SOVBI technologies for thermal insulation of pipelines and equipment
Innovative SOVBI technologies involve using of ultralightweight cast-in-situ foam concrete of 150-200 kg/m3 density as insulating layer for pipelines and miscellaneous equipment.
This technology makes it possible to produce thermal insulation directly on the construction site, and not least importantly, provides for carrying out the work in winter with subzero temperatures up to -25°C. Contrary to insulation from foamed polyurethane and mineral wool, which deteriorate with damaged pipeline waterproofing layer, foam concrete becomes even stronger in dampened state, while coolant delivery causes damp to be pushed out to the peripheral surface, thus ensuring the design heat shielding. Since 1948, there has been a wide application of pipelines with thermal insulation from autoclave reinforced foam concrete, and these pipelines proved to be optimal for continuous service. Since foam concrete passivated the metal pipe surface, acting as corrosion proofing material, pipe replacement was required due to internal corrosion only.
Onsite foam concrete casting provides for significant reduction of pipeline insulation costs through elimination of plant production costs and the need for solid film used for transportation, transshipment, etc.
Standard mobile plants SOVBI may find a broad application in heat shielding for both underground and overhead pipelines as they provide for production of foam concrete of various densities even in winter at temperatures up to -25 0С, enabling foam concrete delivery to the 70 m elevation vertically and 250 m horizontally. The plant is delivered by a light-duty truck, or even in a car trailer, and may be manually rolled over at the site. The plant may be operated by a semiskilled workman.
SOVBI technologies and mobile plants meet various challenges of piping arrangement conditions.
1. Thermal insulation of heating system pipelines for all laying methods.
2. Thermal insulation of equipment external surfaces, steam/gas/water pipelines, gas ducts and air ducts located in buildings, structures and outdoors, with temperature of transported media ranging from – 180 0С to + 600 0С.
3. Surface thermal insulation of pipelines for:
- oil, oil-products, natural, oil gas, manufactured hydrocarbon gases, for production and transportation to consumption areas;
- liquefied hydrocarbon gases, mixtures thereof from gas recovery or gas production regions to consumption areas.
4. Thermal insulation of industrial cooling chambers, oil- and gas storages.
We have developed and registered STO-005-50845180-2007 “Thermal insulation of pipelines and equipment using cast-in-situ non-autoclave foam concrete SOVBI” and have drawn up a manual of template solutions for publication.
Pursuant to this standard, we have carried out works on improvement of insulation coatings on the active heat pipeline section of a major electromechanical plant in St. Petersburg. Pipes of 325 mm diameter were stripped of settled and dampened mineral wool insulating material, rusted metal sheath and were heat shielded with cast-in-situ foam concrete SOVBI of 200 kg/m3 density and 9 cm layer thickness, cast into filling holes of permanent formwork from galvanized sheets at 5 m above ground.
The authorities of this plant decided to adopt this technology for heat shielding of the whole plant pipework. The report on the executed work specifies that temperature measurements both in the vertical and the horizontal pipeline sections evidenced matching of insulation surface temperature with the ambient temperature, the aesthetic qualities and reasonable cost of executed works were also appreciated.
At the moment our partners are carrying out works in St. Petersburg suburbs at Kirishsky oil refinery on insulation of steam lines with carrier temperature 300 °C. The work on replacement of old settled mineral wool insulation with evaporated preservation was started several years ago. Initially, removable plastic formwork had been used. However, permanent formwork from galvanized steel or aluminium sheets turned out to be more suitable for large diameter pipes. When opened a year later, the formwork showed no signs of pipe corrosion or insulation damage. The design of thermal insulation for pipelines and equipment meets the following requirements:
- energy efficiency – optimum thermal insulation design cost/insulation heat loss cost ratio within the expected service life;
- operating reliability and durability – sustains temperature, mechanical, chemical and other loads within expected service life without any degradation of heat shielding properties or deterioration;
- environmental safety and operating personnel safety in the course of operation.
For heat shielding of large diameter pipes the production cost of onsite foam concrete insulation casting is several times lower than that for foamed polyurethane.
Under the agreement with a major Russian energy company, the following issue is being under consideration: the use of foam concrete containing ash derived from waste water combustion for simultaneous heat shielding of trunk lines and road making, through substitution of chip stone with foam concrete which thereby ensures solid base surface and protection of soil against frost heave.
Apart from selling technologies and equipment, we provide training in operation of the same.
SOVBI equipment and technical solutions are provided with patent protection in Russia and abroad, the unlicensed use of the same is forbidden by law.
We guarantee a high level of workmanship.
Compliance certificate No. SDS. TP. SMK. 001789-07 as per International system ISO 9001:2000.
We are ready to demonstrate the onsite operation of our equipment at your convenience.
