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Chemical Process Plants And Flexible Insulation Systems Introduction Insulation is one of the most important parameters for efficiency and sustainability in chemical process facilities, which generally have harsh working environments with high temperatures and various chemicals. Removable Insulation Jacket is an insulation solution that has been widely used in chemical process facilities recently. In this article, the benefits of removable insulation jacket applications will be discussed. What Is Removable Insulation Jacket? Removable insulation jacket is an insulation solution that can be applied to the surfaces of industrial equipment and pipes. Produced with non-combustible and high temperature resistant materials, these jackets provide energy savings by keeping the heat flow under control. In addition, jackets ensure the safety of workers by preventing the leakage of hazardous chemicals. Removable insulation jackets can be used in many industrial environments and can be manufactured to any size and shape. Benefits Of Removable Insulation Jacket Energy Saving: in chemical process plants, equipment and pipes frequently operate at high temperatures. A removable insulation system keeps the heat loss under control by covering the surfaces of the plant components (pipe, equipment, duct, etc.) to be insulated. By means of this, energy consumption in the facilities is reduced by achieving extra energy savings. Easy Maintenance: Removable insulation jackets can be quickly and easily removed, reassembled and partially replaced if necessary. This increases operational continuity by reducing maintenance time (downtime) and costs at the facilities. Safety: In chemical process plants, leakage of hazardous chemicals can pose a serious security threat. Removable insulation jackets cover the surfaces of equipment and pipes, protecting self-integrity in case of leakage of hazardous chemicals and ensuring the safety of workers. Fire Protection: In industrial facilities where flammable and combustible hazardous materials are used or stored in standard processes, “pool type fire, jet fire, explosion and BLEVE” cases are always among the possible risks, and it is possible to experience toxic fallout that threatens the environment and human health after these incidents. In industrial facilities, equipment such as tanks or heat exchangers, pipelines, on-line fittings (valve, flange, etc.), instruments and also carrier steel construction (piperack, etc.) components should be equipped with Passive Fire Proofing (PFP) systems. Flexible and removable insulation jackets are now almost unrivalled in PFP applications, especially in equipment protection. These systems, which are both useful and relatively economical, can be used on actuators, reactors, etc., protect the equipment that is likely to be damaged by fire at the highest level. Environment Friendly: Removable insulation jackets provide environmentally friendly workplaces with their advantages such as being long-lasting, being partially repairable or reproducible even in case of fraying, being easily operable thanks to their modular structure, and not creating waste when they need to be disassembled for the maintenance of the insulated component (pipe, equipment, etc.) Moreover, as insulation performance improves in industrial facilities, the overall energy demand decreases—leading to a significant reduction in CO₂ emissions. This drop in carbon footprint not only supports environmental sustainability but also contributes positively to the long-term future of our planet. Flexibility: Removable insulation jackets have a flexible structure. In this way, insulation jackets for equipment and pipes with complex shapes can be easily designed and manufactured. Besides, the modular structure of such removable systems provides more flexibility. Long Lasting: Removable insulation jackets are made of durable materials and have a long life. This reduces maintenance costs in the facilities and jackets do not need to be changed as often. Removable insulation jackets, which are the most preferred solution in the industry thanks to the above-mentioned benefits, are systems that can be easily designed and applied in addition to these advantages. These jackets can be custom designed according to industrial insulation needs. In addition, they can be produced in various sizes and shapes, and material preferences can be made according to the desired temperature or chemical resistance. This makes them suitable for insulating any type of component (pipe, equipment, duct, etc.). Removable insulation jackets, which provide more advantages compared to conventional insulation methods, are becoming more and more popular in chemical process plants due to the need for less skilled labour. For example, conventional insulation applications usually require a large team of talented insulation workers. Removable insulation systems are manufactured within the manufacturer company and shipped to the field and only assembled in the field. In this way, the off-site workforce to be kept in the facility is reduced by up to 95%, which creates serious advantages in terms of both occupational safety and administrative issues. In addition, when the insulation of a component that is insulated with conventional methods needs to be removed, it can cause serious costs, risk of environmental pollution and more downtime. However, removable insulation jackets eliminate this problem because they are very easy to remove and reassemble. Even any skilled craftsman, often from the maintenance or operating team of facility itself, can easily do this, and there is no need for the off-site labour required to dismantle and reassemble conventional insulation systems. Conclusion We can say that removable insulation systems are the future of industrial insulation applications in many fields, especially in chemical process facilities. Removable insulation jackets, which are flexible enough to meet the insulation needs of any industrial facility in almost every subject, stand out among the above-mentioned benefits, especially thanks to their cost and time saving and environmentally friendly features. In Türkiye, there have been serious developments in the production of removable and flexible insulation systems recently. And thanks to 3D designs and CNC integrated production lines, the way to produce low-cost and high-quality insulation systems could be produced in a short time. While removable insulation jackets, which were preferred for the insulation of high value-added equipment (turbine, etc.) in the past, were mostly supplied from foreign manufacturers through imports, today domestic manufacturers have a significant weight in this sense. By means of this, removable insulation jackets are preferred not only for high value-added components, but also for almost all pipelines, ducts, equipment and other hot components of facility, so, the use of removable insulation jackets

A NEW APPROACG TO PIPELINE INSULATION IN INDUSTRIAL FACILITIES: INSULATION JACKETS Energy efficiency and safety are among the top priorities for businesses in industrial facilities. In this context, the insulation of pipelines is of great importance. Although traditional sheet metal cladding methods are widely used, insulation jackets have become more preferred in recent years. So, why have insulation jackets become so popular? Here is the answer to this question: 1. Durability and Reliability Although traditional sheet metal cladding methods are effective in reducing heat loss in pipelines, they unfortunately have a high risk of deformation in relatively short periods. Any dent or damage on the metal cladding exposes the insulation material to external factors, especially water ingress. In this case, both the insulation capability dramatically decreases, and the risk of corrosion on the insulated line arises. (See https://insulant.pro/corrosion-under-insulation-blog/) Figure 1 Insulation Jackets on Pipeline of a Fertilizer Manufacturing Facility Figure 2 Stress corrosion cracking of an insulated stainless steel condensate line. Source: NASA Corrosion Engineering Laboratory Additionally, the components used within sheet metal cladding methods (spacers, cladding sheets, etc.) can corrode over time, creating other safety risks. However, in lines insulated with insulation jackets, the insulation material is housed within the jacket material, minimizing exposure to external factors. Furthermore, the risk of corrosion in jacket cladding materials is not an issue. The insulation capabilities of lines insulated with insulation jackets last longer compared to those insulated with sheet metal cladding, and the risk of corrosion on the pipeline itself is also minimized. 2. Easy Installation and Occupational Safety Sheet metal cladding requires time and labor for installation and maintenance processes. Insulation jackets, on the other hand, can be easily installed and removed thanks to their modular structures. This significantly reduces the total working time required for insulation tasks in any facility. Since these insulation activities are usually carried out by external labor not working in the facility, occupational safety risks will inevitably arise. For example, insulating a 250-meter pipeline (with a reasonable amount of valves, flanges, elbows, etc.) with sheet metal cladding requires approximately 80 man-days of work in the facility. However, the same application can be completed with insulation jackets in a maximum of 6 man-days. Reducing the working hours of insulation teams unfamiliar with the facility’s specific occupational safety rules means minimizing the risk of potential accidents at least by the same proportion. 3. Maintenance and Repair Ease Maintenance, repair, and inspection (such as weld inspection) activities on a pipeline insulated with insulation jackets are extremely easy due to the modular and removable nature of the jackets. Maintenance activities on the pipe body, line components (valves, flanges, elbows, tees, etc.), and insulation system components can be completed easily and quickly. This feature accelerates maintenance and repair processes, ensuring operational continuity and process reliability. Figure 3 Insulation Jackets and Metal Cladding 4. Flexible and Adaptable Design The designs of insulation jackets are made by expert industrial designers to fit different pipe diameters and shapes. The most suitable design for different and asymmetric geometric shapes is considered in terms of both operational capability (temperature, pressure, mechanical exposure insulation performance, etc.) and installation capability. In insulation applications made with sheet metal cladding, it is generally expected that field workers find solutions, and the insulation application is not separately evaluated for different conditions. This feature allows insulation jackets to adapt to challenging working conditions in the most efficient way and naturally last longer. 5. Cost-Effectiveness For the same amount of insulation application, sometimes sheet metal cladding and sometimes insulation jackets have an initial cost advantage. In some cases, the initial costs may be higher compared to sheet metal cladding, but the long-term cost advantages of insulation jackets outlined above cannot be ignored. Lower energy consumption, reduced maintenance costs, and longer lifespans mean that insulation jackets significantly reduce the total cost of ownership. 6. Energy Efficiency and Reduction of Heat Loss The advantage mentioned in this section is also valid for sheet metal cladding insulation applications at the beginning. However, although traditional sheet metal cladding methods are effective in reducing heat loss in pipes, insulation jackets perform better in this regard. Insulation jackets minimize heat loss and increase energy efficiency thanks to their high insulation properties. This helps facilities reduce their energy costs. Conclusion The use of insulation jackets in pipe insulation in industrial facilities offers significant advantages in terms of energy efficiency, cost-effectiveness, occupational safety, and process reliability. Compared to traditional sheet metal cladding methods, insulation jackets are a more modern and effective solution, contributing to the sustainability goals of industrial facilities.

ENERGY EFFICIENCY CLASSES FOR TECHNICAL INSULATION SYSTEMS CALCULATION METHOD AND APPLICATIONS Introduction Energy efficiency is of great importance in today’s industrial applications. To reduce energy consumption and costs, while also supporting environmental sustainability, insulation systems need to be optimized. Generally, industrial facilities that require continuous insulation and need maintenance or optimization of existing insulation are the most efficient and suitable areas for these applications. In this context, the EN 17956 standard is an important tool for evaluating and classifying the energy performance of industrial insulation systems. What is the EN 17956 Standard? EN 17956 is a European standard that determines the energy performance of insulation systems used in industrial applications. As of December 1, 2024, it has come into effect in all 34 countries that are members of CEN/CENELEC, including Turkey. This standard classifies insulation solutions into energy efficiency classes, ranging from A (most efficient) to F (least efficient). This classification indicates the potential of insulation solutions to reduce energy consumption and CO2 emissions. Scope of the Standard EN 17956 applies to technical insulation systems for operational installations such as pipes, ducts, tanks, equipment, and embedded components in industrial facilities. The standard determines the energy efficiency classification of insulation systems for an operational temperature range of -30°C to +650°C. However, other insulation applications such as designing safe surface temperatures for personal protection and preventing condensation are outside the scope of this standard. Benefits of the Standard Energy Efficiency: The standard ensures the optimization of insulation systems, thereby reducing energy consumption. Cost Savings: Effective insulation reduces energy consumption, thereby lowering operating costs. Environmental Impact: Improved insulation significantly reduces CO2 and other greenhouse gas emissions, supporting environmental sustainability. Compliance and Benchmarking: The standard provides a clear framework for complying with energy efficiency regulations and benchmarking performance. Implementation Steps To implement the EN 17956 standard, the following steps should be followed: Select the Insulation Energy Performance Class: Determine the required energy efficiency level according to your needs, technical specifications, or current regulations. Identify the Component: Determine the type and size of the component to be insulated. Determine the Process Temperature: Identify the maximum operating temperature of the component to be insulated. Interpret the Results: Evaluate the maximum allowable heat loss specified by the standard for the selected energy class and other parameters. Recent Developments With the “Energy Efficiency Class Calculation Tool” developed by EiiF, when you enter the energy class determined within the scope of the EN 17956:2024 standard, the operating temperature, and the shape/size details of the component to be insulated, the maximum heat flux density for the selected energy class and the approximate thickness required for insulation are automatically calculated. You can obtain the necessary heat flux and thickness information for the targeted energy class for any component in your facility at any time from the INSPRO website at this link. https://insulant.pro/energy-efficiency-class-calculator/ Conclusion The EN 17956 standard is an important resource for increasing energy efficiency in industrial insulation systems. The lack of reference for the design of insulation applications in industrial facilities has also been significantly addressed thanks to EN 17956. By complying with this standard, you can meet your energy performance needs, achieve significant cost savings, and contribute to environmental sustainability.