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PLAINTIFF'S
EXHIBIT
DUP-2352
ASBESTOS CONFERENCE RICHMOND NOVEMBER 17 AND 18, 1983 SOFT COVERINGS
C. M, GARDNER, JR. SEAFORD, DELAWARE
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-30UPDATE ON "SOFT" REMOVABLE/REUSABLE INSULATION
R. M. Norris
FIGURE 1 Soft.removafcle/reusable thermal insulation was first introduced t m the Fibers Department in the' mi'd-1970 ' s at Kinston and at Seaford and perhaps on a small scale at some other sites. There were some distinct advantages to soft insulation over other removable/reusable insulation types because it was much quicker to install and remove; and if the materials of construction were right for the temperatures, it would last longer, -too.
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Second, the blankets, in the early years, were not very prett They v/ere instead baggy and wrinkly.
FIGURE 3
Last, but not least, the materials used were not always comp at.idle with process temperatures; and as a result, the cloth frequent became scortched, thus, adding to the unsatisfactory appeara.nc:e .
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FIGURE 4
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So for several years, the use of soft insulation really did not expand very much.
In 1982 at the charter meeting of the Textile Fibers Thermal Insulation Committee ,_we established soft insulation as a program of high priority and "agreed that we needed to document quantita tively just what the stake was for converting to blanket msulatior
Thermal Efficiency
The first thing we did after we returned from" the meeting was invite George Lang to'come to Seaford and make a comparison, using his Heat Flow Meter (HFM), of two screw melters -
FIGURE 5 one covered with calcium silicate and the other with blanket ir.suia
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The results of this test indicated a 25% improvement with blanket insulation. In fact, they had to turn off the zone 5 heater right after start-up because the barrel was too hot.
Then we asked George to confirm these results in the lab and he set up a section of 4" pipe at the Test Center where he comoared 2" of calcium silicate and 2" of Thermal Insulating Wool (TIW).
Measuring the amount of electrical energy needed to control the pipe at 450F, 550F, and 650F, George found a 15 to 231 savings with blanket insulation.
I hlai ve a. simalifi^d at Marti is vi'llle , /Wh
plotted the results TIW is a siipetL^or silicate
t designed hy Jim Fetter
g th^rbreak, I have
^ 'they/Clearly/show n cbmpared With
/.that
COST-LABOR/MATERIAL
Let us take a look at two examples which may serve to illustrate how the cost of blanket insulation compares with calcium silicate First, the inert gas heaters at Seaford Plant are fairly straight
forward. It costs $1500 to insulate them with calcium silicate. In 1982, we got a quote of $3M from Construction to make two blankets.
Second, the autoclaves are rather complex with many valves and flanges.
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FIGURE 7
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FIGURE 11
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FIGURE 13
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-27Event with rigid insulation, they were not very attractive so we covered them with a "tin can" to make them pretty.
FIGURE 15
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Let us talk about the cost to maintain this autoclave with an average of one 0/H each year. Bv competitive bidding, the installed cost of this blanket is $2500.
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Now let us compare the cost of maintaining an A/C with blanker insulation.
Autoclave
Cost to maintain (1 0/H per year) when covered with calci1.
silicate
_i . .
Removal
3 man days
Installation
6 man days
Routine maintenance
24 man days
Material
$6 00/year
Initial cost soft insulation $2500
Cost to maintain soft insulation (1 O/H per year)
Removal
.5 man days
Reinstall
1 man day
Routine maintenance
8 man days
Material
-..... -
$100/year
Savings
Labor at 24 man days/year
$ 3.3M/year
Energy (25* impr.)
$ 3.0M/year
Material (after first year)
.5M/year $6.8M
1st Year
3rd Year
- NROI
207%
233%
Now look at the savings! Over $3M in labor alone. A total of $6800 savings on $2500 investment. I wish I could get that kmc of return from my private investments.
And it looks good too!!
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FIGURE 21
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What materials do we use? We have standardized on three insulating materials for our blankets, but there is ho doubt some we have not tried, we are using TIW Type I. TIW Type II which is approximately two times as dense as Type I and Temp. Mat which is still denser than Type II.
FIGURE 22
The outside cloth is an F.G. cloth treated with silicone for water/dirt resistance, it is good for 500F.
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-43The inside cloth, you see here on. this pipe cover, is plain high temp, glass cloth good for 1000F.
FIGURE 24 This is a close up of the closures that we use at Seaford. They consist of lacing rings, washers, Pan Ty cable ties, and makes a very attractive cover. Here we see various views of the blanket on our T13 CP vessels.
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FIGURE 25
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FIGURE 26 FIGURE 27
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FIGURE'2 8
Adherence to Spec.
We have spent quite a lot of time developing a specification for the Department which we can all use with confidence. One thing must be remembered. The blankets we make or buy are on li as good as the spec they are made by.
For example, we must insist that the installed thickness is per spec.
FIGURE 29
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Here is a cover made for a 1" dow pipe. The spec calls for 6" of installation compressed to 4" with 3" minimum installed thick ness. So you can see there is the required amount of insulation in this blanket; but low and behold, when they install the hard ware, they have actually pinched the ends to 2" or less. Joints are another area where we must, both for process reasons and for energy reasons, insist on vendors meeting the spec.
FIGURE 30 Here is a view showing several good butt and overlapping joints. On butt joints, where the fit is not good, we sometimes use what we call "Belly Bands" which cover the butt joint to insure thermal integrity. WITSre an overlapping joint is used, the O/L must be 3" and a draw down wire must be used to seal it.
Summary in summary then, I have tried to show that the economics over whelmingly support continued use of soft insulation. The spec must be closely followed if we are to reap the benefits of energy savings, and the TF spec puts us on the leading edge cf the state of the art in soft insulation technology; and we will continue to revise and upgrade cur spec as we learn new and better techniques.
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