ANNEX 15: OPTIMELT Flue Gas Recirculation Equipment

Specification
Date: 11 Aug 2016
Revision: E

This preliminary specification is intended for vendor technical qualification for

procurement of equipment under EU Grant LIFE15 CCM-NL-000121. It
contains the necessary information to assess the scope. A final specification
will be prepared later to allow submitting a detailed quote. The FGR (Flue Gas
Recirculation) equipment will be installed at a glass plant in Leerdam in The
Netherlands.

The FGR directs hot flue gas from the outlet of two heat recovery
regenerators to the furnace flue gas system. Part of the exit gas, from the first
regenerator, is recirculated to the inlet of a second regenerator. The system
will use flue gas from a glass furnace and switches the distribution of the gas
between the inlets of the regenerators about every 30 min. Details are given
further below.

The bidder is requested to quote the following scope and services in

compliance with European standards:

1. Description of Scope
The flue gas recirculation equipment has two functions (see Figure 1):
1. It moves the flue gas from one regenerator through the high
temperature fan and directs it to the existing downstream flue gas
system and
2. It diverts part of the flue gas to the other regenerator as flue gas
recirculation (FGR) flow
3. Instrumentation is included to measure flue gas temperature,
pressure, oxygen concentration, and mass flow for process control
4. Instruments are included to provide output signals for fan shaft
speed, fan vibration, fan shaft bearing temperature, proportional valve
position, and limit switches for on/off valve position

The system consists of 300 and 600mm diameter fabricated stainless steel
pipe. Two 600 mm diameter pipe size butterfly switching dampers, and two
300mm diameter pipe size butterfly recirculation damper are used to change
the direction of the flow and allow the cyclic operation of the FGR equipment.
A high temperature fan moves the flow of flue gas, between the two
regenerators, and to the flue gas system. The fan electric motor speed can be
adjusted with a variable frequency drive to adjust the FGR flow. A fifth
butterfly damper is used at the fan outlet to control the flue gas pressure after
the fan.

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Figure 1: Simplified Flow Diagram for FGR System

The pipes are made from ASTM type 316 stainless steel or equal, rolled and
welded from sheet or supplied as seamless or welded standard pipe, with a
3mm minimum pipe wall thickness, to minimize corrosion. All equipment that
conveys flue gas is insulated on the outside. Insulation shall be protected by
aluminum metal cladding. The terminal point of the FGR equipment is at the
connection to a large refractory brick structure that is part of the flue gas
system. An existing induced draft fan provides the flow of the flue gas that is
not recirculated back to the regenerators to the atmosphere. Figure 2 shows
the preliminary arrangement.

Terminal pipe connections at the regenerators and at the outlet of the system
to the flue gas system are to be supplied as plain pipe end to be field cut as
required and seal welded to a square stainless steel plate bored to fit the plain
pipe end. The refractory brick structures are metal clad with 5mm thick carbon
steel plate, with open ports at the connection points. The flat square
connection plate is positioned over the plain pipe terminal end, and seal
welded to the cladding for the refractory brick structure to locate the pipe at
the port connection, and then welded to the plain end pipe to make the
connection gas tight.

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 300mm Dampers

Expansion Joints

600mm Duct
EXIT Flue Gas
(additional 90 deg
elbow and pipe
600mm not shown)
Dampers

Connection to Left and

Flue Gas Fan
Right Regenerators

Figure 2: Preliminary Arrangement of Scope (fan located on platform)

The equipment will be made from welded subsections that are connected by
bolted plain flanges, with Flexitaulic Thermiculite gasket material (or equal),
minimum 3mm thickness. Large blind flanges are used to allow maintenance
and cleaning. FGR skid piping, flanges, and fittings are made of ASTM type
316L (UNS S31603, 1.4404) stainless steel. Vendor shall submit their flange
detail drawing for approval by buyer.

The equipment described in this specification does not include oxygen piping
or equipment designed for oxygen service that is needed for the OPTIMELT
system. The requirements for oxygen equipment are detailed in a separate
specification. The fabrication of oxygen systems requires special attention to
codes and standards, cleanliness and material choices. Only certified vendors
can fabricate oxygen systems.

1.1. OPTIMELT FGR Equipment

Item Description
1 Flue gas recirculation equipment, as shown in Praxair drawing L-1
RFG Skid, Rev 2, date 2/25/2016, and as listed in the BOM,
including:
a. 2 pieces switching butterfly damper with open/close
actuators for 600mm pipe size for high temperature 750°C
service

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 b. 2 pieces recirculation butterfly damper with positioning
actuators for 300mm pipe size for high temperature 750°C
service
c. interconnecting 600mm and 300 mm SS316L (UNS S31603,
1.4404) stainless steel, or rolled and welded pipe with
expansion joints as required for thermal movement
d. associated safety, electrical and measurement equipment,
as listed in the BOM
e. Weather tight, local electrical panels as required for
integration into plant control system. All wiring shall be pre-
wired internal to the panel to a local terminal junction. All
equipment and frames must be grounded in accordance with
the local electrical code.
f. flanges and gaskets as shown in the arrangement
g. 12 each, 50mm diameter nozzles with flanges for
measurement equipment, drain valves and injection nozzles
h. External insulation of pipes, with quick open joints at all
access flanges to facilitate maintenance
2 Detail mechanical design drawings for the components
3 Detail electrical design drawings for scope
4 Component sourcing in EU
5 Fabrication of system
6 Factory checkout
7 Shipping to customer site
8 Detailed installation drawings, Electrical and Mechanical Installation
at customer site, and tie-in with regenerators and flue gas lines
9 Design and construction of local supports for equipment from painted
carbon steel
10 4 weeks commissioning and startup assistance (provide excess
pricing)

For the installation at the buyer’s site and tie-in with regenerators and flue gas
lines the vendor needs to understand and work around all other existing or
new steel structures and electrical systems. These details will be
communicated at a later point. Likewise, for the construction of local supports
for equipment a detailed understanding of the existing and or planned steel
structure is required. Vendor will be provided in the future with adequate
information to design and install these supports.

1.2. Items Excluded from Scope

Buyer will procure the following items directly from other vendors. They will be
either delivered to the bidder’s fabrication shop for integration or directly
delivered to the glass plant (to be determined).
• High temperature fan with VFD control,
refer to PX-0501-DSH-T114, rev0 RFG Fan Data Sheet

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1.3. Information that is part of this Specification
• General arrangement drawing of equipment
• Process and instrumentation Diagram (P&ID) outlining tags of
measurement equipment and limit switches
• Bill of Material (BOM). Vendor is requested to source these parts in the
European Union according to local codes and indicate exceptions
taken to providing this service

1.4. Codes and Standards

All equipment must comply with CEE directives and local country codes of
The Netherlands. Specifically, the following directives apply. The
subcontractor must guarantee the conformance to all mentioned standards for
the equipment build.
• Pressure Equipment Directive (PED) 1997/23 CE
• EN 746-2 concerning combustion equipment
• Low voltage directive 2006/95/CEE for low voltage panels and control
panels
• Machine directive 2006/42/CE for HMI and safety
• Electromagnetic emissions and protections 2004/108/CEE
• Machine directive (2006/42/EG)

Additional standards are:

• NEN-EN-IEC 60204 Electrical safety for machines.
• NEN-EN 13480 Metalen industriele leidingsystemen
• NEN-EN-ISO 3834 – Quality requirements for welding - Kwaliteits
eisen van smeltlassen van metalen
• EN ISO 15614-1 Welding procedures
• EN ISO 9606-1 Welder Certification

2. Specification Details
Any changes to the P&ID, BOM or use of “non-standard” fabrication practices
shall be communicated to and accepted by buyer and the fabricator via an
“engineering change request” prior to implementation.

2.1. General Requirements

2.1.1. Vendor shall submit detail fabrication design description,
drawings, inspection scope, and list of documents provided for
approval prior to start of fabrication. Vendor shall submit a
general arrangement drawing with their quotation for review.
Special attention shall be given to the orientation of flanges as
well as locations and directions of all flanges, measurement
equipment and connecting piping to ensure accessibility and
ease of maintenance. The high temperature fan to be supplied

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 by others must be integrated by the vendor into the equipment
supplied.
2.1.2. Vendor shall submit welding procedures and welder
certifications for buyer’s review and approval.
2.1.3. All components shall be oriented so that they are easy to read
and manual components are easy to access.
2.1.4. All jagged welds and sharp edges are to be ground smooth to
prevent injury.
2.1.5. All bolting, mating flanges, and gaskets for all inlet and outlet
process piping to be supplied unless stated otherwise
2.1.6. All equipment must pass following tests (with certification).
Vendor will repair welds or joints that require rework due to
leaks and or improper quality at no cost to buyer.
− Leak test (according to PED and buyer agreement)
− Pressure test (according to PED and buyer agreement)
− Dry functional test (if applicable)
− Flow test (according to buyer agreement after installation)
2.1.7. CE documents will be by others, tag plate shall be supplied by
vendor
2.1.8. The skid shall be tarped for shipment. Flanges shall be capped
or plugged with a fabricated cover, or plastic cap, to prevent
damage and contamination.
2.1.9. All enclosures rated less than NEMA 12 shall be shrink-wrapped
prior to shipping or transport.

2.2. General Frame/Support Steel Fabrication

2.2.1. Vendor is responsible for designing the system pipe supports.
All dimensions in the general arrangement drawing are to be
considered “reference”. Vendor shall submit design for pipe
support for approval prior to start of fabrication. The thermal
expansion and free movement of sections must be considered,
foundation loads, and equipment center of gravity, and lifting
points shall be shown on Vendor’s drawings
2.2.2. Lifting lugs are to be included over the center of gravity of
subsections over 50kg.
2.2.3. Supporting frame members must be made of square profile
40x40 mm, or larger if required by load analysis. Any frame
components or supports shall be of welded construction
throughout with continuous welds up to 6.3mm on both sides. All
frame welds must be cleaned and brushed (no sharp edges).
2.2.4. All frame components attached to the ground shall have square
plates (min 100 x 100 mm) with four holes of 12 mm diameter to
fix the components to the floor.

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 2.2.5. Weld spatter is not permitted anywhere on the frame and must
be ground off prior to painting.
2.2.6. The location of the electrical panel(s) near all components will
be determined by the vendor in consultation with the buyer.
Vendor must submit the chosen location of the panel and the
support structure of the panel for approval prior to fabrication.

2.3. Flue Gas Piping Requirements

2.3.1. Pipe Material for the flue gas piping is ASTM SS316L or DIN
1.4404 (UNS S31603), or rolled and welded fabricated pipe from
type 316L plate material or equal, with external ceramic fiber
insulation rated for 800°C use or better and aluminum lagging to
reduce outside temperature to less than 60°C. Vendor to provide
a heat loss calculation for their scope of equipment based on
650°C internal temperature.
2.3.2. Welding procedures in accordance with EN ISO 15614-1 and
approval of welders according to EN ISO 9606-1.
2.3.3. Weld spatter on piping (internal or external) is unacceptable.
2.3.4. Blind flanges should be fabricated from plate steel instead of
purchased pipe flanges to reduce weight. The minimum flange
thickness should be 6mm up to 200mm diameter, 10mm up to
300mm diameter, and 12mm up to 600mm diameter. Flanges
larger than 200 mm to have lifting lug(s) permanently attached.
2.3.5. Flange bolting shall be adapted to the flange rating and having a
minimum of 3 free threads.
2.3.6. All pipe clamps above 3” or DN 80 are to be of a “heavy-duty”
style. Where pipe expansion is required the supports shall be
designed to allow movement.
2.3.7. Thread-o-lets and weld-o-lets are not to protrude into piping
obstructing the flow of the gas.
2.3.8. All piping/tubing shall be tagged with arrows indicating the flow
direction as well as the fluid on both inlet and outlet
2.3.9. Switching dampers (600mm pipe size) should be butterfly
damper valve with internal metal seal strips, flange connections
and a maximum 10% leakage in the closed position. Service
temperature should be 750°C. The actuator should be a ¼ turn
pneumatic actuator with solenoid valve and limit switches for
open/close operation
2.3.10. Recirculation dampers (300mm pipe size) should be butterfly
damper valve with internal metal seal strips, flange connections
and a maximum 10% leakage in the closed position. Service
temperature should be 750°C. The actuator should be a ¼ turn

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 pneumatic actuator for proportional operation with I/P controller,
4-20mA feedback and limit switches.
2.3.11. The equipment contains several expansion joints that must fulfill
the following design requirements:
1) Bellows Geometry:
a) Bellows Material; SA240-T316 (Alloy 316L, UNS S31603,
1.4404)
b) Collar Material; SA240-T316
c) Bellows inside diameter; 300mm, 600mm, 800mm
d) Outside Diameter; Vendor specific
e) Standard plate flange
f) Inserted sleeve to be concentrically welded
Note: The number of convolutions, individual ply thickness,
number of plies, bellows length, and effective bellows area to be
included in the drawing.
2) Design information for all expansion joints;
a) Design Pressure: 35kPa
b) Design Temperature: 800°C
c) Axial Compression: 40mm
d) Axial Extension: 40mm
e) Lateral (+): 10mm
f) Lateral (-): 10mm
g) Angular (+): 5deg
h) Angular (-): 5deg
Note: Fatigue characteristics and bellows stress analysis
calculation to be included (cycles to failure), axial, lateral,
angular and torsional spring rates to be included with the
pressure thrust at design pressure.

2.4. Natural Gas Piping Requirements

2.4.1. Welding procedures in accordance with EN ISO 15614-1 and
approval of welders according to EN ISO 9606-1. All welds are
to conform to EU welding standards including, but not limited to
those specified in the separate Safety and Standards document
that is part of this specification.
2.4.2. Weld spatter on piping (internal or external) is unacceptable.
2.4.3. For the natural gas piping union type connections or threaded
connections are preferable for DN50 or below. Above this
diameter flanged DIN connections must be used, if not
otherwise specified on the drawings, or specifications for supply.
2.4.4. Carbon steel piping sections for natural gas shall be painted
yellow per Libbey Standard TOALG01 after welding and prior to
assembly. Final touch-up of the paint is to be completed after
site installation and checkout.
2.4.5. All piping is to be schedule 40, single butt weld construction
unless otherwise noted. Below DN15 or ½” tubing is preferred.

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 2.4.6. Flange bolting shall adapted to the flange rating and having a
minimum of 3 free treads.
2.4.7. Support of all piping/tubing up to 3” or DN 80 shall be designed
with “Stauf” supports or equal brands
2.4.8. All pipe clamps above 3” or DN 80 are to be of a “heavy-duty”
style. Where pipe expansion is required the supports shall be
designed to allow movement.
2.4.9. Thread-o-lets and weld-o-lets are not to protrude into piping
obstructing the flow of the gas.
2.4.10. All piping/tubing shall be tagged with arrows indicating the flow
direction as well as the fluid on both in– and outlet

2.5. Instrument Air Piping Requirements

2.5.1. Below DN15 or ½” stainless tubing is preferred.
2.5.2. Flange bolting shall be adapted to the flange rating and have a
minimum of 3 free treads.
2.5.3. Support of all piping/tubing up to 3” or DN 80 shall be designed
with “Stauf” supports or equal brands
2.5.4. Any instrument air header shall be fabricated using 304 or 316
stainless steel to prevent rust. The instrument air tubing shall be
fabricated with 316SS or 304SS. All fittings, unions, reducers,
ect. for instrument air are to be stainless steel.
2.5.5. The finished instrument air system shall be adequately blown
out with clean air and appropriately cleaned prior to installation
of the actuators.
2.5.6. All welds of stainless steel piping are to be wire brushed to
remove/reduce weld heat markings.
2.5.7. Thread-o-lets and weld-o-lets are not to protrude into piping
obstructing the flow of the gas.
2.5.8. When Teflon tape is applied, care shall be taken that no free
Teflon will go into the instrument or the piping. When using liquid
sealing material such as “Loctite” approval shall be given by
buyer before the start of fabrication.
2.5.9. All piping/tubing shall be tagged with arrows indicating the flow
direction as well as the fluid on both in– and outlet
2.5.10. Final placement and routing of instrument air is to be determined
during assembly/installation to minimize interference with other
skid components.

2.6. Instrument Air Piping Requirements

2.6.1. Below DN15 or ½” stainless tubing is preferred.
2.6.2. Flange bolting shall be adapted to the flange rating and have a
minimum of 3 free treads.

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 2.6.3. Support of all piping/tubing up to 3” or DN 80 shall be designed
with “Stauf” supports or equal brands
2.6.4. Any instrument air header shall be fabricated using 304 or 316
stainless steel to prevent rust. The instrument air tubing shall be
fabricated with 316SS or 304SS. All fittings, unions, reducers,
ect. for instrument air are to be stainless steel.
2.6.5. The finished instrument air system shall be adequately blown
out with clean air and appropriately cleaned prior to installation
of the actuators.
2.6.6. All welds of stainless steel piping are to be wire brushed to
remove/reduce weld heat markings.
2.6.7. Thread-o-lets and weld-o-lets are not to protrude into piping
obstructing the flow of the gas.
2.6.8. When Teflon tape is applied, care shall be taken that no free
Teflon will go into the instrument or the piping. When using liquid
sealing material such as “Loctite” approval shall be given by
buyer before the start of fabrication.
2.6.9. All piping/tubing shall be tagged with arrows indicating the flow
direction as well as the fluid on both in– and outlet
2.6.10. Final placement and routing of instrument air is to be determined
during assembly/installation to minimize interference with other
skid components.

2.7. Electrical Requirements/Panels:

2.7.1. All electrical requirements are specified in the separate Libbey
general specifications for the engineering of electrical control
systems and the use of components for electric installations
”General specifications and conditions v1.0.6.”
2.7.2. Libbey will place a fully equipped remote I/O cabinet with
sufficient connections in the vicinity of the RFG equipment.
Vendor shall supply all components (sensors, valves) as
described in the B.O.M. and mechanically connect them to the
RFG equipment. Vendor shall wire the electrical components to
the Libbey remote I/O cabinet and connect them according to
the Libbey electrical scheme. Libbey will also place a main
cabinet located in an air-conditioned room nearby (ca. 60m) for
connection of bigger energy consumers such as motors. Motors
will be directly connected to this main control cabinet according
the Libbey drawing. Connections, wiring, cable glands and so on
shall be done as described in the general specification
mentioned under 2.7.1.

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3. Documentation
The following documents must been supplied with the equipment/skid at the
time of the FAT. The language of the documents shall be the original
language of destination of the skid and will be confirmed by the buyer.

3.1.1. Technical documentation of each skid component.

3.1.2. Technical documentation of each major electrical cabinet
component
3.1.3. List of materials (format to be detailed by buyer), this list will be
used to order parts in the future when necessary and hence
must contain all necessary information of the installed parts
such as exact ordering codes, connections, descriptions,
suppliers info, materials, instrument ranges etc.)
3.1.4. Calibration reports of components (when applicable)
3.1.5. O2 cleaning reports (if oxygen piping was included)
3.1.6. General cleaning reports, all inspection reports, material
certifications
3.1.7. Pressure testing reports (according to PED when applicable)
3.1.8. As build electrical drawings
3.1.9. Mechanical lay out drawings (3-D, inventor or Solid works)
3.1.10. As build P&ID’s
3.1.11. CE TAG plate
3.1.12. Copy of CE approval file

During the FAT a punch list will be issued by the buyer, material will only be
released for transport if punch list items have been addressed.

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4. Appendix

4.1. Flue Gas Conditions and Ambient Conditions

Flue gas: Flue gas from oxy-fuel combustion that contains traces of
solid sodium sulphate (<200µm particle size)
Temperature: 600 to 750°C
Pressure: +- 1 kPa with respect to ambient
Water Dewpoint up to 85°C
Typical Composition:
CO2 32.9%
H2O 43.7%
N2 19.7%
O2 1.6%
Ar 2.1%

Ambient Temp. 30 to 50°C

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