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From Efficiency to Safety: Strategies, Benefits, and Real-World Applications of Industrial Thermal Insulation

Fabric expansion joints: how to install them correctly?

Today we are going to talk about fabric expansion joints and their correct installation.

In other previous posts we have focused on: the materials we use to realize them, their maintenance and the advantages that they can entail in a plant.

Why dedicate an article to installation?

A correct installation of the fabric expansion joint is as fundamental as its production. I can have a product perfectly made, using the best materials, but if it is installed incorrectly, the fabric expansion joint is not really effective.

Safety first

It happens that companies get in touch with us to buy fabric expansion joints specifying that they do not need support for the installation .

However, it should be kept in mind that, the installation of fabric expansion joints by unskilled personnel entails a number of safety risks to employees, especially when the system is in operation or in half service. Just recently, two workers of one of our customers were injured, by getting burned while they were assembling our products.

In fact, fabric expansion joints are installed in parts of plant where fluids, in a gaseous state, usually flow and which, besides very high temperatures, may contain chemicals or acidic components. These characteristics make the installation step somewhat “delicate”; this is why it is an operation that should not be underestimated at all.

If the expansion joint is not installed correctly, fluid spills can occur and be a health hazard to operators who, as they pass in the vicinity of these areas, risk being burned or coming into contact with chemical agents.

It is not only people who are at risk, but also any equipment that is in the vicinity of an expansion joint which is leaking.

The operation of the plant

In addition to safety, which we would like to remember comes first, we have to consider the plant performance.

If there are fluid leaks, it means that the plant is not working to its full capacity. In such cases, there is a risk of compromising plant operation with the occurrence of sudden and recurring plant shutdowns.

This situation obviously leads to losses in efficiency and considerable economic damage.

The position of fabric expansion joint

A question to which usually we do not pay attention is space. In many cases the fabric expansion joints have to be installed in narrow spaces, difficult to reach. The operation area for the employees involved is limited and the risk of making mistakes is very high; as a result, the installation becomes more complicated.

And then, in light of these considerations: how can we properly install the expansion joint?

Our answer is: delegate the installation to specially trained personnel or provide for the supervision of skilled technicians. Only in this way, we can be sure to install properly the expansion joint and reduce the risk of occurrence of situations as described above.

We also must keep in mind that no fabric expansion joint has a 100% seal, therefore the proper installation is essential to avoid fluid spills or minimize this possibility.

For all these reasons, we at New Componit have created, within our staff, a division exclusively dedicated to installation or assembly supervision. They are specifically trained technicians with decades of experience on site, able to work anywhere in the world.

Want to improve comfort and performance in your plant with a tailored solution?

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Tipcheck, the energy audit to save money

More and more frequently we hear about Tipcheck, the energy audit. Especially those who work in chemical and pharmaceutical fields will have already heard about it and know the opportunities for energy savings that open up with this analysis.

Although the issue of energy saving is increasingly topical, also because of: increase of price and EU sustainability objectives, many companies still have doubts about this opportunity.

In particular, many people ask themselves: what an energy efficiency implies in practice, what benefits it entails but also what is the initial investment, as well as what is the repayment time.

So let us clarify.

Let’s start from Tipcheck, which, as I said, is an energy audit on plants, which has the scope of drawing up a detailed report about the possible thermal insulation interventions to be implemented in order to reduce energy consumption, achieving real and measurable energy savings.

It is a standardized instrument put in action by the Eiif, the European Industrial Insulation Foundation, with the aim of providing the industrial sector with tools and solutions to save energy and reduce CO2 emissions.

The audit can only be carried out by Eiif’s partner companies, which have been accredited by the certifying agency. This last point may seem obvious but it is not.

In fact, when a matter, such as energy saving, becomes so topical, there are many competent subjects or not who want to “sell” the ideal solution to save on bills.

So my first advice is: pay attention to the interlocutor with whom you choose to collaborate!

The advantages of Tipcheck

The Tipcheck audit highlights how a series of insulation interventions can bring immediate benefits to the company, such as:

  • reducing production costs;
  • increasing energy efficiency;
  • reduction of CO2 emissions;
  • improving process efficiency;
  • reducing risks to personnel and equipment;
  • increasing of business competitiveness.

But I want to remind you that Tipcheck is an audit, so a first step towards energy efficiency, which then a series of concrete insulation interventions should follow.

Furthermore, Tipcheck follows a standardized analysis protocol; therefore, when you reach the implementation step of the recommended indication stated in the report, it is suggested to collaborate with a supplier able to understand the specific needs of your plant and therefore propose the ideal solution.

I say this because recently we at New Componit worked with a company, in the tanneries field, for which we carried out a detailed energy analysis followed by a tailor-made intervention.

We have, in fact, installed insulating jackets in several hotspots which led to energy savings even higher than their expectations.

I finish by saying that, if today there are still many doubts about the benefits of insulation, I think that the Tipcheck is a great tool to overcome some unfounded reservations and evaluate the economic return (and not only) of an investment that still may scare some companies.

We at New Componit are official members of the Eiif (European Industrial Insulation Foundation) since 2019; our accredited staff has been certified to carry out plant inspections and draw up energy-saving insulation studies.

We aim to find insulation solutions, designed according to specific customer needs, focusing on three key factors:

  • the temperatures;
  • the reduction of emissions into the atmosphere;
  • the resulting economic savings.

Want to improve comfort and performance in your plant with a tailored solution?

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Maintenance of fabric expansion joint : what to know

When we speak about plant maintenance, the companies immediately think about activities that take a lot of time and money, without realizing that skipping the periodic maintenance can lead to serious problems.

In fact there is a risk of several problems that may result in sudden plant shutdown.

Can you imagine the damage to production, delays in delivery and customers waiting ?

Therefore, maintenance is NOT a waste of time.

If we talk about fabric expansion joints, the scheduled maintenance must be understood as an integral part of a correct production management.

In fact, the break of a fabric expansion joint can lead to interruption of production, or accident at the workplace.

In order to prevent these events, it is enough to plan periodic checks to find out any problems and intervene before they cause damage.

How to carry out maintenance?

First of all, we must keep in mind that fabric expansion joints are subject to wear, especially if they are subjected to extreme working conditions.

The first signs of wear should be repaired, if possible, or replaced.

After this fundamental premise, let’s see how to carry out the maintenance, step-by-step.

1. Drawing up a preventive maintenance plan

For expansion joints, as well as for other equipment, it is necessary to draw up an annual maintenance plant, taking into account also the type of expansion joint and the condition of the plant.

2. Identifying the maintenance personnel

Depending on the type of plant, a manager must be identified within the company and sufficiently trained to assess the state of the expansion joints.

3. Be in touch with the manufacturer

This point is fundamental and at New Componit we’ll never stop repeating it: the maintenance manager of the company must communicate with the manufacturer of expansion joints or with the company to which it was decided to entrust the controls.

The timing and the type of analysis to be performed, must be defined by expert technicians, depending on the needs of the plant and the working conditions to which the expansion joint is subjected.

4. Draw up a maintenance data sheet

All control and maintenance activities must be recorded in a special tab so that you can easily and quickly access this information.

5. Pay attention to the supplier

Usually companies that produce fabric expansion joints sell their products with a guarantee of several years, but do not take care of their maintenance.

It is therefore essential to buy the fabric expansion joints from a supplier who, in addition to the warranty, is able to support you throughout the life of his product.

We at New Componit not only provide you with the product but we offer a repair and maintenance service, that prevents problems or production interruptions due to a worn joint.

For this reason, we have designed the Efficiency Box® that allows us to respond to every type of customer need, in order to make production systems more efficient and safe.

Efficiency Box® includes:

  • Monitoring of the plant, carried out directly by our skilled staff;
  • Design and supply of the required interventions, with simple but technologically advanced solutions;
  • Installation by New Componit personnel or assembly supervision;
  • Direct assistance and immediate response with a dedicated toll-free number.

Want to improve comfort and performance in your plant with a tailored solution?

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ISO 45001

New Componit and ISO 45001 standard

Why should a small SME invest in health and safety management?

ISO 45001 certification is an International standard that defines the requirements of an occupational health and safety management system and provides precise indications for its implementation.

Being in possession of such a qualifying certification, places a company among the most advanced firms on the Italian and International industrial scene.

Also New Componit decided to adopt ISO 45001.

Want to improve comfort and performance in your plant with a tailored solution?

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How to optimaze your system's consumption thanks to the tipcheck audit

How to optimaze your system’s consumption thanks to the tipcheck audit

Your company could be wasting energy and losing money every minute of its operation.

Who is the culprit? Poorly insulated or not insulated pipes, valves and equipment.

Our specialist can provide you with a technical report about the performance of your system: the “tipcheck” energy audit will show you benefits and future savings, before even starting the project.

Want to improve comfort and performance in your plant with a tailored solution?

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All the advantages of passive fire protections

A fire broke out in a chemical industry: the fire exploded burning thousands of litres of solvents, there was an explosion and in a short time the plant burned down.

Unfortunately, this is not the scene of a film, but it is what happened last year in a company, that deals with the recovery of solvents and disposal of hazardous waste.

Clearly the consequences of this have been devastating and the damage is incalculable.

We report this story to reflect on how dangerous some sites are and how serious the consequences of such events can be, from both health and environmental point of view.

Unfortunately, despite the regulations, there are still many companies that do not take seriously the risk of fire; too often we think “it cannot happen”.

However, there are other companies which are aware of the legislation and  respect it, but do not know that there are systems that can help to reduce the risk of spreading a fire inside a plant.

We are talking about PFP (Passive Fire Protections), passive protection systems that can play a key role in slowing the spread of the fire and limiting its impact on a stream line, protecting it from flames.

When we talk about passive protection we mean all measures (whether they are devices or special materials), that can reduce the consequences of a fire, slowing the spread of flames.

Therefore, PFPs DO NOT prevent the outbreak of a fire, but limit its effects, protecting the “crucial” parts of a plant, which can thus continue to work properly until the situation returns under control.

This avoids or reduces possible interruptions.

To work properly, PFPs must:

  • have precise technical characteristics that guarantee resistance to flame and high temperatures for a certain period of protection;
  • be easily “adaptable” to the specific needs of each production site.

When we talk about these systems, someone is puzzled since he has in mind a product difficult to install, because not customizable according to individual needs. Or he thinks that the system can hinder any maintenance activities.

But there are systems easy to install and remove, without any downtime.

New Componit has been studying PFP systems since 2005 and after years of research and development has designed a flexible system called Pyroproof®, the insulation jacket  that can be custom-made according to customer needs.

Pyroproof® is composed of several layers:  an external cover, a series of reinforcement layers and insulating materials .

New Componit is able to guarantee the performance of this product in different fire scenarios, thanks to the numerous tests carried out over the years:

  • Pool Fire -Type Approval for actuators up to 120 minutes -tested in France at Efectis;
  • Pool Fire – Type Approval for valves up to 120 minutes – tested in France at Efectis;
  • Jet Fire – Type Approval for cylindrical sections and metal structures up to 120 minutes – tested in the UK at Advantica;
  • Blast Test – Type Approval for cylindrical sections and metal structures up to 1.85 bar pressure – tested in the UK at Advantica.

The main characteristics of Pyroproof® jackets are:

  • Easy installation/removal (without stopping the plant);
  • Easy handling;
  • Water, weather, UV, cold, chemical resistance;
  • Custom-made and in any shape.

Want to improve comfort and performance in your plant with a tailored solution?

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