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Marine Applications Challenges and Opportunities
Shipping also is integral to defense strategies and supporting peace on international waters. From aircraft carriers to submarines, the U.S. Department of the Navy lists 296 deployable battleships as of March 2020.3 Additionally, as the coastal defense, search and rescue, and maritime law enforcement branch of the U.S. Armed Forces, the U.S. Coast Guard operates nearly 2,000 vessels including cutters, ice breakers, and patrol boats. Other divisions of the military also commission seagoing vessels such as tugs, fireboats, and workboats. And, of course, there are myriad other marine applications ranging from cruise ships to the increasing use of oil tankers to store crude offshore. On April 24, the Wall Street Journal reported offshore storage of oil increased 76% since March 1, 2020, driven by a glut in supply coinciding with decreased demand during the global pandemic.
Across all these varied vessels, 1 common denominator applies: insulation that can withstand the rigors of the marine environment and comply with standards set by classifying bodies. Mechanical insulation is 1 technology that can help those specifying materials for vessels address the many challenges posed by the marine environment. Installed in onshore applications, mechanical insulation is essential to reduce process- or HVAC-related energy use, lower the load on mechanical equipment and systems, and reduce noise levels.
The marine sector presents some unique challenges when it comes to insulating materials. Mobility is a key factor specific to seafaring vessels. Whereas a building remains at a fixed location across its lifetime, the very nature of marine applications means a vessel may operate in markedly different climates. For example, an aquaculture fleet off the frigid shores of Newfoundland may be redirected to much balmier fishing waters in southeast Asia as seasons change. The vessel will need thermal insulation installed to tolerate temperature variance while keeping crew members comfortable and cargo protected. Another distinguishing consideration that sets insulation used in the marine environment apart from other applications is the liquid nature of the environment. Insulation systems in the marine environment must be able to withstand exposure to water as well as high levels of humidity. On vessels operating in the oil and gas sector, guarding against corrosion under insulation (CUI) is a huge concern, as moisture can collect and erode steel components on pipes and nearby equipment. Systems also must be sealed against the risk of water washing over the deck, posing a threat to equipment, quarters, and anything topside. Even small gaps in insulating cladding can let in enough water to cause significant corrosion issues. CUI also presents an economic cost. The NACE International Impact “International Measures of Prevention, Application, and Economics of Corrosion Technologies Study” published in 2016 notes: “The global cost of corrosion is estimated to be US $2.5 trillion, which is equivalent to 3.4% of the global Gross Domestic Product (GDP) (2013).”4 The report goes on to state that “using available corrosion control practices [could result in an estimated] savings of between 15 and 35% of the cost of corrosion.” Individual safety and environmental consequences are additional costs to consider when it comes to CUI. A third challenge when thinking about insulation for the marine environment is the very limited space aboard most vessels. According to Peter Betti, Senior Project Manager at Performance Contracting, Inc. (PCI), many Navy vessels are designed with specifications requiring redundant equipment, making space a premium. “An engine room is essentially a power plant compressed into a very small area,” Mr. Betti says, noting that space is a significant constraint when installing marine insulation. As a practical example, consider outfitting a bulkhead area, where a 3″ fire protection product needs to be installed while allowing a 5″ standoff from the bulkhead and accommodating heavy pieces of structural outfitting.
Who oversees and certifies the insulation materials used on national and international waters? Regulatory bodies represent both the shipyards and the ship owners. The International Maritime Organization (IMO), U.S. Navy, American Bureau of Shipping (ABS), and DNV-GL are some of the large organizations used to classify American vessels, among others; and International Convention for the Safety of Life at Sea (SOLAS) regulations established by the IMO5 guide the international safety of merchant ships. The SOLAS regulations were adopted more than a century ago, in response to the 1914 Titanic disaster, and multiple SOLAS amendments have followed. The U.S. Navy’s standards (navy.mil) govern vessels commissioned by the U.S. Navy; while the ABS also establishes standards as one of the world’s leading classification organizations addressing technical, operational, and regulatory challenges to support safe, secure, and responsible marine and offshore industries. The standards used by these classification bodies are taken very seriously by engineers, shipbuilders, and shipyards. While insulation represents a very small part of the cost involved in building a ship, failure to select a material in compliance with standards set by classification bodies can bring about a standstill. According to Mr. Betti, “Insulation might cost 1 to 3% of the total cost of a project, but it can completely hold up the entire project if the wrong product is installed.” Understanding and abiding by the standards set by organizations such as IMO, navy.mil, and ABS is critical.
As reflected in the applications above, marine insulation is required to perform many functions, ranging from fire resistance to managing acoustics. Ultimately, there is no silver-bullet, one-size-fits-all insulating material for every marine application. Some manufacturers are taking note of the opportunities the marine sector provides. Just as strategically specified insulation meets diverse performance requirements on land, marine-certified products stand up to challenges at sea and on domestic waters.