Linde Purificador

General Perlite Filling Procedure

Linde AG

Doc. No. Job. No. Item No. Project

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General Perlite Filling Procedure

01 Status

Ausgabe/ ISSUE

09.08.12

Gloeckl

Huber B.

Gloeckl

First Issue

Datum/ DATE

erstellt/ PREPARED

geprüft/ CHECKED

genehmigt/ APPROVED

Bemerkungen/ REMARKS

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Linde AG

General Perlite Filling Procedure

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Content 1. 

Scope ........................................................................................................................................3 

2. 

Purpose .....................................................................................................................................3 

3. 

Definitions..................................................................................................................................3 

4. 

Normative References ..............................................................................................................4 

5. 

Terms and Definitions ...............................................................................................................5  5.1  Expanded Perlite .......................................................................................................................5  5.2  Cold Box Insulation ...................................................................................................................5 

6. 

Quality Assurance .....................................................................................................................5 

7. 

Required Properties ..................................................................................................................6  7.1  General......................................................................................................................................6  7.2  Loose Density and Compacted Density ....................................................................................7  7.3  Compacted Density after Abrasion Test ...................................................................................7  7.4  Mean Particle Diameter.............................................................................................................7  7.5  Thermal Conductivity ................................................................................................................8  7.6  Moisture Content .......................................................................................................................9  7.7  Organic Material Content ..........................................................................................................9 

8. 

Insulation of Cold Boxes ...........................................................................................................9  8.1  Bulk Density at Manufacturing ..................................................................................................9  8.2  Bulk Density after Filling............................................................................................................9  8.3  Volume ....................................................................................................................................10  8.4  Distribution / Vibration / Recharging .......................................................................................10 

9. 

HSE .........................................................................................................................................10  9.1  Classification of the Hazardous Potential of the Insulation Material .......................................10  9.2  Handling of Insulation Material ................................................................................................10  9.3  Protective Measures ...............................................................................................................11 

10. 

Working with Perlite ................................................................................................................11 

11. 

Preparatory work items prior to cold box filling .......................................................................11 

12. 

Basic principles for cold box fillings ........................................................................................13 

13. 

Perlite Filling Method Statement .............................................................................................15 

14. 

Documentation and Quality Recording ...................................................................................16 

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General Perlite Filling Procedure

Linde AG

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1.

Scope

This specification governs the material requirements and the description of the internal Cold Box insulation with expanded perlite for the 1200 MTPD Ammonia Plant, Bulo Bulo / Bolivia.

2.

Purpose

The purposes of this specification are: a) Definition of the material requirements of expanded perlite b) Definition of the use of the expanded perlite as bulk material c) Description of the technical basis for the commercial bid d) Technical support for the inspection prior to and during cold box filling

3.

Definitions

Can

Can – requirements are conditional and indicate possibility open to the user of the specification.

May

May indicates a course of action that is permissible within the limits of the specification.

Should

Should is a recommendation. Alternative solutions having the same functionality and quality are acceptable.

Shall

Shall is an absolute requirement which shall be followed strictly in order to conform to the specification.

Supplier

Linde

Sub-Supplier

Perlite Sub-Supplier

Perlite-Specialist Contractor

Contractor employed by Company to fill cold box with Perlite

Company

Yacimentos Petroliferos Fiscales Bolivianos (YPFB)

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General Perlite Filling Procedure

Linde AG

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4.

Normative References

This specification contains provisions which, through undated references in this text, constitute provisions of other publications. The normative references are cited at the respective part in the text and the publications are listed below. Issues valid at the time of placement of order shall govern. DIN 4102-4

Fire behaviour of building materials and building components - synopsis and application of classified building materials, components and special components

DIN 52612-1

Testing of Thermal Insulating Materials; Determination of Thermal Conductivity by the Guarded Hot Plate Apparatus - Test Procedure and Evaluation

DIN 66145

Graphical representations of particle size distributions - RRSB-grid

EN ISO 787-11

General methods of test for pigments and extenders - Part 11: Determination of tamped volume and apparent density after tamping

TRGS 220

Sicherheitsdatenblatt / Safety Data Sheet

BGI 644 (BG Metall) Gefahren durch Sauerstoff (danger caused by oxigen) Arbeitsgemeinschaft Industriebau e.V.: 

AGI-Arbeitsblatt Q 118:

Luftzerlegungsanlagen (air separation plants)



AGI-Arbeitsblatt Q 141:

Blähperlit als Dämmstoff für betriebstechnische Anlagen (expanded perlite as insulation for operational equipment)

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General Perlite Filling Procedure

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5.

Terms and Definitions

5.1

Expanded Perlite

Expanded perlite will be produced from volcanic rock, mineralogical designation perlite, by shortly exposing the fine-ground perlite ore to temperatures up to 1100 °C in a furnace. During that process the water of crystallization evaporates and expands the softened perlite grain by 15 to 20 fold of its original volume. Thus, an expanded perlite grain with a glassy cellular structure is formed. The chemical analysis of perlite yields a composition of about 75 % SIO2, about 15 % Al2O3 and insignificant parts of other oxides; the specific analysis, however, varies from mine to mine. Further properties of expanded perlite are listed in Table 2. Please note: According latest information delivery condition of perlite is raw perlite for expansion on site before filling of cold box. Due to smaller transport volume raw perlite is delivered. Specialist Contractor is responsible for expansion on site and preparation of required equipment on site.

5.2

Cold Box Insulation

A cold box insulation consists of a gas tight casing, in which equipment and piping are installed, any remaining space is filled with insulating material and a slightly positive gas gage pressure is maintained. The temperatures of the equipment parts are usually between 77 K and 300 K.

6.

Quality Assurance

The properties of expanded perlite are influenced by the specific chemical composition of the volcanic rock existing in the mine and by the individual control of the expansion process at the different manufacturers. For the quality assurance of our products, however, the expanded perlite intended for use shall fulfill the properties required in Table 1. Therefore, the properties (marked in following table with *) are determined in a qualification test, and documented in a test report right before filling on site. A comparison between the determined and the required properties supplies the decision criteria for the use of the insulation material.

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General Perlite Filling Procedure

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7.

Required Properties

7.1

General

The required properties are summarized in table 1.

Table 1: Required Properties for Expanded Perlite No.

Property

Investigation Method

Symbol [Unit]

Threshold Values

1 *)

Loose density

Linde

Sch [kg/m3]

45 to 60

2 *)

Compacted density (tamping volumeter)

DIN EN ISO 78711

St [kg/m3]

55 to 90

3 *)

Compacted density after Linde abrasion test

StA [kg/m3]

<1.8 St

4 *)

Mean particle diameter (RRSB-scale)

DIN 66145

d’ [mm]

0.4d’0.8

5

Angle of repose (h=100 mm)

Linde

 [degree]

33 to 37

6 *)

Capillarity (Pipe Ø 18.5 mm)

Linde

h [mm/h]

<290

7

Thermal conductivity

DIN 52612

 [W/mK]

picture 1

8 *)

Moisture content

PI 118 **)

[weight-%]

1

9 *)

Organic material content Linde

[weight-%]

0.3

*) Will be generally checked during a Linde qualification test as a rule. **) Perlite Institute, New York

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7.2

Loose Density and Compacted Density

Expanded perlite is available as bulk material with a certain grain distribution. The lowest bulk density, which is obtained when filling the material loosely, is known as loose density. By tamping the particles are moving against each other and the smaller ones remain in general in the gaps between the greater ones, until an optimum bulk density, known as compacted density, will be obtained. For all insulations with expanded perlite the compacted density should be achieved, as otherwise a subsequent settlement of the filled in material has to be expected. For perlite qualities which are suited for low temperature insulations the compacted density is about 30 to 50 % above the loose density. By simply continuing the tamping operation the density of the filled in material cannot be increased. An increase is only possible by applying external forces such as e.g. by the proper weight of thick insulation layer or by contraction movements of vessels. In such a case the fracture of the cellular walls on the particle surface leads to a clamping together of individual particles, and the filled in material looses its flow ability partly or even completely. 7.3

Compacted Density after Abrasion Test

An expanded perlite grain has a cellular structure with thin glassy walls. At mechanical loading of the material, e.g. pneumatic conveying in a long pipeline, parts of the cellular walls break off and an unwanted fine abrasion is forming. The resistance against abrasion of an expanded perlite is influenced by the properties of the perlite ore and by the expansion process. The abrasion test carried out in Linde's laboratories is an internal comparison test against standard qualities and gives information if, in case of pneumatic conveying, a considerable increase in density has to be expected. 7.4

Mean Particle Diameter

The mean particle diameter of a bulk material of expanded perlite is determined from a sieve analysis and defines a mean grain size. If expanded perlite is used as a low-temperature insulation material, the mean particle diameter specified in Table 1 has to fulfill the standard requirements of practice. For a too small grain an increase of the density and in particular a higher flow resistance has to be expected when producing an insulating vacuum. For a too large grain the formation of convection and the radiation transmission are increased.

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General Perlite Filling Procedure

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7.5

Thermal Conductivity

Due to the involved costs, the thermal conductivity won't be measured in a qualification test. For a material filled in at atmospheric pressure, the thermal conductivity can be taken from Table 2. It can be used as an approximately parameter as a function of the mean temperature for different densities. Increasing grain size and higher moisture content increase the thermal conductivity.

0,075 192 kg/m3 0,07 160 kg/m3

Thermal Conductivity (W/mK)

0,065

144 kg/m3

0,06

128 kg/m3

0,055

104 kg/m3 80 kg/m3

0,05

64 kg/m3 48 kg/m3

0,045 0,04 0,035 0,03 0,025 0,02 0,015 0,01 100

150

200

250

300

350

400

Temperature (K)

Table 2: Thermal Conductivity of Expanded Perlite as Function of the Temperature

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7.6

Moisture Content

Material coming directly from the furnace has a very low moisture content of up to 0.2 % by weight. For long-time storage in the open air a balance of up to 1.5 % by weight is obtained, depending on ambient humidity. For that reason perlite shall be protected against moisture during transportation and storage. The whole moisture content in the insulating material when e.g. installed in a cold box, diffuses to the cold points of the vessels and precipitates there as ice. In case of discharging a cold box and if a still cold material is pneumatically conveyed with ambient air, the air humidity will be condensing. Depending on the condition of the suction air, the moisture content can rise up to about 5 % by weight. Material being exposed to rain can reach the max. moisture content of up to 900 % by weight. In both cases the material is not usable any longer.

7.7

Organic Material Content

Considering the perlite ore and the high temperature during expansion process, perlite does not contain any organic materials. The firing equipment of the expansion furnace may be a source for contaminations. When using expanded perlite a limiting value of organic material content may not be exceeded, to comply with BGI 644 (Regulation for the Prevention of Accidents, Oxygen). This value has been fixed to 0.3 % by weight. Thus, the degree of contaminations is preset below the value of 0.5 % by weight, which is permissible acc. to BGI 644. The reason for that measure is due to the fact that an investigated sample is not absolutely representative for the whole quantity of insulation material, as an unequal distribution must be expected.

8.

Insulation of Cold Boxes

8.1

Bulk Density at Manufacturing

The maximum allowable bulk density for expansion in a portable furnace on site is up to 60 kg/m³; efforts should be made to obtain a bulk density of about 45 kg/m3.

8.2

Bulk Density after Filling

The maximum allowable bulk density after pneumatic filling directly from the furnace on site: 55-65 kg/m3 (Empirical values of Linde for calculating the weight of the filled in perlite).

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8.3

Volume

The Supplier shall specify the insulating volume. The Perlite Supplier Specialist shall determine the required perlite quantity to be delivered for that purpose. For details please refer to: Linde Doc. No.: &AA-0100 W-DW 1001 "PERLITE VOLUME" 8.4

Distribution / Vibration / Recharging

In order to avoid recharging and / or to reduce the recharge quantity, the Perlite Specialist Contractor should take appropriate measures to support a uniform distribution. For that purpose, the Perlite Specialist Contractor shall submit a specific vibrating procedure together with the quotation. In any case, the consent of Company's responsible shall be obtained.

9.

HSE

In general the HSE requirements of YPFB/Bulo Bulo project shall be considered as mandatory. 9.1

Classification of the Hazardous Potential of the Insulation Material

The manufacturer respectively the supplier shall examine, classify and identify the insulation material with respect to the hazardous potential. If the material has to be rated as potentially hazardous, a safety-datasheet (according to TRGS 220) shall be delivered / attached to the filling procedure and shall be available on site. For the rating "harmless" a document of compliance shall be attached to the filling procedure. Anyway the manufacturer/supplier shall consider the subsequent handling of the insulation material. 9.2

Handling of Insulation Material

The supplier of the insulation material shall prepare a risk assessment related to the job site considering the handling of the insulation material. The above mentioned manufacturer's identification shall be observed.

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9.3

Protective Measures

As basis the EC safety data sheet (91/155/EWG) can be referred on, which states that expended perlite is classified as a non - toxic, low risk material, but the recommended safety equipment should be used as required for particular task. Safety shoes, overalls, gloves, safety goggles, adequate fine particulate masks and hard hats shall be used in general. If (e.g. on job sites outside of the EC) no information regarding the hazardous potential of the insulation material is available by the manufacturer and the rated insulation material is not available elsewhere, the use of the above mentioned safety equipment is strongly recommended. Caution: Perlite products can contain crystalline silica, which is considered to be a nuisance dust. Inhalation of high amounts of any nuisance dust over long periods can overload the lung clearance mechanism and make the lungs vulnerable to respiratory disease.

10.

Working with Perlite

Personnel involved in working with bulk perlite shall be trained in safe and correct methods of handling perlite and its characteristics. This training shall be recorded. Working crews shall be experienced in perlite handling and shall be supervised.

11.

Preparatory work items prior to cold box filling - This preparatory work shall be done by Company and/or Contractor on Site! -

The following listed single points shall be checked and confirmed by Company in writing to the supplier. Before receipt of that confirmation and the release for filling the manufacturer / supplier is not allowed to start with the cold box filling. Please note: The following list is as a basis for a check list. The purpose of this list is to give a general overview of the work before perlite filling of cold boxes can be started. In any case please also refer to the following governing Documents: Linde Doc. No.:

&AA-1386 L-ZT1001 "Transport, Lifting and Erection of Cold Box"

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1)

Cold box fittings including piping and instrument lines, shall be installed, tested and accepted with respect to alignment, process, cold shrinkage and supports. This procedure shall be recorded.

2)

Non-destructive tests, pressure- and leakage tests shall have been successfully completed and logged.

3)

All installation clamps of horizontal installed cold box valves shall have been removed prior to stuffing the bulkheads with mineral wool.

4)

The bulkheads of the flanged items, refrigeration fittings, flow measuring and others shall be prepared for the box filling, stuffed with mineral wool and sealed.

5)

The bellows at the valves shall be sealed with silicon.

6)

The N2 purge gas pipes in the box are supplied to site lagged with Fategon”, i.e. the box purge system shall be prepared for feeding N2 gas. "Fategon" layers installed at supplier's workshop have to be inspected on site by Company and in case of damages or losses reinstalled.

7)

All temperature measurements- and heating units for dry pressure relief shall have been checked for function ability and logged by responsible electrical installation personnel.

8)

The internal box space, including lateral and diagonal struts shall be cleaned and dry.

9)

All combustible materials shall have been removed from the cold box inside.

10)

The internal box spaces shall be blown out with warm, dry, oil-free air to remove any residual moisture.

11)

The dummy passages of the plate-fin heat exchanger shall be prepared for the box perlite filling. Therefore at all PFHE all temporary preservation valves have to be opened for discharge of N2 filling, preservation valves have to be removed and hole of preservation valves have to be covered with self adhesive aluminium tape.

12)

Safety devices (meshes, nets or grating covers) shall be prepared and fitted to the filling openings, manhole covers and the exhaust openings on the roof.

13)

Scaffolding shall be removed completely.

14)

The internal process piping shall have been under a pressure of approximately 0.5bar during scaffolding removal and no leaks have been noted. This shall be recorded.

15)

The proper function of the temperature measurement and heating units for dry pressure relief shall have been checked during removal of the scaffolding. This shall be recorded.

16)

All measuring lines are installed and tested at suppliers workshop, but have to be visual inspected about damages on site.

17)

All manhole covers shall be fitted with the specified sealing (refer to cold box shell penetration drawings attachment 1 to 2 in this document, and for typical parts to LS49306). The sealing shall have been cleaned.

18)

All safety flaps shall have to be visually inspected for damages, proper installation and sealing seat after transport/lifting and all sealing faces and sealing shall have been cleaned.

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19)

All safety flaps shall have been locked prior to perlite filling (please refer to attached marked drawings).

20)

The bottom of the temperature junction boxes shall have been filled with sand and covered with thin layer of concrete to ensure gas–tightness.

21)

Bridge Cold box (Expander Duct) is finally (gas tight) connected to cold box.

12.

Basic principles for cold box fillings

1)

The perlite shall be conveyed pneumatically by means of dry, oil-free air. If there is no dry, oil-free air available also dry N2 can be used taking special precautions.

2)

All openings / manholes of the box except the filling manhole in use and the exhaust opening shall be closed and protected during perlite filling (please refer to attached marked drawings). Ingress of rain, snow or other moisture into the box shall be avoided. If the protective measures are not sufficient to ensure the above mentioned requirements during extreme weather conditions, the perlite filling shall be interrupted and the box shall be sealed for the period of interruption.

3)

It is strictly forbidden to enter the box after the filling process has been started!

4)

All openings which won't be needed for perlite filling shall be sealed and permanently locked. This shall be done with acceptance of suppliers Commissioning Group. The details shall be given in the filling procedure by the Perlite Specialist Contractor.

5)

Filling shall always be carried out in sections from level to level starting at the bottom moving to the top (please refer to attached marked drawings).

6)

The maximum filling height from level to level shall be specified by the Perlite Specialist Contractor and shall be confirmed by Company.

7)

To ensure a homogenous filling of the cold box as far as possible, perlite should be filled in via manholes that are either diagonal to each other or at the extreme ends on the longer side of the box. Details shall be given by the supplier in the filling procedure. Please refer to attached drawings with marked positions of manholes.

8)

The quality of the produced / filled perlite shall be checked and recorded according to chapter 14 of this specification.

9)

It's generally not allowed to fill in damp perlite. Please refer to moisture content specified in chapter 7.6.

10)

Exhaust filters shall be installed by the supplier on the roof at the manhole openings. The number shall be given by the Perlite Specialist Contractor in the filling procedure.

11)

No pressure shall be applied to the piping system within the box while the valves are locked.

12)

To reduce nuisance dust the open manholes in filling process should be covered by filter cloths as far as possible.

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13)

If required (in case of heavy rain, longer stop of perlite filling etc.), the box shall be flushed with dry purge N2 to avoid moisture inside of the cold box.

14)

To ensure a proper perlite distribution, the cold box section that is actually being filled by means of a perlite production plant shall be vibrated below the perlite level. For this purpose, vibrators shall be installed on the outside wall of the cold box. The vibrator settings shall be determined on site together with the Perlite Specialist Contractor installation manager to ensure the level of vibration moment as low as possible. The basic principle shall be given by contractor in the filling method statement.

15)

The box pressure shall be checked and recorded during perlite filling via process control system. The max. allowable pressure during perlite filling shall be limited to the max. allowable pressure of the cold box itself. Please refer to given pressures in the Installation, Operation and Maintenance Instruction (IOMI).

16)

No vacuum shall exist in any part of the cold box as this would attract moisture from the outside.

17)

After filling of every section a visual check shall be performed from outside through openings left open for perlite filling to ensure that no hollow spaces have been formed under equipment, fittings and piping. If required, the vibration procedure shall be repeated. It is strictly forbidden to enter the box for the visual check.

18)

For safety reasons and to prevent any unwanted material from falling into the cold box from the roof, a safety basket shall be installed in the filling opening.

19)

During the filling of the top section of the cold box it might be needed to distribute the perlite into the corners manually by using suitable tools.

20)

The perlite level shall be checked through the roof manholes after approximately 1 week of operation. Precautions shall be taken to ensure the physical inviolability of personnel due to escaping N2 gas and nobody can fall into the perlite and become submerged. If required, the perlite shall be topped up as described. This check and replenishment shall be part of the contract between Company and Perlite Specialist Contractor.

21)

Further annually checks of the perlite level shall be done during operation of the plant. This is not part of the contract and shall be done by Company's Maintenance Group and/or Perlite Specialist Contractor.

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13.

Perlite Filling Method Statement

Together with the quotation the Perlite Specialist Contractor shall submit a Perlite Filling Method Statement. This procedure shall describe in detail all information required to enable Company to perform a qualified evaluation. This procedure shall include but not be limited to the following details:



required space for production and storage on site



ground condition for production- and storage area



road blocking



number of expansion furnaces



dimension and weight of the expansion furnace



pump capacity



number of personnel



delivery and storage of raw perlite (given by Sub-Supplier according Linde requirements/Standards)



working sequence, shift / round-the-clock



estimated running time for the whole job



supply of gas



supply of electrical power connections



consumption of electricity



supply of compressed air



supply of N2



vibration procedure / - tools



transport equipment



lifting equipment



supply of fire fighting equipment



supply of personnel safety equipment



lightning of the working areas



height of filling sections

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Linde AG

General Perlite Filling Procedure

Doc. No. Job. No. Item No. Project

: : : :

1386 R-SP 1001 8950 AYCH 137-L Bulo Bulo

Geschäftsbereich Linde Engineering Page 16 of 16 page(s)



sequence of perlite filling



location and number of inlet openings

14.

Documentation and Quality Recording

The perlite supplier shall ensure and check the quality of the produced and filled perlite as defined in this specification. The supplier shall generate the following quality records and shall submit them to Company construction site management.

a)

Signed evaluation of the following samples in comparison to the requirements of this specification. The corresponding samples shall be stored for later analysis. 1 weight sample (1 liter) each hour 2 samples (1 liter each) per day to be stored for later analysis

b)

Signed record of positive visual check for each filled box section.

After completion of the cold box filling the stored samples shall be sent to Linde laboratory, for analysis. The construction management is responsible for the contemporary dispatch to Linde.

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Marked position of safety flap valves

Marked position of manholes that can be used for Perlite filling