TC Ceramic

Liquid Ceramic Insulation Coating

Steam Plants  

Some of the largest Steam distribution systems in the world are using TC Ceramic in their steam plants and steam systems.  TC Ceramic is eliminating almost all of the insulation concerns in this industry where energy conservation is of utmost importance.

1.        STEAM PLANTS

TC Ceramic is being used as insulation against hot pipes and chilled pipes in steam plants.

a.         Hot pipes are coated for:

i.          Personnel protection against burns.

ii.          Will withstand up to 500 degrees, using only about 120 to 160 mil (3.0 to 4.0 mm) sprayed directly onto the substrate.

iii.         Reduce energy loss.

iv.         Corrosion reduction

b.         Chilled pipes are insulated against

i.          warm ambient air

ii.          condensation

iii.         corrosion.


            TC Ceramic is sprayed directly onto the substrate surface, therefore minimizing or even eliminating any condensation caused by warm ambient temperatures.  Pipes, valves, stanchion, elbows and fittings are easily coated as well, as conventional insulation does not fit in these areas, therefore cannot insulate for the best possible result. 


2.         STEAM TUNNELS

TC Ceramic is being used to coat the pipes in underground tunnels to

a.         Reduce the heat in the tunnels

b.         Reduce energy loss

i.          Through the pipe surface

ii.          Through the stanchion holding the pipe

iii.         Protect against flooding problems such as

(1)        destruction of conventional insulation

(2)        loss of energy through the pipe

(3)        steam turning to water in the pipe due to the flooding cooling effect

(4)        hot/boiling water in the tunnel

(5)        increased maintenance on pumping equipment do to the hot water

(6)        additional corrosion on the pipe and stanchion

            Because TC Ceramic is impervious to water, a temporary flood of a hours to a few days, or ground water exposure will not affect the insulating properties.  TC Ceramic is not intended to be submerged in water over a long period of time, however, submertion of a few hours to a few days generally will have no impact on TC Ceramic. 


3.         MANHOLES

            For existing systems, MANHOLES seem to be where TC Ceramic has dramatic benefits to the system for a number of reasons. 

a.         First, and foremost, the heat in the manhole itself is causing endless problems

i.          excessively hot manhole covers.

ii.          pipes, fittings, elbows and valves in the manhole are many times not insulated, thus very hot and causing the manhole to be extremely hot

b.         Coating of the exposed hot surfaces with TC Ceramic provides the following benefits

i.          the temperature s drops dramatically (between 50F to 80F reduction).  Now there is no need to ventilate the manhole before employees have to work in them.  This is a significant labor savings.

ii.          Personnel protection - reduction of burn injuries

iii.         Reduction of corrosion of the metal surfaces

iv.         Reduction of re-insulation problems and high costs due to periodic flooding.

v.         Reduction of boiling water risks when flooding occurs

(1)        water temperature may be reduced to very warm

(2)        no boiling water under insulation

(3)        reduction of cost of pumping equipment due to the lower water temperature.

(4)        reduction of risk of injury due to extremely hot water.

c.         Coating manhole covers may not be necessary due to the reduced temperatures in the manhole, if the exposed hot surfaces are already coated with TC Ceramic.  If piping is not coated in the manhole, then the manhole cover may be coated with TC Ceramic to reduce the risk of burn injury on the top of the manhole cover due to high temperature.  To coat the manhole, it must be coated in the following manner: All exposed surfaces, including the underside, the top, the edges and the collar of the manhole support ring.


4.         VAULTS

            Vault walls may also be coated to protect the vault from the constant extreme temperatures related to the steam system and the ground water problems of flooding and seepage.  Coating the vaults walls with approximately 60 to 120 mil ( 1.5mm to 3.0mm) provide some of the following benefits:

a.         Keeps the vault from drying out which causes the concrete to crumble.

b.         Flooding and moisture penetration into concrete, which causes further degradation of the vault, can be minimized.