Download - Trac-Loc Tank Insulation for increased Safety and Guaranteed Financial & Operational advantages
TRAC‐LOC®VERTICAL
STANDING SEAM TANK
INSULATION SYSTEM‐
GUARANTEED FINANCIAL & OPERATIONAL ADVANTAGES
Pentair Industrial Heat Tracing Solutions – Trac‐Loc® Tank Insulation System
September 20, 2016
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PENTAIR
Trac‐Loc® for Tanks Introduction & Concept
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PENTAIR
PENTAIR OFFERS A HEAT MANAGEMENT SOLUTION (HMS) APPROACH
• Insulation of tanks and pipes (pre‐insulated) with Trac‐Loc® concept• Tracing including monitoring and control• Heat tracing power cables, signal cables, cable tray, panels, etc.
• Tank Terminal benefits
– Single contract partner for full HMS:• Financial, contractual and operational advantages
–Guarantee on savings:• Investment costs• Operational costs• Execution schedule
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TRAC‐LOC® OVERVIEW
Trac‐Loc® is a standing seam insulation system that offers tank owners a superior system compared to conventional insulation methods
Ideal for large flat‐bottomed storage tanks used for storage of materials that are sensitive to temperature fluctuations to reduce heat loss or gain
Reduces a customer’s TIC (Total Installed Cost) by compressing schedules and eliminating the use of scaffolding
Reduces a customer’s TOC (Total Operating Cost) by providing a thermally superior and lower maintenance insulation system
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Trac‐Loc® Applications
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PRODUCT STORAGE/TANK FARMS
• Main Benefits of Trac‐Loc®
– Decreased Project Costs• No Scaffolding
• Fewer welding requirements
• Less indirect field costs
• Fewer required direct field man hours
• Lower maintenance costs
• Total Heat Management System (HMS)
– Works in conjunction with heat tracing to provide a complete Heat Management System (HMS) for temperature sensitive products
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Product storage tanks are usually found at refineries and terminals, either heated or unheated, and they are used to store a wide array of products
Examples: Crude oil, sulfur, refined products, asphalt, fuel oil, biodiesel tanks
Pentair Industrial Heat Tracing Solutions – Trac‐Loc® Tank Insulation System
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THERMAL ENERGY STORAGE (TES)
• Main Benefits of Trac‐Loc®
– Aesthetics• Multiple color schemes
• Suitable for urban landscapes
• Can incorporate design themes from adjacent structures
– Superior Design• 100% vapor‐sealed system with integral foil‐vapor barriers
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Application in which water is chilled during “off‐peak” hours and stored for daily HVAC use.
Examples: Chilled or heated water for use in HVAC systems
Pentair Industrial Heat Tracing Solutions – Trac‐Loc® Tank Insulation System
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EQUIPMENT/VESSELS
• Main Benefits of Trac‐Loc®
– Decreased Project Costs• No Scaffolding
• Less indirect field costs
• Fewer required direct field man hours
• Lower maintenance costs
– Total Heat Management System (HMS)• Works in conjunction with heat tracing to provide a complete Heat Management System (HMS) for temperature sensitive products
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Non storage process equipment requiring thermal insulation either for personnel protection or heat conservation
Examples: Digesters, Coke Drums, Heated Process Vessels
Pentair Industrial Heat Tracing Solutions – Trac‐Loc® Tank Insulation System
PENTAIR
TECHNICAL CONCEPT
The concept is based on vertical insulating panels prefabricated in workshop which are assembled on Site by a seam system.
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TECHNICAL CONCEPT
• A cable is fixed around the tank. Stainless steel clips fixed on this cable are captured within the seam made between two panels.
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TRAC‐LOC® MATERIAL SELECTION
INSULATION TYPE K‐FACTORBTU*IN/HR*FT*°F
MAX EXP. TEMP MAX PANEL LENGTH
% MOISTURE ABSORBENCY
POLYISOCYANURATE .17 250°F (121°C) 75’ – 0” 0.2%
FIBERGLASS .24 850°F (454°C) 30’ – 0” >20%
MINERAL WOOL .26 1200°F (649°C) 30’ – 0” >20%
CELLULAR GLASS .30 800°F (427°C) 30’‐ 0” 0%
COMPOSITE PANEL VARIES 500°F (260°C) 50’‐ 0” VARIES
JACKETING TYPE GAUGE TYPE PAINT OPTION
MOISTURE BARRIER
ALUMINUM (STUCCO EMBOSSED) 0.024” (0.6mm) 3105 H154 √ √
STAINLESS STEEL (STUCCO EMBOSSED) 0.016” (0.4mm) 304 2b √ √
COATED STEEL (e.g. GALVALUME) 0.022” (0.5mm) AZ55 GRADE 80 √ √
Thermal Insulation
Metal Jacketing
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TRAC‐LOC® MATERIAL SELECTION
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HOW TRAC‐LOC® IS INSTALLED
Aircraft‐Grade Stainless Steel Cables are buckled
to the tank/vessel
Panels are hoisted into place and clipped to the
cables
Adjacent panels are joined together to create
the final seam
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TRAC‐LOC® PANEL SEAMING PROCESS
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CELLULAR GLASS FOOTER OPTION
Prevents moisture from being absorbed by the insulation system in areas prone to CUI
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DOME
> 1.5:12 Pitch or dome
CONICAL / FLAT
<1.5:12 Pitch
TRAC‐LOC® TANK ROOFS
Pie shaped gores fit to the tank radius and curved to the dome radius, if required.
Superior design with ultimate moisture prevention.
Allows equivalent expansion / contraction with the tank roof.
Parallel panel design for flat and low cone (≤1.5:12) tank roofs.
Most economical fabrication and installation design.
Provides expansion / contraction latitudinal in the seams and longitudinally with expansion joints, if required.
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TRAC‐LOC® SYSTEM FEATURES AND BENEFITS
Vertical, double locking standing seam insulation panels
Pre‐fabricated one piece construction
Eliminates costly scaffolding
Compresses field construction schedule and man‐hours
Virtually maintenance free
High wind resistance
Thermally efficient
Aesthetically superior
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Trac‐Loc® vs. Other Insulation Systems
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TRAC‐LOC® vs. OTHER STANDING SEAM COMPETITORS
• Insulated 1,000 + tanks of all temperatures, designs, etc.
• The most experienced crews in the industry. Multiple supervisors with 15+ years of Trac‐Loc® experience. We have seen it all!
• Comprehensive offering of product enhancements to suit specific customer needs
• 180° mechanically folded seam. Other profiles are structurally and aesthetically inferior
• Roof expansion / contraction joints with preventative moisture barrier
• Superior insulation materials utilized. With 15+ years of experience we know which products work best for the applications
• We insulated the 2009, 2010 and 2011 STI Tanks of the Year
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Trac‐Loc® Tank Insulation System vs.
Conventional Tank Insulation System
SAFETY Smaller crew size, fewer installation steps, fewer field hours vs. Larger crew size, more installation steps, more field construction hours
COST No scaffoldingMinimal welding requirement vs. Scaffolding required
Insulation support pins and rings required
PERFORMANCE Fewer and more productive field work hours vs. Requires 2‐3 times more field hours
SCHEDULE Compresses field schedule due to fewer field work hours vs. Requires 2‐3 times more field hours, stressing schedule demands
MAINTENANCE Minor caulking maintenance around penetrations vs. Regular, involving band tightening and replacing weathered insulation,screws, etc.
AESTHETICS Superior vs. Inferior
DESIGN LIFE 25+ Years vs. Equal with regular maintenance
SECUREMENT All internal protected from the elements by the insulation system vs. All external subject to the elements
QUALITY 100% hermetically protected from the elements withminimal rivets vs. Exposed to elements with multiple laps and screws, requires regular
maintenance
WIND >110 m/hr ( 177 km/hr) vs. <70 m/hr (112 km/hr)
Pentair Industrial Heat Tracing Solutions – Trac‐Loc® Tank Insulation System
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TRAC‐LOC® vs. CONVENTIONAL SYSTEMS
0
5
10
15
20
25
30
35
40
45
25' 50' 75' 100' 125' 150' 175' 200'
Cost/Area
TANK DIAMETER
TRAC‐LOC® vs. CONVENTIONAL TOTAL INSTALLED COST (TIC) BY AREA
Trac‐Loc®
Conventional
$
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Benefits of the Trac‐Loc®Concept to Tank Owners / Operators
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BENEFIT ON SCHEDULE
Time usually spent on Site and related to construction is transferred to manufacturing activities in workshop controlled environment
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Tank erection
Insulation Site
TimeConventional insulation
Time
Tank erection
Insulation Site
Insulation Workshop
Trac-Loc insulation
GAIN ON SCHEDULE
Pentair Industrial Heat Tracing Solutions – Trac‐Loc® Tank Insulation System
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BENEFIT ON SAFETY
• Use of a hanging basket instead of scaffolding
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BENEFIT ON CORROSION UNDER INSULATION
• Fully locked double seam system eliminates water penetration resulting in a reduction of under insulation corrosion
• No fibrous insulation materials, minimum degradation, closed cell structure, no water/fluids absorption
• Next to the support ring, no rim or other welding is required on the side walls resulting in a minimization of locations where under insulation corrosion could develop itself
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BENEFIT ON LIFETIMELong lifetime (with stable insulation behaviour over the lifetime) due to applying PIR
• Closed cell structure• No degeneration• Minimum water absorption
0.02
0.08
0.04
0.06
0.03
5% 10% 15%0%
Mineral Wool80 Kg/m3
Cork
Extruded Polystyrene foam80 Kg/m3
Polyurethane80 Kg/m3
Expanded Polystyrene foam80 Kg/m3
Volume related moisture content %
Ther
mal
con
duct
ivity
W/m
°K
The graph shows that a 5% increase in water contents results in a 200% increase in the thermal conductivity of mineral wool
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BENEFIT ON ENERGY USAGE
High energy savings (due to applying PIR insulation material instead of mineral wool) resulting in substantial yearly savings and a reduction of the carbon footprint
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BENEFIT ON ENERGY USAGE
High thermal insulation resistance of PIC material resulting in:
• Less energy needed to maintain the content of the tank at the required temperature
• Long cool down cycle
• Trac‐Loc® tank cool down from 80ºC to 60ºC at an average ambient temperature of 12ºC takes 1664 hours or almost 10 weeks
• Conventional insulated tank cooling under the same conditions takes 1332 hours or 7.8 weeks
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BENEFIT ON TOTAL COSTS OF OWNERSHIP (TCO)
Cost comparison between Trac‐Loc® and conventional systems
• Investment + maintenance + energy over the life time minimizing the TCO
• Results– Annual savings
– Payback period
– R.O.I. (extra investment – annual savings)
• High importance of TCO versus the Total Investment Cost (TIC)
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Highest Quality Final Product
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HIGHEST QUALITY FINAL PRODUCT
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HIGHEST QUALITY FINAL PRODUCT
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HIGHEST QUALITY FINAL PRODUCT
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HIGHEST QUALITY FINAL PRODUCT
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HIGHEST QUALITY FINAL PRODUCT
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