In industrial processes, the temperature control can be of great importance. The installation of heat tracing with or without additional insulation systems is often an effective way to prevent undesirable cooling effects or to compensate for heat losses in a process component or pipes. Like any heat tracing solution the design is tailored to the requirements of the application.

Electrical heat tracing or steam tracing

IC provides solutions for both electrical and steam tracing. Due to its easy installation and relatively maintenance-free use electrical heat tracing is most commonly used. Steam tracing is often only applied when steam is directly available on site, and/ or the power consumption of an alternative electrical heat tracing would be very high. Applications of this type of tracing may be for the heating of very large storage tanks and pipes with large diameters.

Installation of electrical heat tracing

Electrical tracing is very flexible and therefore easy adapt to the shape of process components and pipes. When dealing with existing process installations the tracing cables are pulled into trace conduits at the location. Heat tracing cables may be installed continuously on pipelines or water lines, or only at specific locations where unwanted cooling can cause e.g. freezing, crystallisation or coagulation of media. With some new installations the tracing can also be applied in the IC workshop prior to insulating process components. The installation can be done in conjunction with engineering upfront and test reports (MEG), with as built documentation afterwards.

Heat tracing in combination with extra insulation

Because IC also provides thermal insulation solutions, the heat tracing can be combined with additional insulation systems and mattresses. The systems consist of (removable) customised casings or mattresses and/or pipe casings. In addition, IC supplies complete heating jackets.

Heating Jackets
Flexible heating jackets offer a very efficient way of evenly heating and insulating in one. With these integrated heating solutions, installations can easily be kept at the right temperature. Are you carrying out maintenance of the installations? Then the jackets can be quickly and easily removed using Velcro fasteners. This also allows the systems to offer the required flexibility in research applications. We have by now equipped a significant number of ‘objects’ with flexible heating jackets in oil & energy labs.

The advantages of heating jackets:

• Easy to remove and reusable
• Easy to install, even in complex situations
• Long lifespan
• Made to size in the shape of vats, pipes, valves or pumps
• Temperature range 0° to 900°C
• Efficient heating system
• Optimal heat distribution
• Waterproof and resistant to chemicals
• Also available with Atex certificate.

Advice, thermal calculations and installation service

The design and construction of heat tracing solutions is always performed in close cooperation with our clients. Since every installation is different IC will look closely at your temperature requirements, safety restrictions and process needs. Next to the installation we also provide design and engineer support were required. We can help you with different kinds of thermal calculations, like heat absorption vs power consumption, max surface temperature and heat up/ cool down times.  Guarantees on achievable results of combined tracing and insulation systems are possible. Contact us for more information.
 

Case study data sheets

#21 Insulation & tracing offshore

Cold insulation requires a high level of craftsmanship; any small non-system application or vapour barrier penetration can cause significant icing. Faults cannot just put the process at risk and influence the quality of products but may also lead to considerable energy and evaporation loses or unwanted pipe corrosion.

High-performance insulation systems

The liquefaction, storage and transportation of cryogenic media such as LNG (-160°C) or LPG requires high-performance insulation systems. Parameters such as thermal stresses, vibrations and required safety provisions have to be considered when engineering, manufacturing and installing cold insulation systems for these applications.

Insulation systems for liquid oxygen (-183°C) and liquid nitrogen (-196°C) require again a different kind of approach. For example, the insulation and cladding of liquid oxygen vessels or pipes must be absolutely grease free to avoid any risk on spontaneous ignition.

Multi-layer cold insulation

Often, multi-layer constructions consisting of different materials, protective layers and at least one but possible more vapour barriers are needed to achieve an adequate cold insulation. Materials like Polyisocyanurate (PIR) and Polyurethane (PUR) rigid foam or cellular glass may be used in these layers and a cladding of e.g. stainless steel, aluminised steel or UV cured GRP is applied to provide the necessary weather protection.

Applications of thermal insulation

Thermal, cold and cryogenic insulation can be installed on piping systems with large and small diameters as well as mobile containers, ships, off shore applications, vertical cryo tanks and large storage tanks.

Advice and installation service

The Design and construction of cold and cryogenic insulation systems is always performed in close cooperation with material manufacturers and our clients. IC is aware that each installation has its own requirements and next to the construction and installation we also provide design and engineer support when required. Contact us for more information on cold / cryogenic insulation systems.

Case study data sheets:

#20 Insulation of trailers and tanks

#24 Cryogenic insulation

The provision of thermal insulation at industrial facilities is often initiated by a desire to increase safety and process reliability, and at the same time to reduce energy consumption and CO₂ emissions. For over 40 years, IC constructs and installs customized solutions for the efficient isolation of heat generating applications but also cold processes.

The application of thermal insulation

Thermal insulation is for example applied on hot surfaces like exhaust systems to protect personnel against burning. It can be applied as an anti-freezing system on e.g. potable water lines or fire water lines. Also processes can be further optimized by improving process heat conservation or by avoiding crystallisation or coagulation of media. The engineers of IC can install the thermal insulation in combination with electrical or steam heat tracing to even further improve process and minimize risks.

Composition of the insulation

The thickness of the applied insulation will be fully dependable on the installation or pipework and defined thermal requirements. Where needed IC can apply multi-layer constructions with different insulation materials and one more vapour barriers. Also metal casings are often an integral part of the insulation to provide even further protection or to enable an easy removal of the insulation for maintenance purposes.

Insulating jackets and mattresses

IC produces tailor made industrial insulating jackets and mattresses in house. Due to the great flexibility they can easily be fitted on e.g. turbines, engines, heat exchangers, valves, extruders and process tools and lines. The removable insulation mattresses by IC enable equipment to be well insulated in addition to providing easy access to components bellows. The mattresses and jackets can be coded by IC to avoid miss fittings after overhauls or maintenance work on installations.

Energy saving potential and calculations

With well-engineered thermal insulation big savings can be achieved. Not only savings in production costs but also in an indirect way reducing CO₂, NO_x and SO₂ emissions and minimizing carbon footprint of end products. The savings can be proven in calculations where IC can help you with, for example calculations like; max surface temperature, heat loss and heat up/ cool down times. IC can also help clients visualise their return on investment and calculate the corresponding repayment period of a selected insulation system.

Where to start?

In general, our recommendation is to start with a site survey. With collected information and insulation requirements a plan of action will be made including the design, operations planning and installation. Contact us for more information on tank insulation solutions.

Case study data sheets:

#21 Insulation & tracing offshore

#22 Insulation of exhaust systems

#28 Personal protection panels

IGNIS PFP-BOX ™ - Jet Fire Protection

The IGNIS PFP-BOX ™ provides highly effective protection against potential jet fires in the oil and gas industry. Fires in this industry can have catastrophic consequences, and proper protection of critical and explosive components is essential. The IGNIS-PFP BOX is a customized and certified fire protective box, panel or wall made out of 316 stainless steel material with a composite multi-layer insulation core that provides superior passive fire protection.

Class JF150 - The ultimate protection for equipment and personnel

Fire protection boxes can be fully customized to fit the application that can be both offshore and onshore. The panels from which the boxes are constructed, have been tested at flame temperatures of 1,150°C and provide a fire protection for 2.5 hours under extreme jet fire load. During this exposure, the panels retain their integrity and ensure, thanks to the high-quality insulation core, for a relatively small and defined temperature increase on the inside. The double-sided stainless steel 316 panel provides a weatherproof, corrosion-resistant and maintenance-free protection.

Lloyd's certified - ISO 22899-1 2007

The IGNIS-PFP panel, which is the building block for IGNIS-PFP BOX has been tested for 2.5 hours according to the ISO 22899-1 2007 Jet Fire standard on the DNV GL test site at Spadeadam in the UK. At the end of the 2.5 hours of intensive exposure, a stable average cold face temperature of 178°C has been registered. 

The test has resulted in a successful Lloyd’s Register Certification (no. SAS F160347). The certificate and additional information are available on request.

Also for fire protective wall or panel

With the self-supporting structure the IGNIS-PFP BOX is also suitable for use as a fire protection wall or panel. The appropriate fire resistance class of the other structural elements and compounds is of crucial importance in these applications. For more information about the integration options please contact the advisors of IC.

Hybrid systems – with fire protection jackets

The IGNIS-PFP BOX can be used in conjunction with fire-resistant jackets or mattresses as a hybrid system. The Jackets, provided by a partner of IC are also certified in accordance with ISO 22899-1 2007.

Hatches and entries

The IGNIS-PFP BOX can be provided with fire proof pipe penetrations, inspection hatches and air vent openings. Jet fire tests have been conducted at the Health & Safety Laboratory (HSL) in Buxton UK. During the tests, all elements retained full integrity and the air vent closed within 5 seconds after first flame contact. After one hour, the maximum temperature at cold face side remained limited to temperatures between 90°C and 150°C.

Installation of the fire protection and maintenance

Besides the installation IC also provides aftercare in the form of maintenance and periodic inspections of the fire-protecting installations. Also future assistance can be given when removing and placing the boxes and/or panels. Customized service contracts are available on request.

More information

Do you want to know more about jetfire protection with the IGNIS-PFP BOX or fire-resistant jackets/ mattresses? Please contact us or request a quotation.

Download the product leaflet of the IGNIS-PFP BOX.