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REMOVABLE INSULATION SYSTEMS ON EQUIPMENT Process equipment such as reactors, product tanks, raw material tanks or flash tanks in industrial facilities must be insulated depending on their operating temperatures. The reasons or advantages of the relevant insulation application are as follows: Saving Energy Maintaining Process Reliability Personnel Protection Protection for Anti-Freezing and Winter Conditions Fire Proofing Sound Insulation Environmental Awareness (reducing CO2 emissions, etc.) Saving Energy is usually the main reason for conventional insulation applications. However, maintaining the stability and/or reliability of the process, especially in chemical process facilities, is one of the main motivation sources for insulation applications. Regardless of the reason, after an equipment is insulated, the integrity of the insulation system on it should not be compromised and it should perform close to the manufacturing design. The fact that the parameters determined to ensure process reliability, such as raw material (or semi-products) temperature, vary according to ambient conditions are factors that will have a direct impact on the succeeding sub-processes and affect the entire production. In equipment insulations such as reactors, product tanks, raw material tanks, etc. the main reasons (saving energy, process reliability, etc.) should be provided, as well as the parameters determined by considering the operation and maintenance processes. If there is a need for any activity (regular maintenance, repair, modification, etc.) for a similar insulated equipment, for sure, the first requirement is removing the insulation and performing the relevant activity. Critical parameters for this process: Time for insulation dismantling Waste disposal Re-installation of insulation Insulation performance after re-installation Insulation removal time and re-installation time of the insulation after the relevant activity are the factors that determine the total downtime of the equipment. Sure, these periods should be short, and the required workforce should be easily accessible with low costs. On the other hand, the control and disposal processes of the wastes that will occur during the dismantling are situations that create both extra labour and extra costs, as well as environmental awareness. At the end of all these, the fact that the reassembled insulation system performs close to its original design is also a reason for preference for the facility management. Because, as stated above, insulation performance is a very critical parameter in terms of both energy saving and process reliability. Conventional insulation methods include covering the above-mentioned type of equipment with insulation fillings (rock wool, glass wool, nanogel, etc.) and cladding with aluminium or steel alloy sheets as the last layer. In such applications, compliance with the design performance should be inspected throughout the entire construction process, and even periodic controls should be made after the application. In addition, if any activity like maintenance, revision, etc. is needed, the relevant insulation will have to be partially or completely dismantled and reinstalled after the activity. This situation will also result in the permanent presence of a talented insulation team in the facility and the prolongation of the downtime depending on these dismantling and installation times. The situation is completely different in new generation removable insulation applications. In these applications made with flexible and removable insulation systems, there is no manufacturing requirement on the equipment, and even if there is no special insulation competence, it can be easily installed, partially or completely dismantled, and then reinstalled by any personnel. There is no waste in these processes and they are completed in a very short time compared to conventional insulation applications. In this way, equipment downtime is not prolonged due to insulation requirements. There is no performance change in the reinstalled insulation system because there is no need for any intervention that will damage the integrity of the system. Even if there is any damage on any part of insulation, it can be taken care of in a short time by remanufacturing the relevant part. Since the use of external workforce is at a minimum in all of these processes, the risks in terms of occupational safety are also minimized.

Application Of Flexible Insulation Jackets Within Passive Fire Protection Systems Fire safety in industrial facilities is of great importance in terms of reducing operational risks and safety of employees. Since “pool fire, jet fire, explosion and BLEVE” cases are always among the possible risks in industrial facilities where flammable and combustible dangerous materials are used in standard processes such as storage, processing, and transportation. Therefore, serious consequences such as loss of life, chemical spills, environmental and air pollution, toxic fallout, injuries, property loss and loss of process (and business) continuity are very likely to occur after these incidents. The potential consequences of fires in industrial facilities are very serious and strict fire safety protocols and passive fire protection systems are required to prevent or contain such incidents. Passive fire protection systems limit the spread and damage of fire, making the facility safer in the event of a fire. This article discusses the application of flexible insulation jackets used for passive fire protection in industrial facilities. Figure 1 Actuator PFP Cover What are Flexible Insulation Jackets? Flexible insulation jackets are special insulation systems made of components resistant to high temperatures and chemical abrasives. These jackets are customizable products that wrap in-plant components such as pipelines, equipment and tanks and are used specifically for heat, sound and fire insulation. Figure 2 PFP System on a Reactor What are Passive Fire Protection Systems? “Passive Fire Protection” (PFP) systems are systems that aim to keep the spread of fire and damage within the facility under control. It consists of components that prevent fire penetrations and rapid spread of fire by dividing the building plan into certain small zones within a certain architectural structure (building, warehouse, etc.). In industrial facilities, equipment such as tanks or heat exchangers, pipelines, on-line fittings (valve, flange, etc.), instruments and also structural steel construction (piperack, etc.) components are equipped with PFP systems. In facilities equipped with PFP systems, suitable conditions for evacuation and fire intervention and most importantly TIME are gained. For this reason, PFP systems are the most effective solution to minimize the risk in all industrial facilities where flammable and/or combustible materials are used or stored in standard processes or to minimize damage even if the risk occurs. Passive Fire Protection Purposes of Flexible Insulation Jackets: Insulation: Flexible insulation jackets are made of materials resistant to high temperatures, preventing heat transfer to the surrounding areas by insulating the hot surfaces in the facility. Limiting Fire Spread: In the event of a fire, flexible insulation jackets can help contain the fire by preventing the spread of flames and heat. Limiting the Effect of Fire on Equipment: A component (actuator, heat exchanger, tank, cable trays, steel construction, etc.) equipped with a flexible insulation jacket prevents flames and heat from damaging the relevant component for a certain period of time. In this way, valuable TIME is saved and the equipment is prevented from being damaged by the fire until the intervention. Controlling Chemical Leakages: Flexible insulation jackets can help control potential chemical leaks in pipelines and equipment within the facility. Thus, the risk of leaks causing fire is reduced, and in case of a possible fire, the effects of the fire are prevented from increasing exponentially due to these leaks. Figure 3 Drain Plug & Indicator Application Steps: Risk Assessment: The potential fire risks within the facility are evaluated and it is determined which components should be protected with flexible insulation jackets. In terms of human and environmental safety in general and process safety in particular, it is necessary to determine the risky situations in the facility well, to determine the appropriate measures for these risks by experts in this field, to use certified products without quality doubt and to take the necessary precautions. Material Selection: Materials with suitable temperature and fire resistance for a certain period of time (30 minutes, 60 minutes, etc.) according to the relevant standard and resistant to chemical effects are selected. Installation: Flexible insulation jackets are applied to in-plant components with appropriate assembly methods under competent supervisory control. Correct fitting ensures the jackets work effectively. Periodic Controls: The applied flexible insulation jackets should be checked preferably annually. The jackets those have been disassembled for maintenance and similar interventions or damaged due to external reasons should be intervened immediately. Post-Fire Controls: If a fire has already been occurred in the facility, the condition of the flexible insulation jackets after the fire should be checked and any damage or abrasion should be immediately intervened. Figure 4 Sample Design Conclusion: There will always be a fire risk in industrial facilities where flammable and combustible hazardous materials are used or stored in standard processes. These risks may be due to many different reasons, depending on the characteristics of the facility. First of all, it is a must to take the necessary measures to prevent the fire and be prepared in case it does. Passive fire protection systems in industrial facilities become more effective with the use of certified flexible insulation jackets without doubts of quality. These jackets are made with materials resistant to high temperatures, preventing heat transfer during fire, protecting the relevant component for a certain period of time and keeping the spread of fire under control. The correct selection, installation and periodic maintenance of flexible insulation jackets are of critical importance in terms of facility safety.

INDUSTRIAL INSULATION APPLICATIONS AT NUCLEAR POWER PLANTS Nuclear facilities, where most of the energy produced is obtained through nuclear reactions, harmful substances that can harm the environment for many years are also released. Therefore, the safe and sustainable operation of nuclear facilities is extremely important to keep possible environmental pollution under control. Industrial insulation systems play an important role in the safe and sustainable operation of nuclear facilities. There are two main systems in nuclear power plants, they are called Nuclear Island and Turbine Island. The Nuclear Island is the restricted zone within the boundaries of the Containment, where the nuclear reaction takes place. The Turbine Island, on the other hand, is the whole of the systems in which the steam (sometimes pressurized water or heavy water) produced by the heat energy obtained by the nuclear reaction is converted into electrical energy. Apart from these, we can also talk about a third main system called BOP (Balance of Plant), which includes all auxiliary components other than these systems. All these main systems have industrial insulation applications. In the maintenance and repair activities of the facility, removable flexible insulation systems are generally used in nuclear facilities so that the insulation can be easily disassembled and reassembled in the same way after the operation, especially in cases where emergency intervention is required. This is where the biggest difference lies compared to industrial insulation applications in other power plants or similar process facilities. Because the urgency of maintenance and intervention in nuclear facilities is many times higher than in all other facilities due to high environmental risk factors. Removable insulation systems are a type of industrial insulation lining that can be applied to the surfaces of equipment, pipelines, valves and other components in nuclear facilities. It is designed so that when there is a need for intervention on the insulated component (pipe, equipment, etc.), it can be disassembled locally or completely and easily reassembled when the process is completed. For this reason, it is essential that any module should not exceed a certain weight level (usually 20-25 kg). In addition, there are important parameters to be considered in the design, manufacturing and assembly processes of removable isolation systems used in nuclear facilities. The parameters considered in the design of conventional insulation systems, especially thermal insulation capability, acoustic insulation capability, waterproofing, resistance to chemical or similar corrosive substances, fire resistance and even passive fire protection, are also taken into account in nuclear facility insulations. However, the most important difference at this point is the applications in the Nuclear Island zone of the facility, which is also called the Containment. When these applications are compared with conventional insulation systems, there is almost a whole other universe of parameters considered. Containment; is a large zone that includes the nuclear steam supply system (NSSS), which may consist of a reactor, piping, pumps, valves and other miscellaneous components and equipment. NSSS has a very large net positive heat load. The insulation on the hot service piping and equipment inside the containment has one purpose; “controlling cooling loads.” Whether connected directly to a body of water (e.g., river, lake, sea, etc.) or to vapor compression cooling (air conditioning), the cooling system must remove this heat. In nuclear power plants, mostly mineral wool, calcium silicate, fiberglass, nanogel and similar microporous products are used as insulation materials, various refractory materials when necessary, and reflective metallic materials or technical textiles with fireproof properties are used as claddings. Cassette type insulation modules (figure-1) produced with metal cladding materials have recently been replaced by completely removable insulation jackets made of fireproof fiberglass material (figure-2 and figure-3). The thermal, seismic and other safety requirements of both methods are taken into consideration during the design phase, and they are produced as such. Again, in both applications, each of the modules is labelled with its own unique codes, and it is delivered with assembly drawings in which their positions are indicated with every needed detail. Removable insulation systems can be used in the expansion or renovation projects as well as the construction of the facility. In addition, worn or damaged module or modules can be reproduced by the manufacturer. In conclusion, removable insulation systems are an important technology that increases safety and sustainability standards in nuclear facilities. These systems ensure that the harmful substances that may arise during the operation of the facility are kept under control and that the efficiency in energy production is increased. However, it is extremely important that these systems have high design standards, the correct selection of materials, and the implementation of appropriate installation and maintenance processes. NOTE: The content of this article is informative and useful about insulation systems in nuclear facilities. However, you should not forget that nuclear facilities are a serious and sensitive issue, and only the project designers and owners are authorized/responsible for the design and implementation of any nuclear facility. Therefore, the article should be used appropriately by citing the source and relying on completely accurate and reliable information. Finally, due to the sensitivity of nuclear facilities, it is important for companies and experts operating in the nuclear energy sector to act carefully and responsibly for the use of the article.

INSPROJACK® for Flanged Valves In this article, we will provide information about globe valves while discussing how these valves should be insulated. Globe valves are responsible for the movement of fluids such as steam, water, gas, or other fluids in the system by opening or closing with the help of a disc attached to the end of the valve stem, above the point of fluid passage. Globe valves are particularly suitable for operating under high pressure and temperature compared to other valve types in their class. Therefore, globe valves should be preferred in cases where there is high-pressure flow and the system is exposed to the atmosphere. Today, globe valves are preferred in many fields, especially in geothermal and petroleum refinery systems. The operating costs of such large systems, along with additional costs arising from energy loss, can lead to significant losses both for the sustainability of natural resources and the costs borne by the user. INSPROJACK is a complete solution partner with the possibility of up to 95% energy savings at this point. Let’s take a look together at the advantages of the removable insulation jacket, INSPROJACK. INSPROJACK offers you the most suitable design, Although globe valves are manufactured to world standards, they are equipment that can have different insulation needs depending on their usage locations and installation methods. Therefore, as INSPRO, we design your removable insulation jacket with our design team in the most suitable dimensions for you. Discover the ease of installation with INSPROJACK, INSPROJACK removable type globe valve jackets provide incredible ease of installation with long-lasting Velcro and Kevlar lacing cord with high durability. Even a person who has never installed a removable insulation jacket before will be able to easily install it within 5 minutes. Price/performance relationship in INSPROJACK, In INSPROJACK removable type globe valve jackets, we offer our customers the most suitable solutions by using insulation materials with low thermal conductivity, such as rock wool, ceramic wool, aerogel, in appropriate insulation thicknesses. Our coated and uncoated fiberglass fabrics are your long-term solution partner in indoor and outdoor environments. It provides long-term energy and budget savings to users by covering the initial investment cost within 6 months. INSPROJACK and quality, We guarantee maximum efficiency and long-term use for our globe valve jackets produced specifically for customer needs. You can reach us for INSPROJACK removable type globe valve jackets, which you will have in the shortest time with our assembly service.

Valve Insulation Jackets Traditional methods in industrial insulation applications are now being supported and improved by different alternatives. One of the most noteworthy among these new alternatives is the removable flexible insulation jackets. These jackets can be used on various equipment bodies, such as steam turbines, heat exchangers, chimney and exhaust outlets, and most commonly on connection elements such as pipes, valves, and flanges. In this article, we will share essential information about these products, commonly known as “Valve Jackets,” based on INSPRO’s experiences from production to end-users. Valve and flange insulations are traditionally designed as removable types because these elements often require intervention during operation for calibration, repairs, or other needs. The application of Valve Jackets is one of the first solutions that come to mind in this regard, as it is a more flexible and easily applicable method compared to other techniques. Well-designed valve jackets minimize the costs that businesses incur due to heat loss and are practical products that can be reused in maintenance and similar interventions. To design jacket-type applications correctly, it is essential to have complete knowledge of equipment dimensions, fluid temperatures passing through the equipment, external factors, and the operating principles of the equipment. With these values, necessary calculations should be made, and materials and production methods should be selected. In valve jacket applications, since no equipment usage is required, its application is simple in narrow and restricted spaces. Due to its easy removal and installation during the testing and commissioning processes, it minimizes material waste and provides a significant advantage in terms of disassembly/assembly time. While the initial investment costs are lower than many applications, it is also a method that claims to be competitive in terms of price/performance. Removable insulation jackets for valves and flanges have become a popular application in recent times, requiring serious engineering calculations and material knowledge. Leveraging extensive manufacturing and application experience, engineering understanding, and a broad supply chain, INSPRO offers the best products and services to its customers without compromising on quality.

CINI – International Standard for Industrial Insulation CINI was established on July 28, 1989, with the aim of standardizing industrial insulation methods and specifications and minimizing Corrosion Under Insulation (CUI) mechanisms. International companies such as Shell, DSM, DOW, Akzo Nobel, and the former Hoogovens (now Tata Steel) joined forces to establish the Industrial Insulation Committee (CINI), affiliated with the Dutch Insulation Association (VIB). Undoubtedly, there was a significant need for quality standardization in industrial insulation, and CINI continued to evolve, covering sectors such as the oil and gas industry, chemical and petrochemical industry, process industry, power plants, LNG terminals, etc. CINI has become a global reference for thermal insulation design and implementation. Acting as a reliable reference point for insulation companies, material suppliers, consultants, professionals, educational institutions, and government agencies, CINI has played a crucial role in the continuous development of industrial insulation. Organization The CINI organization consists of 10 working groups (committees) comprised of experts in their respective fields. All committees consist of directors (asset owners), insulation companies, and consultants. The technical coordinator serves as the head of these committees. Depending on developments in the industry and the field, working groups come together to review or discuss specific topics. The results of all working groups are compiled in annual updates. All recommendations are reviewed by the Revision Committee, directly affiliated with the board of directors. The technical coordinator is responsible for organizing the annual update. The CINI Guide is updated annually, focusing on the latest technology and proven techniques. The practical experience, accumulated knowledge, and quality of the CINI Guide have a proven track record worldwide. CINI Guide – “Insulation for Industry” The CINI Guide serves as a reference for professionals dealing with technical insulation. It is updated annually. Users can easily navigate the CINI Guide, with convenient search paths (flowcharts) quickly leading to the section containing all the necessary information. The guide includes explanatory visuals, especially on insulation systems ranging from extreme heat to extreme cold (cryogenic) and also covers many aspects of acoustic insulation. For more information, visit https://www.cini.nl/en/

Insulation of a Tank with an Operating Temperature of 40°C There are various reasons for both isolating and not isolating a hot piece of equipment, and you can find them in the relevant article. See: https://insulant.pro/why-insulation-necessary-and-why-do-we-neglect-it/ Taking these reasons into account, we will evaluate the case of “insulation of a tank with an operating temperature of 40°C” with technical calculation tables. The relevant tank has a diameter of 12.22 meters and a height of 13.75 meters, located in an industrial zone near the sea in Kocaeli, Turkey. Generally, insulation of such storage tanks is neglected, and the reasons for this, as detailed in the referenced article, are competence, cost, and potential risks associated with the insulation system. We will evaluate these reasons with technical calculation tables as follows: Insulation Competence Since the process is typically the priority in any operation, the personnel are competent in ensuring the reliability of the process. It is not expected to have competent personnel within the operation specifically for insulation needs since the insulation of any equipment or pipeline is considered a secondary element. This approach is reasonable in terms of cost management. However, providing this competence externally, rather than through employment, is an alternative solution. As seen in the continuation of this article, even for a tank with an operating temperature of 40°C, there are significant cost and environmental impact advantages to having a robust engineering approach for such insulation projects. See  https://insulant.pro/engineering-and-design/ Potential Risks of Tank Insulation In an uninsulated tank, there is no mechanism for corrosion under insulation. However, in this case, we would incur a significant obligation both in terms of cost and environmental impact. Therefore, a robust engineering infrastructure and, different from traditional practices, a high-standard insulation application can minimize potential risks and provide comfort in terms of cost, environmental impact, and process reliability. Real Cost of Insulation Contrary to popular belief, insulation cost has never been the top priority parameter for the design and selection of an insulation system in operations. If it were, we would see much more capable and robust insulation systems in all industrial facilities today compared to the existing ones. A cost analysis was performed for the case of “insulation of a tank with an operating temperature of 40°C,” and all results can be seen in the summary table below: Before reading this table, it is essential to examine the parameters on which the calculations are based: Only the tank surface is considered in the calculations; a separate table would be needed for details such as the roof, etc. It is assumed that the insulation will be made with 125 kg/m3 rock wool insulation material and 1.0 mm aluminum trapezoidal sheet. Wind speed is assumed to be 1.6 m/s, and the average ambient temperature is 14.7°C. These values are crucial because both ambient temperature and wind speed are significant factors affecting heat loss calculations. It is essential to compile these values from scientific studies or reports published by official authorities. Both ambient temperature and wind speed are crucial factors in heat loss calculations. The relevant tank is assumed to have an operating time of 5,000 hours/year and an economic life of 20 years. Cost calculations include an annual 1.2% interest cost, 1% maintenance cost, and 1% price variation coefficient. The unit energy cost is 0.1489 EUR/kWh, including a 60% efficiency and natural gas as the source. The table compares three different variations: i. Uninsulated Tank ii. 50 mm Insulation Application This thickness is generally preferred for similar 40°C tank insulation applications. iii. 200 mm Insulation Application The economic thickness value resulting from the calculations. As seen in the table, leaving the tank uninsulated has a significant cost and environmental impact. While an uninsulated tank will cause over 7,000 tons of CO2 emissions throughout its economic life, this value can be reduced to around 200 tons with 50 mm insulation and to about 100 tons with 200 mm insulation. It does not make sense to base the cost comparison on an uninsulated surface, as there is a significant total cost of around 3.4 million Euros due to substantial heat loss. However, thicknesses of 50 mm and 200 mm insulation will provide a more meaningful comparison. The heat loss generated by the tank throughout its economic life, along with insulation investment and insulation maintenance, will be 289,525 Euros for 50 mm insulation and 183,680 Euros for 200 mm insulation. In other words, choosing optimum economic application over traditional 50 mm insulation can result in a cost advantage of over 100,000 Euros in total. It should be noted that the insulation costs considered in the table are significantly higher (compared to similar applications in Turkey) than traditional insulation practices. This is because a high standard of insulation application is assumed to minimize potential damages caused by the insulation system, including under insulation corrosion mechanisms. In conclusion, for a tank with an operating temperature of 40°C, equipping it with 200 mm high-standard insulation is the optimum choice both economically and environmentally. Of course, the operation may have different parameters; for example, there may be a much greater sensitivity regarding the risks of the insulation system. In this case, a higher value would be added to the insulation maintenance cost in the calculations, and the results would be interpreted accordingly. In any case, conducting thermal insulation inspections and making optimal insulation system calculations are necessary for any equipment or pipeline above ambient temperature.

Why is Insulation Necessary and Why Do We Neglect It? Professionals in industrial facilities generally share a common understanding: “Insulation is a crucial parameter for various reasons.” However, the insulation system is often the easily overlooked first component of the entire facility, from the design stage to maintenance and improvement needs, consistently lagging behind the primary process requirements of the plant. So, let’s first summarize the reasons for the need for insulation: Reasons for Insulation: First and foremost, it must be determined which of the following or which combinations justify the need for insulation:- Energy Savings Preservation of Process Reliability Personnel Protection Protection Against Freezing and Winter Conditions Fire Insulation Sound Insulation Environmental Awareness As explained in the opening paragraph, the preservation of process stability is the primary reason for insulation in most industrial facilities. The subsequent priorities are usually personnel protection and prevention of freezing, both supporting the goal of process stability. In conclusion, it is understood that insulation is almost always considered only as an auxiliary element for the main process of the facility, and other justifications are often neglected unless a mandatory process is required. But why is that? Now, let’s examine some reasons against insulation: Low Standards and Non-Mandatory State: When a new industrial facility is constructed, contractors tend to fulfill contract terms for all kinds of work, including insulation. As understood from the paragraph above, process reliability is the top priority even during the design and construction stages of an industrial facility. This priority will not change throughout the lifetime of the facility. Therefore, proper insulation is often neglected from the design/construction stage and continues through the operational stage. Companies also tend to use their own procedures, often prepared with outdated requirements that need updating at best, as there is no mandatory requirement for proper insulation. However, there are continuously updated standards (such as CINI) to determine insulation specifications independently of questionable procedures. These standards include design and application specifications based on scientific facts and are often updated periodically. For more information: https://insulant.pro/cini-international-standart-for-industrial-insulation/ Competence: It is evident that industrial insulation is not a simple system that can be designed and maintained appropriately without the necessary qualifications. Partly for this reason, old procedures are not adequately updated. However, this challenge can be overcome by hiring/appointing qualified personnel and/or obtaining services from an experienced company in the relevant process. For more information:  https://insulant.pro/services Cost: When there is an investment plan on the table, any asset owner naturally seeks the highest return on investment (ROI) possible. The key parameters are the construction, operation, and maintenance costs over a specific period. Again, process reliability becomes the top priority for any industrial facility, and the maintenance or improvement of construction or insulation systems becomes “extra” expenses that need to be minimized. However, of course, when considering an insulation system, the whole equation involves much more than just costs. Evaluating the value of money over the working life and lifespan of an insulation system involves a kind of multi-variable equation, often revealing surprising results that contradict traditional insulation practices. For more information: https://insulant.pro/services The payback period for insulation costs for an uninsulated high-temperature component (pipe, fitting, tank, equipment, etc.) on the table is sometimes less than a month. If we are doing insulation for improvement or repair, this period usually does not exceed one year. Potential Risks of Isolating a Component From the perspective of a process engineer, an insulation system has some potential risks. One of them is the observation of leaks in a connection element. For example, an insulated flange or valve becomes unobservable if it leaks under insulation, damaging the connection element and process reliability. However, these barriers can be overcome by using appropriate accessories integrated with the insulation system. https://insulant.pro/corrosion-under-insulation Another risk, which is the most significant, is the phenomenon of Corrosion Under Insulation (CUI). CUI is a term used for various corrosion mechanisms but is usually caused by the presence of electrolytes such as rainwater or leaking liquids containing chlorine. https://insulant.pro/cini-international-standart-for-industrial-insulation/. When dealing with CUI risks, priorities should include long-term solutions and minimizing future failures. Of course, this struggle requires top management with sufficient budget and effort as long as the facility continues to operate. In conclusion, a well-designed insulation system contributes directly to the facility’s profit as more than just a specification or adherence to outdated procedures. CONCLUSION A correctly designed insulation system has many advantages, such as reducing costs, reducing environmental impacts, and preventing the entire process system from being overloaded. Additionally, we have summarized the disadvantages of an insulation system investment and rational solutions to them above. In conclusion, insulation inspections using scientific methods will help facility management make the right decisions. A well-designed insulation system, which is more than just preparing a specification or adhering to old-fashioned procedures, can contribute directly to the facility’s profit.

Corrosion Under Insulation Corrosion Under Insulation (CUI) is a term for various types of corrosion mechanisms, but it is always caused by the presence of electrolyte containing chlorides. The main reasons are: – Rainwater or heavy mist – Leaked or spilled liquids from process – Condensation All equipment and pipelines are in danger if they are operating between -5oC and +180oC. Also out of range components are in danger too if cyclic operation or dead/live process is on the table. Insulation System’s Effect All kind of equipment and pipeline having hot insulation cover are in danger of CUI, as insulation material creates an ideal combination for water and steel surface contact in long term. Certainly, insulation’s role becomes more or less effective for CUI according to the engineering of the system. This is a multi-disciplinary phase that includes the mechanical design of the equipment/pipeline and its harmony with insulation as it is part of the whole system. The cladding and insulation material choice and their installation specifications become the most effective parameters of CUI mitigation. And yes, “mitigation” is the optimum strategy during the war against CUI. In order to do so, the items below should be considered during the design phase: 1. Insulation Material Choice Most hot insulation materials have a lot of open space or porosity in them. Actually, insulation materials can be defined as open-cell or closed-cell according to their permeability. If water leaks into the insulation material and the operating temperature is not hot enough to quickly get rid of it, then any unprotected steel surface will be affected by CUI because of this very ideal ambience. Choosing optimum insulation material is the critical decision at design phase. Alternative options can be found at: https://insulant.pro/insulation-materials/ 2. Cladding or Jacketing The purpose and practicality of the cladding system, defines the parameters at design phase. There could be some common purposes like mechanical resistance and weather protection, or some other purposes like chemical resistance, need for vapor barrier, accessibility, etc. Cladding can be subdivided into metal and non-metal, each of which has specific characteristics and a scope of applications. Alternative options can be found at: https://insulant.pro/insulation-cladding/ Also, flexible insulation jackets are remarkable solutions for insulation and maintenance purposes. Alternative options can be found at: https://insulant.pro/insulation-jackets/ Even the cladding is metal or non-metal or flexible cover, the supporting accessories like drain plugs or inspection ports could be very helpful to mitigate CUI. Alternative options can be found at: https://insulant.pro/corrosion-under-insulation/ Besides, there are still some other design options such as non-contact systems which is based on creating a gap between insulation and hot surface or between insulation and cladding. In order to do so, spacers could be used and extra chance for aeration and drainage could be given to the water trapped inside. Frankly, this is a pre-design phase issue which is very important as whole insulation system design would be based on it. It is always useful to choose an international standard (such as CINI) which is constantly updated to determine insulation specifications without relying on questionable procedures. Such standards include design and implementation features based on scientific facts and are constantly updated, usually on an annual basis. For more information: https://insulant.pro/cini-international-standart-for-industrial-insulation/ QA/QC during construction is often left to the insulation contractors’ organization sometimes without any inspection and test plan (ITP). According to the complexity of the project, it is usually useful to invest in independent autonomous QA/QC party that is also drawing up inspection and test programs (ITP), in which critical “hold” and “witness” points are checked. These steps are vital when commissioning and setting up an inspection and maintenance strategy. For more information: https://insulant.pro/services/ 4. Maintenance and Inspection Needs During Operation Accessibility for maintenance and inspection purposes during opertaion should be considered at design phase. For example, making it possible to easily change gaskets or check for leakage can determine insulation design for valves. Removable insulation covers or inspection ports over cladding are best instruments for the purpose. For more information: https://insulant.pro/insulation-jackets/ Return on Investment (ROI) As expected, CUI mitigation and/or optimum insulation approaches come with a surcharge comparing with conventional insulation systems. But it is very obvious that an optimum insulation system has a great cost advantage than the traditional ones. For more information: https://insulant.pro/tank-insulation-with-40-operating-temperature/ Also, CUI mitigation and a maintenance policy according to this have a direct link to overall facility efficiency. And since investors talk in terms of money, these figures become important those causes remarkable results in ROI calculations. Continuity Remarkable know-how about CUI has been accumulated in the last decades. Unfortunately, plenty of them has been disappeared according to senior managements’ “process-first” approaches. Since there is no academic department for “industrial insulation”, this knowledge accumulation has been kept by insulation professionals, manufacturers, and contractors. Therefore, facility owners should keep multi-disciplinary approach to the whole system starting from design, continues at construction and whole life cycle of the components of the facility. Then we can come to a significant point for a continuous approach for CUI mitigation and insulation awareness. CONCLUSION A proper insulation system has many advantages such as reducing costs, mitigating environmental effects, helping the whole process system not to be worked overloaded, etc. For more information: https://insulant.pro/why-insulation-necessary-and-why-do-we-neglect-it/ CUI mitigation is a multi-system approach including metallurgic design, mechanical design, surface protection, insulation, etc. For an optimum and proper insulation system all relevant disciplines should be combined within engineering aspect which can directly contribute the efficiency of the facility only by itself.