How Industrial Insulators Deteriorate

When you work in manufacturing, you understand the strain your machines endure. Though engineers craft them to be resilient and long-lasting, there comes a time when parts inside the machines wear down. Here is how industrial insulators deteriorate and what to do about it.

What Are Industrial Insulators?

Industrial processes often require extreme environments to fabricate products. High pressure, high heat, and surging electricity all contribute to the crafting of materials. Insulators protect the people, products, and machines from these harsh elements and ensure a smooth operation. So, what exactly are these industrial insulators, and what do they do?

Insulator Types

Staff utilize all sorts of machines in industrial facilities, from forklifts to lasers. These machines utilize insulators to operate at full capacity. Insulators are not a monolithic category—there are numerous kinds of insulators that professionals use in industrial settings. The two main types that require close attention are thermal and electrical insulators.

Thermal Insulators

Imagine you work at an industrial facility and operate an induction furnace. As the name implies, this would mean you work around extremely high heat at the mouth of a furnace. You will need thermal insulators to prevent the heat from escaping the confines of the heater and impacting the rest of the operation. For example, our thermal insulating sheets at Red Seal Electric Company equip industrial facilities with non-asbestos thermal insulation material that keeps heat where you want it. Without a high-quality insulator, extreme heat can seep out of unseen cracks and either overheat surrounding areas or ignite nearby flammable items.

Electrical Insulators

Like thermal insulators, electrical insulators work to manage the elements. Electrical insulators control electrical flow and keep it within the right boundaries. Electricity is essential to power almost every tool in an industrial setting, making the electrical housing in these high-energy machines all the more critical. Engineers utilize nonconductive materials to craft electrical insulators, so the electrical current flows in the right direction. Any break in the insulation can result in shocks, electrocutions, and even electrical fires.

How Do They Deteriorate?

Seeing how critical insulation is to a safe and productive work environment, you can understand why any deterioration can result in catastrophic consequences. Yet how do parts designed to withstand high heat and strong electrical current break down?

Thermal Deterioration

Like all machine parts exposed to intense conditions, thermal insulation loses its efficacy over time. High heat takes a toll on parts, even the ones built to withstand it. Temperature extremes produce thermal stress, which weakens the insulation over time. Additionally, materials age over time, and their effectiveness changes with that age. Depending on the chemicals you expose the insulation to, the air pressure and compression it undergoes, and the vibrations from surrounding machined processes, this deterioration can happen sooner than you think. That's why you must choose high-quality materials to begin with, so you needn't replace thermal insulation so quickly.

Electrical Deterioration

Electrical insulation is similar to thermal insulation in that they both deteriorate due to the same outside stresses. However, electrical insulation deals with an entirely different element: electricity. While heat deals its own damage, electricity is much subtler and even produces heat on its own.

Many machines operate at full capacity for long periods, increasing the internal heat around all interior components, including electrical housing. Temperature is an aggravating factor in electrical deterioration since it increases the malleability and molecular movement of the insulating material. This, in turn, increases the impact of electricity flowing through it. Electrical insulation also deteriorates when exposed to voltage peaks that test the material's tolerance and arc resistance.

Why Does This Happen?

Understanding how deterioration happens is one thing; knowing why it does is quite another. If you know what shouldn't happen, it doesn't mean you can prevent it. The reasoning behind thermal and electrical deteriorations matters, so that prevention tactics are effective. This means diving deep into the fundamental nature of these elements.

Heat Impacts

At its core, heat manipulates the particulate movement of substances, increasing their molecular vibrations. These rising movements increase the friction between particles, thereby creating heat. The compounding effect of microscopic kinetic activity produces the heat you can see and feel. When heat reaches high enough temperatures, materials begin to break down. Some substances melt while others burn, but either way, the kinetic activity weakens the interatomic bond. Engineers choose materials that can withstand these forces, but prolonged exposure will fundamentally weaken these bonds and lead to microscopic cleavage, which then leaves insulating boards and pieces susceptible to macroscopic cracks.

Electrical Impacts

Conductors and insulators are the key components that determine electricity's flow in every electrical system, even industrial ones. The insulators stop and direct this movement, keeping the moving electrons in their bounds. The voltage, or pressure of the electrical current, pushes these electrons through the conductors to complete work. When the voltage is too high, the electrical pressure surges, straining the insulator's electrical neutrality. These voltage changes can wear out the insulator over time, resulting in lower resistance to electrical flow. As a result, the worn insulator will have no power to stop electricity from flowing through its otherwise impenetrable boundaries.

What Can You Do About It?

Machine breakdown happens slowly, but there is a definite point of no return. That's why you must pay attention to the parts themselves before anything drastic occurs. You must first take stock of all your machines and note which ones have thermal and electrical insulators. Write down the specific characteristics and materials, so you avoid replacing pieces incorrectly. Consider setting a maintenance schedule with routine inspections every week, month, and year. With a thorough monitoring and evaluation program, you can keep your machines running efficiently and safely.

Knowing how industrial insulators deteriorate equips project managers, maintenance crew, and engineers alike to head off any dangerous problems. Insulation is critical to industrial operations, so pay attention to their health. If you need replacement parts for an industrial insulator, contact us at Red Seal Electric Company to hear about our thermal and electrical insulation options.