What is a Thermal Blanket?

A thermal blanket is a flexible insulated covering that creates a protective barrier around hot surfaces in an industrial engine or exhaust system. Blankets are typically installed on components with running temperatures likely to exceed 200?C. The composite insulating medium reduces surface temp, mitigating the risk of fire or other heat related damage.

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Purpose

Thermal blankets offer several levels of protection for engines. The main purpose is to prevent engine fires by reducing surface temperatures below the flashpoint of common flammable fluids. A small leak or accidental overspray may cause debris or fluid to come into contact with highly heated surfaces, becoming a source of ignition. By insulating the heat source and creating a physical barrier, thermal blankets significantly reduce the risk of fire.

Additional benefits include minimising heat transfer to sensitive components such as sensors or electrical wiring, preventing premature wear from heat stress, and reducing the risk of burns. Improvements in fuel economy have also been observed, as it takes less time for the turbo to regain operating temperature and prevents heat transfer to the intake air, leading to better combustion efficiency.

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Applications

Thermal blankets can be installed on any machinery where there is a need to reduce surface temperature. Light or heavy vehicles, off-road mining equipment, or fixed plant such as generators. Though they are mostly fitted to mufflers, exhaust pipes, and turbos, any machinery surface with a high surface temperature could benefit from an insulated cover. Further to this, thermal blankets can safeguard sensitive equipment and tanks from outside temperatures, whether hot or cold. With battery technology increasing, thermal protection is now being utilised to protect batteries from climate extremes and general engine heat.

For maximum safety and effectiveness, it is important to ensure thermal blankets are snug and securely fitted to the machine. Loose fitting covers can be ineffective, but they are also a major safety hazard, increasing the risk of flammable material build up.

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How are they made?

A basic thermal blanket consists of three mechanically bonded layers: an inner face barrier, an outer face barrier, and the insulation in between. Depending on application, the materials used in thermal blankets can include:

?Outer Layer (Cold side)

????????? - Silicone coated wire

?????????- Teflon impregnated fabric

Middle Layer (Insulation)

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?Inner Layer (Hot side)

?????????- Silica fabric

?????????- Stainless steel foil

?????????- Stainless steel knitted mesh

Quality materials are critical for thermal blankets as they must be able to withstand extreme temperatures, but also need to be flexible, strong, durable, and resistant to oil, fuel, and moisture.

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Benefits of blankets

Thermal blankets work predominantly to mitigate fire risk by insulating the heat source and then acting as physical barrier, isolating it from flammable material or contaminants. But there are other benefits to installing thermal protection on your plant or machinery.

Because the overall engine temp is reduced by the thermal blankets, there is less cool down time required for before a technician can access the engine bay, meaning critical maintenance can be carried out without delay. Reducing touch temperatures also protects operators and other people who may contact the machine.

The performance of certain parts such as the turbocharger can be disrupted by hot weather, causing it to work harder, ultimately wearing it prematurely. Conversely, equipment such as fluid tanks are in danger of freeze damage and lengthy delays in colder climates. Protecting components from ambient temperatures in hot or cold environments are another benefit of blankets.

The thick and durable material of the blankets acts as a cushion and can protect pipes and components from abrasions, debris, or accident damage. This is especially important when it comes to bends and edges that require moulded blankets that are fitted securely.

A major advantage of thermal blankets is that they’re versatile and cost effective. Because they fit within the existing frame of the machine, they do not require any removal of parts, making installation and maintenance easy. Blankets are highly customisable, and the specs can be altered by shape and size or by material, conforming to a broad range of applications.

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Thermal blankets are an integral safety feature for any industrial machinery, but the benefits reach further than just fire mitigation. By protecting engine components from damage, weather, and premature wear, thermal blankets provide a flexible and cost-effective solution to the running of heavy equipment.

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