The Problem

Burn and scald injuries lead the way in workplace injuries that result in lost time from work (average of 5 days per year per burn or scald according the National Institute for Occupational Safety and Health (NIOSH) Publication No. 2004 -146). The economic impact to employers and employees alike as a result of these injuries can be overwhelming. A recent study conducted in Oregon State suggested the average cost in that state for burn injuries is $5,400 USD per incidence!

The Hazards

A major burn hazard source is found in industrial plants that utilize steam process lines. In many typical applications hot steam lines are initially covered with a permanent fixture of hard lagging and mineral wool insulation. As plant processes evolve or if system problems occur, sections of insulation are often removed for troubleshooting, pipe replacement or line reconfiguration. The removed sections of insulation are usually irreparably damaged. Replacement costs for these small sections can be cost prohibitive utilizing traditional insulation techniques. The result is that the insulation is often never replaced thereby creating a potential burn hazard.

A second major burn hazard source occurs at high temperature flexible (steam/oil/heat traced) hoses that are connected to moving machinery or equipment. Traditional hard lagging insulating technologies are not flexible and therefore are not capable of servicing these hoses. The result is that the hoses are left un-insulated thereby creating a potential burn hazard for personnel who service or operate adjacent equipment.

The scenarios above represent just two of literally thousands of common applications where the potential for a serious workplace burn injury exists.

The Solution

Recent advancements in thermal protection technologies are utilizing closed cell silicone sponge rubber materials to create a wrap for protecting hot process lines. Unlike traditional mineral wool the sponge wrap system does not required a hard lagging to contain the insulation material. It is extremely flexible and may be cut to length with an ordinary pair of scissors to allow for easy installation by in house maintenance staff.

In many cases the insulation wrap is equipped with a hook and loop closure to further simplify the installation on existing lines without line disconnection or interruption. The hook and loop closure also allows for easy access to process lines while performing maintenance procedures or trouble-shooting system components.

Due to its ease of installation and removable characteristics the sponge wrap provides a good solution for protecting flexible hoses and sections of process lines that are otherwise left void of insulation.

The Technology

This new technology introduces the use of closed cell silicone sponge rubber as a thermal protection medium. This material has a very low thermal conductivity and a high temperature resistance making it an excellent choice as a burn protection medium.

Unlike traditional insulation technologies (consisting fibrous materials and hard outer cladding) silicone sponge rubber wrap is easy to install and does not require the expertise and skills of a professional contractor. The result is that the cellular silicone sponge wrap is a cost effective technology that is well suited covering a variety of potential burn surfaces.

The closed cellular nature of the silicone sponge rubber does not allow for water or other liquids to infiltrate ("wicking") through the insulation medium. This enables the material to function effectively as an insulator in exterior environments when exposed to rain and other elements.

The inherent flexibility of the sponge wrap combined with the aforementioned properties, makes it an excellent technology for providing burn protection from high temperature flexible hoses and sections of process lines that are left void of insulation.

The Benefits

With a minimal initial capital investment a typical plant can be equipped with silicone sponge burn protection to significantly reduce the risk of workplace injuries resulting in lost time.

In addition to minimizing burn injuries, protecting un-insulated pipes will increase the overall plant efficiency leading to a reduction in energy costs.

The Conclusion

Protecting un-insulating hot process lines with cellular silicone rubber sponge technologies will demonstrate unrealized energy savings while creating a safer workplace environment.