ENERGY SAVING BY USING PREINSULATED SUPPORTS Optimisation of

ENERGY SAVING BY USING PRE-INSULATED SUPPORTS

Optimisation of the energy use in industrial systems • A simple way of increasing the efficiency and performance of a process is to ensure that it is properly insulated. • Good Engineering. • Avoid old specifications and switch to new specification focusing on energy savings. • Minimising energy consumption and maximising the effective lifetime of the plant are highly valuable benefits of a well-insulated process.

Keeping thermal losses in heat transfer small Traditionally, energy efficiency efforts have focused only on a few large energy consumers like fired heaters, boilers, and electricity for compressors etc. 1 Pipe and flange leaks 2 Steam trap failure 3 Relief valve seat passing or release 4 Heat exchanger, Cooling Tower

Heat loss through Pipe Supports systems CONVENTIONAL DESIGN WELDED SHOE CLAMPED SHOE

Heat Loss due to conduction 5

CONVENTIONAL DESIGN (CLAMPED)

CONVENTIONAL DESIGN (WELDED SHOE)

CONVENTIONAL DESIGN (WELDED TRUNNION))

DISADVANTAGES 1 HUGE AMOUNT OF HEAT LOSS (HEAT LOSS CALC IN NEXT SLIDES). 2 3 4 5 GALVANIC CORROSION BETWEEN PIPE AND SUPPORT MATERIAL. 6 DEVELOPMENT OF STRESS CONCENTRATION ON PIPES (WELDING). 7 PERFORMING STRESS RELIEVING PROCEDURE WHICH CONSUMES LOT OF TIME BECAUSE OF STEPS INVOLVED (48 TO 72 HRS): A. PRE HEATING B. SOAKING C. COOLING D. UT / RT (TWICE – ONE BEFORE PWHT AND ONE AFTER PWHT) REQUIREMENT OF EXOTIC MATERIAL. REQUIREMENT OF EXPERIENCED / SKILLED LABOR FOR WELDING REQUIREMENT OF SPECIAL WELDING PROCEDURE TO BE FOLLOWED FOR WELDING OF PIPE SHOE WITH PIPES AT FABRICATION SHOP / AT SITE.

“Hot Piping”: Insulated Supports CPA designs and supplies Hot Shoes using different types of insulating materials that ensure the minimum size of insulation thickness but at the same time minimise heat loss and maximise load bearing capability

Promasil and Monolux 500/800

Promasil and Monolux 800

Promasil and Monolux 500

Promasil and Monolux 800

8 NPS & 24 NPS- Heat Transfer

ADVANTAGES OF PRE-INSULATED SUPPORTS 1 IMMEDIATE THERMAL BREAK- SIGNIFICANT REDUCTION IN HEAT LOSS. 2 3 4 5 6 7 8 NO MORE CONTACT BETWEEN DISSIMILAR MATERIAL. NO MORE WELDING. SO NO PRESTRESSES DEVELOPMENT. 9 COST SAVINGS NO MORE REQUIREMENT OF EXOTIC MATERIAL. LABOR WITH MINIMUM SKILLS CAN BE TRAINED FOR INSTALLATION. PIPE SYSTEM CAN BE PRE-ASSEMBLED PRIOR TO PROJECT STARTUP NO MORE PWHT. PRE-INSTALLATION REDUCES LABOR TIME IMPROVING PROJECT SCHEDULE AND REDUCING COSTS.

ENERGY SAVING 17

24 NPS- Shoe (2 Webs)

CLIENT’s EXISTING DESIGN 19

CPA DESIGN 20

78% heat loss reduction using insulated system 21

PRE-INSULATED SUPPORT TYPES (INSULATION MATERIAL OPTIONS) 1 CALCIUM SILICATE 2 3 4 HIGH DENSITY PUF FOAM GLASS COMPOSITE MATERIAL 22

LB Composite SR NO DESCIRPTION 1 THERMAL CONDUCTVITY (500º C) (W/m. K) 2 REDUCED INSULATION THK. (500º C, 24 INCH FOR 35º C SURFACE) NEW DESIGN (CALCIUM SILICATE) PROPOSED (COMPOSITE) >. 13 0. 04 400 mm (35º C) 175 mm 250 MM (45º C APX) 3 COMPRESSIVE STRENGTH (MPa) < 10 > 200 4 BENDING STRENGTH (LON/LAT) (MPa) <8 > 60 5 FRAGILE YES NO 6 HYGROSCOPIC (WATER ABSORPTION) YES NO 23

Thank You 24 Contact- info@cp-ltd. co. th