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Facility-Wide Approach
 Figure 1
 Figure 2
 Figure 3
 Figure 4
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Use a Facility-Wide Approach
A facility-wide approach to specification and selection of removable-reusable insulation systems is important. It's vital in reviewing and determining where these systems can be used and how to gain optimum results. A comprehensive review helps blunt the tendency to simply pick out single random pieces of equipment in a process-chain, to the exclusion of all others. Doing anything other than a full review doesn't really make sense-certainly not from an economical standpoint in terms of operating or maintenance cost, nor process stability, or with regard to the environmental emissions which accompany lost energy. An example of this approach's outcome is shown in photo of a pumping station and reactor lines (see Figure 1).
In the photo, all equipment that might otherwise be left uninsulated, either due to its awkward shape, location, or need for quick maintenance accessibility and fast return to service, has been insulated with a removable-reusable system. The component parts consist of removable-reusable insulation to cover the pumps, instrumentation, pump inlet and outlet valves, check valve and the reactor lines in the background. For a closer look at removable-reusable insulation covering various types of equipment, take a look at the pictures of the twin pump station (Figure 2), the motor driven butterfly valve (Figure 3) and the gate valve (Figure 4).
Performing such a facility-wide review may seem daunting, but to simplify this task, break it into manageable parts. Divide the overall facility into its various systems. For example, in a thermal power plant, boiler water feedheating and turbine condensate collection would be examples of systems. From this list, perform a drawing and/or process & instrument diagram (P&ID) review to help identify and list hardware items in the system. Then perform a field review. This examines the equipment as presently installed and how it's insulated. From the field review, create an action list of all those items of hardware that are uninsulated, poorly insulated, or traditionally difficult to insulate with "rigid" insulation. Factors which play into this include the shape, size, maintenance requirements, location, elevation above ground, physical environment the equipment is in and myriad other reasons. In conducting the field survey, don't forget such none-obvious items as pipe spools, manways and flange joints.
 From this review, equipment that has traditionally been left bare, unaddressed, or inconveniently covered with traditional rigid insulation and metal are prime targets for covering with removable-reusable insulation systems. The identified equipment is gaining or losing heat, wasting energy, and costing a significant amount of money in operating and maintenance costs.
As an aid to this review, contemplating other industries where removable-reusable insulation systems are extensively used also helps focus attention on identifying the type, need and locations for installation. Removable-reusable insulation systems are extensively used in the offshore oil and gas exploration industry. One example is the Hibernia Oil and Gas rig. There are several reasons for use in this and other marine applications. Though these are specific reasons for marine applications, they're no less applicable to all manner of land-bound facilities, no matter how large or small. So it's important to closely review all factors and reasons for insulating.
For insulating outside, above deck, these factors need to be considered:
- freeze protection
- equipment installed in tight quarters
- instrumentation protection and signal output stability
- waste and environmental issues (If rigid insulation is used and removed, it can't be readily disposed when you're miles from land. It creates a waste issue.)
- minimum down-time (This allows for rapid maintenance access and return to service, especially in adverse environmental conditions and heavy weather.)
- manpower (Small crews only are available to access and complete maintenance. Outside crews can't be easily or rapidly mobilized, if at all. Removal and re-installation of removable-reusable insulation systems is easily accomplished.)
For insulating inside, below deck, consider these factors:
- working environment (temperature control in working spaces)
- personnel protection for hot equipment
- noise abatement
- instrumentation protection and signal output stability
- process stability
Having completed the field and drawing review, and considering where these systems will be used, you're ready to commence the outline specification required for ultimate purchase and installation. This way the insulation, and not your wallet, can start taking the heat.
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