By / par Steve Clayman, Director of Energy Initiatives
When I thought about the title for this article, Star Trek came to mind:
Captain Picard: “Mr. Sulu, engage continuity.”
Mr. Sulu: “Engaged.”
Captain Picard: “Thank you, Mr. Sulu.”
Mr. Sulu: “Captain, our forward sensors are picking up pipe insulation. Should I activate the force field?” (OK. NEVER HAPPENED, but do read on)
So much for outer space: how do we engage “continuity” right in our own backyards? Continuity hasn’t been in place for a long time and continues to remain an issue. I’m referring to the lack of continuity of pipe insulation and vapour barriers on piping systems.
Ball valves represent a typical example of where lack of continuity regularly occurs. What we refer to as the benefits of appropriate insulation thicknesses, energy conservation, personnel protection, and condensation control are conspicuously absent when it comes to ball valves. Why? If the insulation is thick enough, it will interfere with the movement of the ball valve handle. The traditional solution is to stop the insulation and vapour barrier short of the ball valve handle (see photo 1) or cut out an appropriate section to allow for clearance (see photo 2).
Both of these solutions are diametrically opposed to what we, as an industry promote. And yet, there it remains, millions of uninsulated ball valves. What are we doing about it? Well, up until recently, nothing. Zero! De nada!
A ball valve might represent 12” to 18” or more of uninsulated piping. Not much when you consider that length over one valve. Who, then, would turn away over a million feet of pipe insulation? I may be wrong here (and please let me know if I am) but any TIAC member would salivate like crazy to have an additional million plus feet of pipe to manufacture, distribute, and/or install.
So, why have we stayed away from that business and willingly negated some of the very principles we stand for? Let’s try:
- We’re insulators.
- We’re not engineers, mechanical contractors, or plumbers.
- We don’t sell valves or the things that go with this equipment.
- It can’t be done.
Fine. I get that. However, there are solutions, and these solutions have been available for a long time. The solutions are called valve stem extensions. All of the valve manufacturers have this item available for above and below ambient conditions. We’ll take a look at these offerings in a moment. I understand it isn’t “our job” to have valve stem extensions specified, purchased, or installed. Let’s reconsider what “our job” should include.
In my view, “our job” should include removing “impediments to progress”. It should include open and frank discussions about clearance, hangers, saddles, and ball valves. We will only be able to fully promote and advance the mechanical insulation industry when we fully engage with the restrictions others place on our trade. These discussions need to happen with anyone who can possibly influence how mechanical insulation is applied.
I’m not talking about full-blown presentations (although that can’t hurt when appropriate). I’m talking about a casual mention, “Hey, have you seen …?” Let’s have a look at what’s out there when it comes to valve stem extensions.
Ball Valve Manufacturers
They all supply valve stem extensions: Kitz, Apollo, Milwaukee, Crane (see photo 3), Nibco, and Victaulic (more about Nibco and Victaulic below). The valve stem extensions are of sufficient height to allow continuity of the pipe insulation over the valve and still allow the handle to operate. The first four manufacturers have valve stem extensions suitable for above ambient applications. The extension moves with the handle and therefore the vapour barrier can’t be sealed to the extension.
Nibco “NIB-SEAL”
This extension (see photo 4) is a unique design because it answers all of the questions for most hot and cold applications. The extension/handle combo is UL/C-UL rated and is patented. It is insulated and has a plastic sleeve to which the vapour barrier can be sealed. Nibco offers “NIB-SEAL” on brass ball valves of up to 2 ½”.
Victaulic
The Vic ball valve stem extension (see photo 5) can also be used on hot and cold applications. The handle turns a connector shaft within the stationary housing, allowing the vapour barrier to be sealed against the extension housing. Victaulic offers this extension on brass ball valves of up to 2”.
Please note the following:
- The extensions are specific to each manufacturer.
- Existing ball valves can be retrofitted without shutting down the system
- Extensions are available in Canada. Unfortunately, too many wholesale plumbing outlets are not aware of this product. If anyone has a supply issue, please get in touch.
Before proceeding, please review the manufacturer’s data page. If anyone can’t access this information, please get in touch.
We sometimes talk about how little mechanical engineers actually know about mechanical insulation and how little time (if any) is devoted to this area in engineering schools. What engineers do understand is “green”: GHG reduction and energy and water conservation. Yes, insulation insulates, but if you, Mr. Engineer, were to specify ball valve stem extensions, then you help contribute to making our environment a little bit better, and fully comply with NECB-2015. Maybe this sounds a bit too airy-fairy to some, but, you know what? It works. Let’s start the conversation and promote mechanical insulation to one person at a time. That person tells someone else and before you know it you could very well hear your message come back to you. Know what else? This works, too.
No one is really going to do our work for us. We have an obligation to pave the way so that we can be fully effective in how mechanical insulation is applied. We have to make it easy for people outside of our industry to realize what else is available to round the circle.
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