Project Name: SERC

Title: TII 16.05 Thermal and Sound Insulation

AIC:

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50021973 -0.0

Document Nr-Rev:

Hitachi Zosen Inova AG

Table of contents
1

General conventions

1.1
1.2
1.3
1.4

Abbreviations
Intended use
Applicability
Regulations, standards and guidelines

4
4
4
4

Planning basics

2.1

Boundary conditions

2.1.1
2.1.2
2.1.3
2.1.4
2.1.5

Environment
Heat losses
Surface temperature (heat insulation and touch guard
Prevention of condensation for cold media or cold weather
Sound emissions

5
5
5
5
6

2.2

Insulation principles

2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6

General
Insulating material characteristics
Insulating layer thickness(es)
Condensation and cooling insulation, chemical lines
Application of insulant
Trace Heating

6
6
7
7
7
8

2.3

Substructures

2.3.1
2.3.2

Material
Processing and mounting of substructure

8
8

2.4

Cladding

2.4.1
2.4.2

Material for Cladding and sheets

Handling and mounting of metal sheets

9
11

2.5
2.6
2.7
2.8

Fixing components
Seals
Penetrations
Special parts

12
13
13
13

2.8.1
2.8.2
2.8.3
2.8.4
2.8.5

Elbows, shaped parts

Fitting, ports and similar
Tanks
Contact protection for flaps
Accessible insulating casings

13
13
14
14
14

2.9

Removable caps

14

2.9.1
2.9.2
2.9.3
2.9.4

Design
Manholes, inspection openings
Expansion joints
Measuring ports

14
14
15
15

Secondary measures for sound reduction

16

3.1
3.2
3.3

Solid borne sound

Airborne sound
Sound protection enclosures

16
16
17

Quality assurance

18

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Title: TII 16.05 Thermal and Sound Insulation

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4.1
4.2

Insulation inspection
Sound inspections

18
18

Insulation examples

19

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Title: TII 16.05 Thermal and Sound Insulation

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General conventions

1.1

Abbreviations

Hitachi Zosen Inova AG

Table 1: Abbreviations

1.2

Abbreviation

Description

HZI

Hitachi Zosen Inova AG.

Supplier

HZI's sub-contractor

Subcontractor

Suppliers of apparatus and plant components who are not Suppliers to HZI

LV

Goods and services schedule

TII

HZI Technical Implementation Instruction

TSD

HZI Technical Specification Document

Insulating layer thickness/plate thickness

Intended use
The purpose of this Technical Implementation Instruction (TII) is to define the standard
insulation of an incineration and / or gas purification plant.

1.3

Applicability
All subcontractors to Hitachi Zosen Inova AG shall adhere to this TII when supplying goods
and services.
This TII shall be used for all heat insulation, cooling insulation and insulation to prevent
condensation and sound insulation works at the entire plant. Sub terrestrial pipelines are
excluded e.g. district heating pipelines etc.

1.4

Regulations, standards and guidelines

All relevant British and European Regulations, standards and guidelines must be applied.

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Planning basics

2.1

Boundary conditions

2.1.1

Environment

50021973 -0.0

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In accordance with TII 16.01

2.1.2

Heat losses
Maximum calorific losses by thermal insulation: 160 W/m at an ambient temperature of
20 C.

2.1.3

Surface temperature (heat insulation and touch guard

2.1.4

The insulation shall reduce the heat loss from the hot process media and protect the
personnel against burning from touching the hot installations. It shall meet the
requirements of the Health and Safety Executive.
All portions of the plant within reach from a permanent working level (without the
use of portable access equipment) that, during normal operation, run at surface
temperatures of 55C and above, shall be insulated.
The surface temperature of insulated surfaces is limited to a maximum of 55 C at
an ambient temperature of 30C. The ambient temperature will be measured 1.5 m
from the surface in stationary air.
If components with a surface temperature > 55C cannot be insulated due to
confined conditions or for technical reasons (e.g. heat dissipation required),contact
protection is to be provided if the component is accessible from thebase, the stages
or stairs.
All portions of the plant out of reach from a permanent working level (without the use
of portable access equipment) that, during normal operation, run at surface
temperatures of 65C and above, shall be insulated.
The thickness of lagging applied shall be such as to reduce the heat losses to
economic levels. Unless otherwise stated the required thickness shall be such that,
with an air temperature of 30C and, if appropriate, screened from solar gain, the
surface temperature of the lagging insulation material proper before the application
of finishing material or paint shall not exceed the air temperature plus 25C.

Prevention of condensation for cold media or cold weather

In installation areas where condensation can form, condensation insulation must be

provided, e.g. material: PUR (polyurethane)
If liquids can crystallize or freeze at the lowest and above ambient temperature
according TII 16.01 General Information, components conveying liquid are to be
insulated and provided with heating if necessary.
The average temperature must be at least 5C above the crystallization
temperature at any given time or: The thickness of frost protection insulation shall
ensure that there is no more than 10% ice formation in 12 hours, this freezing rate
being calculated for the Site conditions by a method as generally described in EN
norm
If vapours, gases or gas components can condense at the lowest ambient
temperature and below, components are to be insulated against cooling and
provided with heating if necessary. This is in particular to be observed if there is a
risk of corrosion from the condensation.

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2.1.5

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With the exception of saturated steam, the medium temperature must be at least
5C above the condensation temperature at any given time.
Cooling bridges are to be avoided through proper shaping of the insulation.
Trace heating shall be installed in such a manner that pipe sections and equipment
can be removed without to need to disconnect adjacent sections of trace heating.

Sound emissions
If no other sound emission values are given in the specification, in the TSD or in the sound
appraisal, the unit or equipment must have a maximum sound pressure level at the
installation site in the nominal load mode according to TII 16.01 General Information,
chapter 2.4 'Noise emissions within buildings and areas'

2.2

Insulation principles

2.2.1

General
Thermal insulation shall be applied to equipment, plant, and piping operating at
temperatures below the maximum dew-point, where condensation could form to the
detriment of plant structures or equipment or cause discomfort to operating personnel. Low
temperature thermal insulation shall be completely sealed to prevent moisture waterlogging or frost damage to the insulation.

2.2.2

Insulating material characteristics

All insulation materials shall be vermin proof, non hygroscopic, chemically inert when both
wet and dry, and fire resistant. Under no circumstances shall asbestos or asbestoscontaining materials be used. Thermal insulation of pipe work and equipment shall comply
with the relevant recommendations of EN norm. All insulation material offered shall be in
accordance with Standard as applicable with regard to definition, physical characteristics
and tests.
Insulation materials shall be magnesia, calcium silicate, mineral wool or glass fibr e, but
other materials, particularly for low temperature applications, will be considered.
The insulation material must be approved by the Health and Safety Executive.
All insulation external to buildings shall be weather and waterproof. All insulated horizontal
flat surfaces shall be cambered to prevent the formation of puddles and to shed water
Mineral fibre
The insulant shall specifically meet the following requirements:

The insulation materials used shall be fireproof, with minimum dust release, and
approved by the Health and Safety Executive.
Non-combustible
Density 60 - 120 kg/m3
Thermal conductivity of 0.05 W/(mK) at 100C average temperature
Resistant structurally, to rot and to pests
Resistant to deformation in operating conditions and short-term moisture
penetration
Shall not cause any damage to the component material or coating
Bonding agents must withstand the expected stresses and shall not release any
materials when stressed under operating conditions.
High bio soluble fibres
Not classifiable as to carcinogenicity in humans
Length-Specific flow resistance > 40.000 kPa s /m

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Long fibre mineral or stone wool mats, quilted with wire mesh on one side, between 30 and
100 mm thick, are to be used. Galvanized steel wire mesh, with a maximum mesh size of
25 mm and a wire diameter of 0.7 mm. As an alternative, stainless steel wire can also be
used (at temperatures > 400C, stainless steel with a diameter of at least 0.5 mm must be
used)
Loose mineral wool may be used only if the use of mats or shaped parts is impossible for
technical reasons.
In exceptional justified cases the supplier can hand in deviating materials for approval.
In cases where the calculated space for insulation thickness cannot be net, special material
(e.g Microtherm) can be used and has to be notified for approval.
Mats must achieve their nominal thickness in accordance with VDI recommendation 2055
(UK: BS 5422) at a load per unit area of. 1 kN/m

2.2.3

Insulating layer thickness(es)

s* 50 mm or surface temp. < 250C

single layer

50 mm < s* 200 mm

two-part

s*

three and in multiple layers

> 200 mm

*thickness to be used if not specified in a different way in the typicals.

Exceptionally insulation of piping can be made in one lay to a maximal thickness of
100mm.
All insulation joints are to be staggered and any cavities between joints are to be filled with
a suitable material of similar composition to the main insulation.

2.2.4

Condensation and cooling insulation, chemical lines

As an alternative to mineral fibre, flame-resistant foam plastics can be used for
condensation and cooling insulations (test certificate required).
Chemically resistant and flame-resistant foam plastics shall be used (test certificate
required) piping of chemicals at risk of leakage.

2.2.5

Application of insulant
The insulant is to be stored and fitted dry. During mounting work, care must be taken that
no foreign matter gets into the insulant.
Up- and downstream of flanges, valves and other fittings, the insulation may be advanced
only up 200 mm before the flange and in case of weld on site flanges up to 300m before
the flange. Expansion joints, flaps, etc. are excluded. Here, insulation up to the flange must
be used, owing to the cooling bridges (= corrosion danger). See insulation examples under
chapter Fehler! Verweisquelle konnte nicht gefunden werden..
Reinforcement and / or ribs are to be provided with sufficient insulating layer thickness on
all sides to avoid the formation of heating/cooling bridges and in particular to prevent the
median dew point from not being reached.
Insulant is to be cut to size accordingly so that they sit firmly and seamlessly. Mineral fibre
mats are to be tied with galvanized binding wire or mat hooks (at temp > 400C stainless
steel wire has to be used) at impact points, so that these rest firmly against the wall. With
multi-layer designs, mineral fibre mats are to be placed with staggered joints.

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The insulating material on flat and large area has to be fixed with weldings pins. Pins
diameter must be at a minimum of 3 mm. For an insulation thickness of >240 mm, pins
diameter must be 4 mm.Each layer of insulating material has to be held with clips above the
pins.
The number of pins per square meter is set at min 6 qty/m2 on vertical surface and a
minimum 9 qty/m2 on overhead surfaces. This applies for wired mats.
Fixing of the studs by stud welding DIN EN ISO 14555 or hand welding.
Insulating material on round facility parts can be fixed with tensioning straps.
The insulant shall also not slip in case of vibrations, nor sag when placed horizontally, nor
bag when fitted vertically. This is also particularly applicable with objects that are subject to
vibrations, e.g. silos with vibrators.

2.2.6

Trace Heating
In the area of the electrical trace heating, aluminium foil is to be mounted on the trace
heating cables before installing the mineral fibre mat.

2.3

Substructures

2.3.1

All required fixtures are to be supplied and welded by the insulating company.
At components that require mandatory testing or which are coated, all necessary
fixtures are to be welded to the unit by the Supplier (in the factory). The Supplier of
the insulation has to provide the specifications required for the fixtures, carrying and
retaining structures in a timely manner.
All welded joints are to be cleaned and coated.
Thermal expansion of the unit, adequate horizontal and vertical expansion joints or
other appropriate measures shall be incorporated such that no distortions or
destruction can occur under operating conditions.

Material
For fixtures and carrying and retaining structures, in general "black" steel is to be used,
inclusive of corrosion protection in accordance with TII 16.4 "Corrosion Protection".
Usually the materials of the weld-on parts are the same sort of material, from which the
object is. E. g. on boiler walls made of 16Mo3 the webs of substructures should also be in
this material. If using galvanized material, the zinc in the weld zone is to be removed
properly before welding.

2.3.2

Processing and mounting of substructure

2.3.2.1 Piping, circular / round container

The appropriate size and position of the carrying and retaining structures for the
insulation must be co-ordinated by the Supplier / Sub-contractor.
Retaining structures are in principle required with pipes with DN100 and/or an
insulating layer thickness of >= 60 mm. This applies also to larger sizes. They must
be fitted at a distance of no more than 950 mm to ensure an identical insulating
layer thickness and circular form on all sides.
At elbows, adaptors and fittings, substructures are to be provided at the beginning
and end, and if necessary in-between.
Support rings are made of flat steel with at least 30 mm x 3 mm. The maximum
distance of the spacers/support rings has to be max up to 4 meters.

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The webs are to be tilted for approx. 10 mm over 90 (sharp edges are not
permitted).
Vertically placed tanks and vertical pipelines receive clamping rings at intervals of a
maximum of 3.8 m to prevent slipping of the insulation. The clamping rings must be
mounted exclusively with bolts. The material of the inner ring and the bolts should
be made of heat resistant material e.g. the same material from which the object is.
If the heat and cold insulation are built up from the pipe bracket, the metal sheet
jackets are to be placed on S-hooks (made of aluminium sheet strips) and provided
at suitable intervals with adequate sliding seams.
The bars consist of metallic spacers.
To minimize heat / cooling bridges, the substructure is to be designed in such a
way, that the thermal conduction to the cladding sheets will be minimized e.g. with
added intermediate layers of lower thermal conductivity material.

2.3.2.2 Plane surfaces

General:

It is not permitted to weld on pressure-retaining plant parts

Welding work only in agreement with the client and manufacturer of the object to be
insulated
Usage of the same type of material to weld bridges and brackets on to the object
walls

Execution of welding work:

Boundary conditions for welding: see also TII 16.09 Welding for steel structure &
metal sheet construction
Execution of welding work: see also TII 16.09 Welding for steel structure & metal
sheet construction

Welding technical finishing of corrosion protection:

Finishing of welding work: also see TII 16.04 Corrosion protection

Works for the corrosion protection in TII 16.04 Corrosion protection

2.4

Cladding

2.4.1

Material for Cladding and sheets

The sheet thickness which can be used is a minimum of 0.6 mm (or in accordance with
country-specific standards).

Aluminium plate, "stucco" surface.

If produced in trapezoidal sheet metal: Profile 40/183 AIMn1Mg0.5 stucco.

A. Pipes, round ducts and round surfaces:

Material: ALMg2Mn0.8
Form of plate: flat
Surface: Stucco embossed
Thicknesses:

Table 2: Sheet thickness Pipes

External diameter

Aluminium

DN 150

0.6

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Table 2: Sheet thickness Pipes

External diameter

Aluminium

> DN 150, DN 300

0.8

> DN 300, < DN 1200

1.0

> DN 1200

1.2

B. Larger plane surfaces:

Especially for the following plant components trapezoidal sheet must be used:

Boiler (including ash hoppers)

Distribution duct primary air
Primary air preheater
Fabric filter (including hoppers)
Semi-Dry reactor (without cone with venturi)
Flue gas ducts

Material

AlMn1Mg0,5

Form of plate

Trapezoidal, profile 40/183

Surface

Stucco embossed

Thickness

0.8 mm or 1,0 mm, depending from static conditions

C. Surfaces with complicated shape or small flat surfaces:

Especially:

Grate riddling lane 1-3 (zone 1-5)

Ram feeder riddling lane 1-3
Secondary air preheater with silencer
Material

AlMg2Mn0.8

Form of plate

flat

Surface

Stucco embossed

Thickness

0.8 mm or 1,0 mm (acoustic requirements)

Plates 0.5 m for flat, plain sheet surfaces must be diagonally folded.
D. Surfaces subject to be walked upon:
Cladding of exposed areas likely to be stepped upon shall be executed with thicker plates
to prevent damage here from.
Material

Al

Form of plate

flat

Surface

chequered plate (structure see picture)

Thickness

4-8 mm, depending to the required load

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Picture 1: Surface chequered

plate
E. Exception
At well-grounded reasons, exceptionally galvanized steel sheet processed in accordance
with AGIQ 03 can be used. However, this permission must explicitly be granted by HZI.

2.4.2

Handling and mounting of metal sheets

Metal sheet jackets are to be formed and beaded (longitudinal seams may have a
ridge as an exception). In external areas and when exposed to splashing,
longitudinal seams are to be beaded.
Joints are to be overlapped one to each other with at least 50 mm.
Overlaps are to be designed such that the seam openings are pointing downwards
as far as possible. Seam openings pointing upward are not allowed.
For outdoor installations and where wet cleaning is usual, longitudinal and
horizontal overlaps are to be arranged, if possible, facing away from the weather
Longitudinal seams are to be placed on horizontal lines approx. 45 below the pipe
axis, but offset by minimal 50 mm
Circumferential seams:
o Beading to beading connection can be used up to 200C.
o When over 200C girth welds have to overlap 50 mm. Girth welds have to
get a cover beading.
When outdoors:
o Sealing cord can be implemented into the deck beading. See paragraph 2.6.
o Piping with a slope: sheet metal cladding has to be overlapped in direction of
the slope (in the manner of roof tiles).
Horizontal areas need an inclination to avoid collecting of water. The inclination is
at least 3 %. In these cases, diagonal folding of smooth sheet is not allowed.
Thermal expansion at components must be possible with a suitable construction of
the cladding and / or the substructure to avoid damage.
Disks are to be placed in the bead at the ends of the sheet-metal jacket
(Aluminium). To avoid heating and cooling bridges, disks must not get in contact
with the component to be insulated.
All penetrations of the metal cladding, e.g. mountings, bearings, manholes,
measuring ports and the like are to be shaped cleanly and, if required, provided
with screens. For external installation and exposed to splashing, they shall be
provided with liquid deflectors and sealed.
With thermal expansion of the unit, adequate horizontal and vertical expansion
joints or other appropriate measures shall be incorporated such that no distortions
or destruction can occur under operating conditions.

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Fixing components

The materials to be used for fixing components: With aluminium sheet: Cr-Ni steel
at least quality A2
Fixed claddings are to be anchored with self-tapping screws 4.8 mm x 13 mm
Outdoors general technical certified facade fixing screws must be used. The facade
fixing screws have a diameter of 6.3 mm. The diameters of the sealing discs
depend on the plate thickness and on the (wind) loading. These can be 16 mm,
19 mm or 22 mm. Outdoors usually the sealing discs have an EPDM sealing.
The disc parameters to be used results from the certification of the facade screws.
The certificates depend on the manufacturer. So that certification specific facade
screws have to be looked at on a case by case basis.
It is not permitted to fix metal insulation sheets with non-removable fixing elements
(e.g. rivets)
Outdoors a differentiation must be made:
o Sheet metal on sub construction: screw connections with undoable facade
screws
o Sheet metal on sheet metal connections with aluminium sheets outdoors,
must be fixed with stainless steel screws 4.2 mm (broad head)
o For the facade screws 6.3 mm as well as for the sheet metal screws 4.8
sealing discs made of steel with an EPDM sealing have to be used.
o If aluminium sheets with moisture admission are used and vibrations are
expected, screws with steel washers with EPDM-sealing are to be used.

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Trapezoidal sheet metal:

Fastening trapezoidal sheet metal on sub construction
In the even wall surfaces without high suction load; every second low bead
screwed
In the edge and corner areas of the even wall surfaces up to 3 m away
from the edges / corners and in general on round objects. Every low bead
is screwed.
Longitudinal welds of trapezoidal sheet metal among each other: 3 screws
/ rivets per meter weld. The trapezoidal sheet metal is around the weld
area sharply edged and therefore stiffened.

Multipart caps, and those provided for maintenance and control purposes are to be
fitted with lever closures (fastener). Reinforcement sheets are to be attached to the
inner side of the cover to avoid peeling. Unless this is not feasible technically,
clamping straps with lever closures can also be used.
Sheets must not be bolted to fittings and flange connections.

Seals

2.7

Hitachi Zosen Inova AG

Number of screws / rivets:

Sheet metal seams:

At the minimum 6 screws / rivets per meter of seam

2.6

50021973 -0.0

In external areas and where exposed to splashing, metal sheets with steel and with
EPDM-sealing are to be used.
In external areas and where exposed to splashing penetrations of the cover/sheet
(e.g. at suspension points) are to be sealed against the effect of snow and rain with
materials which remain flexible.
The sealant may not be foamed with CFC.

Penetrations
Penetrations of the outer casing, such as consoles, drive units and level probes are to be
cut out cleanly and fitted with easily removable smooth sheet metal rosettes. Here it is to be
noted that the aluminium sheet does not rest directly on the steel (film spacer).
The cladding has to overlap the thermal insulation of the console bracket by at least 100
mm. The design must avoid the formation of cooling bridges.

2.8

Special parts
All components have to be insulated with a sheet metal cover in the proper form.
Considering the requirement it may be necessary to design these sheet metal covers multi
parted. Insulation of all special parts must be removable and easily replaceable.

2.8.1

Elbows, shaped parts

Elbows, branches etc. are to be made of narrow segments, each of the same wideness.

2.8.2

Fitting, ports and similar

Before and after valves and fittings, the step of the insulating diameter has to be
closed by end plates.
Hoods are to be provided at fittings, flanges, expansion joints, measuring and drain
pipes etc.

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2.8.3

Hitachi Zosen Inova AG

If measuring ports are within the insulation, these are to be set in with sheet metal
funnels. Measuring ports in exhaust gas systems are excluded; see insulation
examples in chapter Fehler! Verweisquelle konnte nicht gefunden werden..
For the insulation of all fittings, two or multipart removable caps are to be provided.
The disconnection must be at the drive spindle.

Tanks

2.8.4

50021973 -0.0

The curved tank bottom is to be covered with the "Zeppelin cut".

The insulation is to be designed such that the bolts of the connecting flange union
can be pulled out to their full length.

Contact protection for flaps

Flaps are fitted with an easily removable contact protection made of perforated sheet over
the drive unit and linkage, in accordance with guidelines for safety in the workplace.

2.8.5

Accessible insulating casings

2.9

Removable caps

2.9.1

Accessible insulating linings are to be provided with anti-slip metal sheets

(chequered plates).
The sub-construction is to be adapted to a load of 3.0 kN/m.
The supporting and framework structures as well as their anchors and fastenings
must be dimensioned in accordance with the static requirements. In addition to
the dead loads, for the designing of walkable insulation, the traffic loads specified
by HZI plus a supplement of 0.5 kN/m for suspended loads must be applied.
Individual loads must be separately taken into account.
In special repair zones and in areas where heavy machine parts etc. are moved,
the corresponding traffic load will be specified by HZI (5.0 kN/m).

All components receive caps, such as:

Manholes, inspection openings, expansion joints, flange, measuring ports, knocking
anvils, mounting eyes, stuffing boxes for shaft bearings, etc.

Design
The mat positions in the caps and under the covers must form a closed lagging to the
housing insulation. Counter bearing on flaps do not have to be provided with a removable
cap.

2.9.2

Manholes, inspection openings

Caps for the manholes are to be closed with stainless-steel lever closures. The lever
closures, at least 75 mm long, have yokes and hooks, are self-locking and adjustable. The
caps are to be provided with two handles. Heavy caps have to be provided with sufficient
closures, so they will not tear out easily.
The sub-constructions of the door caps are to be designed as frames with insert and
attached mineral fibre mats and an internal cover (e.g. perforated plate).. Maximum weight
25 kg, otherwise use two parts. In manhole areas, the insulation has to be closed with a
metal bulkhead, so that no residual substance, flue gas or moisture can penetrate (see also
insulation example in chapter Fehler! Verweisquelle konnte nicht gefunden werden.). In
the vicinity of the entrances to manholes, the housing insulation is to be supported and
reinforced in such a way that it can withstand persons stepping in and out without being
distorted.

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Expansion joints
At the Expansion joints, the caps are to be designed such that the movements of the
expansion joints are not impaired. Contact with sharp-edged or pointed trim plates must be
excluded in any case. The mobility of the expansion joints must remain guaranteed, even
with bracket and length variations due to thermal expansions. At the expansion points, care
must be taken to ensure that no distortions or destruction can result (see also insulation
example in chapter 5).

2.9.4

Measuring ports

Measuring ports without measuring instruments are to be designed with removable

caps.
With pressure measuring ports with metering line (Venturi measurement) the
measuring line is to be insulated to at least 1 m.
For measuring instruments, there must be adequate space in the cap for the
insulation.
For measurements, the cover is to be designed in two parts for easy removal of the
measuring device, (see also insulation example in chapter Fehler! Verweisquelle
konnte nicht gefunden werden.)

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Secondary measures for sound reduction

3.1

Solid borne sound

Hitachi Zosen Inova AG

As a priority, the occurrence of sound emissions should be avoided with appropriate

primary measures, e.g. suitable designs and material selection, optimized flow conditions
etc. Otherwise secondary measures are to be provided to reduce solid-borne sound
and/or airborne sound emissions to comply with the stated permissible sound pressure
level.
The secondary measures are to be arranged as near as possible to the noise source.
Components that create vibrations during operation or, owing to their function are subject to
shock and impact forces, are to be decoupled for the avoidance of sound transmissions to
adjacent construction and system components, as well as to the environment, by suitable
insulation and damping elements sound-engineered such that oscillations will not be
transferred to any noticeable extent.
All connections of components to other systems are to be designed force- and moment-free.
This applies in particular to pipes and ducts. The building foundations and/or individual pipe
connections which can be coordinated are exceptions.
If no sound protection measures are prescribed separately or are suggested by
the Supplier / Sub-contractor, the following measures according to the requirements are to
be chosen for solid-borne sound reduction:

3.2

Standardized shock absorbers, e.g. as compound system (metal/rubber or

plastic/metal), for mounting on the building or on frame constructions.
Vibration absorber systems
Rubber or plastic spacers between the component and its support, provided that
the occurring forces are permitting this (e.g. pipe lines, ducts).
If needed, a spacer is also to be foreseen between mounting element (anchor bolts,
bolts, possibly fixing pins) and console plate.
Rubber or plastic spacers at protecting sheets and retention tanks which are
exposed to vibrations.
Expansion joints between aggregate and pipes or ducts.
Decoupling of pipes and ducts with the use of flexible wall and ceiling grommets.
Sound absorbing packing/stuffing, bulky masses or composite sheets with a
dissipation factor as high as possible.

Airborne sound
If no sound protection measures are prescribed separately or are suggested by the Supplier
/ Sub-contractor, the following measures according to the requirement are to be chosen for
airborne sound reduction:

Prefabricated silencers on the suction side and/or pressure side of gas and
vaporous mediums.
Sound insulation of the component with mineral fibre.
Sound absorbing enclosure (cabin), if a silencer or noise insulation of the
component is insufficient or the sound absorbing enclosure (cabin) by its own is
more practical than other sound insulation measures.
Closing of wall and ceiling penetrations of ducts with insulating material and/or
sheets, where required in combination with fire retarding sealing.

Care to sufficient heat dissipation is to be taken at sound insulations with directly applied
mineral fibres and sound absorbing enclosures.
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Hitachi Zosen Inova AG

Sound protection enclosures

The material of the frame construction and the sheet metal casing is to be designed in
galvanized steel with suitable corrosion protection in accordance with TII 16.04 "Corrosion
Protection". The material of the sheet metal casing is to be designed in accordance with the
required sound absorption and chapter 2.4. Usually for sound insulations heavier steel
sheets will be used - or aluminium sheets weighted with an added sound absorbing coating.
For the necessary inspection and maintenance, the sound absorbing enclosure must be
easily accessible or easily removable. In the accessible part of the sound protection
enclosure the insulation has to be protected outside with sheet metals and inside with
perforated sheets. If there is any danger that combustible components (e.g. oil) may
penetrate, suitable preventive measures are to be taken.

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Quality assurance

4.1

Insulation inspection

50021973 -0.0

Hitachi Zosen Inova AG

At HZI's request, the Supplier / Sub-contractor shall check compliance of the surface
temperature during the plants operation by random temperature measurements, as
evidence of the quality of the insulation.
IMPORTANT REMARK
Insulation of process equipments will be done without any cold bridges as far as technically
possible in order to avoid any corrosion risk. Check of these insulated surfaces will be done
by infrared cameras borne by the final customer SITA after the hot commissioning. The
supplier must be present.

4.2

Sound inspections
Based on a noise expertise HZI can carry out random checks and assessments of the
installed components.

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Hitachi Zosen Inova AG

Insulation examples
See in the appendix the following insulation examples:
Insulation Type

Drawing No

Measuring port with and without measuring instrument insulation principle

10117701

Insulation distance to platform (page 3/4)

10135355

Profile-hollow (page 4/4)

10135355

connection to steel structure

10138683

Fastening pins for insulation

10139093

Expansion joint insulation principle for gas temperature > 200 C

10140312

Expansion joint insulation principle for gas temperature < 200 C

10140314

Insulation P+T-Studs long

10140315

Manhole and openings

10140319

Insulation Doors

10140463

injection lance reflux CFB reactor

10140465

Insulation manhole and opening at the boiler

20002548

Insulation of bigger areas like boiler- and other walls incl. sealing

20002394

Insulation Typicals Filter 2006C

40012602

Ducts-Flange Connection

40013695

Recirculation Hopper

40012604

Remark: This list might be extended with further typicals during the project.

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