F3 Fujairah · HRSG Units 11/12/21

F3 O&M Co
HRSG Thermal Upgrade

Non-metallic Expansion Joints · Steam Valves · Flanged Connectors

April 2026 · Ref INZ-2026-F3-001 · UK Patent GB2508992.1

Executive Summary

Project at a Glance

Modular insulation upgrade for 654 thermal components across 3 HRSG units at the F3 Fujairah Power Plant. Based on 8,000 operating hours per year.

Annual Savings
1,132,285
AED per year · 30,170 MWh saved
Payback Period
~12
months · break-even < 1 year
CO₂ Reduction
6,700
tonnes per year avoided
Project Investment
1,118,000
AED · all-inclusive
Net Heat Rate
−6.5
kJ/kWh · ~0.10% improvement
Gas Saved
~3M
m³ natural gas per year
Total Energy
102,935
MMBtu saved annually
15-Year Value
>15M
AED cumulative savings

* Based on average 2025 actual heat rate: 6,164.94 kJ/kWh (Net, LHV). Estimated annual net export: ~16.8 TWh/year (2.4 GW installed capacity, ~7,000 operating hours/year). Gas price: 11 AED/MMBtu.

The Problem

Exposed Hot Surfaces · Continuous Heat Loss

Thermal Survey at HRSG Units 11/12/21

Our on-site FLIR thermal survey at F3 Fujairah identified 654 uninsulated thermal components across three HRSG units. Surface temperatures up to 300°C on non-metallic expansion joints, valves, and flanged connectors create:

  • Continuous radiative and convective heat losses
  • Burn risk for operators and maintenance personnel
  • Elevated ambient temperature in trenches and pipe galleries
  • Wasted thermal energy: ~30,170 MWh/year
  • ~6,700 tonnes/year of avoidable CO₂ emissions
FLIR thermal image - expansion joint 194.4°C
FLIR thermal image - bellows 165.7°C
Scope of Work

654 Components · 3 HRSG Units

Every component identified, measured, and engineered. Inzonex Modular Insulation panels designed to fit each surface precisely — clamshell construction with snap-fit assembly.

Bellows trench overview Expansion joints row Uninsulated valves HP drum head Steam header piping Flanged connections
Interactive Model

Explore a Typical Bellows Trench · Before & After

Drag the slider to compare exposed bellows with the Inzonex Modular Insulation upgrade. Click any of the 4 hotspots for per-bellows heat loss data. Toggle Thermal Vision to see the 190°C surface heat. This view shows ONE typical trench — similar configurations in different combinations repeat across the project.

Equipment Breakdown

Component-by-Component Savings

Per ISO 12241 heat-loss calculation methodology. Single typical bellows: 5.55 kW exposed → 0.18 kW with Inzonex (96.8% reduction).

Category Component Qty Surface Temp Annual Savings (AED)
Expansion Joints Round non-metallic bellows 312 190°C 750,000
Expansion Joints Oval non-metallic bellows 36 190°C 110,000
Steam System Steam valves & flanges 252 180°C 272,285
Total (654 components) 654 — 1,132,285
The Solution

Inzonex Modular Insulation

Inzonex insulation layers

Materials & Compliance

  • Outer Shell: Silica-coated fabric, flame-retardant, abrasion-resistant, UV protected
  • Insulation Core: High-temperature mineral wool, up to +600°C continuous
  • Fasteners: AISI 316 stainless steel snap buttons
  • Stitching: Meta-aramid thread, +220°C continuous (ceramic up to +1000°C available)
  • Certifications: EN 13501-1 Class A1, REACH/RoHS, ASTM E84

Clamshell Construction · Tool-Free Access

Inzonex Modular Insulation for bellows comes as two symmetric half-shells that close around the equipment like a clamshell. Snap-fit fasteners allow installation and removal in seconds — without tools, without disassembly, without process shutdown.

For HRSG environments, panels use silica-coated fabric and AISI 316 stainless fasteners engineered to withstand temperatures up to 1000°C with full corrosion resistance.

Performance Benchmark
190°C
Bare bellows surface
≤55°C
With Inzonex (safe touch)
5.55 kW
Heat loss per bellows
0.18 kW
With Inzonex (−96.8%)
Investment

Transparent Pricing

🇦🇪
Sold and Delivered in the UAE via Authorised Partner
Alyaseah Oil and Gas Industry Supplies & Services L.L.C (OGISS)
UAE-based supply and logistics. Invoicing, customs clearance, and on-site coordination handled locally.
Inzonex Modular Insulation — Complete Project
654 components across HRSG Units 11, 12 & 21
Payback ~12 months
✓ Engineering & design (per drawing) — included
✓ Production & quality control — included
✓ Delivery to F3 Fujairah site — included
✓ On-site installation supervision — included
✓ Post-install FLIR thermal verification report — included
✓ 36-month warranty on shell & fastening system — included
Total Project Cost (all-inclusive)
VAT not included
1,118,000 AED
Installation
  • ✓ No HRSG shutdown required
  • ✓ Phased rollout during normal operation
  • ✓ Estimated install: 2–3 weeks
  • ✓ Coordinated with plant maintenance team
Verification and Warranty
  • ✓ Post-install FLIR thermography of all components
  • ✓ Surface ≤55°C confirmed in writing
  • ✓ 36-month structural warranty
  • ✓ ESG savings report for annual audit

Ready to Recover 30,170 MWh per Year?

Start saving 1,132,285 AED annually. Payback in ~12 months.

Approve Proposal →