Expert experiences show that in industrial plants about 10% or more of the equipment is uninsulated or covered with damaged insulation. Furthermore, the level of insulation applied is typically based on a minimum investment decision following requirements regarding the maximum surface temperature to avoid personal injuries, minimum process needs or based on generic maximum heat loss rates only. Requirements like cost-effectiveness or maximum energy efficiency of the insulation system are therefore often not considered. In the past, when fuel prices were lower energy efficient insulation would not have led to a large difference. Nowadays, the price of energy is higher and is expected to grow even further. As a result there is an increasing gap between current and cost-effective insulation levels. Additional costs for CO2 emission allowances will accelerate this trend and further increase the savings potential. The total cost-effective savings potential amounts to about 480 PJ and 37 Mt CO2 per year for industry. In other words, more than 4% of total industry fuel consumption and emissions. The savings potential exists across all regions, sectors, equipment and operating temperatures.

1. 25.04.2013
EiiF Presentation
European Industrial Insulation Foundation
www.eiif.org

2. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
2
EiiF European Industrial Insulation Foundation
Who is EiiF?
Independent and non-profit Foundation
Registered in Emmen (Luzern) with offices in Gland (near Geneva),
Switzerland
Article 2
Purpose of the foundation
The Foundation engages itself throughout Europe, exclusively and irrevocably,
on a non-profit basis for the deployment of sustainable insulation systems in
industrial plants and in the industrial environment with the aim of saving energy,
reducing CO2 emissions and realizing the best possible noise and fire control
systems.

3. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
3
We Power Sustainability

4. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Source:PaulaReyGarcía,
DGEnergy,EuropeanCommission

5. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Source:PaulaReyGarcía,
DGEnergy,EuropeanCommission

6. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Source:PaulaReyGarcía,
DGEnergy,EuropeanCommission

7. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
7
EiiF strategy to stop energy losses
Proof (facts & figures)
• EU-Study
• Best practise examples
Building Awareness (awareness &
knowledge)
• Communication
• Coordination & networking
TIPCHECK Programme
• TIPCHECK engineers
• TIPCHECK audits

8. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Split responsibilities between:
Project manager,
Maintenance manager
Maintenance budget
Additional investment
in insulation
Energy Costs
Energy budget
Invest
only
once
Save
every
year!
Split responsibilities & budgets
Energy Manager
CEO & CFO

9. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
9
EU-Study: Climate protection with rapid payback
Current (A) Cost-effective (B) Energy-efficient (C)

10. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Result: 620 PJ Energy Savings Potential
The annual cost-effective
savings potential is 620 PJ
=
Energy consumption of the
entire Dutch industry.

11. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Result: 620 PJ Energy Savings Potential
The annual cost-effective savings
potential is 620 PJ
=
The Energy consumption of
10 million
households

12. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Result: 620 PJ Energy Savings Potential
In return 15 coal-fired power plants of 500 MW could be switched off
15

13. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Result: 49 Mt CO2 Reduction Potential
The annual CO2 reductions potential is equivalent to the emissions of
18 million middle class cars (running 12 500 kilometres per year)
18 million cars

14. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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No Limits
The savings potential exists across all:
• Regions
• Sectors
• Equipment
• operating temperatures.

15. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
15
Attractive payback times
Uninsulated and damaged parts
offer attractive payback times:
Payback times are typically
less than one year
(life time = 15 years)

16. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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One-time Investments offer high annual Savings
3.5 billion euro900 million euro
Insulating bare surfaces to cost-effective levels and repairing damaged insulation
would save about 460 PJ = about 75% of the entire Savings Potential
One time investment: High annual Savings:

17. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
17
Quick Calculation of typically un-insulated parts
Size Heatloss
Bare pipe 25 mm 80 mm ∆ bare, 80mm ∆ 25 mm, 80 mm ∆ bare, 80mm / ∆ 25 mm, 80 mm
[inch] [W/m] [W/m] [W/m] [W/m] [W/m] [-]
8 2657 220 92 2565 128 20
10 3197 281 111 3086 170 18
12 3664 297 127 3537 170 21
Savings potential of insulating
un-insulated vs. improving
existing insulation (25mm)
approx. 20 times higher

18. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Quick Calculation of typically un-insulated parts
Achievable savings
Size
Insulation
Thickness
specified
Energy
saving
CO2-emission
reduction
Total
saving
[inch] [mm] [W/m] [kg/m/a] €/a
8 80 2565 5133 700
10 80 3086 6140 825
12 80 3537 7078 950
Calculation for Singapore average weather conditions
(Source: NEA Meteorological Services)
Temperature medium: 200 °C
Ambient temperature (annual average): 27.2 °C
Wind velocity: 2 m/s
Steam generation efficiency: 75 %
Price of energy: 8 €/GJ
Trading value CO2-emissions: 7 €/tonne

19. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
19
Quick Calculation of typically un-insulated parts
How many un-insulated parts do you have on your plants?
Nr. of items X 800,- € = large savings
500 X 800,- € = 400’000,- €
Size
Insulation
Thickness
specified
Energy
saving
CO2-emission
reduction
Total
saving
[inch] [mm] [W/m] [kg/m/a] €/a
8 80 2565 5133 700
10 80 3086 6140 825
12 80 3537 7078 950

20. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
20
TIPCHECK Standard
TIPCHECK = Technical Insulation Performance Checks
A. Standardised energy auditing tool to evaluate
industrial insulation systems with the aim to improve
the energy efficiency of industrial processes
-> standardized TIPCHECK audits
B. Qualification programme for Insulation engineers
-> certified TIPCHECK engineers
(Minimum Requirements: 4 years experience, university degree in engineering, ability to calculate
& design industrial insulation systems, EiiF member, participate in one week training course, pass
test, refresh certificate every 3 years)

21. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Missing insulation to protect cold processes

22. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Proof Best Practice examples Cold

23. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Typical situation onsite

24. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Typical situation onsite

25. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Typical situation onsite

26. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
26
TIPCHECK examples
Chemical Plant in France
Key facts:
• 1 employee equiped with a thermografic camera
• 2 weeks on-site
• 400 pictures taken and used for the audit report
Key findings:
• Safety: Burn risk due to missing insulation
• Financial: Money savings due to reduced energy loss
• Energy Efficiency: Energy/heat loss

27. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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TIPCHECK example: Chemical Plant, France
Non-insulated parts of equipment:
Detected burn danger:
Surface temperatures above 280°C bare a great risk of severe burn injuries for staff
Proposed insulation solution:
Installment of mattress insulation to assure surface temperatures below 50°C
Action:
About 30 similar valves were identified and insulated
Key findings - Safety

28. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
28
TIPCHECK example: Chemical Plant, France
Key findings – Energy Efficiency
1. Storage tanks
35 Storage tanks with uninsulated roof tops
Surface approx. 28m2
Temperature of stored liquids: 150˚C
Unnecessary energy loss per year approx. 12.000 MWh
2. Valves
30 Uninsulated valves (see Safety):
Internal temperature: approx. 300 °C
Unnecessary energy loss per year approx. 600 MWh

29. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
29
TIPCHECK example: Chemical Plant, France
Savings potential:
Total unnecessary annual energy loss (valves+tanks): approx. 12.600 MWh
Total annual financial saving potential (4ct/kWh): approx. 505.000 EUR
Investment:
TIPCHECK: approx. 10.000 EUR
Insulation instalment and material costs: approx. 90.000 EUR
Total investment: approx. 100.000 EUR
Payback time: approx. 2,4 months
Key findings – Financial

30. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
30
TIPCHECK example: Refinery, Italy
Refinery in Italy
Doubling the insulation thickness and using better
material cut the heat losses in half.
Energy Savings: 1.021.958 kWh/a
Financial Savings: 75.000,00 EUR
Payback time: 1-3 years*
*The new insulation system had to improve the fire protection, which
lead to more expensive materials than those that would have been
used for energy efficiency only. This higher investement extended the
payback in this example from 1 to 3 years.

31. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
31
TIPCHECK example: Processing plant, Germany
• Tube, ferritic steel, thickness: 5 mm
• Width 1,70 m
• Depth 0,760 m
• Hight 26 m
• Surface 127,92 m2
• Average heatprice 0,033 €/kWh
• Operating hours: 1‘500
• Insulation investment 12.792 EUR
• Energy savings 1.450 MWh/a
• Financial savings 47.800 EUR/a
• Payback time < 3 months
Insulation of an asphalt boiler in Germany

32. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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TIPCHECK
Your
Savings Potential

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EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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How does a TIPCHECK contribute to our Sustainability programme?
FAQ
– Insulation is the first step of initiating measures to reduce energy loss, CO2
emissions and contribute to a cleaner environment
– Besides energy savings potentials insulation offers significant life-cycle cost
reduction potentials

34. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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FAQ
Why should we start to insulate un-insulated fittings, valves,
flanges, etc.?
– EiiF study has proven that by insulating bare surfaces we can reduce up to 95 % of
our energy losses and significantly reduce CO2 emissions.
– We all care about the environment; this is an important step to tap into the energy
savings potential of industrial insulation.
– Insulation investments usually have a payback period of less than one year.

35. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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How do we approach this energy efficiency programme?
FAQ
– Our certified TIPCHECK engineers will analyse the present situation and
come up with a road map to energy savings.
What steps need to be taken in order to implement the road map to energy
savings?
– Our certified TIPCHECK engineers will work closely with all stakeholders
including production, plan/asset integrity, site maintenance, mechanical,
energy management, etc. to define the correct implementation and
execution strategy for your facility.
How long will it take?
– The duration of the project depends very much on the size and scope.
Therefore a detailed project plan will be set up according to client’s needs.
FAQ

36. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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What is the impact on daily operations?
FAQ
– By working in close conjunction with all relevant stakeholders we will mitigate
disruption.
– The work is non-intrusive and all measurements or changes can be done on fully
operational units and therefore will not interfere with on-going production.
What are the technical and operational challenges we’ll have to deal with?
– How to detect and control leaks from valves and flanges?
– How to insure mechanical integrity (e.g. bolts tensioning, mechanical design
temperature limits) of newly insulated parts?
– How to avoid water ingress?
– How to insure mechanical rigidity of insulation covers?
These topics will be addressed in close conjunction with the maintenance and
operations department by the TIPCHECK engineer and his company.
FAQ

37. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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What is expected from everyone working on site?
FAQ
– A careful and professional handling of insulated systems in order to ensure energy
savings
What are the advantages for associates?
– An even safer working environment by substantial reduction of cold or hot hazardous
surfaces
– Better working conditions due to reduced heat radiation
– Personal contribution to a cleaner environment
FAQ

38. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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Summary
The Savings Potential of Industrial Insulation is
This Savings Potential is highly
The Savings Potential can be
large
cost-attractive
tapped today

39. 25.04.2013
EiiF presentation for
European Industrial Insulation Foundation
www.eiif.org
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European Industrial Insulation Foundation
Avenue du Mont-Blanc 33
1196 Gland (Geneva)
Switzerland
Andreas Gürtler
Foundation Director
t: +41 22 99 500 - 70
f: +41 22 99 500 - 71
m: +41 78 69 63 662
e: andreas.guertler@eiif.org
www.eiif.org
EiiF Contact