspen Aerogels, Inc.REV 1.0

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