Inzonex

Gas Turbine GT-12 Assessment

Modular insulation upgrade for a Mitsubishi gas turbine at F3 Fujairah. Explore 5 thermal zones with real FLIR data. Click any section to see heat loss and how Inzonex structured panels replace degraded blanket insulation.

F3 Fujairah Power Plant, UAE · 191.6 m² total surface · 7,000 hrs/year
CURRENT CONDITION
Current
With Inzonex
Click section for thermal data
Degraded / overheating
Upgraded with Inzonex
GT-12 Gas Turbine — Side Profile (Mitsubishi, based on SolidWorks 3D model)
GENERATOR COMPRESSOR COMB. HP TURBINE LP TURBINE EXP. JOINT GT-12 F3 POWER EXHAUST CASING TO HRSG → bar T MITSUBISHI GT-12 HP TOP 210°C HP SIDES 210°C LP ZONE 75°C 300°C EXHAUST 180°C 92.7 m² 53.4 m² 11.3 m² 34.2 m²
Annual Impact Summary — GT-12
0
Current Thermal Loss
MWh (thermal) per year
0
Recoverable Savings
MWh (thermal) per year
0
Electrical Benefit
MWh (electrical) per year
0
Faster Maintenance
vs. traditional blanket system
Section-by-Section Analysis
SectionSurface AreaAvg. TempHeat Loss (kW)Annual Loss (MWhth)Elec. Impact (MWhe)
HP Top Sections23.2 m²210°C103.5711140–215
HP Sides & Bottom69.5 m²210°C202.81,420280–430
LP Section53.4 m²75°C38.121643–65
Expansion Joint (Metallic)11.3 m²300°C96.2657130–200
Exhaust Outer Casing34.2 m²180°C123.0836170–250
Total (5 zones, 191.6 m²)191.6 m²563.63,840770–1,150
Proposed Inzonex System Specifications

Materials

Outer layerFiberglass + Silicone/PTFE
Inner lining (hot side)Silica fabric, up to +1,000°C
Insulation coreMineral wool, up to +660°C
Fastening systemSee Rod Framework below
ReinforcementSS + fiberglass inserts

Performance Targets

Surface temp (accessible)≤ 60°C
Operating hours7,000 hrs/year
Removal speed3–5× faster than wire-tied
Panel weight8–15 kg (one person)
Calculation standardsISO 12241, VDI 2055, ASHRAE
Welding-Free Rod Framework — Concept Design

A welding-free insulation system using embedded steel rods placed between insulation layers to form a support grid. Secured with anti-vibration floating quick-release locks to maintain insulation geometry while allowing rapid removal — replacing all pins, wire and lacing used in traditional systems. The metal framework is positioned behind the insulation layer, operating at 80–150°C instead of 400–500°C. Panel removal: 30–60 seconds, one person, zero tools.

Side Cross-Section — Cut Through Turbine Wall & Insulation Panel
A A ← HOT SIDE (turbine) COLD SIDE (outside) → TURBINE WALL 400–500°C SILICA FABRIC +1000°C INSULATION CORE mineral wool, +660°C UPPER LEDGE RAIL (bolted to turbine flange) LOWER SHELF RING (floating, segmented) OUTER SHELL (PTFE/Silicone) 500°C ~200°C 80°C LAYER A — LOAD-BEARING Rods (AISI 310S, 8–12mm) in sewn silica fabric pockets LAYER B — QUICK-RELEASE LOCKS Over-center toggle latches. Cannot open from vibration. EMBEDDED STEEL RODS Support grid between insulation layers. Hook top = fixed. Bottom = floating (10-15mm for thermal expansion) Mineral wool core surrounds rods — rods at ~150°C Standard SS, not Inconel. 80-90% material cost saving. KEY INNOVATION Metal framework sits BEHIND insulation layer = 80–150°C instead of 400–500°C FIXED ▲ FLOAT ▼ ~160mm total panel thickness

Layer A — Load-Bearing

RodsAISI 310S, 8–12mm, in silica fabric pockets
Upper railAngle bracket on turbine flange
Lower ring4–6 segments, floating fit
Thermal expansionFixed top + floating bottom (10–15mm)
WeldingZero — bolted connections only

Layer B — Quick-Release Locks

TypeOver-center toggle latches
Anti-vibrationCannot open under vibration
OperationOne hand, no tools, <5 sec
Quantity2–4 per panel
Rod endsBall-detent pins, positive lock
Current Avg.
→
With Inzonex
Heat Loss (kW)
Annual Loss
Elec. Benefit
Surface Area