Improvement of heating network insulation
Modernization of the heating network insulation reduced heat losses in pipelines and heat nodes, resulting in savings of 3.1 GWh of energy and 260,100 PLN annually.
The challenge
In the audited industrial plant, the analysis covered heat transmission networks, including steam pipelines and district heating water. The goal was to reduce heat losses in pipelines and fittings and improve the plant’s energy efficiency.
The audit showed that the overall condition of the pipelines and boiler equipment was good, and radiation losses occurred mainly on short sections. In heating networks, losses were higher in heat nodes and on pipelines, particularly where insulation was missing on valves and flange connections.
Our approach
The DB Energy team carried out:
- a detailed energy audit of transmission networks using a thermal imaging camera,
- identification of locations with excessive heat losses in pipelines and fittings,
- development of modernization recommendations considering easy disassembly and future maintenance,
- calculation of energy and cost savings resulting from improved insulation.
Solution
The modernization included:
- use of thermal insulation covers or mineral wool covered with foil in previously uninsulated areas, e.g., on valves and flange connections,
- maintaining the good condition of existing insulation on water collectors,
- optimizing heat losses across the entire transmission system without hindering maintenance and operation.
The total investment cost amounted to 113,100 PLN.
Results
The actions taken by DB Energy resulted in:
- reduction of energy consumption: 3.1 GWh/year,
- financial savings: 260,100 PLN/year,
- reduction of heat losses in pipelines and heat nodes,
- improvement of energy efficiency in transmission networks,
- simple and durable solution allowing easy disassembly and maintenance of insulation.
Conclusions
Improving heating network insulation is an effective action for optimizing energy losses in industrial plants. Even with well-maintained existing pipelines, targeted actions in critical areas allow achieving measurable savings with relatively low investment costs.
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