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Fabric Expansion Joints and Compensators

Insulation of a simple valve in your industrial plant

 Can the insulation of a simple valve, in your industrial plant, save simultaneously energy, money and reduce CO2 emissions?

The answer is obviously “yes’, of course it can”… just imagine that, by insulating a single industrial valve (currently not insulated), in one year, we would save the energy needed to drive a Tesla model S for more than 20000 km. Rather impressive, isn’t it?

The information is real and comes from a 2020 official study drawn up by Eiif ( European Industrial Insulation Foundation).

Furthermore in Italy the potential savings, coming from the insulation, would be equal to the annual energy consumption of more than 1 million of houses or 2,1 millions of cars, based on the national average energy consumption.

At the European level, the potential savings coming from the only industrial insulation are equivalent to the annual energy consumption of over 10 millions of houses or 20 millions of cars.

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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 .

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certificazione Atex

Are fabric expansion joints and thermal insulation jackets subject to Atex certification?

No, they are not and now I try to explain you why.

The legislative regulations concern all the equipment and protection systems intended to be used  in potentially explosive atmospheres.

  • Fabric expansion joints
  • Rubber expansion joints
  • Insulation covering

These products do not carry a flammable fluid and are part of a system which is already subject to ATEX certification.

The equipment defined by ATEX directive are: “machines, systems, fixed or mobile devices, components and control instruments, detection or prevention systems which are partially or entirely intended for the generation, transport, storage, measurement, control and energy conversion and/or treatment of materials which may cause an explosion due to their potential ignition sources “. (Article 1, paragraph 3)

The equipment which are part of ATEX directive have an independent function and their own ignition source.

Products that are in accordance with the definition of equipment but do not have their own ignition source are “outside the scope of ATEX directive”. Therefore, products such as manual valves, pressure gauges, pressure regulators, etc. are “outside the scope of the directive” if an ignition risk analysis shows that they do not have their own ignition source.

This does not include ignition hazards resulting from assembling these products in a circuit.

However, when we know that our products will be used in the Atex area, we use fabrics suitable for this type of environment, which are conductive, i.e. with a surface resistance a value that determines their absolute suitability for this use.

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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.

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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!

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How to plan the maintenance of fabric expansion joints before a plant downtime occurs?

The scheduled maintenance of fabric expansion joints has to play an important role in the proper management of production.

Some companies consider the periodic maintenance as a waste of time and money, thinking that it is enough to intervene only when a problem arises.

Skipping the periodic maintenance hoping to save money can be a dangerous mistake, which could cost a sudden stop of the activity and a consequent damage to production, with all the problems that this situation would cause: delays in delivery, product batches to rebuild, equipment to rebuild, etc.

In short , scheduling a periodic maintenance is the first step not to fall into a serious loss of time and an unexpected economic waste which would be difficult to recover.

Is it convenient to plan a periodic maintenance of fabric expansion joints?

Like all other machine components, also fabric expansion joints are subjected to wear and tear, in particular in extreme working conditions.

Not all textile expansion joints are the same, so their working life cannot be predicted exactly.

However, they should not be underestimated, as they play a decisive role in the good operation of the whole system.

The failure of a fabric expansion joint can have even worse consequences than those we have seen so far.

A sudden accident not only causes damages to production, it can also cause an accident to the workers, endangering their health and causing a host of legal (as well as moral) problems for the company.

Is it really worth risking all this?

On the other hand, a regular check helps to identify all the problems – even the smallest ones – so that they can be dealt with immediately.

Fabric expansion joints have to be replaced or repaired at the first sign of wear.

This why a check-up or a thermographic analysis of expansion joints is important to see if the whole system, where they are installed, is working at the correct temperature.

By scheduling preventive maintenance and respecting the timetable, you do all the necessary to ensure the efficiency of your system and protect the environment and the safety of workers.

How to schedule maintenance of fabric expansion joints?

The preventive maintenance plan must be prepared annually by the maintenance manager in cooperation with the company that has been entrusted with the checks.

The timetable and the type of analysis to be carried out will be defined by technical experts according to the needs of the plant and the working conditions of the expansion joint.

This is why it is important to always entrust periodic inspections to skilled and experienced technicians

In any case, it is also essential to train and raise the awareness of the personnel, so that they are able to check constantly the condition of the expansion joints and request, if necessary, an extraordinary check by specialized maintenance staff.

Finally, remember to record, in a maintenance data sheet, all the maintenance activities carried out, whether ordinary or extraordinary, preventive or corrective.

The aim is to keep a record of the control interventions, so that they are always clear and well defined.

Are you looking for a company specialized in the maintenance of fabric expansion joints?

New Componit offers you a repair and maintenance service that helps you to avoid expensive stop in the production of your plant.

For 30 years we have worked in the production of fabric expansion joints, protections and custom-made products for industrial plants.

Our experienced technicians use a unique and complete analysis method: Efficiency Box® , which guarantees a detailed assessment of your plant and offers you the best custom-made solution.

New Componit also ensures:

  • Efficiency tests
  • A dedicated and skilled team
  • Assistance and periodic checks
  • Certifications and guarantees

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

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