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Table of
o conten
nts
1

General

1.1
1.2
1.3
1.4
1.5

Definition
ns and abb
breviations
Purpose
Applicabiility
Regulatio
ons, standa
ards and g
guidelines
Design and enginee
ering

4
4
4
4
4

Subdivis
sion of duc
cts

2.1
2.2

Air and flue gas rec

circulation p
pipes
Flue gas ducts

6
6

Ducts in steel

3.1
3.2
3.3
3.4
3.5
3.6
3.7

Materialss and sheett metal thicckness

Air and flue gas rec
circulation p
pipes
Flue gas ducts
Reinforce
ements and
d ribbings of rectangular ducts
Flanges
Gaskets
Welding quality
q

7
7
7
7
7
8
8

Ducts in plastic material

m

4.1

Exhaust vapours
v
pipes

Built-in elements
e
and
a consttructions for
f pipes / ducts of steel / pla
astic mate
erial
10

5.1
5.2
5.3
5.4
5.5
5.6

Expansio
on joints
Flaps
Silencer baffles
b
Baffle pla
ate
Fitting pie
eces
Manholess and inspe
ection ope
enings

10
10
10
10
10
10

5.6.1
5.6.2
5.6.3

General
Arrangeme
ent of manho
oles and insp
pection openings
Constructio
on guidelines
s

10
10
11

5.7
5.8
5.9
5.10
5.11
5.12

Measurin
ng ports
Measurin
ng length
Data sheets for elem
ments
Fastenerss
Earthing, equipoten
ntial bondin
ng
Insulation
n

11
11
11
11
12
12

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Fastenin
ng constru
uctions

13

6.1

Steel stru
ucture, sup
pports and suspensio
ons

13

6.1.1
6.1.2

Supports
Suspension
ns

13
13

6.2
6.3

Fastenerss
Bracing structures
s

13
13

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Genera
al

1.1

Definitions and abbrevia

ations

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Table 1: Definitions and abbrevviations

1.2

Abbrevia
ation

De
efinition

HZI

Hiitachi Zosen Inova AG

Supplier

Su
ub-contracto
or of HZI

Sub-conttractor

Su
uppliers of ap
pparatus and plant comp
ponents whoo are not sup
ppliers to HZI

TII

HZ
ZI Technical Implementa
ation Instruction

LV

Go
oods and se rvices sched
dule

DIN

Ge
erman Institu
ute for Stand
dards

DIN EN ISO

Eu
uropean Stan
ndards base
ed on DIN Sta
andards

Te
emperature i n C

Purpose
With this Technical Implementa
ation Instruction (TII) the
t
design of air pipe
es and flue gas
ducts shall be standa
ardised; thi s TII applie
es to all tec
chnical unitss, which are
e operated with
under pressure or with low ove r-pressure. This TII do
oes not appply to building servicess air
ducts.

1.3

Applica
ability
This TII shall be obs
served by a
all Sub-conttractors to Hitachi
H
Zossen Inova AG
A and its SubS
contractorrs when sup
pplying good
ds and serv
vices.

1.4

Regulattions, sta
andards and guidelines
All relevan
nt British an
nd European
n regulation
ns, standard
ds and guid elines mustt be applied
d.

1.5

Design and eng

gineering
g
The follow
wing regulations and re
ecommenda
ations have to be consi dered:

Fo
or ducts pos
sitioned outtside of buildings, the calculations
c
s of the wind
d loads musst be
made accord
ding to DIN EN 1991-1
1-1. For rec
ctangular duucts, a sno
ow load is to be
ad
dditionally considered
c
a
according to
o the British
h Standard.
Arrrangementt of expan
nsion joints
s and fixtures: the thhermal exp
pansions of
o all
co
omponents are to be co
onsidered
ducts and built-in
Th
he dimensio
ons of the d
b
elem
ments are to be selectted so that flow
ve
elocities are
e of
15
5 m/s (load point 1, 100
0%) for air pipes
p
and wet
w flue gass ducts,
17
7-18 m/s (lo
oad point 1
1, 100%) fo
or flue gas recirculatioon pipes an
nd dry flue gas
du
ucts,

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an
nd so that flow detachm
ments can be avoided (higher floow velocities
s are allowe
ed in
byypass pipes
s/ducts and
d primary air zone/elem
ment air pippes). Diffuse
ers shall no
ot be
placed directly before an
nd/or after rectangular
r
elbows.
If drainages in steel pip
pes/ducts (grading
(
of horizontal pipe) are inevitable, they
must be electrically heatted (preven
ntion of cold bridges). W
With GRP ducts,
d
draina
ages
in a sufficientt number an
nd at the de
eepest pointts are to be provided.

es and ductts are laid next to eac

ch other orr one abovee the otherr, the distan
nces
If pipeline
between them shall be
b sufficienttly. It should
d be paid atttention to thhe following
g points:

It must be po
ossible to pe
erform subs
sequent ass
sembly workks to a grea
at extent witthout
hindrance an
nd without d ismounting of other du
ucts or duct parts.
Fittings, mea
asuring portts and flaps
s shall be easily
e
accesssible, controllable from
m all
sid
des and operable witho
out restrictions.
It must be po
ossible to m ount and re
emove insulating materrials without hindrance.
Flange conne
ections sha ll be located
d staggered
d.
Ex
xpansion joints are to b
be accessib
ble to the grreatest exteent possible.
Das sind
s
Sachen
n die unsere
e Planer ma
achen mss
sen.
Where the
e ducts are
e passing w
walls, they shall
s
be con
nstructed w
with bushing
gs and slee
eves,
and shall be enclosed
d to seal ag
gainst dust and water. Fire insulattion shall be
e in accorda
ance
with requirrements fro
om the autho
orities.

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Subdiv
vision of
o ducts
s

2.1

Air and flue gas

s recirculation pipes

2.2

Hitachi Zosen
Z
Inova AG

Prrimary air fo
or temperatu
ures up to 250
2 C
Se
econdary air for tempe
eratures up to 100 C, in case of m
malfunction up to 400 C
Siidewall air for
f temperattures up to 100 C
Flue gas recirculation fo
or temperattures up to 300 C, in case of ma
alfunction up
u to
40
00 C
Va
arious burner pipes forr temperatures up to 80
0 C
Se
ealing air piipes for tem
mperatures up
u to 170 C
C
Exxhaust vapo
our ducts fo
or temperatu
ures up to 80
8 C

Flue ga
as ducts

Flue gas duc

cts for tempe
eratures fro
om 120 C to
o 300 C
Flue gas duc
cts for tempe
eratures 120
1 C
Flue gas duc
cts for tempe
eratures 300
3 C

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Ducts in steell

3.1

Materia
als and sheet mettal thickn
ness

Hitachi Zosen
Z
Inova AG

Materials of fitting gaskets,

g
exxpansion jo
oints and gasket
g
mateerials of fla
anges mayy not
consist of materials containing
c
a
asbestos or other mate
erials requiriing marking
g. The mate
erials
must be heat- and ag
ge-resistantt and suitable for the re
equired tem peratures.
Upon requ
uest of HZI, the supplie
er must sub
bmit a certificate of the material.

3.2

Air and flue gas

s recirculation pipes
Table 2: Material Airr and flue g as recircula
ation pipes
Tempera
ature

Material (miinimum qua

ality)

< 300 C,
in a malfu
unction brieflly to 400 C

S235 JR

The plate thickness (according tto DIN EN 10029,

1
class
s "B"), indeppendent of the diamete
er, is
generally:

3.3

fo
or air pipes 4 mm
fo
or flue gas pipes
p
5 mm

Flue ga
as ducts
Table 3: Material Airr and flue g as recircula
ation pipes
Tempera
ature

Material (miinimum qua

ality)

120 C
C

See chapterr Fehler! Verrweisquelle

konnte nich
ht gefunden werden.

120 C

See chapterr Fehler! Verrweisquelle

konnte nich
ht gefunden werden.

300 C,
in a malfu
unction brieflly to 400 C

S235 JR G22

> 300 C

P265 GH

The plate thickness (according

(
tto DIN EN 10029, clas
ss "B") of fluue gas duc
cts, indepen
ndent
of the diam
meter, is 5 mm or morre. These requirement
r
ts are not too be applie
ed to rubberrised
flue gas ducts.

3.4

Reinforrcements
s and rib
bbings off rectang
gular duc
cts
Rectangullar ducts must
m
be p
provided with ribs forr reinforcem
ment. The material must
m
correspon
nd to that of the duct.

3.5

Flanges
s
For the de
esign please
e note that:

Th
he flanges are to be d
designed ac
ccording to the HZI flannge table (u
uniformly fo
or air
an
nd flue gas pipes)
Th
he duct con
nnection fla
ange is to be
b adapted to the flangge design of
o the apparratus
orr componen
nt.

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Gaskets
s
Table 4: Gaskets
Product

Temperrature rang
ge of
applicattion

Material

Poten
ntial supplierr

Universal PTFE
gasket ta
ape

max. +2
270 C

Mono-directionaal
orie
ented PTFE

Aspag
g AG
8152 Glattbrugg;
G
Angst+
+Pfister
8050 Zurich
Z

Graphite flat gaskets

with high-grade steel
foil

max. +4
450 C

Purre graphite
pre
essed

Aspag
g AG
8152 Glattbrugg;
G
Angst+
+Pfister
8050 Zurich
Z

The gaske
et must be selected a
according to
o the temp
perature rannge of the application and
must be documented
d on data sh
heets.

3.7

Welding
g quality
y
Air-tight or gas-tight design
d
requ
uired. Welding seams of air/flue ggas recircula
ation pipes,, flue
gas ducts or suspens
sions/suppo
orts must ha
ave the follo
owing weldinng quality:

BS
S EN ISO 5817,
5
class "C"

s
whic
ch must pe rform a sub
bordinated function
f
(foor example duct stiffeners),
Welding seams,
can only be
b carried out accordin
ng to welding
g quality cla
ass D.

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Ducts in plasttic mate

erial
Ducts in plastic
p
material are to b
be used as follows:
f

4.1

Exhaus
st vapourrs pipes
Table 5: Material Ex
xhaust vapo
ours pipes
Tempera
ature

Material (miinimum qua

ality)

< 80C
C

Polypropylenne (PP)

Material th
hickness for PP is to b
be specified
d by the ma
anufacturerr and shall however no
ot be
less than 6 mm.
The PP manufacture
m
ers regulatiions are to be followe
ed for the pproduction, installation and
use of gasskets.

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Built-in
n eleme
ents an
nd cons
structions for pipes / ducts of
steel / plastic materia
al

5.1

Expans
sion jointts
Normally expansion joints are to be designed in su
uch a way that they can
c
adjust to a
maximum of 10% axial and a m
maximum off 5% in radial directionn regarding height. If la
arger
expansion
ns are to be absorb
bed, the expansion
e
joints
j
mustt be pre-s
stressed du
uring
installation
n (note on drawing
d
req uired, indic
cation of pre
e-stress meaasurements
s).

5.2

Flaps
The dimen
nsions of the flaps (flan
nges, cleara
ances) must corresponnd to the HZ
ZI -flange ta
able.

5.3

Silence
er baffles
s
It must be
e possible to
o dismount tthe silencerr baffles thro
ough the duuct opening
gs provided for it.
Depending
g upon sp
pace cond itions, the whole silencer can also be dismantled
d for
dismounting the baffles.

5.4

Baffle plate
p
In rectang
gular duct elbows, b
baffle plates
s or guide
e vanes arre always to be insta
alled
(exception
n: flue gas bypass du
ucts). To avoid
a
turbulent flows, guiding plates are to
o be
provided also
a
in straig
ght duct secctions, if req
quired.

5.5

Fitting pieces
p
At the pip
pes and duc
cts, fitting p
pieces are to
t be provid
ded at apprropriate points, with which
w
dimension
n deviations
s from build ing parts and components can bee compensa
ated. The fiitting
pieces havve to be ide
entifiable on
n the execution drawings (fasteneed angle pro
ofiles, accorrding
to flange table).
t

5.6

Manholles and inspectio

on openings

5.6.1

General
For inspecction, repairr and replaccing of built--in parts, the ducts muust be provid
ded with access
openings. The openiings are to be arranged in such a way thaat they are located nexxt to
platforms so that the
e work can
n be performed safely
y. Neverthelless, if there is dange
er of
falling dow
wn, specially
y designed fastening spots
s
are to be provideed for hangin
ng up a seccurity
line for pe
ersonal safety. In additi on, a dange
er sign shall be installeed that points to the danger
of falling down.
d
The positiion of the manholes
m
iss to be defined in the inspection concept. Fo
or maintena
ance
work/repairs, e.g. at flaps
f
and s lide valves,, the manho
oles must bbe installed in the proximity
of these components.

5.6.2

Arrangem
ment of manholes
m
a
and inspec
ction open
nings
With the fo
ollowing ins
stallation co
omponents, manholes are
a absoluteely required
d:

Be
efore and after silence r or in the frront side of the casing
Be
efore and after air pre--heater
Be
efore or afte
er flaps in th
he recircula
ation pipes and
a flue gass ducts
Du
uct burner

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Ba
ag filter
Be
efore and after the eco
onomiser
Ru
ubberised flue
f
gas duccts (e.g. for checking ru
ubberising)
Fo
or cleaning purposes in
n horizontall pipes and duct sectioons
An
n inspection
n and clean
ning opening
g is to be fo
oreseen at tthe collecto
ors at the en
nd of
prrimary/secondary air piipes and flu
ue gas recirc
culation pippes.

Construc
ction guid
delines
ER 2.38. Visit
V
Doors
The minim
mum size fo
or the visit d
doors (except if otherw
wise specifieed) will be 600
6 x 600 mm
m x
mm or equ
uivalent surrface for parrts under prressure.
Visit doorrs in hoppe
ers shall b
be vertical, equipped with a defflector. The
e length off the
horizontal part will ex
xceed the ra
adius of the cone of pro
oduct due too natural slo
ope
n openings smaller tha
an DN 500 are
a to be ex
xecuted acccording to British
B
Standard
Inspection
(without slewing mec
chanism), a ccess open
nings largerr or equal D
DN 500 are to be execcuted
with latera
ally opening
g slewing me
echanism according
a
to
o British Staandard.
The dimen
nsions of the access op
pening shall be as spe
ecified below
w:

Bo
ottom of the
e access op
pening max.. 500 mm over the foottstep level
Ro
ound acces
ss openingss always witth 800 mm
m (howeverr at least with 500 mm)
m
Re
ectangular access ope
enings at le
east 600 mm
m wide andd with minim
mum area of 0.5
m2

ensions abo
ove cannot be attained
d, the acces
ss openingss are to be designed
d
for the
If the dime
greatest possible
p
dim
mensions. T
The minimum dimensio
on must nott be smaller than indiccated
in British Standard.
S

5.7

Measurring ports
s
The meassuring ports
s are to be placed acc
cording to th
he indicatioons on the P&ID. The type
and positio
on of the measuring po
orts is spec
cified by HZII.
In particular it is to be noted tha
at emission measuring ports can be position
ned later, du
ue to
their requiired release
e by the autthorising ag
gencies which is expeccted to occu
ur only at a later
time.

5.8

Measurring length
When dettermining th
he lengths a
and design
n of measurring sectionn, the specifications off the
measuring
g instrumen
nt manufactturers are to
t be follow
wed. Accesss to the measuring po
oints
must be unhindered and
a safely a
accessible.

5.9

Data sh
heets for elementts
Definite dimensions sheets
s
musst be available for all componentss that are to
o be built into or
onto the duct.
d

5.10

Fastene
ers
The materrials of the fastening e
elements (screws, nuts
s, plain wasshers, retain
ning rings/ssheet
metals etcc.) must be as follows: => projekts
spezifisch anzupassen

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Within the
e range * "C
C1", "C2" an d "C3":

galvanis
sed steel, aat steel strructure hot dip
galvanis
sed

Within the
e range * "C
C4", "C5-I / C
C5-M":

steel black with coorrosion protection / CRC

Ni-Mo-s
steel qualityy A4

* see TII 16.04

1
Fastening elements at
a the same
e connectio
on are to be
e carried ou t in the sam
me material and
with the sa
ame surface
e quality.

5.11

Earthing, equipotential bonding

g
With pipe and/or duc
cts for comb
bustible liqu
uids or gase
es, an earthhing lug is to be place
ed at
each flang
ge. Each fla
ange screw
w is to be by
ypassed with a flexiblee copper ca
able. Each pipe
and/or eacch duct is to
o be conneccted at leas
st once with the main eearthing system.
The execu
ution and arrangemen
a
nt of earth plates, equ
uipotential bbonding cab
bles (PAK) and
earthing cables
c
(EC) must be do
one so that an equipote
ential bondi ng and a co
onnection to
o the
foundation
n earthing system
s
are cconstantly available.
a
When carrrying out the PAK an
nd EC, it should be noted
n
that tthe conducting connecction
cannot be
e impaired by corrosio
on. The bolt connectio
ons at flangges are nott to be used as
connection for equipo
otential bon
nding, due to
t the risk of
o corrosionn or owing to existing nonconducting
g anti-corro
osion coatin gs.
PAK and EC
E are to be provided as follows:
PAK at duct sectio
on connectiions (e.g. fla
anges, expa
ansion jointts)
PAK at
a connecttions (e.g. flanges, expansion
e
joints) bettween ductt sections and
equipm
ment.
EC from ducts dirrectly to earrthing lugs or
o to the sup
pport or steeel structure
e.
When con
nnecting an
n EC to sup
pports or to
o a steel strructure provvided by a third party, the
supplier/sub-contracttor must che
eck whethe
er a connecttion to the ffoundation earthing
e
sysstem
exists.
The arrangement of the
t earthing
g plates is to
t be indica
ated to HZI in a timely manner so
o that
the necessary earthin
ng lugs can be included in the com
mponent.

5.12

Insulatiion
The required insulatiion of the d
ducts is to be carried out accordding to TII 16.05 "The
ermal
Sound inssulation.
All flue ga
as ducts must be equip ed with insu
ulation pins.

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Fasten
ning con
nstructiions

6.1

Steel sttructure, supportts and su

uspensio
ons

Hitachi Zosen
Z
Inova AG

The design must basically corresspond to TII 16.3 Stee

el structuress.
ote:
Please no

6.1.1

Po
ossible add
ditional load
ds due to deposits
d
of dust and aashes are to be taken into
acccount for the flue gass ducts of th
he raw flue gases. Forr the calcula
ation, it is to
t be
asssumed that the free d uct cross se
ection is red
duced up too 30% by de
eposits and
d that
the deposits will
w have a density of 500
5 kg/m3.
Th
he deflectio
on of the fo
orces mustt be so tha
at overstresssing canno
ot result att the
fastening spo
ots, pipeline
es and the connected
c
componentts. In particu
ular, no harrmful
efffects shall occur
o
at the
e pipe walls.
A mounting and
a supportt or suspens
sion is not permitted
p
att the following points:
insulated parts
a cover ssheets
gratings and
W
When
carryin
ng out pipe//duct fix mo
ounting, hea
at bridges aare to be av
voided (the
ermal
se
eparation plates require
ed).
Su
uitable supports and ssuspensions are to be
e provided for all com
mponents, which
w
arre built into or between
n the ducts (e.g.
(
duct burners, silenncers etc.).

Supports
s
In additio
on to the steel
s
profile
es indicate
ed in TII 16.3 Steel structures, standard
dised
supporting
g and/or sus
staining ele
ements (also
o hot dip ga
alvanised orr similar) can be used.
The pipe or duct sec
ctions betwe
een two expansion join
nts must bee supported
d in such a way
that one bearing point
p
is laiid out as a fixed bearing
b
andd the othe
ers as floa
ating
bearings/ffriction bearrings. The flloating bearrings are us
sed to absoorb the therm
mal expansiions.
Sliding and fixed poin
nt constructtions are ca
arried out with all bracinngs and sto
oppers and shall
be fastene
ed permane
ently.
Suitable materials
m
or coatings arre to be use
ed for friction surfaces.

6.1.2

Suspens
sions
spring suspensions are to
To suspen
nd pipes an
nd ducts, wh
hich underg
go vertical expansions,
e
be used. They
T
are to be selected
d uniformly throughoutt the entire pplant.
Spring susspensions which
w
are sstate-of-the--art are to be used. Sp ring suspen
nsions are to
t be
provided as a close
ed design. The spring
gs are to be
b fed into the pot so
o that theyy are
frictionlesss as much as possible
e. A scale must
m
be atttached to thhe spring pot
p to adjust the
load.

6.2

Fastene
ers
Desig
gn according
g to TII 16.3
3 " Steel strructures"

6.3

Bracing
g structu
ures
Desig
gn according
g to TII 16.3
3 " Steel strructures"

Print date 13.09.13 13:11

La
ast saved 13.09.13

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