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

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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 GALVANIC CORROSION BETWEEN PIPE AND SUPPORT MATERIAL.

3 REQUIREMENT OF EXOTIC MATERIAL.

4 REQUIREMENT OF EXPERIENCED / SKILLED LABOR FOR WELDING

5 REQUIREMENT OF SPECIAL WELDING PROCEDURE TO BE FOLLOWED FOR WELDING OF PIPE

SHOE WITH PIPES AT FABRICATION SHOP / AT SITE.

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)
 “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 NO MORE CONTACT BETWEEN DISSIMILAR MATERIAL.

3 NO MORE REQUIREMENT OF EXOTIC MATERIAL.

4 LABOR WITH MINIMUM SKILLS CAN BE TRAINED FOR INSTALLATION.

5 NO MORE WELDING. SO NO PRESTRESSES DEVELOPMENT.

6 PIPE SYSTEM CAN BE PRE-ASSEMBLED PRIOR TO PROJECT STARTUP

7 NO MORE PWHT.

8 PRE-INSTALLATION REDUCES LABOR TIME IMPROVING PROJECT SCHEDULE AND REDUCING

COSTS.

9 COST SAVINGS
ENERGY SAVING

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24 NPS- Shoe (2 Webs)
24 NPS-Heat Loss
CLIENT’s EXISTING DESIGN

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CPA DESIGN

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78% heat loss reduction using insulated system

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 Heat Loss & Commercial impact

Heat loss due to the existing RIL design 795.23 W

Heat loss as per new CPA design 171.78 W

Heat loss difference per Support 623.45 W

Heat loss for 300,000 Supports 187035000 Watt

Total heat loss 187035 KW

Heat Loss in MMBTU (1 megawatt = 3.412141633128 MMBtu /hour) 638 MMBTU/hr

Total heat loss in 1 year 5590544 MMBTU/Year

Total USD 67086523 USD

Total USD lost due to heat loss in 1 year23 67 Million USD

 PRE-INSULATED SUPPORT TYPES
(INSULATION MATERIAL OPTIONS)

1 CALCIUM SILICATE

2 HIGH DENSITY PUF

3 FOAM GLASS

4 COMPOSITE MATERIAL

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 LB Composite
SR NO DESCIRPTION NEW DESIGN PROPOSED
(CALCIUM SILICATE) (COMPOSITE)

1 THERMAL CONDUCTVITY > .13 0.04

(500º C) (W/mK)

2 REDUCED INSULATION THK. 400 mm (35º C) 175 mm

(500º C, 24 INCH
FOR 35º C SURFACE) 250 MM (45º C APX)

3 COMPRESSIVE STRENGTH (MPa) < 10 > 200

4 BENDING STRENGTH (LON/LAT) <8 > 60
(MPa)

5 FRAGILE YES NO

6 HYGROSCOPIC (WATER ABSORPTION) YES NO

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 Thank You

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Contact- info@cp-ltd.co.th