Thermal insulation

Abstract

Insulation module for an insulation system / arrangement to insulate process equipment can have a seal / gasket receiving portion 18 to restrict or prevent moisture ingress between interior facing surfaces of modules or have a labyrinthine or staggered interface join between modules 12. Modules 900 can be three-dimensional printed and can include insulation voids or cavities 914 which can be created by three-dimensional printing part of the module. One or more recess can be created by the three-dimensional printing to receive the gasket / seal between modules.

Description

THERMAL INSULATIONTECHNICAL FIELD

[0001] Embodiments of the present invention relate to thermal insulation, and / or monitoring one or more conditions, such as temperature, humidity, moisture, pressure, at insulated installations / components, such as for protecting cold service piping and equipment and / or cryogenic and other process installations, such as valves, flanged joints and connections to tanks.BACKGROUND TO THE INVENTION

[0002] Industrial piping systems include those for use in the liquefied natural gas (LNG), liquefied petroleum gas (LPG), chemical and petrochemical industries. Such systems may be both complex and expensive.

[0003] Such systems may handle highly corrosive materials, especially under high temperature and pressure conditions.

[0004] LNG and LPG installations process, transport and store liquefied gas at extremely low temperatures. The gas is condensed into a liquid at close to atmospheric pressure by cooling it to approximately -162 °C (-260 °F).Maximum transport pressure can be at around 25 kPa (4 psi) (gauge pressure), which is about one-fourth times atmospheric pressure at sea level.

[0005] The natural gas stream is typically separated into the liquefied petroleum fractions (butane and propane). These are typically stored in liquid form at relatively low pressure. Ethane and methane being the lighter fractions of the natural gas are liquefied to make up the largest proportion of the liquefied natural gas (LNG) to be transported or stored.

[0006] The natural gas fed is pre-treated to remove water, hydrogen sulphide, carbon dioxide, benzene and other components that would otherwise freeze at the low temperatures needed for LNG storage or damage the LNG plant. LNG typically contains more than 90% methane, with small amounts of ethane, propane, butane and nitrogen. One of the risks of LNG production is a rapid phase transition explosion (RPT), which occurs when cold LNG comes into contact with water.

[0007] Consequently, materials of construction and process operations for such systems are carefully selected having regard to process conditions. Such materials are often relatively expensive, and failure may cause significant environmental and safety hazard not to mention substantial expense of replacement.

[0008] The piping system will, most commonly, be insulated. In the industrial context, the objective of insulation of a component is to maintain a desired temperature within that component. Thus, in a chemical plant, tanks and pipes may hold or carry materials such as flowable solids / slumes, gases or liquids which must be maintained within controlled temperature limits for efficient use within the process being conducted within the chemical plant.

[0009] Since insulation tends to cover the surface of a metallic pipe and pipe connections, corrosion due to the aforementioned moisture ingress / formation between the insulation and pipe can progress unnoticed until failure occurs, unless the insulation is properly applied and sealed around the pipe and any associated connections. As insulation is a critical element of most industrial piping systems, a good deal of attention has been directed to the corrosion under insulation problem.

[0010] LNG / LPG processes, transport and storage containing liquefied gas under pressure and at very low temperature need to be insulated to very high standards. LNG insulation systems can fail due to moisture infiltrating theinsulation system, risking corrosion of the insulated pipe / components and potential icing up of the pipe / components. Formation of ice on cryogenic LNG pipes and components adds significant weight, which can cause support system failure. Therefore, protecting cold process equipment from moisture damage is important in cold process facilities such as LNG plants, that can be operating at approximately -161 °C (-258°F). This temperature puts piping and components well below ambient temperature when in operation. Piping and components can also have to cycle between cold and ambient temperatures during shutdown periods and back to cold conditions upon reinstatement.

[0011] LNG facilities may be located in warm, humid climates (such as around 32°C (90°F) with humidity levels around 90%). Water vapour transmission (WVT) may ingress through joins and gaps in the insulation system. Warmer air has a higher capacity for vapour pressure, or the stage when water exists in equilibrium as liquid and vapour. When that equilibrium changes or meets a colder surface, water condenses until a new balance is reached. The differential between ambient and LNG system operating temperatures increases the vapour pressure, driving moisture toward the colder object, and heightens the risk for moisture to penetrate permeable or incorrectly installed or damaged insulation systems. Once moisture starts to collect in LNG system insulation, there is a risk of it freezing, which will increase damage to the insulation and further reduce its effectiveness. Damage to insulation can continue as moisture travels closer to the surface of the pipe or other component. It is possible for moisture intrusion to create a freeze thaw movement pattern as pipe temperature cycles during use and shutdown periods.

[0012] Two recent arrangements for insulating valves and flanges on cold service piping and equipment are known, being conventional rigid cold insulation components and in-situ foam injection.

[0013] Thermal insulation for cold service piping and equipment includes requirements to conserve energy while preventing water or moisture fromreaching the valves and flanges through the insulation or at insulation terminations (i.e. forming a vapour barrier).

[0014] Rigid foam insulation pieces are installed in steps & staggered to prevent straight through joints / direct cold path from the outside through to the flange and valves surface and to prevent condensation or ice build-up outside the insulation. The insulation cannot have voids or air gaps where ice can build-up if the vapour stop or vapour barrier is breached.

[0015] Insulation joints must be installed with an offset (staggered I stepped) between layers of the insulation. A permanent vapour stop must be installed on all joints (mastic type), and a permanent vapour barrier must be installed to fully seal the insulation system. Installation is very slow and requires a high degree of manual skill, and installation may not be feasible or cost effective for many liquified natural gas (LNG) constructions where there are installation time constraints.

[0016] Such rigid foam insulation can be installed and removed for visual inspection of the underlying pipe. However, there is an inherent risk with rigid foam currently used due to the high degree of manual skills required to install it properly. Gaps and voids can exist in the first layer of rigid foam insulation hidden under a second, staggered, layer. Inspection is only possible during installation or by removal and re-installation of the outer layer(s).

[0017] Cold boxes are insulated using foam injection on site. Such in situ foam insulation is formed by injection of polyurethane (Pll) expanding foam (PUF) around the pipe, joint or valve. However, the expanding foam may not fill properly to the pipe / flange crevices as it expands due to the complex shapes. Voids and gaps can exist within the expanded foam and will not be visible once the solid outer crust forms, and inspection is not possible other than be removal / destruction of the cured foam. The injected foam cold boxes are not reusable. PUF requires specially trained installers and equipment, adding to costand complexity of installation. Daily batch testing and trials need to be conducted to ensure quality of production of the PUF.

[0018] Published patent document US 2020 / 0278070 discloses an insulating cover for chilled water pipe elements and couplings, the cover being in two cover portion halves and having a continuous seam between the cover portions, the seam filled with sealant. US 202 / 0278070 is not directed to cryogenic applications. However, the seal material is also a relatively thin bead within the groove of the seam close to the external surface and therefore prone to weathering failure.

[0019] Published patent document GB 2200962 discloses an insulating cover for a pipe fitting with the cover including a pair of mating cover halves having a rib and groove arrangement whereby the rib locates into the corresponding groove. However, the insulating cove provides relatively poor thermal sealing for cryogenic applications subject to vapour condensation on the surface fo pipes which can promote corrosion and fracturing of the insulation.

[0020] Published patent document DE 202011108044 discloses a thermal insulation arrangement whereby the inner insulation material can be trapped in the seam between the outer shell halves to improve sealing, without mention of a separate gasket or gasket material within the insulation material interface.

[0021] It would therefore be beneficial to provide thermal insulation for cold service piping and equipment, such as valves, flanged joints and connections to tanks, that alleviates one or more disadvantages of known insulation regimes or at least provides a useful alternative.

[0022] It is to be understood that, if any prior art is referred to herein, such reference does not constitute an admission that the prior art forms a part of the common general knowledge in the art, in Australia or any other country.SUMMARY OF THE INVENTION

[0023] With the aforementioned in mind, one or more embodiments of the present invention provides an insulation module, or insulation module arrangement, for insulating a process component, such as for extreme cold / cryogenic applications.

[0024] Embodiments may include an insulation arrangement for insulating a process component, the insulation arrangement including an external cladding arrangement and a plurality of insulation portions including at least a first and a second insulation portion, which, in the assembled insulation arrangement define at least an upper channel and / or lower channel configured to receive at least one respective upper or lower infill insulation material.

[0025] The insulation arrangement may include a seal material provided in the respective channel between the respective insulation portion and the respective upper or lower infill insulation material.

[0026] The seal material may be or include a compressible material. For example, the seal material may include a rubber material, preferably a synthetic rubber material, such as an EPDM rubber. The seal material may be adhered or bonded to the insulation material and / or the infill insulation material.

[0027] In use, the seal material may be compressed in an assembled said insulation arrangement. The seal material may be compressed to about 80% of original thickness in the assembled insulation arrangement.

[0028] One or more further embodiments of the present invention provides an insulation arrangement for insulating a process component, the insulation arrangement including an external cladding arrangement and a plurality of layers of aerogel insulation material.

[0029] The aerogel insulation may be in multiple layers with staggered joins between layers.

[0030] The cladding may a plurality of fasteners, wherein the fasteners cause the seal material to be compressed when tightened. The cladding may be of metal, such as stainless-steel, and may have panels, such as first and second side panels, at least one upper panel and / or at least one lower panel. Fastener portions, such as brackets, may be attached to the panels.

[0031] The fasteners may be provided such that they clamp across joints of the insulation to compress the seal material, in use.

[0032] Embodiments may include at least one insulation module covered or encased with a primary vapour barrier layer.

[0033] At least one seal material, such as an EPDM sponge rubber, may be provided at joint / mating surfaces. The seal material may provide a gasket. The seal material may be adhered or otherwise bonded, directly or indirectly, to insulation material of the respective module, such as to be integral with the respective module. It will be appreciated that, at least when compressed, the seal material e.g. EPDM, forms a hermetic seal, effectively blocking both liquid water and vapour transmission at such joints.

[0034] As mentioned above, embodiments may include aerogel-based insulation material. Embodiments include the aerogel insulation material (e.g. Pyrogel, Cryogel) made vapour-resistant through the application of a moisture resistant backing material, such as aluminium foil laminate with polyester backing on both faces of the aerogel, which acts as a vapour barrier.

[0035] Embodiments may include the aerogel provided as aerogel blankets, being preferably hydrophobic. They repel liquid water and prevent water from adhering to or penetrating the surface. The nanoporous structure has a highinternal surface area and does not support capillary action. Advantageously, when installed in multiple / laminated staggered layers, the likelihood of moisture ingress via wicking is negligible.

[0036] Despite its hydrophobicity, vapour permeation may still occur through the fibrous matrix. A vapour seal material may be provided. For example, butyl rubber with aluminium foil backing tape to seal the joints.

[0037] Embodiments may include sealing material, such as EPDM rubber, which may include EPDM gaskets, along module edges. The seal material may be adhered or otherwise bonded to the respective edge(s).

[0038] When the insulation modules are assembled around a target process equipment / installation, such as a valve, pipe or union, the seal material, e.g. gaskets, are preferably compressed, forming a continuous vapour seal. The seal material may preferably be compressed up to around 80% of original uncompressed thickness.

[0039] As noted above, compression of the seal material (e.g. EPDM) may be maintained by fastening across the joint interface. For example, having one or more fasteners clamping the respective joint interface together. One or more fastener portions may be directly opposite each joint interface.

[0040] Fastening arrangements may include anti-vibration compression means, such as anti-vibration compression washers, to retain clamping force over time.

[0041] Embodiments may include a plurality of insulation module components, such as a minimum of four modular components. Embodiments may include step-staggered layered polyisocyanurate (PIR) foam or polyurethane (PUR) foam, or a combination of the PIR and PUR rigid foams, or cellular glass or foam glass,or a combination of any two or more thereof, configuration(s) providing superior interlocking and vapour / moisture ingress resistant structure.

[0042] Embodiments may include not having upper joint lines on the top surface, thereby enhancing the integrity and weatherproofing of the cladding system, watershed and better overlap system for the cladding.

[0043] Embodiments do not require cladding fasteners to be elevated, enabling the development of a more compact and effective fastener system.

[0044] Embodiments include the seal material, such as EPDM rubber, at an external interface of the modules, preventing water or moisture from contacting the internal insulation, such as PIR.

[0045] The cladding arrangement may include at least one support for the seal material. The seal material may be applied to the cladding member / shell, such as by friction / interference fit, compression fit, bonding / adhering, or a combination of any two or more thereof. At least one, preferably both, of two opposed first and second cladding members / shells include a respective support for a said seal material. The at least one support may include a projecting wall or channel portion of the respective cladding member / shell. The interface between any two of the cladding members / shells, such as one of the first and second cladding members / shells and the upper or lower insulation member, may include a respective seal material support.

[0046] The module may include a first module having an exterior facing surface and an interior facing surface, wherein the interior facing surface includes at least one of: i). a gasket receiving portion for at least one gasket for sealing the module to a respective second insulation module to restrict or prevent moisture ingress through an interfaced join between the first and second interior facing surfaces and / or ii). an inter-engagement arrangement including a projection and / or a recess for inter-engagement with a respective recess and / or projectionof the second said insulation module to provide a labyrinth or staggered interface join between the first and second modules.

[0047] Embodiments of the present invention may include an insulation system including multiple insulation modules configured to insulate a process component (such as a pipe, valve, flanged connection or storage connection), wherein the insulation modules together inter-engage to provide an indirect linear or labyrinthine interface join therebetween.

[0048] One or more embodiments of the present invention can mitigate vapour drive and protect cold process installations and liquified natural gas (LNG) facilities.

[0049] The insulation module may include the gasket receiving portion and the inter-engagement arrangement.

[0050] The exterior facing surface may be generally or substantially part cylindrical, optionally providing a half cylinder surface.

[0051] The first module may be of one piece or monolithic moulded rigid foam insulation material. The first module may include insulation material of cellular glass, foam glass, polyisocyanurate (PIR) foam or polyurethane (PUR) foam, a combination of the PIR and PUR rigid foams, or a combination of any two or more such insulation materials.

[0052] The module may include the at least one gasket mounted to and / or adhered to the gasket receiving portion.

[0053] The insulation module may include at least one end seal arrangement for sealing against moisture ingress from the exterior to the interior. The end seal arrangement may include at least one end seal at at least one of two end interiorfacing surfaces of the first module, preferably at each of both of the opposed end interior facing surfaces.

[0054] The end seal arrangement may include one or both of: i. at least one end seal provided within a recess at the respective end of the first module; or ii. at least one insulation seal for sealing against insulation or a vapour barrier on a pipe or other process installation.

[0055] A water / moisture vapour barrier layer may be disposed radially outwardly with respect to the outer / exterior surface of the module. The material of the layer must have very low water vapour transmission rate (WVTR) and may be or include a metallic foil, such as aluminium foil, polymeric film or laminate.

[0056] The insulation module may include the at least one end seal and the at least one insulation seal, wherein, in use, the at least one end seal and the at least one insulation seal compress together providing a moisture barrier.

[0057] One or more embodiments of the present invention may include an insulation arrangement including a first insulation module and a second insulation module, the first and second insulation modules configured to seal around a process installation against moisture ingress, and the insulation arrangement including at least one gasket providing a seal between the first and second modules and / or including an inter-engagement arrangement providing a labyrinthine interface join between the first and second modules.

[0058] The first module and / or the second module may include one or more of rigid foam material, cellular glass and / or foam glass, polyisocyanurate (PIR) foam or polyurethane (PUR) foam or a combination of the PIR and PUR rigid foams.

[0059] The insulation arrangement may include the at least one gasket and the inter-engagement arrangement.

[0060] The at least one gasket may include a flexible material and may be replaceable, such as being a service part when the module is removed from installation for inspection and reused. The gasket may be longitudinal, preferably with a circular, square, rectangular or other polygonal cross section. The gasket receiving portion may include at least one recess in the interior facing surface.

[0061] The insulation arrangement wherein the inter-engagement arrangement may include at least one projection on at least one of the first or second module and a respective recess on the other of the respective second or first module, such that, on assembly together with the interior facing surfaces coming together, the respective projection(s) and recess(es) inter-engaging to provide the labyrinthine interface join.

[0062] The insulation arrangement may include an end seal arrangement between at least one of two longitudinally opposed ends of the assembled first and second modules to the process installation, the end seal arrangement including at least one end seal and / or at least one insulation seal. The end seal arrangement may include at least one end seal and the at least one insulation seal.

[0063] The at least one end seal and the at least one insulation seal may be arranged and configured to compress together to form a moisture barrier between an exterior and the interior of the assembled first and second modules.

[0064] The inter-engagement arrangement may be disposed inboard of a peripheral longitudinal edge of the respective module.

[0065] Preferably, the at least one gasket is disposed between the peripheral longitudinal edge of the module and the inter-engagement arrangement of that module.

[0066] The inter-engagement arrangement may include at least a portion thereof disposed between the at least one gasket and a space for a flange joint or valve body of a valve of the process installation to be insulated.

[0067] The at least one gasket, when applied to the respective interior facing surface (e.g. mating or meeting face) may be longitudinally linear, may have a linear longitudinal intermediate portion and at least one curved end portion. The at least one gasket and the respective projection or recess portion of interengagement arrangement may have corresponding profiles on the interior facing surface of the module.

[0068] It will be appreciated that the at least one projection and / or at least one recess of a module inter-engage with the respective recess and / or projection arrangement of another module when the interior faces are brought together around the process installation / equipment to create a convoluted interface which avoids the need for multiple separate layers of insulation with staggered joins. The inter-engagement arrangement being integral to the module(s) reduces the need for multiple components, layers of insulation, simplifies installation and alleviates the risk of human error on installation of the insulation.

[0069] Embodiments of the present invention can include one or more benefits of reduced schedule risk through offsite works, efficient installation - cost savings, reduced reliance on equipment (with associated risk of potential breakdowns and need for permits, such as hot working permits for Pll injected foam installation), saving in labour and materials, reduced inspections on foam, flow rate, density checks. Reusable insulation reduces carbon emissions and reduces need for chemicals to be stored on site.

[0070] One or more embodiments of the present invention provide(s) engineered removable modular insulation arranged and configured to prevent a direct cold path to an insulated component (such as a valve or flange joint) and provides a vapour seal at the joints of the removable modules.

[0071] Embodiments can include a gasket inserted into the pre-formed insulation module. The gasket can be configured to be compressed and seal both circumferential and longitudinal joints of the modules (such as two halves) compressed to each other.

[0072] Preformed rigid insulation modules may be created by machining rigid foam material (such as PIR, PUR, cellular glass, foam glass) e.g. using a minimum 3-axis CNC routing machine, to create steps and offsets in the insulation and reinforcements that prevent direct cold path from the outer / exterior surface of the insulation to the insulated component.

[0073] The insulation module may have a length, such as to extend along a portion of pipe, and an insulation thickness of insulation material (such as the PIR, PUR, cellular glass or foam glass, or a combination of two or more thereof).

[0074] The insulation module may have a cavity, hollow or recess, such that, when two or more insulation modules are brought together around a component to be insulated, the respective cavity, hollow or recess of each said modules at least in part defines a space within the insulation for the component.

[0075] Additional insulation may be provided on / around the component, with the insulation modules extending therearound. The length of the respective module(s), in use, may extend over insulation in situ, such as extending over pipe insulation covering a pipe.

[0076] One or more embodiments of the present invention may provide a cladding arrangement for protectively cladding at least one component of insulation overran installation process component (such as a valve or pipe flange joint). The cladding arrangement may include at least one cladding member.The at least one cladding member may include or be predominantly of stainless steel or other metal. The cladding arrangement may include multiple claddingmembers, such as shells / shell halves to clad around insulation / an insulated component, such as an LNG plant component (e.g. valve, flanged joint).

[0077] The cladding arrangement may include a fastener arrangement having at least one adjustable fastener including a threaded adjuster.

[0078] The cladding arrangement may include a cover arrangement to cover at least a portion of a meeting, join or gap between opposed cladding portions. The cover arrangement may include at least one cover configured to cover peripheral regions or edge portions of the cladding member(s). The cover may include at least one elongate member, which may be C shaped in cross section. The respective elongate member may be slid to cover recurved / reversed edge portions of the cladding. The cover arrangement can provide a weather cover to help prevent rain or other atmospheric originating moisture from entering the join in the cladding. The cover arrangement may preferably be provided for an upper meeting, join or gap at opposed peripheral regions or edge portions of the cladding member(s).

[0079] The cover arrangement may retain the cladding closed around the insulation. The cover arrangement may augment the fastener arrangement and / or ensure the cladding remains closed around the insulation.

[0080] The cover arrangement may provide a retainer arrangement, such as the cover providing at least one retainer configured to retain edge portions of the cladding member(s). The respective retainer may, in use, engage directly or indirectly with portions of the cladding member(s).

[0081] The cladding arrangement may include a fastener arrangement including at least one support portion, preferably attached to at least one respective cladding member. For example, the at least one support portion may include a strap, band or other mount portion attached to the respective cladding member. Attachment may be by fastener(s), welding (such as spot welding) or acombination thereof. Each cladding member may include multiple said support portion spaced apart from one another.

[0082] The respective support portion may incorporate or have attached thereto a fastener portion, such as to be used to releasably fasten the cladding members together around the insulation modules of an insulation assembly.

[0083] Fasteners provided to retain the cladding members together when mounted around the insulation modules may include self-levelling fasteners, such as having fastener portions that rotate to orient towards each other during application / tightening.

[0084] The cladding arrangement may include an upper cover and / or a lower cover. The upper cover and / or the lower cover may respectively cover an upper join or a lower join between said cladding members when positioned to clad around the insulation modules.

[0085] The upper cover and / or the lower cover may be attached, such as permanently or removably attached to one of the insulation cladding members of the cladding arrangement. For example, one or more of the covers of the cladding arrangement may include an attachment means for releasably fastening at least a portion of a respective said upper cover or lower cover thereto. The upper cover and / or the lower cover may be removably attached to the cladding member(s) by threaded fasteners, such as nuts, e.g. wing nuts.

[0086] One or more of the cladding members may include at least one handle, such as a hand grip, to aid application and / or removal of the respective cladding member relative to the insulation module(s) arranged to for covering by the cladding arrangement.

[0087] One or more embodiments of the present invention may include a cap configured to cover an opening through the cladding members where a valvespindle projects therethrough. The cap may be a one-piece device or may be of multiple components connected together, such as two halves fastened together. The cap may be milled, 3D printed or moulded, or a combination thereof, such as of a polymer material.

[0088] The cap may include a space therein for insulation material. The insulation material may be contained by the cap to insulate around the stem / spindle of the valve passing through the cap.

[0089] An insulation material, such as a non-setting mastic vapour sealant may be provided between the cap and insulation module material otherwise exposed from the cladding member(s) adjacent the spindle passing therethrough.

[0090] A valve 314 (valve body 314a) may be 3D scanned, and the shape thereof used as a model to produce, e.g. using CNC machining, a cavity within two insulation module halves to reduce empty space gap within the insulation arrangement.

[0091] At least one resilient member may be provided, such as between a portion of the respective cover and the cladding member.

[0092] At least one sealing member may be provided to seal the join or gap between the edges of the cladding member(s). The at least one sealing member may include a portion that extends into the join or gap between the edges and into the insulation, e.g. to seal therebetween and / or prevent moisture ingress through the join / gap.

[0093] The at least one sealing member including a resilient member provided between the cladding and the insulation. Alternatively, a separate resilient member may be provided, or both may be provided.

[0094] The at least one sealing member may have a T-shaped / T-section seal.

[0095] Embodiments may include features wherein opposed edges of the at least one cladding member may meet or overlap or may have a gap (which may be sealed by at least one sealing member).

[0096] The fastener arrangement can be provided to fasten together portions of the cladding arrangement, such as to hold closed together the opposed edges. The fastener arrangement may include at least one, preferably multiple, adjustable fasteners. One or more said adjustable fastener may include a threaded adjuster, such as at least one screw / helical thread adjuster. The adjustable fastener arrangement can be used to preset a clamping force for the cladding when closed around the insulation.

[0097] The fastener arrangement can include at least one mount attached to the respective cladding member. Preferably respective said mounts are provided adjacent and / or at the respective edge of the cladding member.

[0098] The adjustable fastener can include a threaded member, such as a threaded nut type member, provided to tighten and / or adjust the fastener arrangement.

[0099] A retainer arrangement can be provided to retain the cladding closed around the insulation. The retainer arrangement can augment the fastener arrangement and / or ensure the cladding remains closed around the insulation in the vent that the fastener arrangement fails or is otherwise released or loosened (such as by vibration or thermal expansion and contraction events).

[0100] The retainer arrangement may include at least one retainer. The at least one retainer may retain edge portions of the cladding member(s) together in a closed orientation. For example, the respective retainer may engage with portions of the cladding member(s), such as flanges provided by folded / reversed edges.

[0101] The at least one resilient member may be provided between a portion of the cover or retainer and the cladding member, such as acting as a cushion, providing a resilient bias to help maintain the cover arrangement or retainer arrangement in a retaining orientation and / or preventing rubbing / abrasion between the respective cover or retainer and the cladding.

[0102] The at least one sealing member may be provided to seal the join between the edges of the cladding member(s). For example, a T-shaped seal may include a portion that extends into the join between the edges and into the insulation. A further portion of the T-shaped seal may extend over or under the edges of the cladding member(s).

[0103] The sealing member may include a resilient member provided between the cladding and the insulation. Closing force applied by the fastener arrangement and / or the retainer arrangement may assist to apply pressure to the seal to help ensure sealing.

[0104] Sealing may be provided between outer side surface and one or more ends of the cladding. Sealing may be provided between one or more ends of the cladding and an installation component / insulation.

[0105] One or more forms of the present invention can include at least one sensor arrangement to monitor for presence of or change in at least one condition within an insulation arrangement of a process installation, such as monitoring for leakage of an insulated flanged joint or valve and / or for moisture / vapour ingress into the insulation. Internal leakage or moisture / vapour ingress can result in ice build-up within the insulation, causing insulation failure (and therefore further ice build-up) and / or corrosion of metal process installation components.

[0106] Embodiments can include a sensor tube. The sensor tube can be sealed internally to prevent vapour ingress and / or fluid egress through the tube.

[0107] The sensor tube may include polytetrafluoroethylene (PTFE) (aka Teflon TM) material. A body of the tube, such as the central tube portion between opposed ends may be made of PTFE. The tube may include metal glands with at least one expanded PTFE seal.

[0108] It will be appreciated that the sensor tube through which the sensor passes can allow installation of different types of sensor, such as: presence of fluid (liquid / gas presence), temperature, humidity, water, ice formation.

[0109] Embodiments provide a sensor tube enabling or including installation of at least one sensor to monitor an internal condition within an insulated module arrangement around a process installation, such as a flanged joint or valve.

[0110] The sensor tube may be installed through at least one insulation module, such as at the manufacturing or assembly stage of the insulation arrangement about the process installation or during pre-assembly (e.g. off-site, prior to assembly on-site).

[0111] The sensor can be operatively connected to a monitor device, which may be by wireless or wired connection. The monitor device may be enabled for communication with a remote location, such as by wireless transmission via an antenna of the monitor device.

[0112] A further form of the present invention provides an insulation module for insulating a process component. The insulation module can include a sensor tube passing from an exterior through material of the insulation module, the sensor tube configured to receive or house at least part of a sensor device.

[0113] The sensor tube can be sealed internally against vapour ingress and / or fluid egress through the sensor tube.

[0114] The sensor tube can be sealed externally thereof to the insulation module, to cladding about the insulation module or to a vapour barrier.

[0115] The sensor tube can be sealed externally thereof to the insulation module internally of the insulation module and / or externally of the insulation module to prevent moisture passing along an exterior surface of the sensor tube through the insulation material.

[0116] Embodiments may include a method of insulating a cryogenic installation includes 3D scanning at least a portion of the cryogenic installation, creating at least one shaped insulation module from the 3D scan, assembling the insulation module around the at least a portion of the cryogenic installation in situ.

[0117] The at least a portion of the cryogenic installation may include a valve. The shaped insulation model may be created by moulding, cutting or milling an insulation material from data of the 3D scan. The insulation material may include PIR, preferably between 40 kg / m3and 80 kg / m3, more preferably 80 kg / m3

[0118] Embodiments may include cladding the installed insulation with a metal cladding. Embodiments may include providing a labyrinth join between insulation modules and a gasket material. The gasket material may be between insulation modules and towards an exterior of the insulation modules relative to a projection and recess inter-engagement arrangement between the insulation modules. The gasket or other seal material may be compressed as the modules are forced towards each other / brought together. The gasket and / or seal material may include EPDM rubber.

[0119] Embodiments may include providing a cap on the insulation arrangement, the cap being around a stem of a valve of the cryogenic installation. Embodiments may include providing at least one of an upper cover or lower cover over a join between insulation modules. The upper cover or lower cover ca bearranged to cover cladding over the insulation material. The cladding may include a metal cladding, such as cladding members / covers.

[0120] It will be appreciated that embodiments may be directed to engineered cold insulation for valves and flanges. Embodiments provide ‘removable’ and optionally ‘reusable’ insulation modules that traditional cold insulation and PUR foam injection (destroyed during removal) cannot offer.

[0121] Embodiments may include gasket insulation sealing (e.g. EPDM rubber, expanded silicone) compressed to form a seal on both circumferential and longitudinal joints. Embodiments may include preformed rigid insulation (e.g.PIR, Cellular Glass) cut into shape, such as using 4-axis CNC routing machine, to create labyrinth shapes preventing a direct cold path from the outside to inside the surface of the insulation. Use of non-setting mastics e.g. butyl rubber based, used as a vapor barrier sealant to seal end joints.

[0122] Embodiments may include an insulation module for an insulation arrangement, the insulation module including a plurality of enclosed insulation voids. At least some of the plurality of voids may be within or formed by an insulation structure.

[0123] Embodiments of the insulation module may include an insulation structure including a three-dimensional (3D) printed structure. The insulation module may include an outer shell structure. The outer shell structure may be integral with the insulation structure. The outer shell and the insulation structure may be three-dimensional (3D) printed e.g. as a one-piece structure or separately 3D printed and joined / bonded together.

[0124] The voids may include holes and / or air gaps. The voids may be provided by an open cell or closed cell structure.

[0125] Embodiments may include at least one layer of a flexible insulation medium. The flexible insulation medium may include an aerogel material. The at least one layer of the flexible insulation medium may be provided on an inside face of the respective module, so as to, in use, face towards an installation to be insulated relative to the voids.

[0126] Embodiments of the insulation module may include at least one recess arranged and configured to receive a seal material therein. The at least one recess may be provided within and / or along at least a longitudinal edge or face of insulation module. The at least one recess may be formed by three-dimensional (3D) printing of the insulation module. The seal material may include an EPDM rubber or the like.

[0127] The seal material may be arranged and / or configured to seal longitudinal joints between adjacent said insulation modules of an insulation arrangement of a plurality of said insulation modules around an installation to be insulated.

[0128] Embodiments may include an integral fastening portion for fastening the insulation module to another said insulation module. The integral fastening portion may be three-dimensional (3D) printed as part of the insulation module’s structure.

[0129] Embodiments may include an insulation arrangement including a plurality of the aforementioned insulation modules. The insulation modules may be arranged and / or configured to releasably attach together around an installation (such as pipework, valving, flanged joint) to be insulated.

[0130] Embodiments may include at least one gasket of sealing material between adjacent said insulation modules. Embodiments may include a vapour barrier material provided externally of the insulation modules, such as adhered / bonded to an outer surface thereof, and / or provided internally, such asbetween flexible insulation medium and the voids and / or between the flexible insulation medium and the installation to be insulated. The vapour barrier material may be provided between the respective insulation module and an outer cladding.

[0131] The three-dimensional (3D) printed insulation module may be printed from polymer material or filament, such as one or more of polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), polyethylene terephthalate glycol (PETG), thermoplastic polyurethane (TPU), nylon or polycarbonate (PC).BRIEF DESCRIPTION OF THE FIGURES

[0132] One or more embodiments or examples of the present invention will hereinafter be described with reference to the accompanying Figures, in which:

[0133] Figure 1 shows a longitudinal sectional view of embodiments of the present invention applied to a flanged joint and a valve.

[0134] Figure 2 shows a cross-sectional view in detail of at least one embodiment of the present invention applied to a flanged joint.

[0135] Figure 3 shows a cross-sectional view in detail of at least one embodiment of the present invention applied to a valve.

[0136] Figures 4A to 4C show respective longitudinal, horizontal B-B and transverse A-A cross sections, according to an embodiment of the present invention with respect to a valve application.

[0137] Figures 5A to 5D show respective longitudinal (Fig 5A), horizontal Fig 5B C-C and transverse Fig 5C A-A, Fig 5D B-B cross sections, according to an embodiment of the present invention with respect to a flange joint application.

[0138] Figure 6 shows detail of one module of an assembled thermal insulation system according to an embodiment of the present invention

[0139] Figure 7 shows an exploded view of components of a thermal insulation system according to an embodiment of the present invention, examples according to one or more embodiments of the present invention.

[0140] Figures 8A and 8B show portions of the module to pipe seal arrangement according to at least one embodiment of the present invention. Figure 8A shows the end seal in the end recess of the module and the insulation seal mounted to the insulation / vapour barrier of the pipe. Figure 8B shows the end seal and insulation seal brought together within the end recess of the module to seal the end portion of the module around the insulated pipe.

[0141] Figures 9A and 9B show an arrangement for sealing between two modules using a removable gasket according to an embodiment of the present invention. Figure 9A shows portions of the two modules ready to come together with the removable gasket in a channel / recess of one of the modules. Figure 9B shows the portions of two modules brought together face-to-face and the gasket received in the respective channel / recess of each module. A secondary gasket is provided in at least one, preferably both, of the channels / recesses prior to receiving the gasket (primary gasket), according to an embodiment of the present invention.

[0142] Figures 10A and 10B show an alternative arrangement for sealing between two modules. Figure 10A shows portions of the two modules ready to come together, each having a sealant / mastic material in a base of the respective channel / recess.

[0143] Figure 10B shows the removable gasket in the channels / recesses of the modules with the portions of the two modules brought together face-to-faceand the gasket received in the respective channel / recess of each module, and the sealant / mastic helps to seal the ends of the compressed gasket.

[0144] Figure 11 A shows an example of how plain butted joints in a two-layer insulation arrangement can open up creating a cold path allowing condensation / moisture or ice formation on a surface of a pipe of a cryogenic installation.

[0145] Figure 11 B shows an example of a two-layer insulation arrangement including a labyrinthine path and gasket arrangement according to an embodiment of the present invention.

[0146] Figures 12A to 12C show views of an assembled insulation arrangement incorporating insulation modules according to an embodiment of the present invention. Figure 12A shows an external view. Figures 12B shows section view A-A of Figure 12A. Figure 12C shows section view B-B of Figure 12A.

[0147] Figures 13A to 13B show a cladding arrangement applied over thermal insulation, according to an embodiment of the present invention.

[0148] Figures 14A to 14C show a cladding arrangement applied over thermal insulation, according to an embodiment of the present invention. Figure 14B shows sectional view A-A of Figure 14A. Figure 14C shows sectional view B-B of Figure 14A.

[0149] Figures 15A to 15D show views of a fastener arrangement for the cladding, according to an embodiment of the present invention. Figure 15B shows a sectional view A-A of Figure 15A, and Figure 15C shows detail B in a partial sectional view from A-A of Figure 15B. Figure 15D shows top view / plan view detail of an end of the cladding.

[0150] Figure 16A shows the sectional view B-B as in Figure 14C. Figure 16B shows detail C of a retainer arrangement in Figure 16A.

[0151] Figure 17A shows a cross-sectional view of cladding and insulation about a flange joint according to an embodiment of the present invention. Figure 17B shows detail B from Figure 17A.

[0152] Figure 18A shows a cross-sectional view of cladding and insulation about a flange joint according to an embodiment of the present invention. Figure 18B shows detail C of Figure 18A.

[0153] Figures 19A and 19B show sensor arrangements according to an embodiment of the present invention.

[0154] Figures 20 and 20D (Detail) shows application of a sensor arrangement according to an embodiment of the present invention. Sensor details provide an exemplary representation only. Figure 20 shows a partial cross section showing an opening into the module to receive a sensor arrangement. Figure 20D (Detail) shows a detailed view of the sensor arrangement within the opening.

[0155] Figures 21 A to 21 C show applications of a sensor of a sensor arrangement according to an embodiment of the present invention.

[0156] Figure 22 shows detail of a sensor arrangement penetrating insulation and cladding of a process installation according to an embodiment of the present invention.

[0157] Figure 23 shows detail of a sensor and tube for a sensor arrangement according to an embodiment of the present invention.

[0158] Figures 24A and 24B show first and second inter-engageable insulation modules according to an embodiment of the present invention.

[0159] Figures 25A to 25D show a cladding arrangement for insulation modules (shown in half-section), according to at least one embodiment of the present invention.

[0160] Figures 26A to 26C show a cladding arrangement over insulation modules according to at least one embodiment of the present invention.

[0161] Figures 27A to 27E show features of an alternative arrangement for cladding and insulation modules, according to at least one embodiment of the present invention. Figure 27A shows features in end-on cross section and detail. Figure 27A1 shows detail of seal contact between internal components in Figure 27A. Figures 27B to 27D show views of insulation module components. Figure 27E shows a cutaway perspective interior view.

[0162] Figures 28A to 28D show respective end cross section (Fig. 28A), side cross-section A-A (Fig. 28B), end cross-section B-B (Fig. 28C) and perspective views (Fig. 28D) according to at least one alternative embodiment of the present invention.

[0163] Figures 29A to 29H show features of an alternative arrangement for cladding and insulation modules, according to at least one embodiment of the present invention. Figure 29A shows an end view of a cladding assembly around insulation modules, with Detail C. Figure 29B shows a side view. Figure 29C shows a top view. Figure 29D shows a perspective view. Figure 29E shows end cross section A-A. Figure 29F shows detail D of Figure 29E. Figure 29G shows end cross-section B-B. Figure 29H shows detail E of Figure 29G.

[0164] Figures 30A to 30E show features of cladding and insulation module arrangement according to at least one embodiment of the present invention.

[0165] Figures 31 A and 31 B show features of cladding and insulation module arrangement according to at least one embodiment of the present invention.

[0166] Figures 32A to 32D show features of cladding and insulation module arrangement according to at least one embodiment of the present invention.

[0167] Figures 33A to 33D show features of cladding and insulation module arrangement according to at least one embodiment of the present invention.

[0168] Figures 34A to 34D show features of cladding and insulation module arrangement according to at least one embodiment of the present invention.

[0169] Figures 35A to 35D show features of cladding and insulation module arrangement according to at least one embodiment of the present invention.

[0170] Figures 36A to 36D show features of an alternative cladding and insulation module arrangement according to at least one embodiment of the present invention.

[0171] Figure 37 shows an end cross section view of a cladding and insulation module arrangement according to at least one embodiment of the present invention.

[0172] Figure 38 shows a cross section through an alternative embodiment of the present invention incorporating insulation having a plurality of insulation cavities.

[0173] Figure 39 shows a perspective partial exposed view revealing internal arrangement for an insulation arrangement according to a further embodiment of the present invention.

[0174] Figure 40 shows a side view of an insulation arrangement according to at least one embodiment of the present invention.

[0175] Figure 41 A shows a transverse cross section of a clad insulation arrangement according to at least one embodiment of the present invention. Incorporating insulation with a plurality of insulation cavities. Figure 41A1 shows detail of the insulation incorporating cavities of the cross section shown in Figure 41A.

[0176] Figure 42A shows a perspective view of an insulation arrangement according to at least one embodiment of the present invention. Figure 42B shows a plan view (aerial / top view) of the embodiment shown in Figure 42A.

[0177] Figure 42A1 shows a longitudinal cross section view of the embodiment shown in Figures 42A and 42B.DESCRIPTION OF PREFERRED EMBODIMENT(S)

[0178] In the following detailed description, reference is made to accompanying drawings which form a part of the detailed description. The illustrative embodiments described in the detailed description, depicted in the drawings and defined in the claims, are not intended to be limiting. Other embodiments may be utilised, and other changes may be made without departing from the spirit or scope of the subject matter presented. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

[0179] The insulation module and module arrangement accommodate the special challenges inherent in thermal insulation of process installations, particularly cold / cryogenic insulation of flange joints, valves and pipe connections to tanks for cold / cryogenic process installations. Chief of these challenges is the need to accommodate the high thermal stresses induced by a temperature differential of some 200°C to 250°C between the interior of insulated componentand ambient environment, and prevention of moisture from the exterior to the insulated components to prevent corrosion and insulation damage / failure.

[0180] Referring now to exemplary embodiments in Figures 1 to 8B, there are shown insulation modules configured for use in thermal, particularly cold / cryogenic, applications. Modules 12 are assembled around a component of a process installation, such as a flange joint, valve or tank connection. The module assembly / arrangement insulates the component and provides continuity between pipe insulation or other insulated arrangements.

[0181] One or more embodiments of the present invention provides a insulation system 10 including multiple thermal insulation modules 12. Embodiments can include two or more such modules 12.1 , 12.2...12. n.

[0182] Each module 12 may be of or include a rigid foam material, such as PIR and / or PUR foam. Polyisocyanurate (PIR) foam is essentially modified polyurethane (PUR) foam. Two advantages of PIR foam are improved fireresistance and excellent insulation properties. PIR offers the following advantages: superior R-Value and thermal performance, moisture resistance, dimensionally stable, excellent fire test performance, unaffected by commonly used construction adhesives and solvents. Rigid polyurethane (PUR) foam is a very versatile option. It provides physical strength and mechanical and thermal properties.

[0183] The multiple modules are configured to be mounted around a pipe, flange joint, valve or other cold service equipment (such as a join to a tank). The modules can be removable.

[0184] The module(s) 12 can be formed of pre-cut rigid foam, such as using a CNC router. Each module may be arranged and configured so as to minimize void / air gap to be packed / filled with a fibre insulating material, such as glass wool material, when the modules are assembled together.

[0185] Embodiments can include at least one gasket 14 provided between mating / meeting faces 16A, 16B of the modules 12A, 12B. The at least one gasket 14 may be compressed when the respective modules 12 are brought together to seal the join therebetween.

[0186] Each module may retain at least one respective gasket 14 such that a pair of the modules 12A, 12B come together each with the at least one gasket 14 to form the seal. One of the modules 12A, 12B may retain more than one gasket 14 or a single continuous gasket 14.

[0187] Retaining the respective gasket 14 may be by adhesive and / or sealant or by compression in a channel or groove 18 of the respective module 12. The adhesive or sealant may be provided in the channel or groove 18.

[0188] Two or more of the modules 12 may be brought together around the fixture to be insulated, such as a flanged joint, a valve (which may have flanged connector or other feature. The modules may be covered / wrapped with a moisture barrier material. The moisture barrier material and modules may be covered with a cladding, such as a stainless-steel cladding / jacket.

[0189] The at least one gasket 14 may provide a longitudinal seal along a meeting / mating face 16 of one module to the respective meeting / mating face 16 of another module 12.

[0190] The at least one gasket 14 may be of or include a flexible material, such as a closed cell insulation material i.e. EPDM / EPDM rubber (ethylene propylene diene monomer / ethylene propylene diene monomer rubber), Neoprene, EPTFE (Expanded Polytetrafluoroethylene) for cold temperature from a maximum 30°C.

[0191] Meeting / mating faces of the modules may include at least one interengagement arrangement, such as inter-engageable projection 20 and recess 22 arrangement.

[0192] The at least one inter-engagement arrangement may include at least one projection on a first said module and at least one corresponding recess on a second said module, such that, when brought together, the at least one projection of the first module engages into the respective at least one recess of the second module.

[0193] A said first module 12 can have a combination of at least one projection and at least one recess, wherein, in use, a corresponding module (second module) has respective at least one projection and at least one recess that respectively inter-engage with the at least one recess and at least one projection of the first module.

[0194] Multiple ones of the same module may be configured to inter-engage. Therefore, only one module structure can be required. A first said module can be provided, and a second matching module can be provided but flipped so that the projection and recess arrangement between the two (first and second) modules inter-engages.

[0195] It will be appreciated that the projection and recess arrangement provides a non-linear direct moisture path i.e. provides a labyrinth, stepped or staggered path preventing moisture from the exterior from otherwise directly penetrating in a linear path to the insulated pipe, valve, flange or other equipment. The projection and recess arrangement provides an effective overlap between portions of the insulation material of the assembled modules (e.g. first and second modules).

[0196] As mentioned above, the at least one gasket 14 may be provided in a channel or groove 18 of the respective module 12. The channel or groove can bea gasket recess. When the modules are assembled together, a portion of the gasket 14 can reside in one channel or recess 18 and a second portion of the respective gasket 14 can reside in a respective channel or recess 18 of the second module. Consequently, the gasket residing in opposed channels / recesses of the two modules provides a labyrinth, stepped or staggered path to moisture.

[0197] Each module 12 may form half of a cylindrical insulation module assembly i.e. the first and the second modules to be brought together around a pipe, valve, flange joint or other equipment to be insulated can provide at least part of a generally or substantially cylindrical insulation assembly.

[0198] An end seal arrangement may be provided. Each module may include an end seal arrangement to seal between the respective module and adjacent insulation (such as on the pipe or other fitting / equipment) or for sealing to the pipe or other fitting / equipment itself.

[0199] For example, an inner circumferential end portion 24 of the module 12 can include at least one module end seal recess 26 to receive at least a portion of at least one respective module end seal 28. The module may include a respective module end seal recess at each respective end portion 24 thereof. Each respective module end seal recess and the respective end inner seal may be substantially semi-circular.

[0200] The insulation system 10 may include an insulation seal 30, such as to seal a gap between the module and insulation 32 on the pipe 34 or other fitting / equipment. The insulation seal may be an annular seal. Alternatively, the insulation seal 30 may be partially annular (such as a semi-circular seal) arranged to provide staggered seal ends with respect to the ends of the end seal, when assembled.

[0201] The end seal and / or the insulation seal may be attached with adhesive, sealant or mastic 35, 37. Figures 8A and 8B show the successive steps in bringing together the end and insulation seals (28, 30). The end seal can be provided within the end recess of the module. The insulation seal can be provided on the insulation (such as on the vapour barrier) on the pipe. Mounting the module to overlap over the insulation along the pipe can include receiving the insulation seal within a part of the end recess, such that the end seal and insulation seal compress together to seal against moisture ingress at the end of the assembled modules and provide a labyrinthine path against moisture ingress.

[0202] Packing pieces 36 may be provided between the modules when assembled together. The packing pieces may fill spaces 38 within the assembled modules 12, such as one or more spaces between a flange joint 40 and adjacent insulation 32. The packing pieces may be of the same material as the module(s) 12 e.g. PI or Pll rigid foam, cellular glass or foam glass.

[0203] The packing pieces can be provided each having the same insulation thickness as the piping insulation 32. The Packing pieces can be provided to suit the actual site condition and minimize the gap between insulation.

[0204] Padding, insulating and / or resilient material and / or a natural or synthetic wool type material 42, such as a resilient wool or glass fibre matting, may be provided within the assembled modules, such as around the flange joint 40 and / or valve 44.

[0205] Installation can include providing a glass fibre fabric or needle felt material cushioned around the valve or flanges and configured to a shape and size that preferably substantially or completely fills any empty space / void between the modules and the valve / flanges when the modules are assembled together around the respective valve / flanges.

[0206] A removable material, such as a cushioning material and / or thin flexible insulation material and / or aluminium foil vapour barrier, can be inserted on one side of the flange(s) or valve(s) and then filled with the resilient or loose wool materials.

[0207] Embodiments can include a vapour barrier 33 on the outer surface of the rigid foam modules / components. The vapour barrier 33 can include a non- permeable, moisture proof layer, such as provided by butyl adhesive mastic with an aluminium foil backing.

[0208] One or more embodiments of an insulation system of the present invention may include two modules 12, such as two pieces of prefabricated PIRPUR rigid foam, which can be removable after installation over a pipe joint / flange joint, valve or other fitting, such as for inspection and maintenance. Each module 12 may pre-cut PI / PLI rigid foam material, such as using a CNC router designed to minimize void / air gap to be filled with packing and / or resilient materials such as PI / PLI packing pieces and / or glass wool materials.

[0209] Joints between modules can be sealed using a gasket 14 (e.g. flexible insulation type, which can be elongate and of round or rectangular or other shape in cross section) installed in between faces of the two (2) rigid PIR / PUR modules and compressed together to form a seal when the mating / meeting faces are brought together.

[0210] The gasket may include the use of an EPTFE gasket, optionally in combination of non-setting mastic material (e.g. elastomer based sealant material) between the modules.

[0211] The gasket can be elongate and optionally of round or rectangular or other shape in cross section. The gasket can be installed in between faces of the two (2) rigid PIR / PUR modules and compressed together to form a seal when the mating / meeting faces of the modules are brought together.

[0212] A sealant, such as a non-setting sealant, can be provided as the gasket and / or a seal. A non-setting gasket / sealant having flexibility and ability to move / flow can help to seal gaps and / or seal against suction caused by internal to external temperature difference / gradient.

[0213] The non-setting mastic material may be provided in the channel or recess 18 of the respective module and the gasket applied to the non-setting mastic such that, when the modules are brought together, the non-setting mastic at least partially seals between the gasket and the respective module.

[0214] The module 12 to pipe 34 seal arrangement according to at least one embodiment of the present invention can provide at least one seal to prevent moisture ingress from an exterior to an interior of the assembled modules or any significant distance into the join between assembled modules. See, for example, Figures 8a and 8B.

[0215] According to one or more embodiments, the end seal 28 in the end recess 26 of the module 12 and the insulation seal 30 adhered / mounted to the insulation / vapour barrier 33 over the insulation 32 of the pipe 34 become compressed together to form a suitable moisture seal. However, it will be appreciated that only one of the end seal or insulation seal may be provided, with sufficient sealing compression between the end of the module and the pipe insulation / vapour barrier to prevent moisture ingress. In the case of a single seal, the single seal may be provided in the recess of the module or on the pipe insulation / vapour barrier.

[0216] Figure 8B shows an example of the end seal 28 and insulation seal 30 brought together within the end recess of the module to seal the end portion of the module around the insulated pipe.

[0217] The insulation system 10 may be arranged and configured to be removable and insulation can be re-used / re-installed to reduce reinstatementworks compared to other insulation arrangements (such as injected foam options).

[0218] It will be appreciated that site installation is efficient and suits new LNG constructions and shut down where the works can be planned and fabricated ahead. This reduces the site installation time, which is important for new LNG projects and shutdowns.

[0219] One or more advantages of embodiments of the present invention includes modularization scope of work where the insulation modules can be installed and then removed and reinstalled at site if needed during site hydrotest. This reduces project cost on site installation and ongoing maintenance / inspection.

[0220] The module or each module may include at least one water vapour barrier layer on an exterior thereof. The module or each module may include at least one cladding distinct from said at least one water vapour barrier layer. An outermost cladding layer may take the form of a metallic or polymeric material such as aluminium or steel.

[0221] The cladding may be or may include metal, such as stainless-steel cladding, or GRE (glass reinforced epoxy) or UV-cured GRP (glass reinforced plastic) cladding material, or a combination of any two or more thereof. Corrosion resistant material is preferred.

[0222] The cladding may have alternative or additional features, such as fabricated and installed with a fireproofing material or cryogenic spill protection material.

[0223] The cladding may include or provide a water vapour barrier layer. The water vapour barrier layer may be disposed radially outwardly of the module and may be formed from a material selected from the group consisting of metallic foils, polymeric films, mastics, and fibre-reinforced such materials.

[0224] Embodiments of the module 12 can include at least one cavity 46 therein to receive the component to be insulated when the modules are applied to the component to be insulated. The at least one cavity can be sufficiently large to receive packing and / or resilient material to further insulate the component and / or to assist filling the cavity to reduce unfilled space therein 42.

[0225] In at least one advantageous embodiment, the module may provide a pre-formed insulation module, which may be a semi-cylindrical module, optionally with a moisture barrier layer and / or cladding layer over an exterior surface of a rigid foam body.

[0226] Many components such as tanks may be insulated using similar preformed modules which need not be at all cylindrical in geometry. The determining factors in selection of the design of the module are as follows: the geometry of the component to be insulated, insulation requirements and cost.

[0227] An arrangement for sealing against moisture ingress between two modules 12 can include a removable gasket 14 with the gasket received in the respective channel / recess 18 of each module. A secondary gasket 50 can provided in at least one, preferably both, of the channels / recesses 18 prior to receiving the gasket 14 (primary gasket). The secondary gasket 50 can be adhered or sealed (such as by adhesive or sealant 48) or otherwise attached in the base of the channel / recess See, for example, the embodiment shown in Figures 9A and 9B.

[0228] An alternative arrangement for sealing against moisture ingress between two modules 12 can include having a sealant / mastic material 52 in a base of the respective channel / recess. The removable gasket 14 in the channels / recesses of the modules with the portions of the two modules brought together face-to-face and the gasket received in the respective channel / recess of each module, and the sealant / mastic 52 helps to seal the ends of the compressed gasket. The gasket (e.g. primary gasket) can be compressed in thechannels / recesses of the modules and consequently expands to seal against moisture ingress. See, for example, the embodiment shown in Figures 10A and 10B.

[0229] Figure 11 A shows an example of how plain butted joints (no step / offset) in a two-layer insulation (56.1 - outer layer, 56.2 inner layer) arrangement can open up, thereby creating a cold path allowing condensation / moisture C to ingress towards the pipe 34 or ice formation on a surface of a pipe 34 of a cryogenic installation.

[0230] An example of a two-layer insulation arrangement incorporating at least one embodiment of the present invention provides a labyrinthine path and gasket arrangement, as shown by way of example in Figure 11 B. An outer layer of insulation 62.1 includes modules 12 incorporating a projection 20 and projection receiving recess / channel 22 arrangement and / or a gasket 14 and associated gasket receiving recess(es) 18. The projection and recess arrangement provide a labyrinthine path as a barrier to moisture ingress or otherwise allowing a pathway for moisture to track internally to external or vice versa. The arrangement can include the gasket 14 adhered, sealed or otherwise present in corresponding gasket recesses 18 of the modules, thereby providing sealing and providing additional reinforcement of the joint and insulation arrangement as a whole.

[0231] It will be appreciated that cellular glass insulation is completely impermeable. The material is also non-absorbent according to ASTM C240 (Standard Test Methods for Testing Cellular Glass Insulation Block).

[0232] Additionally, cellular glass insulation has a water vapour permeability of 0.00 ng / Pa s m2(0.00 perm in.) when tested according to the ASTM E96 (Standard Test Methods for Water Vapor Transmission of Materials) Procedure B (wet cup) method, and does not increase in weight when exposed to 90% humidity. Weight gain in insulation resulting from moisture accumulation causedby surrounding humidity can overload pipe supports and cause damage to piping and equipment, reducing the lifespan of the system.

[0233] Embodiments with insulation and / or accessories can reduce the risk of stress corrosion cracking. Metal pipes can be at risk of corrosion under insulation (CUI) when moisture penetrates insulation. LNG facilities typically use stainless steel piping. However, these pipes have the potential to develop stress corrosion cracking (SCC) when water infiltrates the insulation and certain chemical conditions are met. SCC can occur when stressed pipes, or pipes under pressure, are in contact with water and specific chemical elements - often chlorides. Even when not in use, LNG pipes are stressed because of their production process, and when also exposed to moisture and non-neutral chemical conditions, they are at risk of cracking. Temperature cycling periods may increase this danger.

[0234] One way to improve system resilience is to select insulation accessories, such as jacketing, cladding, mastics, and vapour barriers. With permeable insulation, any damage to these materials leaves the insulated system vulnerable to moisture penetration. Poorly installed and / or improperly selected accessory products place system performance and lifespan at risk. The establishment of an effective vapour retarder for the insulated cryogenic system is jeopardised by the use of inappropriate materials or poor installation.

[0235] When a vapour barrier jacketing is installed with correctly applied impermeable insulation, such as close-cell cellular glass insulation, and insulation joints are sealed, it helps protect the system from freeze-thaw damage and supports joint integrity.

[0236] Combining impermeable insulation with the selected accessories also helps compartmentalise the insulated system, which further reduces the risk of catastrophic failure by isolating insulated sections and preventing the migration of moisture if a particular location is compromised.

[0237] Maintaining thermal efficiency and dimensional stability: it is to be understood that use of properly designed insulation systems to reduce heat transfer in United States of America industry facilities lowers energy consumption by approximately 200 million barrels per year (bpy) of oil.

[0238] In an LNG system, insulation can be used to help maintain pipes at a pre-set temperature by minimising heat flux, which supports lower operating costs. The intrusion of moisture into insulation surrounding LNG pipes reduces thermal efficiency and increases energy consumption. Industry studies have noted that open cell insulating materials see up to a 23% increase in thermal conductivity following a 1 % increase in moisture.

[0239] Although low-permeability insulation is often used in a system composed of multiple layers of both insulation and vapour barrier jacketing, the installation of an impermeable insulation eliminates the need for more than one vapour retarder, reducing field labour and install costs.

[0240] Another element to consider when selecting and designing insulation for LNG pipes to prevent premature system failure is the substance’s co-efficient of thermal expansion (CTE). Thermal insulation and steel piping will expand or contract at different rates with changing temperatures. When an LNG system is cooling to operating temperature, the insulation and pipe will contract by different amounts.

[0241] In one study, both polyisocyanurate and cellular glass insulations were lowered from ambient to -170°C (-274T). The amount both materials contracted was compared to contraction rates for both carbon and stainless steel experiencing the same temperature drop. Throughout that temperature change, cellular glass insulation tightened.

[0242] One or more embodiments of the present invention may provide a cladding arrangement 100 for protectively cladding at least one component ofinsulation 12 over an installation process component (such as a valve or pipe flange joint). At least one cladding member for covering insulation. Opposed edges of the at least one cladding member 102 can cover the insulation. Edge portions 102a, 102b of the cladding member(s) may meet or overlap. The opposed edge portions may close together (meeting or leaving a gap) or may overlap.

[0243] A fastener arrangement 104 can fastener together portions of the cladding arrangement, such as to hold closed together the opposed edge portions about the insulation. Multiple adjustable fasteners can be provided. One or more said adjustable fastener may include a threaded adjuster arrangement, such as at least one screw / helical thread adjuster (which may include a threaded shaft 110 connected directly or indirectly with respective mounts 108a, 108b). The adjustable fastener arrangement can be used to preset a clamping force for the cladding when closed around the insulation. The adjustable fastener can include a threaded member, such as a threaded nut type member, provided to tighten and / or adjust the fastener arrangement.

[0244] A respective fastener arrangement can be provided on an outer side surface of the cladding arrangement and / or on one or more end portions of the cladding arrangement. For example, fasteners 104 can be provided on the outer side surface (such as a cylindrical outer surface) and / or fasteners 106 can be provided at end portions.

[0245] A cover arrangement 112 can be provided to cover a meeting, join or gap between peripheral regions or edge portions of the cladding member(s) 102 where it / they meet when closed around the insulation 12.

[0246] The cover arrangement can augment the fastener arrangement and / or ensure the cladding remains closed around the insulation in the vent that the fastener arrangement fails or is otherwise released or loosened (such as by vibration or thermal expansion and contraction events).

[0247] The cover arrangement may include at least one cover 112a. The at least one cover can cover the meeting, join or gap between opposed peripheral regions or opposed edge portions of the cladding member(s), which can help to prevent moisture ingress at that join / meeting / gap.

[0248] Such peripheral regions or edge portions 102a, 102b of the cladding member(s) 102 can be retained in a closed orientation by the fastener arrangement and / or the cover arrangement. The cover arrangement can augment the fastener arrangement. For example, if a portion of the fastener arrangement were to fail or loosen, the cover arrangement can help to prevent the cladding member(s) from opening too wide. For example, the respective covervl 12a may engage with portions of the cladding member(s), such as flanges provided by folded / reversed edges 114a, 114b. The cover arrangement can include the at least one cover to deflect or prevent moisture / water (such as rainwater) from ingress past the cladding.

[0249] Optionally, at least one resilient member 118 may be provided between a portion of the cover 112a and the cladding member 102, such as preferably acting as a cushion, which can provide a resilient bias to assist maintain the cover arrangement in a covering orientation and / or preventing rubbing / abrasion between the cover and the cladding.

[0250] At least one sealing member 116 may be provided to seal the gap / join between the edge portions 102a, 102b of the cladding member(s). For example, a T-shaped seal member 116 may include a first portion 116a that extends into the join between the edge portions and into the insulation.

[0251] At least one further / second portion 116b of the T-shaped seal may extend over or under the edges of the cladding member(s). It will be appreciated that the at least one sealing member may include multiple portions / separate components.

[0252] The at least one sealing member may include a resilient member provided between the cladding and the insulation. Closing force applied by the fastener arrangement and / or the cover arrangement may assist to apply pressure to the seal to help ensure sealing.

[0253] Respective sealing arrangements can be provided between: 1 . the outer side surface / cylindrical side surface and the / each respective end, and / or 2. between the / each respective end and the membrane / insulation around an installation component (such as a portion of pipe). For example, a side to end sealing arrangement 120 can be provided and / or an end to installation fitting sealing arrangement 126. The side to end sealing arrangement 120 can include at least one band / clip, such as stainless-steel band clips.

[0254] Sealant 128 can be provided between the cladding / insulation and the installation / pipe (e.g. to the pipe insulation or vapour barrier). Preferably the sealant is non-setting and / or flexible. The sealant can be provided at at least one edge of the side to end sealing arrangement 120 (e.g. at the edge of a band clip).

[0255] The cover arrangement can include at least one end cover 122 provided to cover the gap / join / meeting between peripheral regions / edge portions at the end(s) regions of the cladding member(s).

[0256] Embodiments can include at least one sensor arrangement 200 to monitor for presence of or change in at least one condition within an insulation arrangement of a process installation, such as monitoring for leakage of an insulated flanged joint or valve and / or for moisture / vapour ingress into the insulation

[0257] A sensor tube 202 can be sealed internally 208, 210 to prevent vapour ingress and / or fluid egress through the sensor tube 202.

[0258] The sensor tube may include polytetrafluoroethylene (PTFE) (aka Teflon TM) material. A body 202a of the tube, such as the central tube portion between opposed ends 202b, 202c, may be made of PTFE. The tube may include metal glands 208a, 210a, with at least one expanded PTFE seal.

[0259] It will be appreciated that the sensor tube through which the sensor passes can allow installation of different types of sensor, such as for sensing: presence of fluid (liquid / gas presence), temperature, humidity, water, ice formation, pressure, or change in any one of the aforementioned monitored conditions.

[0260] Embodiments provide a sensor tube 202 enabling or including installation of at least one sensor 201 to monitor an internal condition within an insulated module 12 arrangement around a process installation, such as a flanged joint or valve.

[0261] The sensor tube 202 may be installed through at least one insulation module 12, such as at the manufacturing or assembly stage of the insulation arrangement about the process installation or during pre-assembly (e.g. off-site, prior to assembly on-site). The insulation module 12 can include a passage 203 for the sensor tube / sensor (see Figures 20 and 20D (Detail) of Figure 20).

[0262] The sensor can be operatively connected to a monitor device 220, which may be by wireless or wired connection. The monitor device may be enabled for communication with a remote location, such as by wireless transmission via an antenna of the monitor device. Wireless transmission can be by Bluetooth, or other electromagnetic (EM) protocol.

[0263] An insulation module 12 for insulating a process component can include a sensor tube 202 passing from an exterior through material of the insulation module, the sensor tube configured to receive or house at least part of a sensor device 201 .

[0264] The sensor tube 202 can be sealed internally, such as against vapour ingress and / or fluid egress through the sensor tube. The sensor tube can be sealed externally thereof to the insulation module, to cladding about the insulation module or to a vapour barrier.

[0265] The sensor tube can be sealed externally thereof to the insulation module internally of the insulation module and / or externally of the insulation module to prevent moisture passing along an exterior surface of the sensor tube through the insulation material.

[0266] One or more embodiments may include 3D scanning a valve 303 to produce a valve model to create therefrom a CNC, moulded or milled insulation arrangement, which may include insulation modules having at least one cavity 310 (e.g. 310a, 310b) therein defining a space consistent with the external shape of the scanned valve. It will be appreciated that the insulation modules having the respective cavity provide improved insulation around the valve body due to the cavity matching the actual valve body rather than known insulation being packed with separate insulation on an oversize cavity.

[0267] An insulation arrangement 300 can include insulation modules 302 (e.g. insulation arrangement module halves 302a, 302b). A groove 304 can receive a gasket 316 (such as an EPDM rubber material). A male projection 306 can be received in female groove 308 in an opposite insulation module. The cavity 310 can be formed / moulded / machined in the module(s) based on a scanned valve body - each module 302a, 302b having a cavity portion 310a, 310b to the shape of the valve body. Offset 312 on the end joints can help to compress a seal member 318 for sealing around circumferential joints around a pipe or valve body.

[0268] A cap 320 (such as a stem cap to go around the valve stem / spindle) can be mounted / fastened onto the cladding. Alternatively, or in addition, the capcan clamp around the valve stem (such as with insulation material packing therein). Cap fasteners can fasten cap portions together around the stem.

[0269] Insulation 322 material can be provided within the cap to insulate around the valve spindle / stem 314. Mastic (non-setting) 324 can be provided as a vapour seal under the cap to reduce / prevent vapour reaching the insulation under the cladding where the cap meets the cladding.

[0270] The, or each, cladding member 311 may include (attached thereto or integral thereto) a support member 326 having thereon at least one fastener 328. The, or each, fastener 328 may be self-levelling e.g. may align a fastening direction with an opposite fastening member on the opposite cladding member, such as by having a rotating / pivoting fastening portion 329.

[0271] Embodiments may include a fastener 330 arrangement for an upper and / or lower cladding cover. The upper or lower cover 331 is arranged to cover a respective upper or lower join between cladding member 331 halves. The, or each, cladding member may include a handle or grip 332, preferably one at each end thereof. A flexible seal 337, such as a non-setting mastic, can be provided for sealing ends of the insulation arrangement. Arrangements can include at least one end cap (cladding end cap) 338.

[0272] Embodiments provide an engineered cold insulation arrangement for valves and / or flanges in cryogenic / very cold applications, such as around -170 to -196 degrees C. The insulation can be arranged and configured to be removable and reusable e.g. with minimum or no destruction of the insulation modules upon removal. Traditional cold insulation and polyurethane (PUR) foam injection cannot offer such opportunity to safely and practically inspect a valve or other insulated installation without destruction of the insulation. Embodiments of the present invention enable improved inspection over known arrangements.

[0273] Embodiments can include gasket / seal insulation (e.g. EPDM rubber, expanded silicone) compressed to form a seal on both circumferential and longitudinal joints between insulation modules.

[0274] Preformed rigid insulation modules (e.g. PIR, cellular glass) can be moulded or cut to shape, e.g. using 4-axis CNC routing machine, to create labyrinth shapes preventing a direct cold path from the outside to inside the surface of the insulation.

[0275] Non-setting mastic(s), e.g. a one component, butyl rubber-based product, such as 95-50, can be provided as a vapour barrier sealant in the joints, such as between cellular glass, polyisocyanurate (PIR), to seal end joints.

[0276] According to one or more embodiments, rigid insulation material (e.g. polyisocyanurate, PIR) is engineered and cut using a CNC / milling machine.Vapour seal on the joints is achieved using a combination of EPDM rubber a nonsettling mastic sealant. Metal clamps with self-aligning fasteners, with optional compression springs, can be used to maintain even pressure on / around the PIR and the EPDM rubber enabling a mechanical seal on the joints. A valve stem cap with insulation can be employed to ensure an air-tight seal on the stem and later can house a sensor.

[0277] Production and installation can include - scan the valve, machine / cut / mould the insulation modules to accommodate the valve shape to avoid / reduce gaps between valve body and insulation modules, assemble the insulation modules and cladding around the valve onsite in situ. 80 kg / m3insulation material is preferred.

[0278] Embodiments may include 50mm EPDM rubber for the gasket / seal material, which may be compressed (such as by 20%) to suitably seal longitudinal joints to prevent ice or condensation penetrating any significant distance into thelongitudinal joints. The labyrinth path and gasket / seal prevent significant vapour / ice propagation into the insulation module joint(s).

[0279] Embodiments can include 30mm wide x 15mm thick EPDM rubber compressed (such as by at least 20%) and reinforced with non-setting mastic sealant applied underneath the circumferential joints. The stem cap may be sealed around the stem with injected non-setting sealant.

[0280] The metal clamp arrangement, such as with the spring washers, retains the butted joints / faces of the insulation modules closed.

[0281] Embodiments may include an insulation module arrangement 400 having opposed insulation modules 402, 404, with at least one upper insulation module 406 and at least one lower insulation module 408. The at least one upper insulation module can provide at least one respective infill piece for a space between the opposed insulation modules 402, 404. Likewise, the at least one lower insulation module 408 can provide at least one respective infill piece for a space between the opposed insulation modules 402, 404.

[0282] A sealing material 414, such as EPDM, can be provided to seal between respective insulation modules 402-408. The sealing material may be adhered by an adhesive 416 to the respective insulation module.

[0283] Joints between the opposed insulation modules 402, 404 and the at least one upper insulation module 406 and / or between the opposed insulation modules 402, 404 and the at least one lower insulation module 408 may provide a labyrinth path restricting or preventing moisture ingress to an interior 401 being insulated, such as a very cold pipe or valve.

[0284] One or more said joints can be sealed by a seal arrangement 410, such as including a sealing material 414 (such as EPDM), which may be adhered / bonded to the respective insulation module by an adhesive / bondingagent 416. The respective insulation module may be or include PIR 412, or other insulating medium. An embodiment is shown by way of example in Figure 27A. Detail of seal arrangement of at least one embodiment shown in Figure 27A1 .

[0285] At least one alternative embodiment of the present invention provides a cladding and insulation arrangement 500 having multi-layered insulating medium 512 within a cladding 501 arrangement. The insulating medium can include or be an insulating gel product, such as an aerogel. The insulating medium 512 can be provided in overlapping layers having staggered / offset joints to restrict or prevent ingress of moisture.

[0286] The cladding arrangement can include opposed cladding panels 502, 504, and at least one upper cladding panel 506, 508 and at least one lower cladding panel 510. The cladding panels can be clamp closed around the multilayered insulation medium 512 by a clamp arrangement 514. The cladding can be metal cladding, such as stainless steel.

[0287] At least one metal clad landing piece 516 can be provided with seal material installed circumferentially to align with end joints of the respective insulation modules.

[0288] A stem cap 518 can be provided, such as for the stem of a valve being insulated. The stem cap 518 can be 3D printed and helps to seal around the valve stem.

[0289] Seal material 520, such as EPDM rubber, can be provided to seal between the exterior cladding panels and the multi-layered insulation medium 501.

[0290] Embodiments may include insulation modules, which may include a metal cladding, insulation material, and optionally, a seal material (such as an EPDM gasket).

[0291] Embodiments may include insulation material, such as PIR / hard foam, having at least one step portion. Preferably, the respective insulation material may have upper and lower step portions.

[0292] When at least two such insulation materials are brought together, such as when assembled together around process / installation equipment to be insulated, the consequent interface may provide a respective channel between the two insulation materials, which may be at least partially filled by one or more further portions of said insulation material, preferably all being of the same type of insulation material. The insulation material may provide an insulation module or module portion.

[0293] The respective channel may include at least one upper and / or at least one lower channel. An upper insulation module / material may be provided within the respective upper channel. Likewise, a lower insulation module / material may be provided within the respective lower channel.

[0294] One or more external fasteners may clamp cladding around the insulation modules / materials.

[0295] Embodiments include layered insulation material 612, 712, 812. The layered insulation material may include an aerogel insulation material. Joints between adjacent layers may be overlapped / staggered to provide a labyrinth / convoluted path to restrict or prevent moisture / vapour ingress. For example, see Figure 37.

[0296] Seal material, such as EPDM rubber, may be included as longitudinal and / or circumferential sealing material.

[0297] Embodiments may include the cladding including support for the seal material. For example, the seal material may be applied to the claddingmember / shell, such as by friction / interference fit, compression fit, bonding / adhering, or a combination of any two or more thereof.

[0298] For example, as shown by way of exemplary embodiment in Figures 32A-3D, the exterior cladding, such as the two opposed first and second cladding members / shells 602-610 can include a respective support 603, such as a projecting wall or channel portion. The respective support 603 can be part of the cladding member / shell, such as stainless-steel. Therefore, the support can be integral to the respective cladding member / shell.

[0299] The seal material 620 can be provided on each cladding member / shell 602-610 such that, when brought together around the item / equipment to be insulated (e.g. a valve or pipe joint) the seal members contact and are compressed together, preferably by around 20% of the respective seal material’s thickness (e.g. compressed to 80% of original thickness). See, for example, Figures 33A-33D.

[0300] Alternatively, one of the cladding members / shells 602-610 can have the seal material configured to fit up to the respective support on the opposing cladding member / shell.

[0301] Embodiments can include the multi-layered insulation material 812 arranged and configured, in use, within the cladding arrangement, and the cladding member(s) / shell(s) (602-610) can include support for the seal material, such as an EPDM rubber. See, for example, Figures 36A-36D and end section view Figure 37.

[0302] For example, one or more embodiments may include an insulation arrangement with exterior cladding 700. For example, as shown by way of exemplary embodiment in Figure 36. The insulation medium / material can be or include an aerogel 712. A vapour barrier 713 can be or include a primary vapour barrier. Seal material 720 can be or include EPDM.

[0303] An alternative cladding and insulation arrangement 800, such as shown by way of an exemplary embodiment in Figure 37, can include insulating / insulation medium (e.g. an aerogel) 812, vapour barrier (e.g. primary vapour barrier) 813 and seal material (e.g. EPDM) 820.

[0304] As shown by way of non-limiting embodiments in Figures 38 to 42A1 , embodiments can include an insulation module 900 for an insulation arrangement 901 . The insulation module can include a plurality of enclosed insulation voids 914.

[0305] At least some of the plurality of voids 914 may be within or formed by a solid structure 912 of the module 900. For example, the insulation module internal structure 912 may be formed by 3D printing with the voids integral therein created by the ‘framework’ or ‘scaffold’ formed by the 3D printed structure.

[0306] The insulation module 900 may include an outer shell structure 903. The outer shell structure 903 may be integral with the internal structure 912 forming the voids or cavities 914.

[0307] It will be appreciated that the voids or cavities can contain gas, such as air or other gas or mixture thereof. It is not preferred that the voids or cavities contain a vacuum, though their internal pressure may be higher or lower than than ambient air pressure.

[0308] The outer shell 903 and the internal insulation structure 912 may be three-dimensional (3D) printed e.g. as a one-piece structure or separately 3D printed and joined / bonded together. That is, the insulation module may have a three-dimensional (3D) printed body 901 .1 incorporating the outer shell 903 and the insulation structure 912 forming the voids / cavities 914.

[0309] The voids or cavities may include holes and / or air gaps. The voids or cavities may be provided by an open cell or closed cell structure. A closed cellstructure is preferred for improved insulating properties relative to an open cell structure.

[0310] Embodiments can include an insulation arrangement 901 having a plurality of the insulation modules 900 (e.g. 902, 904, 906, 908).

[0311] Embodiments may include at least one layer of a flexible insulation medium 924, 926. The flexible insulation medium may include an aerogel material. The at least one layer of the flexible insulation medium 924, 926 can be provided on an inside face 936 of the respective module 900, so as to, in use, face towards an installation to be insulated relative to the voids or cavities 914.

[0312] Embodiments of the insulation module may include at least one recess 918 arranged and configured to receive a seal material 920 therein. The at least one recess 918 can be provided within and / or along at least a longitudinal edge or face or flange of insulation module. The at least one recess 918 may be formed by three-dimensional (3D) printing of the insulation module.

[0313] The seal material 920 may include an EPDM rubber or the like. The seal material 920 may be arranged and / or configured to seal longitudinal joints (e.g. against moisture / water ingress) between adjacent said insulation modules 900 9902, 904, 906, 908) of an insulation arrangement 901 of a plurality of said insulation modules around an installation to be insulated.

[0314] Embodiments may include an integral fastening portion for fastening the insulation module to another said insulation module. The integral fastening portion may be three-dimensional (3D) printed as part of the insulation module’s structure. The respective fastening portion may be a flange 902A,B, 904A,B, 906A,B, 908A,B of the respective insulation module 902, 904, 906, 908.

[0315] Embodiments may include an insulation arrangement 901 including a plurality of the aforementioned insulation modules 900. The insulation modulesmay be arranged and / or configured to releasably attach together around an installation (such as pipework, valving, flanged joint) to be insulated.Embodiments may include at least one gasket of the sealing material 920 between adjacent said insulation modules 902, 904, 906, 908.

[0316] Embodiments may include a vapour barrier material 928 provided externally of the insulation modules, such as adhered / bonded to an outer surface thereof, and / or provided internally, such as between flexible insulation medium and the voids and / or between the flexible insulation medium and the installation to be insulated. The vapour barrier material 928 may be provided between the respective insulation module and an outer cladding. The insulation module(s) can be covered with a primary vapour barrier to keep water vapour permeance within specification limits.

[0317] The three-dimensional (3D) printed insulation module may be printed from polymer material or filament, such as one or more of polylactic acid (PLA), acrylonitrile butadiene styrene (ABS), polyethylene terephthalate glycol (PETG), thermoplastic polyurethane (TPU), nylon or polycarbonate (PC).

[0318] The insulating voids / cavities can cover more than 50% of its surface area. Thermal conductivity control can be further controlled when combined with other insulation materials, such as flexible aerogel or rigid PUF / PIR.

[0319] The thickness of the 3D printed body can be such that the glasstransition (Tg) temperature limit is not exceeded.

[0320] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.List of reference numerals in drawings:10 - insulation system12 - insulation module (e.g. PI Pll rigid foam), 12.1 , 12.2... 12. n.14 - gasket / primary gasket (can be adhered or freely located / partially located in channel / recess)16 -mating / meeting face of module (interior surface)18 - longitudinal channel or recess in meeting / mating face for gasket 1420 - projection (male) to go into recess 22 for staggered / labyrinth join structure22 - recess (female) to receive projection 20 for staggered / labyrinth join structure24 - module end26 - module end seal recess28 - module end seal30 - insulation seal32 - insulation on pipe33 - vapour barrier over insulation on pipe34 - pipe35 - adhesive / sealant retaining end seal36 - packing piece(s)37 - adhesive / sealant retaining insulation seal38 - space for receive packing piece(s)40 - flange joint42 - resilient material and / or needled felt, such as a cushion with loose wool packing materials44 - valve46 - cavity defined by module to receive component to be insulated48 - Adhesive / sealant retaining gasket in channel / recess 1850 - secondary gasket in channel / recess52 - sealant for sealing base / end of channel / recess54 - pipe interior - e.g. at -165°C56 - standard insulation layers (butt joined) - 56.1 outer layer, 56.2 inner layer58 - condensation direct path through outer layer of insulation60 - condensation path through inner layer of insulation62.1 - outer layer of insulation incorporating embodiment of present inventionC - condensation / moisture100 - cladding arrangement102 - cladding member(s)102a, 102b - cladding member(s) respective edge portion104 - fastener (side)106 - fastener (end)108a / 108b - mounts110 - adjuster112 - cover arrangement112a - cover114 - peripheral region / edge portion114a, 114b - reverse / folded / flange peripheral region / edge portion of cladding member(s) 102116 - sealing member(s)118 - resilient member(s)120 - corner seal122 - end cover124 - end peripheral region / edge portion126 - cladding end to pipe seal128 - flexible (preferably non-setting) sealant200 - sensor arrangement201 - sensor202 - sensor tube for housing sensor or part thereof202a - sensor tube body202b - sensor tube outer end202c - sensor tube inner end203 - opening / passage through insulation module204 - support plate (inner)205 - plug (e.g. PTFE)206 - support plate - (outer)208 - tube seal arrangement (inner end)208a - internal gland / seal210 - tube seal arrangement (outer end)210a - internal gland / seal212 - vapour barrier (vapour stop)213 - internal space214 - sealant (outer)216 - plate218 - lead to sensor219 - sensor antenna220 -monitor device (connected to sensor - wireless or wired)222 - antenna for monitor device300 - Insulation arrangement302 - insulation modules (insulation arrangement module halves 302a, 302b)303 - valve (valve body)304 - groove to receive gasket (groove halves 304a, 304b)306 - male projection to be received in female groove in opposite insulation module308 - female groove to receive therein male projection of opposite insulation module310 - cavity formed / moulded / machined in modules based on scanned valve body - each module 302a, 302b having a cavity portion 310a, 310b to the shape of the valve body311 - cladding member312 - offset on the end joints to compress seal member for sealing around circumferential joints around a pipe or valve body314 - valve spindle / stem316 - polymer gasket (e.g. EPDM rubber)318 - polymer seal - end (e.g. EPDM rubber)320 - cap322 - insulation cap to valve spindle / stem324 - mastic (non-setting) vapour seal326 - support member (for fastening cladding member around insulation module)- fastener on support member (self-levelling fastener)- pivoting / rotating fastening portion- fastener (upper or lower cover to cladding)- upper or lower cladding cover- handle / grip on cladding- existing pipe insulation and cladding- cladding swage- flexible seal / non setting mastic- end cap (cladding end cap)- primary vapour barrier- frost plate / cover- fastening point for fastener (upper / lower cover to cladding)- existing pipe- cladding and insulation arrangement- interior- insulation module (first)- insulation module (second)- upper insulation module (infill piece)- lower insulation module (infill piece]- seal arrangement- insulation material (e.g. PIR) of modules- sealing material (e.g. EPDM)- adhesive / bonding agent- cladding- clamping arrangement- cladding and insulation arrangement- cladding arrangement- cladding panel (first)- cladding panel (second)- upper cladding panel- upper cladding panel- lower cladding panel - insulating / insulation medium (e.g. an aerogel) - vapour barrier (e.g. primary vapour barrier) - clamp - clamp bracket - metal clad landing piece - valve stem cap - seal material (e.g. EPDM) - cladding support - insulation medium (e.g. PIR, preferably milled) - cladding and insulation arrangement - cladding arrangement - cladding member / shell / panel (first) - cladding member / shell / panel (second) - upper cladding member / panel - upper cladding member / panel - lower cladding member / panel - insulating / insulation medium (e.g. an aerogel) - vapour barrier (e.g. primary vapour barrier) - clamp - clamp bracket - metal clad landing piece - valve stem cap - seal material (e.g. EPDM) - cladding support - insulation medium (e.g. PIR, preferably milled) - alternative cladding and insulation arrangement - insulating / insulation medium (e.g. an aerogel) - vapour barrier (e.g. primary vapour barrier) - seal material (e.g. EPDM)- alternative cladding and insulation arrangement - insulating / insulation medium (e.g. an aerogel) - vapour barrier (e.g. primary vapour barrier) - seal material (e.g. EPDM) - insulation module .1 - integral shell and insulation structure (body) - insulation arrangement - 1stmodule / portion (e.g. 3D printed) A, 902B - Flange - 2ndmodule / portion (e.g. 3D printed) A, 904B - Flange - 3rdmodule / portion (e.g. 3D printed) A, 906B - Flange - 4thmodule / portion (e.g. 3D printed) A, 908B - Flange - outer face (module portion outer face) - insulation structure of the insulation module - voids or cavities of or in the insulation structure - secondary insulation / sealing material (e.g. EPDM) A - secondary insulation / sealing material (adhered to module)B - secondary insulation / sealing material (adhered to pipe) - recess to receive seal material - seal material - pipe A - pipe - flange outline - pipe insulation layer (e.g. aerogel) - pipe insulation layer (e.g. aerogel) - vapour barrier material - fastener - cladding - flexible insulation material - inner face

Claims

CLAIMS:1 . An insulation module for insulating a process component, the module including a first module having an exterior facing surface and an interior facing surface, wherein the interior facing surface includes at least one of: i). a gasket receiving portion for at least one gasket to restrict or prevent moisture ingress through an interfaced join between the first and second interior facing surfaces; ii). an inter-engagement arrangement including a projection and / or a recess for inter-engagement with a respective recess and / or projection of the second said insulation module to provide a labyrinth or staggered interface join between the first and second modules.

2. The insulation module of claim 1 , wherein the insulation module includes the gasket receiving portion and the inter-engagement arrangement.

3. The insulation module of claim 1 or claim 2, wherein the exterior facing surface is generally or substantially part cylindrical, optionally providing a half cylinder surface.

4. The insulation module of any one of the preceding claims, wherein the first module has a one-piece body of moulded rigid material.

5. The insulation module of claim 4, wherein the rigid material includes polyisocyanurate (PIR) foam, polyurethane (PUR) foam or a combination of the PIR and PUR rigid foams, or a combination of the PIR and PUR rigid foams, or cellular glass or foam glass, or a combination of any two or more thereof.

6. The insulation module of any one of the preceding claims, including the at least one gasket mounted to and / or adhered to the gasket receiving portion.

7. The insulation module of claim 6, wherein the at least one gasket includes a flexible material.

8. The insulation module of claim 6 or claim 7, wherein the at least one gasket is a replaceable component for when the module is reused.

9. The insulation module of any one of the preceding claims, including an end seal arrangement for sealing against moisture ingress from the exterior to the interior.

10. The insulation module of claim 9, wherein the end seal arrangement includes an end seal for at least one of two end interior facing surfaces of the first module, preferably at each of both of the two end interior facing surfaces.11 . The insulation module of claim 10, wherein the end seal arrangement includes one or both of: i). at least one end seal provided within a recess at the respective end of the first module; or ii). at least one insulation seal for sealing against insulation or a vapour barrier on a pipe or other process installation.

12. The insulation module of claim 11 , including the at least one end seal and the at least one insulation seal, wherein, in use, the at least one end seal and the at least one insulation seal compress together providing a moisture barrier.

13. An insulation arrangement including a first insulation module and a second insulation module, the first and second insulation modules configured to seal around a process installation against moisture ingress, and the insulation arrangement including at least one gasket providing a seal between the first andsecond modules and / or including an inter-engagement arrangement providing a labyrinthine interface join between the first and second modules.

14. The insulation arrangement of claim 13, wherein the first module and / or the second module includes rigid foam material, optionally polyisocyanurate (PIR) foam or polyurethane (PUR) foam, or a combination of the PIR and PUR rigid foams, or cellular glass or foam glass, or a combination of any two or more thereof.

15. The insulation arrangement of claim 13 or claim 14, including the at least one gasket and the inter-engagement arrangement.

16. The insulation arrangement of any one of claims 13 to 15, wherein the at least one gasket includes a flexible material.

17. The insulation arrangement of claim 16, wherein the at least one gasket is replaceable.

18. The insulation arrangement of any one of claims 13 to 17, wherein the inter-engagement arrangement includes at least one projection on at least one of the first or second module and a respective recess on the other of the respective second or first module, such that, on assembly together with the interior facing surfaces coming together, the respective projection(s) and recess(es) interengaging to provide the labyrinthine interface join.

19. The insulation arrangement of any one of claims 13 to 18, including an end seal arrangement between at least one of two longitudinally opposed ends of the assembled first and second modules to the process installation, the end seal arrangement including at least one end seal and / or at least one insulation seal.

20. The insulation arrangement of claim 19, wherein the end seal arrangement includes the at least one end seal and the at least one insulation seal.21 . The insulation arrangement of claim 20, wherein the at least one end seal and the at least one insulation seal are arranged and configured to compress together to form a moisture barrier between an exterior and the interior of the assembled first and second modules.

22. An insulation system including multiple insulation modules configured to insulate a process component, wherein the insulation modules together interengage to provide an indirect linear or labyrinthine interface join therebetween.

23. A cladding arrangement for protectively cladding at least one component of insulation overran installation process component incudes at least one cladding member.

24. The cladding arrangement of claim 23 including a fastener arrangement having at least one adjustable fastener including a threaded adjuster.

25. The cladding arrangement of claim 23 or claim 24 including a cover arrangement to cover at least one join between opposed cladding portions.

26. The cladding arrangement of claim 25, wherein the cover arrangement.

27. The cladding arrangement of claim 25 or 26, wherein the cover arrangement includes at least one cover configured to cover edge portions of the cladding member(s).

28. The cladding arrangement of claim 27 wherein the respective cover is applied, in use, over reversed edge portions of the cladding member(s).

29. The cladding arrangement of any one of claims 25 to 28, including at least one resilient member between a portion of the respective cover and the cladding member.

30. The cladding arrangement of any one of claims 23 to 28, including at least one sealing member to seal the join or gap between opposed peripheral regions or edge portions of the cladding member(s).31 . The cladding arrangement of claim 30, wherein the at least one sealing member includes a portion that extends into the join or gap between the peripheral regions or edge portions edges and into the insulation.

32. The cladding arrangement of claim 30 or 31 , the at least one sealing member including a resilient member provided between the cladding and the insulation.

33. The cladding arrangement of any one of claims 30 to 32, wherein the at least one sealing member includes a T-shaped / T-section seal.

34. An arrangement for a sensor to monitor for presence of or change in at least one condition within an insulation arrangement of a process installation, the arrangement including a sensor tube passing from an exterior to an internal space within the insulation arrangement enabling provision of a sensor to sense a condition change within the internal space.

35. The arrangement of claim 35, wherein the sensor tube is sealed internally against vapour ingress and / or fluid egress through the sensor tube.

36. The arrangement of claim 34 or 35, wherein the sensor tube includes or is made of polytetrafluoroethylene (PTFE) material.

37. The arrangement of any one of claims 34 to 35, wherein the sensor tube is installed through at least one insulation module.

38. The arrangement of claim 37, wherein the sensor tube is pre-installed through the at least one insulation module prior to installation of the insulation module about a process installation.

39. The arrangement of any one of claims 34 to 38, including a monitor device operatively connected to the sensor.

40. The arrangement of claim 39, wherein the sensor and the monitor device are operatively connected by wireless or wired communication or connection.41 . An insulation module for insulating a process component, the module including including a sensor tube passing from an exterior through material of the insulation module, the sensor tube configured to receive or house at least part of a sensor device.

42. The insulation module of claim 41 , wherein the sensor tube is sealed internally against vapour ingress and / or fluid egress through the sensor tube.

43. The insulation module of claim 41 or 42, wherein the sensor tube includes or is made of polytetrafluoroethylene (PTFE) material.

44. The insulation module of any one of claims 41 to 43, wherein the sensor tube is pre-installed through the at least one insulation module prior to installation of the insulation module about a process installation.

45. A method of insulating a cryogenic installation includes 3D scanning at least a portion of the cryogenic installation, creating at least one shaped insulation module from the 3D scan, assembling the insulation module around the at least a portion of the cryogenic installation in situ.

46. The method of claim 45, wherein the at least a portion of the cryogenic installation includes a valve.

47. The method of claim 45 or 46, wherein the shaped insulation model is created by moulding, cutting or milling an insulation material from data of the 3D scan.

48. The method of claim 47, wherein the insulation material includes PIR.

49. The method of any one of claims 45 to 48, including cladding the installed insulation with a metal cladding.

50. The method of any one of claims 45 to 49, including providing a labyrinth join between insulation modules and a gasket material.51 . The method of claim 50, wherein the gasket material is between insulation modules and towards an exterior of the insulation modules relative to a projection and recess inter-engagement arrangement between the insulation modules.

52. The method of claim 49 or 50, wherein the gasket or seal material includes EPDM rubber.

53. The method of any one of claims 45 to 52, including providing a cap on the insulation arrangement, the cap being around a stem of a valve of the cryogenic installation.

54. The method of claim 49, including providing at least one of an upper cover or lower cover over a join between insulation modules.

55. The method of claim 54, wherein the upper cover or lower cover is arranged to cover cladding over the insulation material.

56. An insulation arrangement for insulating a process component, the insulation arrangement including an external cladding arrangement and a plurality of insulation portions including at least a first and a second insulation portion,which, in the assembled insulation arrangement define at least an upper channel and / or lower channel configured to receive at least one respective upper or lower infill insulation material.

57. The insulation arrangement of claim 56, wherein the first and second insulation portions and the upper or lower infill insulation material form a generally Y-shaped interface join in transverse cross-section of the insulation arrangement.

58. The insulation arrangement of claim 56 or 57, including a seal material provided in the respective channel between the respective insulation portion and the respective upper or lower infill insulation material.

59. The insulation arrangement of claim 58, wherein the seal material is a compressible material.

60. The insulation arrangement of claim 59, wherein the seal material includes a rubber material, preferably a synthetic rubber material, such as an EPDM rubber.61 . The insulation arrangement of any one of claims claim 58 to 60, wherein the seal material is adhered or bonded to the insulation material and / or the infill insulation material.

62. The insulation arrangement of any one of claims 56 to 61 , wherein the seal material is compressed in an assembled said insulation arrangement.

63. The insulation arrangement of claim 62, wherein the seal material is compressed to about 80% of original thickness in the assembled insulation arrangement.

64. The insulation arrangement of claim 62 or 63, wherein, the cladding has a plurality of fasteners, wherein the fasteners cause the seal material to be compressed when tightened.

65. The insulation arrangement of any one of claims 56 to 64, wherein the cladding arrangement includes at least one support for the seal material.

66. The insulation arrangement of claim 65, wherein the seal material is applied to the cladding member / shell, such as by friction / interference fit, compression fit, bonding / adhering, or a combination of any two or more thereof.

67. The insulation arrangement of claim 65 or 66, wherein at least one, preferably both, of two opposed first and second cladding members / shells include a respective support for a said seal material.

68. The insulation arrangement of any one of claims 65 to 67, wherein the at least one support includes a projecting wall or channel portion of the respective cladding member / shell.

69. An insulation arrangement for insulating a process component, the insulation arrangement including an external cladding arrangement and a plurality of layers of aerogel insulation material.

70. The insulation arrangement of claim 69, wherein the aerogel is in multiple layers with staggered joins between layers.71 . The insulation arrangement of claim 69 or 70, wherein the aerogel insulation material is vapour-resistant by a moisture resistant backing material.

72. The insulation arrangement of any one of claims 69 to 71 , wherein the aerogel insulation material includes layers of aerogel blankets.

73. The insulation arrangement of any one of claims 69 to 72, wherein the cladding arrangement includes at least one support for the seal material.

74. The insulation arrangement of claim 73, wherein the seal material is applied to the cladding member / shell, such as by friction / interference fit, compression fit, bonding / adhering, or a combination of any two or more thereof.

75. The insulation arrangement of claim 73 or 74, wherein at least one, of two opposed first and second cladding members / shells include a respective support for a said seal material.

76. The insulation arrangement of any one of claims 72 to 75, wherein the at least one support includes a projecting wall or channel portion of the respective cladding member / shell.

77. An insulation module for an insulation arrangement, the insulation module including a plurality of enclosed insulation voids or cavities.

78. The insulation module of claim 77, wherein at least some of the plurality of voids or cavities are formed by or within an insulation structure.

79. The insulation module of claim 78, wherein the insulation structure includes a three-dimensional (3D) printed structure forming a framework or scaffold creating the voids or cavities.

80. The insulation module of any one of claims 78 to 79, wherein the insulation module includes an outer shell structure.81 . The insulation module of claim 80, wherein the outer shell structure is integral with the insulation structure.

82. The insulation module of claim 81 , wherein the outer shell and the insulation structure are three-dimensional (3D) printed as a one-piece structure or are separately 3D printed and joined together.

83. The insulation module of any one of claims 77 to 82, wherein the voids or cavities include holes and / or air gaps.

84. The insulation module of any one of claims 77 to 83, wherein the voids or cavities are provided by an open cell or closed cell structure.

85. The insulation module of any one of claims 77 to 84, including at least one layer of a flexible insulation medium.

86. The insulation module of claim 85, wherein the flexible insulation medium includes an aerogel material.

87. The insulation module of claim 85 or 86, wherein the at least one layer of the flexible insulation medium is provided on an inside face of the respective module so as to, in use, face towards an installation to be insulated relative to the voids.

88. The insulation module of any one of claims 77 to 87, when the module includes at least one recess arranged and configured to receive a seal material therein.

89. The insulation arrangement of claim 88, wherein the at least one recess is formed by three-dimension (3D) printing of the insulation module.

90. The insulation arrangement of claim 88 or 89, wherein the seal material includes an EPDM rubber or the like.91 . The insulation arrangement of any one of claims 88 to 90, wherein the seal material is configured to seal longitudinal joints between adjacent said insulation modules of an insulation arrangement of a plurality of said insulation modules around an installation to be insulated.

92. The insulation arrangement of any one of claims 77 to 91 , including an integral fastening portion for fastening the insulation module to another said insulation module.

93. The insulation module of claim 92, wherein the integral fastening portion is three-dimensional (3D) printed as part of the insulation module’s structure.

94. An insulation arrangement including a plurality of the insulation modules according to any one of claims 77 to 93, wherein the insulation modules are configured to releasably attach together around an installation to be insulated.

95. The insulation arrangement of claim 94, including at least one gasket of sealing material between adjacent said insulation modules.

96. The insulation arrangement of claim 95 or 96, including a vapour barrier material provided externally of the insulation modules.

97. The insulation arrangement of claim 96, wherein the vapour barrier material is provided between the respective insulation module and an outer cladding.

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