KAEFER Integrated Services Pty Ltd An Introduction to Insta-Lag and TIPS 1
Prefabricated Insulation Systems The prefabricated Insta-Lag and TIPS insulation systems are designed by KAEFER as innovative, safe and effective pipe and vessel insulation systems for hot applications. These system meets the requirements of a state-ofthe-art insulation technology combined with advanced installation process for a safer, faster and more effective construction. Insta-Lag : TIPS : Prefabricated Pipe Insulation System Prefabricated Tank Insulation System 2
Challenges of Conventional Insulation Methods The conventional method of insulation faces some disadvantages: > Highly labour-intensive > Site safety issues > Scaffold required for all installation work > Variable quality of insulation. > Program management issues > Progress totally controlled by events on the site > Not easily removable for maintenance > Declining trade skills > Man-made mineral fibre issue TIPS and Insta-Lag avoid site issues and improve the site installation 3
Insta-Lag > Insta-Lag has been designed for use on process pipework for temperature control, energy conservation and as personal protection in hot applications. > Based on the Isometrics and the specification, Insta-Lag is prefabricated in controlled areas outside of the site in a workshop. > Insta-Lag is available for pipes > In a temperature range up to 450 degrees > For pipe diameters from 15 to 600 mm > For insulation thickness from: 25 mm > Insulation material: Mineral wool > Metal outer cladding material: Aluminum, stainless steel, colorbond steel, galvanized steel 4
Insta-Lag Installation Pipes pre-insulated at ground level with Insta-Lag can be lifted onto pipe racks 5
Insta-Lag Installation Each module interlocks with its neighbour forming a structurally fixed joint and fully weatherproof external cladding Efficient and clean installation Reduced need for scaffold 6
Conventional versus Insta-Lag Thermal Insulation for Hot Service Typical Programme of Works MORE FLEXIBLE ON SITE PLANNING The use of Insta-Lag reduces construction time Using Insta-Lag man hours on site can be reduced significantly TIME SAVED 7
Advantages of Insta-Lag for Construction > Simplified on site installation and acceleration of installation > Reduction of airborne man made mineral fibres. All exposed insulation surfaces, on Insta-Lag pipe sections, are treated for fibre encapsulation > Reduction of on site hours - reduction of overall manning level for installation > Savings for scaffolding > Majority of work is undertaken off site in a controlled environment > Less qualified installers can be used > Gain in the total quality of the installation 8
Advantages of Insta-Lag for Maintenance > Easily removable > Can be used several times > No need of specialist tradesmen 9
TIPS > The inclusion of the tank insulation panel system (TIPS ) in KAEFER s range of products and services is part of an ongoing policy of supplying clients with a comprehensive range of innovative industrial products. > TIPS is a generic design which can be adapted to meet specific roof and wall insulation and cladding requirements. > As with all KAEFER products, the TIPS system is tested to meet stringent quality control standards. 10
TIPS > Factory engineered and manufactured insulation system > KAEFER engineers design the complete system > Material selection > Cladding materials > Panel size > Fixing method > New tanks can be setup for TIPS at the time of fabrication beneficial especially in remote locations > Panels can be provided to include any conventional insulation > System is totally flexible in regard to the types of metal finish 11
TIPS Installation Tank diameter should be at least 3 meter Support rings at 1200mm centres TIPS panels are screwed directly on support rings Bottom support ring 100mm from base 12
Advantages of TIPS BENEFITS: > Reduces site installation hours by more than half. > Can significantly reduce scaffolding costs: Usually the installation can be performed from mobile access equipment. > Reduces corrosion under insulation on tanks. > Is manufactured off site > Can significantly reduce accommodation costs in remote locations due to the reduced site hours. > Directly impacts in a positive way on site safety and industrial relations. > Creates great flexibility within the construction schedule due to the reduced site hours required for installation. 13
References (extract) > Cawse Nickel (Insta-Lag ) > Alcoa Wagerup Alumina Refinery (Insta-Lag and TIPS ) > Port Campbell Gas Facility Victoria (Insta-Lag ) > Nabalco NT Alumina Refinery (Insta-Lag and TIPS ) > Alcoa Kwinana Alumina Refinery (Insta-Lag ) > QAL Gladstone Alumina Refinery (Insta-Lag and TIPS ) > Qenos NSW Chemical Plant (Insta-Lag ) > Alpart Jamaica Alumina Refinery (TIPS ) > Comalco Alumina Refinery (Insta-Lag and TIPS ) > Alcan Gove Alumina Refinery (Insta-Lag and TIPS ) > Worsley Alumina Refinery (Insta-Lag and TIPS ) 14
KAEFER Contacts For further information on KAEFER as well as for the complete address list of our branch offices you may also refer to our homepage www.kaefer.com.au KAEFER Integrated Services Pty Ltd 8 Bradford Street Phone: +61 8 9224 4600 Kewdale WA 6105 Fax: +61 8 9224 4691 Australia www.kaefer.com.au info@kaefer.com.au 15