{"id":14909,"date":"2025-10-01T16:31:59","date_gmt":"2025-10-01T16:31:59","guid":{"rendered":"https:\/\/insulation.org\/io\/?post_type=articles&p=14909"},"modified":"2025-11-04T18:34:27","modified_gmt":"2025-11-04T18:34:27","slug":"nia-member-fit-tight-covers-discusses-system-design","status":"publish","type":"articles","link":"https:\/\/insulation.org\/io\/articles\/nia-member-fit-tight-covers-discusses-system-design\/","title":{"rendered":"NIA Member Fit Tight Covers Discusses System Design"},"content":{"rendered":"\n
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Project Snapshot<\/h2>\n\n\n\n

NIA Member Company:<\/strong> Fit Tight Covers (FTC)
Industry Segment:<\/strong> Industrial
Type of Plant\/Facility:<\/strong> Renewable Natural Gas Facility
Temperature Range:<\/strong> High-Temperature System
Region: <\/strong>Midwest
Insulation Materials:<\/strong> Piping \u2013 Alpha FCF-1650, Texo Type E Glass Mat Vessels \u2013 Owens Corning L-3.7 Utilicore
Jacketing: <\/strong>Alpha FCF-1650
Other: <\/strong>12-gauge stainless steel lacing anchors, 2\u201d Nomex Velcro, Braided Kevlar Drawstrings<\/p>\n\n\n\n

Project Description and Goals<\/h2>\n\n\n\n

This new construction project was completed at a renewable natural gas landfill site in the Midwest. Capture and processing of natural gas is a growing sector in sustainable energy, and this project is one of more than a dozen sites FTC\u2019s customer is bringing online across the United States.<\/p>\n\n\n\n

The facility owner\/operator, who also served as the construction manager, had both short- and long-term goals for the project. For the construction phase, the goals were to get the facility up and running as quickly and efficiently as possible, with a solution that would meet the long-term goals as well. Those long-term, post-construction goals included energy savings, process control, and personnel protection\/safety.<\/p>\n\n\n\n

Challenges<\/h2>\n\n\n\n

One challenge of working on a project within an ongoing, larger rollout of multiple facilities is that any difficulties encountered on an early job like this one could have a negative ripple effect on other sites as well. For example, failure to meet the aggressive schedule on this project, or being slow to adapt to last-minute design changes, had the potential to disrupt the customer\u2019s construction and operations schedule on a much larger scale, as FTC was responsible for fabrication and hiring the contractors to install the insulation systems on all the sites.<\/p>\n\n\n\n

FTC Vice President and General Manager Calvin Brasel explained how the company met this challenge: \u201cWe were able to measure, design, and fabricate a solution to help the customer get their plants online faster [including this one]. By using CAD [computer-aided design] and automated cutting tables, we were able to reproduce each part exactly. In the process, we reduced any errors or repairs that would have delayed construction.\u201d Being able to prefabricate the covers for vessels and piping enabled FTC to shorten the project\u2019s duration\u2014not a common occurrence on new construction efforts, and certainly a boost for the customer.<\/p>\n\n\n\n

The next challenge came from Mother Nature, as weather threw the project team something of a curve: brutal winter temperatures caused the design team to refine how much of the equipment (instrumentation in particular) needed to be insulated. FTC worked up a modified \u201cwinterization\u201d package to accommodate the harsh conditions and kept the project on track.<\/p>\n\n\n\n

Perhaps the greatest challenge resulted from the nature of starting up a new facility like this. The customer sought to begin operations as soon as possible, with all the insulation installed to achieve the energy savings and process control\u2014not to mention personnel safety\u2014beginning Day 1. At the same time, facility personnel would need direct access to much of the equipment during the startup phase, when bolts on piping items required retorquing and systems would be adjusted to optimize performance.<\/p>\n\n\n\n

While these seemingly competing priorities would pose a trial for non-removable insulation, FTC\u2019s custom-designed covers facilitated removal and replacement of the insulation during this critical phase. Over the long term, the solution also will make it easy to remove and replace insulation when facility equipment undergoes maintenance and repair. Even the adsorber vessels and loop piping were insulated with the removable covers, providing an additional layer of protection. This strategic choice will help prevent potential damage and reduce repair needs during the routine replacement of the media contained within the vessels, ultimately contributing to the overall durability and efficiency of site operations. As an added benefit, the covers require no personnel training to remove and replace. As Brasel notes, those working at this type of facility\u2014many of whom have worked all over the world, including the Middle East\u2014know the equipment well, so \u201cworking high-temperature Velcro and D-rings with straps, depending on the system,\u201d is certainly within their skill set.<\/p>\n\n\n\n

Photos 1<\/em> through 4<\/em> show the finished product.<\/p>\n\n\n\n

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FTC\u2019s Solution<\/h2>\n\n\n\n

FTC recommended, and the owner\/operator selected, removable insulation covers for all flanges, valves, and equipment to address concerns about startup costs and maintenance efficiency. The solution has the additional benefit of reducing waste\u2014a critical consideration at a facility whose mission is sustainability. While hardcover conventional insulations must be discarded and replaced after being removed so plant personnel can perform inspections or maintenance, FTC\u2019s removable blankets are designed to be easily reinstalled, which saves both landfill space and money for the facility owner.<\/p>\n\n\n\n

For efficiency and quality assurance, FTC worked from component skids, fabricating and installing covers on the actual equipment before the components were shipped to the site. The skids included metal platforms containing all the piping to be mounted atop the vessels, as well as some of the smaller vessels. The project team took measurements from the skids, fabricated the removable covers, brought on installers, and shipped the skids out to the project site pre-insulated. Brasel notes, \u201cThe schedule is important to a client. When they start a site, they\u2019re trying to condense the schedule to get the site operating as quickly as possible. An advantage of this approach is that a lot of the equipment shows up already insulated. With the exception of just a few parts\u2014like large vessels\u2014the site kit is already built. They don\u2019t have to wait on a contractor to cut jacketing material or insulation.\u201d<\/p>\n\n\n\n

As alluded to earlier, the approach also provided quality assurance at the fabrication stage, as the CAD and automated cutting provided accurate, repeatable results. Because FTC sews its covers in the actual shape of the equipment\u2014from a single valve to an entire piping system\u2014the products fit the system perfectly. Finally, FTC performed quality control prior to releasing the skids, thoroughly inspecting each piece of equipment to ensure durable seams and complete insulation coverage.<\/p>\n\n\n\n

Table 1<\/em> offers an overview of insulation system components, as well as product types and brands used. All materials and product types were selected for the temperature, weather, and chemical resistance properties. In addition to the ease of using Velcro for plant personnel, FTC\u2019s covers require no wiring. Brasel notes, \u201cWiring can be a safety hazard\u2014cutting it, it goes into the skin\u2014and on the ground, it gets stuck in people\u2019s boots.\u201d Personnel protection is critical to this customer\u2014which made insulating all the small pressure skids vital. Brasel explains, \u201cThe piping gets hot, and site personnel have to get around it to work on it, take the piping apart.\u201d<\/p>\n\n\n\n

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Project Takeaways<\/h2>\n\n\n\n

Brasel says this project exemplifies a few themes common to most successful FTC projects.<\/p>\n\n\n\n

Getting Insulation Experts Involved Early Saves Time and Money<\/strong>
FTC wrote the specifications for the entire insulation package\u2014to include this site and all the others this customer is rolling out. This not only ensured an effective solution to meet all the short- and long-term performance objectives, but it also allowed seamless execution of the fabrication and installation. If a site required a slight change\u2014e.g., if a bracket was moved to accommodate specific site conditions\u2014FTC was able to adapt quickly.<\/p>\n\n\n\n

Be Open to Good Ideas from All Sources<\/strong>
Calvin Brasel emphasizes that having an open mind and constantly learning and adapting is good for business\u2014your own and your customers\u2019. In this case, he says, \u201cWith industrial plants utilizing prefab skids to reduce cost and construction timelines, why not do the same thing with insulation?\u201d As an added benefit, because FTC was capable of fabricating everything for the skids at its 20,000+ square foot facility in Evansville, Indiana, Brasel notes, \u201cOur costs to fabricate the removable insulation covers for multiple sites did not vary or increase across the United States.\u201d<\/p>\n\n\n\n

Work with People You Trust<\/strong>
One theme that seems to run across all projects, when you have a job as important as this\u2014remember, this project was just one of many sites for this customer, all with aggressive construction schedules\u2014calling on companies you know you can count on is vital. FTC worked with several other NIA members to install this and similar projects:<\/p>\n\n\n\n

    \n
  • Caldwell Insulation, Inc.<\/li>\n\n\n\n
  • Gribbins Insulation & Scaffolding<\/li>\n\n\n\n
  • Insco Industries, Inc.<\/li>\n\n\n\n
  • Irex Contracting Group<\/li>\n<\/ul>\n\n\n\n

    FTC\u2019s own project managers, CAD designers, and design engineer also deserve recognition for the company\u2019s success on this project. Brasel says, \u201cwithout everyone working on it, this would not have been a successful completion.\u201d<\/p>\n\n\n\n

    Plan for Future Growth<\/strong>
    One takeaway that may not immediately come to mind when one thinks of why a mechanical insulation project was successful is a company\u2019s commitment and ability to plan to meet future requirements. The construction industry at large has been dealing with a labor shortage for years, and FTC has innovative strategies to grow the company\u2019s personnel pipeline to keep pace with corporate growth. An internship program that draws from a local technical school, as well as local high schools, provides more potential talent each summer than the company can typically use. For students attending college, FTC brings interns in during school breaks, in addition to the summer. Brasel adds, \u201cFor full-time students in training, we work around their college class schedule.\u201d<\/p>\n\n\n\n

    According to Brasel, \u201cIt takes 3 years training a fabricator to get to their full potential.\u201d He adds, \u201cWe just hired a manufacturing engineer that we\u2019re training in estimating.\u201d The program is clearly paying off: Of six interns FTC has brought on board, all but one have stayed with the company while attending college and post graduation.<\/p>\n\n\n\n

    Pride in a Job Well Done<\/h2>\n\n\n\n

    A second-place win in the NIA competition with highly qualified peers is extremely satisfying, and Calvin Brasel also takes tremendous pride in a job well done. \u201cWhen you see the vessels, all the parts going together perfectly, 24 to 30 pieces assembled that fit that well, that\u2019s what stood out on this project. You can see lots of blankets on piping systems, but those vessels, the tops of the vessels are like 32 feet up,\u201d he marvels, concluding, \u201cIf it doesn\u2019t fit right, it\u2019s not Fit Tight.\u201d<\/p>\n\n\n\n

    About Fit Tight Covers<\/h2>\n\n\n\n

    FTC manufactures removable and reusable thermal insulation covers for commercial and industrial mechanical piping and equipment. The company is proud to be an insulation cover fabrication shop in the Midwest capable of servicing nationwide demand with the highest grade of removable insulation covers. With over 20,000 square feet of space and an experienced team of full-time fabricators, FTC can quickly and accurately produce any type of removable cover.<\/p>\n\n\n\n

    Please review their application pages for a sampling of some of the company\u2019s work, as well as the materials available for certain specs and temperature requirements.<\/p>\n","protected":false},"excerpt":{"rendered":"

    Fit Tight Covers\u2019 project highlights innovative approaches to get a new renewable natural gas facility up and running quickly.<\/p>\n","protected":false},"author":[149],"featured_media":0,"template":"","categories":[675,692,725],"class_list":["post-14909","articles","type-articles","status-publish","hentry","category-system-design","category-insulation-design","category-september-2025","author-ann-hennigan-grace"],"acf":[],"yoast_head":"\nNIA Member Fit Tight Covers Discusses System Design - Insulation Outlook Magazine<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/insulation.org\/io\/articles\/nia-member-fit-tight-covers-discusses-system-design\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"NIA Member Fit Tight Covers Discusses System Design\" \/>\n<meta property=\"og:description\" content=\"Fit Tight Covers\u2019 project highlights innovative approaches to get a new renewable natural gas facility up and running quickly.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/insulation.org\/io\/articles\/nia-member-fit-tight-covers-discusses-system-design\/\" \/>\n<meta property=\"og:site_name\" content=\"Insulation Outlook Magazine\" \/>\n<meta property=\"article:modified_time\" content=\"2025-11-04T18:34:27+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/insulation.org\/io\/wp-content\/uploads\/sites\/3\/2025\/11\/IO251003_01.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"1788\" \/>\n\t<meta property=\"og:image:height\" content=\"1141\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Est. reading time\" \/>\n\t<meta name=\"twitter:data1\" content=\"9 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\/\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\/\/insulation.org\/io\/articles\/nia-member-fit-tight-covers-discusses-system-design\/\",\"url\":\"https:\/\/insulation.org\/io\/articles\/nia-member-fit-tight-covers-discusses-system-design\/\",\"name\":\"NIA Member Fit Tight Covers Discusses System Design - 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