We analyze the factors that are related to a bad installation of these systems, including high economic losses and failures in the performance of their functions. by Duván Chaverra Agudelo
The bad installation or poor maintenance of a thermal insulation system can bring problems in energy consumption, CO2 emissions, temperature loss, in the increase in the utility bill and, of course, in the same systems. René Ruano Domínguez, from General Energy Engineering, emphasizes the previous introduction: "In the heat transfer processes, which are present in the technical systems of industrial and commercial buildings, a good percentage of the possible energy losses that affect, for example, the energy bill (cost) can be focused; these losses are directly linked to more CO2 emissions into the atmosphere, since usually the energy that is lost has been generated from a fossil fuel." It is important to highlight step by step the failures that must constantly be sought in the insulating materials and the systems that have them and observe the adverse effects that may originate according to the failures detected. Marco Antonio Téllez, from Trocellen's technical support area, gave some indications. "That they are not torn, scratched, detached, imprisoned (for example in the support points of the pipe supports it is frequently found that these supports are exercising their support function directly on the insulation, causing loss of effective thickness of insulation at that specific point), that all the joints of duct segments (elbows, transformations, etc.), have a good seal and there is no opportunity to have losses (of energy or condensation) in these points, "explained the expert. Marco Antonio also highlighted the importance of maintenance that emphasizes verifying that the insulating material is free of dust, oils and other chemical solutions, in addition to being protected. "That they have the appropriate protections; for example, in outdoor installations they must have their mechanical protection: double sheet (double duct, usually 26 gauge), exterior paint (based on water applied on insulation in ducts or pipes); here it depends on the type of insulation and the recommendation of the personnel involved: engineers, supervisors or maintenance managers." Finally, it must be checked whether the piping and duct system presents unfavorable operating conditions: condensation, energy losses or gains (heat or cold systems) and excessive noise (in thermally insulated ducts, noise reduction is also important, depending on the type of insulation). The quality of the materials is also a determining factor during its installation. After having identified the aforementioned errors, the necessary corrections are taken. Results of poor insulation
Marco Antonio summarizes in a single word the consequences of the bad installation of a thermal insulation system: loss. Both in efficiency, performance and above all in the safety of workers: - Loss of efficiency in the system (either cold or heat), therefore energy is lost that is equal to money; for example, an air conditioning system to maintain controlled humidity and temperature conditions (21°C and 50% RH), can suffer variations of up to 30% derived from a bad installation of the insulation or a failure that is presenting.
- Direct losses on the installations at the time when the duct or pipe suffers from excessive condensation resulting in corrosion problems, not only on these elements, but also on those to which the effects of said condensation could reach: ceilings, ceilings, electrical installations, various service pipes, etc.
- Losses related to the safety of personnel who are directly or indirectly involved in the insulated system: consider a network of pipes with fluid circulating at extreme temperatures (whether cold or hot), and that has poor thermal insulation, will most likely lead to consequences involving the health of such personnel (from a simple burn to an accident of major consequences).
- Loss of efficiency in the system, which results in a drastic change in the conditions established from the project that will most likely result, not only in the isolated system, but in other associated directly or indirectly.
For his part, René Ruano indicated that he lived a case that serves as a record of the multiple affectations suffered by a bad installation, in which it was not considered to correctly isolate the metal roof of a large ship or workshop 100 meters long by 70 wide, where a production line composed of various energy systems was installed that required a precise and complex automation. The investment in repair exceeded the initial one. "The temperature on the deck reported between 70 and 80ºC. The high temperature outside, compared to that of the interior, which of course was high with respect to the environment but much lower than the outside, made the heat flow by radiation to the interior of the ship, with such magnitude that it was unbearable for the workers who had to perform the tasks and attend to the flow of production", René said. The General Energy Engineering professional also explains that he had to repair a system installed in a shopping center that had more than 10,000 meters of pipe that conducts cold water and that was composed of a circulation system with three circuits (the primary, the secondary and those that feed each of the levels of the shopping center). The failures generated the following problems: a) Heat gain due to different concepts that meant cold losses, greater electricity consumption and high bill costs.
b) Condensation of water that fell on false ceilings and on corridors and flooded the warehouse that was in the basement, causing the destruction of expensive materials of the building and of the products that were stored in the premises of the Warehouse of the Shopping Center.
c) Effects on the health of workers who operated in areas of high humidity, presenting, for the most part, respiratory conditions. "The cause was due to the poor selection of the insulating material, its sizing and, mainly, a deficient, improvised and irresponsible assembly of the thermal insulation, without taking into account thermal bridges, level crossings, adjustment of the insulation to the pipe diameters, thicknesses appropriate to temperatures and how to guarantee the vapor barrier, among other things, "- commented René Ruano. Prediction and prevention
Once the problems and consequences have been identified, another important step in this whole process is maintenance. It is here that the words prediction, prevention, correction and improvement take on more force. For this it is important to perform a visual inspection that detects scratches, tears or any other detail that highlights specific points where the pipe is not properly insulated; also identify points where there is accumulation of water or vestiges of it, and verify that they do not present corrosion. The representative of Trocellen commented in this regard that "the conditions of the pipe network must be checked, so that there are no leakage problems at any point in the network. By doing these verifications we can go on to review details of the insulation such as that it has all its joints sealed and taped, that there are no detached sections, that the mechanical protection is fulfilling its function properly, among others. " In conclusion, according to the examples explained by our guests, generally a repair of a thermal insulation system is more expensive than investing in a correct installation supported by professionals and guaranteed with the best materials. René Ruano Domínguez concludes by talking about the responsibility that members of the industry have in this regard: "Technicians, operators and engineers in the field, both those who act in systems that generate and manage heat, and those who do it with cold, have a great responsibility to know what to do, how to help reduce losses and avoid more polluting emissions. Millions of kilocalories or kw pass through our hands every day, on which we can influence and decide efficiently." To highlight
New developments
Marco Antonio Téllez, from Trocellen's technical service, highlighted the main novelties in terms of products intended for thermal insulation. "Polyurethanes and polyethylene are materials that have demonstrated over the years a high insulation efficiency, not only thermal, but also acoustic (logically without disqualifying others such as: polystyrene, fiberglass, ceramics, etc.; it all depends on the field of application and the process). There have also been developments of elements combined with other materials: "sandwich panels with sheet and mineral wool inside, or with gypsum and mineral wool faces, sheet and cross-linked polyethylene, pre-insulated pipes, etc". "In our case, we emphasize the production processes of our raw material: polyolefins, trying to make the production processes more efficient in order to reduce CO2 emissions that go to the environment and at the same time generating research so that, even from the same foaming process, we find even more advantages of the cross-linked polyethylene that we use in the production of thermal insulation."
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