SMI Impact

The elimination of condensate build-up under insulation

Annual thermal savings of 4% of fuel consumption resulting in $14,400 fuel cost savings

Annual electric savings of 1% of energy consumption resulting in $9,500 electrical cost savings

Customer

A medium-security federal correctional institution with an adjacent minimum-security satellite camp that houses more than 1,000 inmates in southern Texas.

Conditions

The 444,681 sq. ft. facility was opened in 1990 and a majority of the buildings had original equipment dating back to the date of construction. The institution has a centralized campus-type cooling system design consisting of a central plant that houses large centrifugal chillers, cooling towers, and pumps that supply chilled water to all campus buildings. Heating systems are decentralized and are mostly electric coil based.

Problem

Pipe insulation for chilled water systems is specified and installed primarily for process control, condensation control and energy conservation. Insulating chilled water systems requires special attention. When piping and equipment operate at temperatures lower than the ambient air, moisture in the air can condense on the cold surface, or when insulated incorrectly, on or within the insulation system.

The pipe system must be protected by an insulation system with sufficient insulation thickness, an adequate vapor retarder, and be installed correctly for the system to perform. If not, the insulation system can become wet, which can lead to a number of issues such as:

• A degradation of the insulation system service life and performance
• Corrosion of pipes, valves and fittings contained within the insulation system
• The potential for mold growth and water related damage to surrounding materials.

At this institution, insulation in mechanical rooms had lost its vapor seal resulting in condensate collecting on the pipe under the insulation causing mold to accumulate. In addition to the chilled water system degradation, the hot water supply and return piping and system equipment were severely degraded, resulting in unsafe conditions, excessive thermal energy loss, and increasing costs. Some of the piping and equipment were inadequately insulated and missing insulation.

Prior to installation:
Annual propane cost: $180,000 of $1.853 per gallon
Annual electricity cost: $948,700 at a blended rate of $0.0795 per kWh

Solution

SMI was engaged to develop a comprehensive insulation scope of work for the chilled water system to solve for energy efficiency and safety hazards. SMI recommended fiberglass pipe insulation with vapor retarder jacketing systems. Vapor dams or vapor seals were installed at every fourth section and at the termination of all fittings. The butt end of every fourth pipe insulation section had the ends of insulation terminations vapor sealed with vapor retarder mastic.

The scope of work covered all campus buildings and included the installation of new conventional insulation to encapsulate un-insulated equipment, the removal and replacement of degraded insulation, and the turnkey design, development, installation and commissioning of the entire scope of work.

SMI, in partnership with our vendors, measured, designed, and installed over 4,400 linear feet of pipe insulation including in excess of 193 new fittings and bends, and 57 repacked fittings and bends.

Key Actions

The scope of work included thermal efficiency upgrades in sixteen 16 buildings
Develop the final scope of work to include Identify, measure and design uninsulated piping opportunities
Manage purchasing and labor for turnkey installation of pipe insulation
Work with facility managers for site access and utility shutdowns
Complete project commissioning, walkthroughs, and checklists

Conduct training on product and maintenance with facilities management personnel

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