Category Archives: Custom Applications

Attention HMA Plant Operators

Reduce energy cost by 68% with Cool-SkinTM insulation sleeve on hot oil “jumper” hoses.

A typical Hot Mix Asphalt (HMA) plants makes use of hundreds of feet of flexible metal “jumper” hoses to transfer hot oil across connection flanges. These hoses are frequently overlooked by insulation contractors as they usually have a tight bend radius and they are difficult to protect.  In addition the neglected jumper hoses are often considered unimportant because they represent a small portion of the hot oil system.  The reality is that these un-insulated lines result in huge inefficiencies and cost thousands of dollars in wasted energy.  This would is similar to leaving a window open all winter long.  It just doesn’t make good sense.

uninsulated jumper hose

Worbo has developed an effective thermal insulation solution that enables HMA plants to recover significant heat losses on small diameter and tight radius hoses with ease.  Introducing Cool-SkinTM sleeve! 

cool-skin sleeve on jumper hose

Unlike traditional methods such as mineral wool and hard aluminum cladding, Cool-SkinTM is easy to install and does not require expensive insulation contractors.   A hook and loop self gripping fastener is incorporated into its design allowing operations staff efficient access to process lines while performing maintenance procedures or trouble-shooting system components.  Once line interruption is complete, Cool-Skin™ is simply re-installed in a few short seconds. 

An additional important and impressive benefit to the Cool-SkinTM technology is that it incorporates a closed cell insulating structure that will not absorb water or moisture making it an effective insulator even in wet conditions.

Ongoing field monitoring has proven that insulating a flexible metal hose (1 ½” OD) with Worbo’s Cool-Skin™ sleeve at a typical HMA plants will reduce heating cost an average of $30 for every foot of jumper hose in just one short seven (7) month operating season.  In most cases Cool-Skin™ pays for itself within the first four (4) months of installation.

Contact the Worbo team to learn more about how Cool-SkinTM can reduce energy costs at your HMA plant.

Cool-Skin Elbows and Tee’s

In response to a growing demand from our customers, Worbo is excited to announce the release of a new product line of easy to install elbow and tee insulation sleeves for high temperature applications.   Introducing Cool-Skin elbows and tee sleeves by Worbo.

These products offer a fantastic complement to our extremely popular line of Cool-SkinTM sleeves.  They are a perfect solution for insulating hoses and process lines that contain a tight bend radius or for lines that have tee intersections.   Traditionally it has been a challenge for plant engineers and insulation contractors to provide a satisfactory and effective thermal barrier in these areas.  Worbo’s wonderfully simple solution enables our customers to quickly and easily install these removable Cool-SkinTM  insulation components around elbows (from 45’s to 90’s) and at tee junctions.   They offer a very precise fit around a wide variety of diameters to maximize insulation coverage to minimize heat loss and to prevent burn injuries at these tricky locations.

 
Cool-Skin 90 elbow
Cool-Skin 90 elbow
 
Cool-Skin 90 elbow
Cool-Skin 90 elbow
 
Cool-Skin Tee
Cool-Skin Tee
 
Cool-Skin 45 elbow
Cool-Skin 45 elbow

Cool-SkinTM elbows and tees are fabricated from the same tried and tested materials that make up our existing Cool-SkinTM sleeve products.  They are equipped with a durable abrasion resistant jacketing system that encapsulates a clean non-fibrous insulation medium exhibiting an extremely low thermal conductivity to provide a very efficient thermal barrier.  As with many of our Cool-SkinTM products our elbows and tees are supplied with a hook and loop closure for easy installation and removal. 

For applications where radiant heat is a concern our Eko-ThermTM jacketing system may be supplied as an alternative to the standard yellow jacket.  The combination of our shiny aluminized Eko-ThermTM material coupled with our non-fibrous insulation medium offers an effective barrier from conductive heat sources as well as from radiant heat sources.   Up to 90% of radiant heat will be reflected away from the low emissivity and shiny surface of the insulation component.  This doubly effective technology will ensure that the process temperatures can be accurately maintained with a minimal insulation wall thickness.

Eko-Therm elbow
Eko-Therm elbow

This new exciting line of products is yet another example of the how the Worbo research and product development team has demonstrated out of the box thinking to create cost effective and innovative thermal protection solutions.   

 

 

Holding It Together

Here at Worbo Inc. we pride ourselves on providing top quality custom fabricated high temperature insulation components for process lines and equipment. In our view, an essential characteristic of a successful insulation cover is that it must be user friendly. It should be easy to install and easy to remove and reinstall for maintenance. This eliminates the need for expensive insulation contractors and minimizes the loss of valuable production time. Ease of installation is often achieved through the implementation of simple and effective mechanical closures. At Worbo we offer a wide range of fastening systems to create easy to install insulation components that are suitable for thousands of high temperatures applications.  Here’s how we “hold it together”.

 

Grommets and Wire Ties

This method for securing a Worbo insulation component in place employs the use of high temperature grommets in combinations with wire ties. It often consists of a series of grommets (ranging in diameter from ¼” ID up to 1” ID or larger) placed around the perimeter of an insulation component. Grommet holes on one side of an insulation cover will line up with adjacent grommet holes on the opposite side of the cover and will be joined together with a wire tie or metal banding. In many cases this is can be the most cost effective solution.

grommets on Worbo high temp curtain
grommets on Worbo high temp curtain
grommet and wire tie closure on high temperature festoon cable protection system
grommet and wire tie closure on high temperature festoon cable protection system

 

Grommets and Carabiners

In the case of a high temperature insulation curtain application, grommets may be used in combination with spring snap carabiners.   This mechanism will enable a curtain to be suspended from a supporting rod or structure and it will allow for the curtain to slide back and forth creating an access opening when the curtain is not in use. A simple “S” hook also works well for this application as a substitute for the carabiners.

carabiners on high temperature insulated curtain
carabiners on high temperature insulated curtain
high temperature curtain
high temperature curtain

 

Hook and Loop

This is one of our favorites and it comes standard on our Cool-SkinTM sleeve line of products. High temperature hook and loop (Velcro®) is a fantastic closure option that may be exploited on a huge assortment of insulation components.   It’s simple and dynamic. We offer hook and loop in a broad array of widths from as narrow as a ½ inch wide up to six inches wide and beyond. It is available in various profiles that can maximize gripping strength or maximize opening and closing cycles depending on the application. A hook and loop closure provides a very good seal to allow for maximum heat retention and it can be incorporated into virtually any configuration of insulation cover. Thanks for the invention George de Mestral, great idea!

Cool-Skin cover with hook and loop closure
Cool-Skin cover with hook and loop closure
High temperature sleeve with hook and loop
High temperature sleeve with hook and loop
Worbo MSA curtain
Worbo MSA curtain

 

¼ Turn Fasteners

Another great option is the ¼ Turn or Common Sense fasteners. These are great for creating a strong mechanical union between two mating surfaces. They are particularly effective in situations where ease of installation and maximum connections strength are critical. Here’s how it works….a small turnbutton post is secured to the perimeter edge along one side of an insulation cover. This post is then inserted through an oval eyelet mounted on the opposite side of the cover and then it is simply rotated 90 degrees to lock it in place creating a mechanically positive attachment.   The photo below illustrates how this closure works on a trolley skirt installed on an overhead crane festoon protection system.

quarter turn fasteners on high temp trolley skirt
quarter turn fasteners on high temp trolley skirt

 

D-rings and Straps

D-rings and straps are a fantastic option for providing a very snug fit between an insulation sleeve and a hot process line to ensure that heat retention is maximized. This mechanism works in a similar fashion to a chin strap on a standard motorcycle helmet. A high temperature tension strap is inserted through two d-rings that are secured to an insulation component. The strap is then fed back between the two d-rings and pulled tightly. By drawing the strap firmly, this mechanism ensures that the insulation component will fit tightly around the process line. This system also allows for some flexibility with respect to the size of the components being insulated and often a single insulation part may be used for multiple process lines. In this scenario an insulation sleeve is overbuilt to accommodate a largest possible shape and then it may be drawn in with the straps and d-ring arrangement to fit snugly around a smaller line. In many cases this is a one size fits all solution.

d-rings and strap on high temp cover
d-rings and strap on high temp cover
high temp cover for plastic extrusion line
high temp cover for plastic extrusion line

 

Lacing

This is another great low tech option that offers an effective and inexpensive solution for securing an insulation component in place. As with the d-rings and strap method the lacing option will provide a forgiving range of adjustment to allow for a tight fit around various sizes and shapes of equipment.

lacing on a Worbo insulation cover
lacing on a Worbo insulation cover
lacing on an MSA cover
lacing on an MSA cover

 

Zippers

A high temperature zipper is yet another option for securing an insulation component in place. Below is a photo of a zipper that has been effectively utilized in a bellows style insulation boot. The boot has been designed to protect a hydraulic cylinder from molten splash and it is easily installed without disassembling any of the heavy equipment. Notice that the zipper has been secured to the boot in a spiral fashion along its length. This allows for the zipper to be offset between each the corrugations of the bellows to ensure that when the bellows is collapsed it occupies the minimum amount of space.

Worbo high temp bellows with zipper
Worbo high temp bellows with zipper

 

Combination of Different Closure Mechanisms

When one type of closure just won’t do to the trick we can easily incorporate multiple closure mechanisms into a custom fabricated high temperature insulation component for maximum thermal protection and minimum heat loss.

grommets, quarter turn fasteners and hook and loop
grommets, quarter turn fasteners and hook and loop
draw string and d-rings with strap
draw string and d-rings with strap
zipper and hook and loop
zipper and hook and loop

At Worbo one of our primary business objectives is customer satisfaction. We believe we can achieve this through providing high quality and cost effective insulation components that are easy to install. Our expertise and experience with a large assortment of closure mechanisms and fastening systems allows us to provide easy to install components that satisfy our customers.

Cheap Gas Leads to a Hot Problem

New developments in deep shale extraction technologies have lead to an increase in the availability of natural gas in the USA with production up over 25% within the past 10 years.  The abundance of inexpensive natural gas has created exciting alternatives for steel producers.  Specifically direct reduced iron (DRI) fueled by natural gas is being produced on an increasingly larger.  Now more than ever DRI is a cost competitive alternative to traditional coal fired blast furnaces.  And perhaps even more important is that natural gas powered DRI plants potentially have a much smaller environmental footprint.

However, a DRI plant does present a few unique problems.  One such problem occurs in the process gas heater, a key component of a DRI plant that feeds the reduction reactor with makeup gas.  Within the process gas heater, radiant coils are situated on the outlet side of the manifold and they are exposed to temperatures up to 1900oF.  These elevated temperatures have created some difficulty in the welded U-joints connections of the radiant coils.  In some cased the welding has softened to the point where failures have occurred.Extreme temperature insulation cover

Worbo has worked closely with a DRI plant in the USA to develop an extremely high temperate resistant insulation cover to protect the radiant coil U-joints connections from weld failures.  These covers have been specially designed to be removable for ease of installation and to minimize shut down time.   And they can handle the heat.  These covers are capable of withstanding continuous operating temperatures of 2100oF! 

With nearly a full year in service and no weld failures we are proud that we have been able to contribute in a positive way to the development of this fiscally and environmentally responsible steel production technology.  

Reaching the Stars!

Rocket launch

The engineering team at Worbo has played an integral part in the design of extreme temperature insulation systems for a leading aerospace company.  Designed to protect essential components from intense exhaust blast, the Worbo insulation systems performed very well in a recent successful launch.  We continue to work closely with the aerospace industry as new technologies develop.  Next stop….who knows! 

 

Gearing Up with Heavy Equipment Manufacturers

 heavy equipemt

Worbo Inc. continues to fulfill the high temperature insulation needs for many of the world’s leading heavy equipment manufacturers. Engine and equipment manufacturers are facing strict emissions standards. Worbo is well equipped to design and meet growing demand for critical insulation components required in these challenging high temperature applications.

 

Extreme Heat Protection for Power Cables

It is not uncommon for electrical cables in heavy industrial centres to be vulnerable to heat exposure.

Worbo was approached by a steel refinery to develop a thermal protection system for flexible power cables. These cables were in close proximity to extreme infrared radiant heat and flames.

Worbo Engineers were able to develop a customized solution employing Worbo’s Eko-Therm™ technology and high temperature velcro enclosures resulting in a flexible, removable thermal barrier sleeve providing complete thermal protection for the adjacent power cables.

To learn more, refer to our Custom Applications article, High Temperature Molten Splash Protection for Electric Arc Furnace Power Cables.