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INSTRUCTION MANUAL

Gas conditioning tower 52341-02

Insulation and cladding


General description

RAMSINGSVEJ 30 - 2500 VALBY - DENMARK ‹ 100 GLENBOROUGH DRIVE – 77057-3611 HOUSTON - USA ‹ CARRETERA DE LA COURUNA KM. 17-8 – 28230 LAS ROZAS – SPAIN ‹ ESPACE INDUSTRIEL, NORD – 80084 AMIENS CÉDEX 2 - FRANCE
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Enclosures:

Figure 1 (Inlet unit or Cylindrical unit)


Figure 2 (Inlet unit or Cylindrical unit)
Figure 3 (Inlet unit or Cylindrical unit)
Figure 4 (Inlet unit or Cylindrical unit)
Figure 5 (Inlet unit or Cylindrical unit)
Figure 6 (Cone unit)
Figure 7 (Cone unit)
Figure 8 (Cone unit)

Read this erection manual in conjunction with:

- General insulation drawings for the gas conditioning tower.

Table of contents: Page:

1. General ............................................................................................................................. 3
2. Inlet Bend .......................................................................................................................... 6
3. Inlet unit............................................................................................................................. 7
4. Cone unit........................................................................................................................... 8
5. Cylindrical unit above the supporting unit ......................................................................... 9
6. Supporting unit ................................................................................................................ 10
7. Cylindrical unit under the supporting unit ........................................................................ 11
8. Transition unit.................................................................................................................. 12
9. Bottom hopper and outlet................................................................................................ 13
10. Key to sketches............................................................................................................... 14

Performed by / Date Checked by / Date Approved by / Date


JIJ / 030526 JIJ / 030526 MEP / 030526
3 52341-02

1. General

The object of insulating a gas conditioning tower is to ensure that the hot gases will not be cooled to
the dew point during passage through the gas conditioning tower.

Such uncontrolled cooling would result in precipitation of liquid followed by corrosion and
accumulation of dust.

Insulation ensures uniform temperature of the gas conditioning tower, and large thermal stresses
are avoided.

The insulation also ensures that the contact temperature of the cladding will not be too high. The
insulation must be carried out according to existing legislation and standards.

The following parts must insulated and covered with cladding:

- Inlet bend
- Inlet unit
- Cone unit
- Cylindrical unit above the supporting unit
- Supporting unit
- Cylindrical unit under the supporting unit
- Transition unit
- Bottom hopper and outlet
- Dust transport

Insulation:

The insulation consist of heat-resistant mineral wool which is covered with a weather-resistant
cladding.

To fix the insulation use bar iron (fixing iron) ø5 mm, which is welded to the gas conditioning tower
wall. Use minimum 7 per m2.

Before insulation is placed on the gas conditioning tower wall fixing iron (binder) and fixing clamps
must be welded in position.

There must be no insulation in the hollow space between plate side and stiffening iron (angel iron),
because this would prevent thermal radiation and cause thermal bending of the stiffening iron
(angel iron).

The first coat of insulation must be placed over the fixing iron (binder) and locked against the plate
side by means of striker plate. The second coat of insulation is placed over the first coat. The joints
must be staggered in both directions.

Timber or any other inflammable material must not be used as support for the insulation.
52341-02 4

Cladding:

The cladding must be plane plate or corrugated plate. All plate work must be wind and
weatherproof. Specifically at inspection doors, flanges/tubes for lances, leads-in and all kinds of
transitions the waterproofing must be carried out with effective overlapping and proofing.

The cladding must be mounted flexibly with fixing clamps and fastening steel so as to take up
thermal expansion.

The fastening steel must have a maximum length of 2 m, with intermediate spacings of 10-20 mm
due to the possibility of thermal expansion (see figure 3, 4, 5).

The cladding must be fastened to the fastening steel by means of tubular rivets or self cutting
screws with sealing rings. The cladding must not be fastened to the fastening steel near the
spacings.

Fixing clamps must not be welded directly to the gas conditioning tower wall. Fixing clamps must be
welded to the stiffening iron, if available. Please note that a distance must be kept between the
fixing clamp and the gas conditioning tower wall in order to minimize thermal bridge (see figure 1, 2,
7).
If a stiffening iron is not present, the fixing clamps must be separated thermically from the gas
conditioning tower wall by means of a insulating liner (see figure 1, 2, 7).

Fixing clamps must be placed with uniform spacing. Maximum space between two fixing clamps
depends on the dimensions of the fixing clamps, the dimensions of the fastening steel and the local
wind load.

Example 1 2
Dimensions of fixing clamps and fastening steel 30x3 mm 40x5 mm
Maximum space between two fixing clamps 250 mm 500 mm

At horizontal expansion joints, the distance from the outer plate edge to the first row of fixing clamps
above the plate edge must be maximum 200 mm. Correspondingly the distance from the inside
plate edge to the first row of fixing clamps below the plate edge must be maximum 200 mm. The
cross-overlapping of the plates must be minimum 100 mm. This overlap must not be riveted or
screwed together (see figure 1, 2, 7).

The vertical plate joints must be riveted or screwed together with a maximum distance between the
rivets or screws of 500 mm.

For each plate fixing clamps type 1 are used at the top (see figure 1, 2, 3 and 7). Fixing clamps type
2 or type 3 are used for all fixing clamps below.
For the next plate fixing clamps type 1 are used at the top. Fixing clamps type 2 or type 3 are used
for all fixing clamps below etc.
Fixing clamps type 3 (see figure 2 and 5) can be used if type 3 can take up the thermal expansion
in vertical direction. If type 3 can not take up the thermal expansion in vertical direction use type 2.
The brace take up the thermal expansion in vertical direction for type 2 (see figure 1 and 4).
5 52341-02

Thermal expansion horizontal (diameter): ∆D = D ⋅ α ⋅ ∆T


Thermal expansion vertical (hight): ∆H = H ⋅ α ⋅ ∆T
Thermal expansion perimeter (P = π ⋅ D): ∆P = (π ⋅ D) ⋅ α ⋅ ∆T

D: Diameter [m]
H: Hight [m]
P: Perimeter [m]
∆T: Temperature change (Tmax_GCT - Tmin_ambient) [°C]
α: Linear expansion [m/m°C]

Temperature Linear expansion


°C m/m°C
100 12.3⋅10-6
200 12.8⋅10-6
300 13.3⋅10-6
400 13.8⋅10-6
500 14.2⋅10-6

Example
D = 5m H = 20m
Tmax_GCT = 400°C Tmin_ambient = 0°C

∆D = 5m ⋅ 13.8⋅10-6m/m°C ⋅ (400°C - 0°C) = 2.76⋅10-2 m = 27.6 mm


∆H = 20m ⋅ 13.8⋅10-6m/m°C ⋅ (400°C - 0°C) = 11.04⋅10-2 m = 110.4 mm
∆P = (π ⋅ 5) ⋅ 13.8⋅10-6m/m°C ⋅ (400°C - 0°C) = 8.67⋅10-2 m = 86.7 mm

The following mentioned data for insulation and cladding are FLS Airtech standard. However other
data for insulation and cladding may be used.

If the insulation and cladding specification for a special gas conditioning tower are different from the
following mentioned data for insulation and cladding in this manual, the special insulation and
cladding specification must be used.
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2. Inlet Bend

Insulation
Type of insulation *) U-50T + 50T
Thickness of insulation 100 mm
Fastening the insulation Fixing iron ø5 mm. Minimum 7 per m2
Insulation of stiffening iron See figure 1

Cladding
Type of cladding Corrugated plate
Fastening the cladding See figure 1 and 2
Thermal expansion, vertical direction Taken up by the cross-overlapping of the
cladding
Thermal expansion, perimeter direction Taken up by the corrugation of the cladding

Special parts (leads-in) to be insulated:

- Sockets for measuring device.

The fixing clamps for the inlet unit must:


- Take up thermal expansion in vertical direction.
- Transmit wind loads.
- Support the cladding.

*) See Type of insulation drawing.


7 52341-02

3. Inlet unit
Insulation
Type of insulation *) U-50T + 50T
Thickness of insulation 100 mm
Fastening the insulation Fixing iron ø5 mm. Minimum 7 per m2
Insulation of stiffening iron See figure 1

Cladding
Type of cladding Corrugated plate
Fastening the cladding See figure 1 and 2
Thermal expansion, vertical direction Taken up by the cross-overlapping of the
cladding
Thermal expansion, perimeter direction Taken up by the corrugation of the cladding

Special parts (leads-in) to be insulated:

- Sockets for measuring device.

The fixing clamps for the inlet unit must:


- Take up thermal expansion in vertical direction.
- Transmit wind loads.
- Support the cladding.

*) See Type of insulation drawing.


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4. Cone unit

Insulation
Type of insulation *) U-50T + 50T
Thickness of insulation 150 mm
Fastening the insulation Fixing iron ø5 mm. Minimum 7 per m2
Insulation of stiffening iron See figure 7

Cladding
Type of cladding Plane plate
Fastening the cladding See figure 7 and 8
Thermal expansion, vertical/meridian Taken up by the cross-overlapping of the
direction cladding
Thermal expansion, perimeter direction Taken up by the fixing clamps

Special parts (leads-in) to be insulated:

- Support for access facilities.


- Sockets for measuring device.

The plane cladding for the cone unit can not take up thermal expansion in radial and perimeter
direction because the cladding is riveted or screwed together.
Therefore special fixing clamps must be used for the cone unit, the fixing clamps must:
- Take up thermal expansion in radial and perimeter direction.
- Take up thermal expansion in vertical/meridian direction.
- Transmit wind loads.
- Support the cladding.

*) See Type of insulation drawing.


9 52341-02

5. Cylindrical unit above the supporting unit

Insulation
Type of insulation *) U-100T + 50T / U-50T + 50T**
Thickness of insulation 100 mm
Fastening the insulation Fixing iron ø5 mm. Minimum 7 per m2
Insulation of stiffening iron See figure 1 and 2

Cladding
Type of cladding Corrugated plate
Fastening the cladding See figure 1 and 2
Thermal expansion, vertical direction Taken up by the cross-overlapping of the
cladding
Thermal expansion, perimeter direction Taken up by the corrugation of the cladding

The area near the supporting unit (the first 4 m) must be insulated with 150 mm insulation type: U-
100T + 50HA (See Insulation of supporting unit drawing).

Special parts (leads-in) to be insulated:

- Inspection door.
- Flanges tubes for lances (see figure 6).
- Support for access facilities.
- Sockets for measuring device.

The fixing clamps for the cylindrical unit must (see figure 1 - 5):
- Take up thermal expansion in vertical direction.
- Transmit wind loads.
- Support the cladding.

*) See Type of insulation drawing.


**) The area below the consuls is isolated with 150 mm. Below that the isolating thickness is
100 mm.
52341-02 10

6. Supporting unit

Insulation
Type of insulation *) U-150T + 50HA
Thickness of insulation 200 mm
Fastening the insulation Fixing iron ø5 mm. Minimum 7 per m2
Insulation of supporting unit **)

Cladding
Type of cladding Plane plate
Fastening the cladding **)

Special parts to be insulated:

- The hollow space at the supporting unit must be covered with plate. There must be no
insulation in the hollow space between the gas conditioning tower wall and the cover plate. *)

* See Type of insulation drawing.


**) See Insulation of supporting unit drawing.
11 52341-02

7. Cylindrical unit under the supporting unit

Insulation
Type of insulation *) U-100T + 50HA
Thickness of insulation 150 mm
Fastening the insulation Fixing iron ø5 mm. Minimum 7 per m2
Insulation of stiffening iron **)

Cladding
Type of cladding Plane plate
Fastening the cladding **)

*) See Type of insulation drawing.


**) See Insulation of supporting unit drawing.
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8. Transition unit

Insulation
Type of insulation *) U-50T + 50T
Thickness of insulation 100 mm
Fastening the insulation Fixing iron ø5 mm. Minimum 7 per m2
Insulation of stiffening iron *)

Cladding
Type of cladding Plane plate
Fastening the cladding **) see figure 7
Thermal expansion, vertical direction Taken up by the cross-overlapping of the
cladding
Thermal expansion, perimeter direction Taken up by the fixing clamps

*) See Type of insulation drawing.


**) Use the same principle as for the cone unit.
13 52341-02

9. Bottom hopper and outlet

Insulation
Type of insulation *) U-50T + 50T
Thickness of insulation 100 mm
Fastening the insulation Fixing iron ø5 mm. Minimum 7 per m2
Insulation of stiffening iron **)

Cladding
Type of cladding Plane plate
Fastening the cladding **)

Special parts to be insulated:

- Heating elements.
- Inspection door.
- Sockets for measuring device

*) Se Type of insulation drawing.

**) See Insulation drawing for bottom hopper.


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10. Key to sketches

01 Gas conditioning tower wall


02 Stiffening iron
03 Fixing iron type 1
04 Fixing iron type 2
05 Fixing iron type 3
06 Brance
07 Fastening steel
08 Insulation
09 Cladding
10 Fixing iron (binder)
11 Striker plate
12 Insulating liner
13 Flanges/ tubes for lances
14 Cover
15 Fixing iron type 1 (for the cone unit)
16 Fixing iron type 2 (for the cone unit)
17 Space for thermal expansion
18 Tubular rivet or self cutting screw

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Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 7
Figure 8