FIELD OF THE INVENTION
Present invention relates to providing insulations for steam generators for
thermal power plants. More particularly, present invention is related to layout
of penthouse for steam generators having external insulations.
BACKGROUND 5 OF THE INVENTION
Background description includes information that may be helpful in
understanding the present subject matter.
Penthouses are built at top of tower. Boilers having pent house as structural
enclosure situated at top of them enclosing boiler roof, headers, risers, links
10 and coils which are present above roof of the boiler. Purposely a pent house
insulates these components using single enclosure. Effectively penthouse can
be considered as an insulated hot room with dimensions of the order
45mX25mX8m (Lx B X H) which encloses various high temperature boiler
pressure parts situated above roof. Thickness of insulation may vary based on
15 the design parameters and the same is supplied in multiple layers as per
commercial availability.
Penthouse insulation then becomes an important task in penthouse
construction. Penthouse insulation using wool has been discussed in prior arts.
The penthouses were insulated from inside using wool mattresses type
20 insulation. The ceiling of penthouse need to be insulated in overhead position.
Due to flexible nature of wool mattresses and need for handling high insulation
load in overhead position, insulating this part of penthouses become very
cumbersome and time consuming. Also, there are huge numbers of support
hanger rods penetrating the penthouse ceiling, making the insulation job even
25 more difficult. Such kind of layout required to form scaffolding platform to
access ceiling of penthouse, which was time consuming as well as resource
3
consuming. Additionally, rectification jobs at penthouse ceiling required longer
shutdown period and also there was risk of exposure of insulation with
steam/water due to tube failures or due to deposition of fly-ash on insulation
pertaining to various reasons. This direct exposure may result in
damage/sagging of insulation resulting in heat leakages, 5 which eventually
degrade performance level of boilers at high temperature and pressure. There
is no such penthouse model available in the market to provide at such high
level insulation.
Therefore, there is need of penthouses’ layout which are leak proof and could
10 work equally well even at high temperature.
OBJECT OF THE INVENTION
It is therefore an object of the present invention to solve the aforementioned
and other drawbacks existing in conventional penthouse layout.
It is primary object of the present invention to provide a method for insulation
15 of pent house built at top of boilers.
It is yet another object of the present invention that the penthouse insulation
should be fixed firmly with ease of erection.
It is still another object of the invention to provide an insulation layout which
do not get dislodged or peeled off during normal boiler operations.
20 It is yet another object of the invention to protect insulation wool of the
penthouse at tube failures inside the pent house.
It is still another object of the invention to provide an effective heat
conservation method.
4
These and other objects of the present invention will be apparent to those
skilled in the art after a consideration of the detailed description taken in
conjunction with the accompanying drawings in which a preferred form of the
present invention is illustrated.
SUMMARY 5 OF THE INVENTION
The present invention is therefore intended to solve one or more of the above
problems by providing a penthouse insulation layout with new material
specification and arrangements.
The method for insulation boiler penthouse comprising steps of:
10 insulating structural parts of the penthouse with insulation wool, characterized
in that a Resin bonded wool mattress used in the insulation for heat loss
prevention; fixing the insulation wool with the help of insulation fixing pin;
impaling said woolen mattress upon said insulation fixing pin, and welding
retainers to retain the wool.
15 Referring to the embodiments, an insulation is installed on a deck plates with
the help of insulation pin and retainers, wherein the deck plates are supported
between two inverted Tee beams, wherein the two Tee beams are connected
by bolting support plates on it. The inverted tee beams supported with hanger
angles and having provision for expansion such as gap or slot holes. Then
20 covering the said insulation by a carbon steel cover sheet placed over a support
angle.
Referring to another embodiment, a thermal barrier ceramic gasket is provided
between inverted tee beam and a hanger angles. Connecting said inverted
beam and said hanger angles by a nut, a bolt and a washer. Further,
25 connecting said inverted Tee beams, said peripheral beam with the help of
5
support plates. The vertical wall insulation is done with stainless steel cover
sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
The illustrated embodiments of the subject matter will be best understood by
reference to the drawings, wherein like parts are designated 5 by like numerals
throughout. The following description is intended only by way of example, and
simply illustrates certain selected embodiments of apparatus that are
consistent with the subject matter as claimed herein.
Figure 1 illustrates the Overall structural arrangement for New penthouse
10 insulation.
Figure 2 illustrates the cross sectional view of structural arrangement for New
Penthouse Roof insulation.
Figure 3 illustrates typical connection of Tee section for New penthouse roof
insulation.
15 DETAIL DESCRIPTION OF THE INVENTION
While the embodiments of the disclosure are subject to various modifications
and alternative forms, specific embodiment thereof have been shown by way
of example in the figures and will be described below. It should be understood,
however, that it is not intended to limit the disclosure to the particular forms
20 disclosed, but on the contrary, the disclosure is to cover all modifications,
equivalents, and alternative falling within the scope of the disclosure.
The penthouse insulation design consists of insulation design as well as
structural design as described herein.
25
6
Insulation Design
Insulation materials have lower thermal conductivity and they are poor
conductors of heat. Generally, insulations are applied in those areas for
preventing heat losses, for example- furnace, ducts etc. For such purposes
Resin bonded wool mattress for insulation are used 5 in furnace area. The
insulation can be applied on any type of surfaces like plain surface or some
complicated surface, with the help of insulation fixing pin. The wool mattress
is impaled on the insulation fixing pin and retainers are welded to retain the
wool. In penthouse insulation design insulation fixing pins are welded on deck
10 plate. Wool mattress is impaled on it and retained by retainers.
Structural Design
The structural design of penthouse can be further divided in to two parts viz.
a) vertical wall & b) the roof.
The vertical wall of penthouse is made up of steel structure. Skelton of the wall
15 is supported by beams, upon these beams corrugated sheets are placed. On
the corrugated sheet insulation fixing pins are welded. On these insulation
fixing pin wool mattress is impaled and retained with a retainer. Over insulation
stainless steel cover sheet is provided.
The roof of penthouse is also made up of steel structures. However, its design
20 is much more complicated than the design of the vertical wall. Vertical walls
having wool mattress that can be placed on the vertical corrugated wall, but in
case of roof the wool has to be applied in overhead condition which have many
implications like handling high insulation weight, more erection time
consuming, sagging of insulation etc. So to avoid these complication better
25 option is to apply insulation from the top of the penthouse. But in this case,
structural steel is exposed to high temperature and it can damage the carbon
steel structural steel. So a better design with higher grade of alloy steel is to
7
be used for the roof structure formation. Since it will be exposed to higher
temperature, the roof is designed by considering the expansion of structure at
higher temperature.
Referring to the embodiments,
Figure 1 illustrates schematic diagram of a new penthouse 5 insulation design.
The alloy steel inverted tee beam (01) is being shown supported with hanger
angles (02). The stainless steel cover sheet (11) is shown covering the vertical
wall insulation in the arrangement.
Figure 2 illustrates a thermal barrier ceramic gasket (10) being provided
10 between hanger angles (02) and Alloy Steel inverted tee beam (01). Alloy Steel
Nut (07), bolts (08) & washers (09) are provided for connection between them.
Figure 3 illustrates the provision of gap/breaks in Alloy Steel tee beam (01)
along with slot holes for expansion. The connection between two Inverted tee
beams (01) (as shown in Figure-3) and, between Inverted tee beams (01) and
15 peripheral beam (03) (as shown in Figure-1) has been done with the help of
Support plates (14,15) using Nut (07), bolts (08), washers (09) and thermal
barrier gasket (10). The Alloy steel deck plates (12) are placed between two
inverted Tee beams (01). Insulation (04) is installed on deck plate (12) with
the help of insulation pin (05) and retainers (06). To cover the insulation from
20 outside carbon steel cover sheet (16) is placed above support angles (13).
8
WE CLAIM:
1. A method of insulation for boiler penthouse, the method comprising steps
of:
-insulating structural parts of the penthouse with insulation wool,
characterized in that a Resin bonded wool mattress used in the insulation
for heat loss prevention;
- fixing the insulation wool with the help of insulation fixing pin;
- impaling said woolen mattress upon said insulation fixing pin, and
- welding retainers to retain the wool.
2. The method as claimed in claim 1, wherein an insulation (04) is installed on
a deck plates (12) with the help of insulation pin (05) and retainers (06),
wherein the deck plates are supported between a two inverted Tee beams
(01), wherein the two Tee beams are connected by bolting support plates
(15) on it.
3. The method as claimed in claim 2, wherein the inverted tee beams (01)
supported with hanger angles (02) and having provision for expansion such
as gap or slot holes.
4. The method as claimed in claim 1, wherein vertical wall insulation is done
with stainless steel cover sheet (11).
9
5. The method as claimed in claim 2, wherein providing a thermal barrier
ceramic gasket (10) between inverted tee beam (01) and hanger angles
(02).
6. The method as claimed in claim 5, wherein connecting said inverted beam
and said hanger angles by a nut (07), a bolt (08) and a washer (09).
7. The method as claimed in claim 2 wherein, connecting said inverted Tee
beams, said peripheral beam (03) with the help of support plate (14).
8. The method as claimed in claim 1 and 2 wherein covering the said insulation
by a carbon steel cover sheet (16) placed over a support angle (13).