Early on in the proceedings, provision must be made for insulation and the space required for this. Drawings for pipe layouts, for example, should take into account the general rule that cladding around piping requires a space of between 50 to 75mm. The most suitable insulation will depend on the operating temperatures. There are three systems for the insulating of ancillaries. Each type of material has its own specific properties:


Prefabricated PU and EPP insulation For certain kinds of valves, prefabricated and removable EPP boxes are available on the market. These prefabricated boxes are made from PU (polyurethane) and EPP (Expanded Poly Propylene). The idea is that for certain kinds of valves, it is possible to prefabricate standard insulation boxes. Because of maximum temperature resistance, this system is only suitable for central heating installations.

The latest central heating systems generally consist of various central heating groups (units). These units contain various types of ancillaries, three-way valves, pressure regulating valves, non-return valves and pumps, all with varying diameters and capacities. Depending on space, difficult to access piping, i.e. close to ancillaries, is either not insulated at all or only partially using standard piping insulation. In these cases, insulation caps may not be an option. Insulated caps for three-way valves, butterfly valves and pumps are seldom available. If there is a seal in the heating unit for which an insulation cap happens to be available, the pipe cladding and the insulation cap must fit together perfectly. Considering that the space around the seal is often restricted by conduits, brackets and adjacent ancillaries, saws often come in handy to cut everything to make it fit. The result is very badly fitting insulation caps and considerable heat loss. In practise, this system of prefabricated insulation caps is very rarely used. As a result ancillaries are often exposed in pre-insulated systems.

Aluminium sheet metal cladding boxes This type of insulation has the advantage over PU boxes in that aluminium sheet metal cladding boxes can be made-to- measure. Often clip fasteners are used so that the sheet metal cladding boxes can be removed. Despite this, the system has its limitations:
-  Heat transmission through contact with pipes or brackets, raising the external temperature of the aluminium sheeting to
   unacceptable levels.
-  Often not enough attention is paid to insulation so that the aluminium caps need to be padded.
-  They are difficult to remove, especially if rivets were used during assembly.
-  Often it is possible to come into contact with the fibre glass and mineral wool under the cap, which is unpleasant and can cause
   skin irritation
-  They can be difficult to remove for non-specialist insulators, leaving ancillaries exposed.

Insulation blankets As opposed to the above methods of insulation, insulation blankets have relatively few limitations:
-  Insulation blankets are custom-made so the shape of every ancillary is catered, making reassembly relatively straightforward.
-  Ancillaries and parts such as boiler surfaces, manholes and heat exchangers can be insulated easily.
-  Wear and tear is practically non-existent thanks to the combination of glass fabric and synthetic fabric.
-  Glass is a poor conductor of heat, meaning that the outside of the insulation blanket is never too hot to touch.
-  Since the mineral wool content of the insulation is covered on both sides by fabric, you do not come into contact with it.
-  It is the ideal insulation method for areas that are prone to temperature problems.
-  Insulation blankets are maintenance friendly and can be removed and replaced by the client.


Exposed ancillaries and piping Although the quality of piping insulation found in factories is generally acceptable, there are often insulation deficiencies, such as:
-  Insulation that is not replaced where repairs have been carried out.
-  Pipes are left exposed because in this way they are supposed to function as heating for the room.
-  Pipes and ancillaries are left exposed because insulating is considered to be time-consuming during repairs and maintenance activities.

There are several reasons why ancillaries and piping are often left without insulation: -  Underestimating energy loss leading to insulation of ancillaries being ignored.
-  Lack of expertise regarding ancillary insulation among consultants and installers.
-  Insufficient financial means and no budget set aside for insulation.
-  Other priorities and options in terms of energy savings.
-  Lack of expertise required to demonstrate unequivocally energy loss through ancillaries, based on well-substantiated
   cost-benefit analyses.
-  Machine parts are situated so close together making it almost impossible to insulate them properly.
-  Companies underestimate how much heat is lost through exposed pipes and ancillaries.

Cutting corners with insulation is definitely the wrong way to save money. Cost recovery using Thermatras® ancillary insulation in heating installations varies from two to four years.