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Luca Mattioli

Why are traditional insulation systems not always the most suitable solution

Often even if the systems seem to be performing, there are points and junctions where efficiency can be largely improved.

As a matter of facts, it is quite frequent that on traditional insulation systems, in particular if dated, there are problems of energy dispersion. Every dispersion, above all if prolonged over time, causes the company to lose money , as well as a real risks of accidents.

For this reason, it is important to take action, checking the situation of the system and intervening immediately to repair any shortcomings.

An excellent solution to overcome this problem is to use removable insulation, which is an important ally in the energy efficiency, as it allows you to obtain obvious advantages in safety, energy savings and efficiency.

Guaranteed performance : removable insulation

Removable insulation is a flexible insulating jacket that, unlike traditional insulation, can be easily assembled and/or removed.

This is why they are often used in installations where a constant maintenance is required.

However, their high qualitative and structural performance makes them particularly suitable for any type of system, valve, pipe and flange, even where energy loss seems insignificant (but then, in the long term, causes a great deal of energy and money wasted).

The advantages of removable insulation are countless:

  1. Greater safety for personnel (protecting the operator from possible burns and contributing to a cooler, healthier working environment);
  2. Increased energy efficiency and better performance (thermal jackets prevent heat loss and contribute to energy savings, thus reducing consumption and maintenance costs);
  3. Maintenance and checks are quicker and easier to carry out.
  4. Greater impermeability and acoustic insulation (removable insulation is made of high-tech materials and is resistant to atmospheric agents).
  5. Compliance with health and safety regulations.

So, considering the considerable advantages of removable insulation, if you don’t currently have it in your company, it is because you have never tested it.

How to combat efficiency losses

Ensuring the energy efficiency of the installation and preventing efficiency losses is usually the responsibility of the maintenance manager, who often has to find simple solutions to complex problems.

It is not always easy to solve the leakage problems that can occur on a system insulated with traditional insulation.

In this particular context, thermal jackets prove to be important allies: they are able to insulate the system by means of their technical and fireproof fabrics which, since they can be easily removed, can also be easily replaced if worn.

In addition, the greatest advantage of jackets is their perfect fit and compatibility with the structure to which they are applied: through exact measurements, the removable insulations are designed to be a second look for the installation.

This leads to better energy efficiency, greater safety and a guarantee for regulatory standards.

At this point, it is quite clear that using thermal jackets could be an advantageous choice in terms of energy and consequently economicall

Thermographic surveys

To check the health of your system, you can rely on thermographic check that allow you to assess in real time any critical points and the possibilities for intervention.

This is the service that New Componit puts at your disposal: Efficiency Box®, to receive the information you need and take immediate action.

The Efficiency Box® is more than an assessment system, as it is a complete program offering solutions, guarantees and constant support from a team of experts.

The program consists of:

  1. Monitoring of the plant during operation, carried out directly by a New Componit skilled technician;
  2. Design and supply of the required interventions with simple but technologically advanced solutions;
  3. Installation or supervision by New Componit staff;
  4. Direct assistance and prompt intervention, with a dedicated toll-free number (national 800 168 655; international +39 040 9870498);
  5. Immediate return and rapid replacement, within 10 days of delivery in case of defects;
  6. Annual and after-sales check to verify the condition of the product and its operation;
  7. Guaranteed warranty;

With the Efficiency Box® you will be able to improve :

  • PRODUCTION EFFICIENCY
  • ENERGY SAVING
  • SAFETY
  • SUSTAINABILITY
  • ADHERENCE TO EUROPEAN STANDARDS

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Company short-sightedness

Today I would like to share with you something different.

What I call : “ Company short-sightedness”.

Often during my inspections at thermal power plants, cogeneration or energy plants, or in factory production processes, I notice the complete absence of adequate thermal insulation, on equipment which can be filters, valves, flanged couplings, heating pumps, small section of pipe, engine parts.

When I ask : “ Why are these elements not insulated ?

The customers’ answers are almost the same :

-“It has been like this for many years”

– “The insulation cannot be done here”

– “We cannot do the insulation, because we need to do the maintenance”

– “It is more expensive to call someone who does the insulation than everything else”

Here we are, this is what I call : “Company short-sightedness”.

The fact that it has always been like this, does not mean that it is correct.

Actually , over the years, the situation has drastically changed. For example : the cost of energy, but also the safety rules for personnel.

Probably it is true that this type of equipment cannot be insulated, but this only if you think to traditional insulation , if you consider to use a removable fabric insulation, you will immediately obtain the insulation of your equipment and you will also see how easy extraordinary and ordinary maintenance intervention are.

As well as preserving the safety of workers, complying with the new safety standards.

For this reason I suggest you to pay the utmost attention, not to think that this is a cost, but rather that the installation of an  adequate insulation is a saving .

Want to improve comfort and performance in your plant with a tailored solution?

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PFP New Componit

What is a PFP jacket and when is it used?

Passive fire protection systems, better known as PFP, are systems of protection and control, which in the event of fire, have the scope of safeguarding the insulated equipment and ensuring a safe shutdown of the plant.

They have a double purpose:  they preserve the integrity of the instrumentation by acting as insulation during the life cycle and on the other hand, in case of fire, they limit the damage.

As passive protection devices, they are able to counteract both the propagation of fire in space and time, by leaving to people a determined period of time to intervene (equivalent to the protection time required). 

PFP: Where can it be used?

In accordance with art. 4 of Regulation no. 175/1988 fires are classified on a scale A-B-C, according to a high, medium and low risk level.

A PFP is particularly suitable for those fields or company areas where the level of fire risk is always high, due to the presence of flammable substances and/or to the particular conditions of premises, such as: petrochemical plants, refineries, offshore platforms or ships.

In these cases, PFP that can contain the fire and reduce the damage is very effective.

Furthermore, a workplace may have different levels of fire risk, depending on the specific production sites.

These locations include:

  • Areas where work processes require the use of highly flammable substances (such as paints), the use of open flames or the production of a significant source of heat in the presence of combustible substances;
  •  Areas where chemicals are stored or handled;
  •  Areas where explosive substances are stored or handled;
  •  Areas where a considerable amount of combustible material is present;

In these specific cases, installing a PFP device means guaranteeing that the protected equipment will work for a period of time which allow the system to return safe and operative again.

PFP products can be installed directly on valves, actuators, external control units, electrical ducts or any type of equipment that must be protected for safety reasons

PFP: What temperature?

As PFP jackets are used to ensure the proper operation of covered parts, they have to be able to pass special tests and withstand very high temperatures.

As a matter of facts, PFP specifications generally state: “equipment protected against a certain type of fire for a certain period of time, identified in  x minutes.”

In practice, the temperature of an equipment protected by PFP jackets must remain below the critical operating threshold for a given time.

In order to be sure to have operating products, tests must be carried out in accordance with current standards.

To be functioning, the samples tested should faithfully represent the shape of the protection, which will be then replicated in reality.

Generally people are content to test only protections for tubular sections or flat plates, without considering that,  in a real situation , they may not work as expected.

Obviously, the performance required to the PFP and the reference field  will determine the product choice.

In general, the main fire protection devices include:

  • Flexible, i.e. insulating jackets (our Pyroproof ® )
  • Rigid, stainless steel box;
  • in paint, to be applied directly to the equipment.

New Componit’s flexible jackets

To be sure that your equipment is properly protected, you need to rely on expert partners, like New Componit, which has been studying PFP systems since 2005.

New Componit was the first Italian company to certify its PFP flexible jackets against fire. We have invested time, skills and resources to improve and enhance our product. Now our company is one of the world leaders in PFP field.

Thanks to the experience achieved New Componit has developed Pyroproof®, a range of innovative and high-tech PFP jackets.

Pyroproof® jackets are custom-made and designed according to customer’s needs. In addition, they are lightweight, high-performance and resistant to both atmospheric and chemical agents.

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Coibentazione rimovibile NEWCOMPONIT

Why a removable insulation can have a double functionality?

Removable insulation can have a “double functionality”: it can be removed and reinstalled and maintain its performance, unlike what happens with a fixed insulation system.

In fact, to say that a removable insulation system has a ‘double functionality’ is rather reductive: it can be reused three, four, five and more times…

The better the quality of the materials and the technology are, the longer its duration will be.

The advantage of this type of insulation is that it can be removed as often as necessary, making it a practical and economical alternative to more traditional systems.

Do you need to do maintenance? The removable insulation makes your life easier

Whenever you need to carry out ordinary or extraordinary maintenance, on small sections of pipes, valves, flanged couplings, filters, pumps or other components of your system, the first thing to do is to remove and then, reapply the insulation.

But if it is a fixed, traditional installation, the operation becomes rather complicated:

  • It is difficult to carry out and probably requires the intervention of an external company
  • it takes a lot of time;
  • it can be expensive;

In addition, this system is often damaged during removal, reducing its thermo-acoustic protection capacities and resulting also  “ugly” to see. Therefore, when the maintenance is completed and the traditional insulation as to be reapplied, some parts will have to be replaced, increasing the costs.

This approach allows you to save some money on the materials , but not on the  labour, which will still be expensive. The situation is different when  the insulation has been completely ruined during removal, as in this case it will be necessary to replace it completely

On the other hand, if you choose  removable insulation jackets:

  • they can be easily removed and reapplied;
  • installation and removal are very quick, saving time;
  • they do not require the intervention of an external operator;
  • they are cheaper.  Obviously, if you want removable insulation to last a long time, you need to make sure that it is made of high-quality raw materials and by a specialized company with high technical expertise.

Are you looking for reliable, long-lasting removable insulation?

New Componit is an innovation-oriented company with over 35 years  experience in the most advanced solutions for industrial protection and insulation systems.

We work with our customers to optimize their installations, by supplying our removable insulation jackets as an efficient alternative to traditional insulation.

We use a highly reliable working method: Efficiency Box®, our special program that offers a series of services designed to answer all types of needs, in order to make the production systems of all our customers more efficient and safer.

Efficiency Box® includes:

  1. SYSTEM MONITORING, carried out directly by a New Componit qualified
  2.  consultant.
  3. DESIGN AND SUPPLY of the required interventions with simple but technologically advanced solutions.
  4. INSTALLATION by New Componit personnel or ASSEMBLY SUPERVISION on site.
  5. DIRECT ASSISTANCE AND READY FOR WORK with a dedicated toll-free number.
  6. EXTENSION OF THE WARRANTY to 4 years if the removable insulation has been installed by New Componit personnel.

Want to improve comfort and performance in your plant with a tailored solution?

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Special about safety: the thermographic analysis that helps you to avoid plant shutdowns

Textile expansion joints play a very important role in the proper working of your system, as they compensate for the expansion and lessen the vibrations.

For this reason, it is necessary to check accurately and regularly the ducts. Tears, wear and other problems of expansion joints can seriously affect the performance of the whole system, which is why it is essential to carry out a quality check at regular intervals.

We periodically study the type of problems found, their position and size, to finally assess which ones are acceptable and which ones must be eliminated and repaired promptly.

Thermographic  Analysis (a control defined as “non-destructive”, much more advantageous than other invasive procedures) is increasingly used to determine the state of joints, since:

  • it does not modify the expansion joint;
  • it does not require the removal of the expansion joint but can be carried out on site;
  • it can be carried out on all expansion joints in the plant and not on spot checks;
  • it is carried out while the plant is in operation, without having to stop the production.

It is clear that this type of analysis provides advantages that mean significant cost savings. Maintenance is quicker and easier, there are no production stops or unproductive downtime, no need to dismantle parts of the plant and no new welding is required.

Why carry out a thermographic analysis to check your system?

A single failure can be enough for the interruption of the whole department, which can cause disruption and costs for lack of production .

The possibility of avoiding machine downtimes, necessary to replace damaged parts, is certainly one of the most important advantages of preventive qualitative analysis, which allows you to identify any damage and wear to the system at an early stage, taking action before the consequences become important.

Thermographic  Analysis helps you in this way: it is a particular method in which heat detection devices are used to measure the variation of temperature in the different sections of the system.

At New Componit we often use Thermography, a remote sensing technique that allows images to be acquired in the infrared field. In practice, through the use of a thermal camera we are able to convert the energy emitted into a video signal, “mapping” the data that we then go on to analyze in detail.

Thermal analysis allows a quality leap in preventive maintenance because:

  • It is a non-invasive technique, thanks to which measurements can be taken even repeatedly over time, without damaging the joint;
  • It helps to accurately detect any thermal variations before they become critical;
  • It offers the possibility of carrying out targeted and preventive maintenance works, reducing the costs;
  • Avoids disastrous consequences such as sudden system stops or fires;
  • It is carried out while the plant is in operation and therefore does not require machine downtime and production stoppage.

Focusing on prevention and safety can also lead to savings

To carry out a thermographic analysis on your plant means immediately improving the performance of the entire company: in fact, by identifying any anomalies in advance, you have the possibility of intervening before irreparable damage occurs.

When an expansion joint does not work, there is the possibility of failures which not only jeopardize the outcome of production, but also the health of workers.

Thanks to a preventive check, it is possible to avoid sudden plant stoppages and also to schedule maintenance and replacement of expansion joints, avoiding expensive interruptions in the production cycle.

If you are looking for a serious and reliable company to which you can turn for a check-up of your plant, New Componit is for you!

We offer you much more than just a thermal analysis: we have developed a quality control test with our Efficiency Box® to assess in real time and in detail any critical points in the system.

But that’s not all: Efficiency Box® is a complete program offering solutions, guarantees and constant support from a team of experts.

Efficiency Box® consists of:

  1. Monitoring of the system in operation, carried out directly by a New Componit specialist consultant.
  2. Designing and delivering the required interventions with simple but technologically advanced solutions.
  3. Installation by New Componit personnel or assembly supervision on site.
  4. Direct assistance and prompt intervention with a dedicated toll-free number (international).
  5. Immediate return and quick replacement within 7 days of delivery in case of defects.
  6. Annual post-sales check-up to verify the condition of the product and its operation.
  7. Warranty extension to 4 years if expansion joint is assembled by New Componit staff.

Don’t wait too long and prevent any problems: put your trust in safe hands and avoid sudden plant downtime!

Want to improve comfort and performance in your plant with a tailored solution?

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How to calculate the savings given by system insulation?

The reduction of heat loss leads to inevitable energy savings and, before designing an insulation solution, it is normal to wonder how much it is worthwhile to perform thermal insulation and how to achieve it, in relation to a possible return on investment, future gain and optimization of the plant

Therefore, limiting the heat loss of a system does not mean only obtaining savings directly proportional to the energy that is not lost: it also means increasing the performance of the whole system, improving the final result.

How to choose the most convenient insulation?

If you choose the traditional fixed insulation, you have to take into account that, during the maintenance step, the insulation must be completely dismantled.

Therefore, if after the inspection you have to put again the coating, some parts will certainly need to be replaced and this means extra costs.

Furthermore, there is always the risk that a fixed insulation dismantled and then reapplied will not be as efficient and functional as it was at the beginning.

To keep optimal the thermal insulation, a valid alternative for parts such as valves, filters, flanged couplings, small sections of pipe and heat pumps could be a removable fabric insulation.

This solution allows you to carry on all the necessary maintenance, because it can be easily removed and reapplied, without  changing its performance.

By choosing removable insulating jackets, you will not have to incur extra costs after each inspection. There will therefore be direct savings and a greater guarantee of thermal insulation over time.

However before choosing a thermal insulation solution rather than another, it is necessary to dwell on a further fundamental consideration:

How much do you save ?

To calculate the energy savings over time, mathematical formulas are used, they take into account multiple parameters, even if, in general, it can be said that the better isolated the system is, the lower the energy expenditure will be.

Economic savings will therefore be linked to factors such as :

  • Thermal performance of the insulation;
  • DT of system;
  • Surface area that will be isolated.
  • Type of circulating fluid and its emission coefficient
  • System operating time taken into consideration
  • Energy cost

Taking into account all the points above, you can make an estimate of the actual savings.

To make such a calculation, the best way is to contact an expert specialized in insulation, who will be able to solve any doubts by providing you  with custom-made advice.

New Componit: the specialist in removable insulation

If you are looking for expert and prepared people, who can find the best solution for your system, we can help you!

We are oriented towards innovation, but we have over 35 years of experience in the most advanced solutions for industrial protection and insulation systems.

Our insulation removable jackets are the best alternative to traditional insulation, to guarantee optimization and long life to your systems.

Before designing a custom-made proposal, we carry out an analysis of the situation and study the most effective solution to increase the performance of your system.

This is possible thanks to Efficiency Box® our special program, which offers a series of services designed to meet any type of need in order to make more efficient and safer the production systems of all our customers.

Efficiency Box® includes:

  1. Plant monitoring,carried out directly by a NEW COMPONIT skilled technician.
  2. Design and supply of simple but technologically advanced solutions.
  3. Installationby New Componit staff or supervision on site.
  4. Direct assistance and prompt intervention by freephone number
  5. Warranty extension to 4 years,  if the removable insulation has been assembled by NEW COMPONIT staff.

Want to improve comfort and performance in your plant with a tailored solution?

Request Your Free TIPCHECK Audit Now
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