insulation of piping and equipment

8/10/2019 Insulation of Piping and Equipment

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Insulation of Piping and Equipment

ES-14-102-14

Version No. 7.0 Page 1 of 32

Document last modified: 22 November 2013. Date printed: 12 February 2014.

This is a Controlled Document that complies with

Wesfarmers Chemicals, Energy & Fertilisers formatting and Quality Control standards.

Please check that this is the latest available version before use.

Title: INSULATION OF PIPING AND EQUIPMENT

Number: ES-14-102-14

Version Number: 7.0

Date Revised: 22 November 2013

Owner: Manoj Thakur

Authoriser: Manoj Thakur

Reasons for Creating

or Amending

Document

New Owner

New Authoriser

Full Review of Document

Actual Change Details: Australian and British Standards updated.

The word Superintendent replaced with Responsible Officer

TABLE OF CONTENTS

1. SCOPE ....................................................................................................................................... 4

2. DEFINITIONS OF TERMS ..................................................................................................... 4

3. APPLICABLE STANDARDS .................................................................................................. 4

4. INSULATION LIMITS ............................................................................................................ 7

5. INSULATION MATERIAL ..................................................................................................... 8

5.1 TYPE AND PURPOSE OF INSULATION .......................................................... ................ 85.2 INSULATION IDENTIFICATION CODES ........................................................................ 85.3 INSULATION PROPERTIES .............................................................................................. 95.4 INSULATION THICKNESSES ......................................................................................... 105.5 CONSTRUCTION .............................................................................................................. 10

6. CLADDING MATERIAL ...................................................................................................... 11

7. INSULATION ACCESSORIES ............................................................................................ 12

7.1 MATERIALS ...................................................................................................................... 127.2 SUPPORT RINGS, LUGS AND STUDS .................................................... ....................... 13

8. PREPARATION AND PROTECTION ................................................................................ 13


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9. APPLICATION ....................................................................................................................... 13

9.1 GENERAL REQUIREMENTS .......................................................... ................................. 139.2 INSULATED PIPEWORK ................................................................................................. 169.3 INSULATED EQUIPMENT .................................................... ........................................... 169.4

STORAGE TANKS ............................................................................................................ 17

10. INSPECTION AND TESTING .............................................................................................. 18

10.1 QUALITY CONTROL ....................................................................................................... 1810.2 INSPECTION ....................................................... ........................................................... .... 18

11. REPAIRS ................................................................................................................................. 18


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APPENDIX 1 - HOT SERVICE - INSULATION TYPES A AND B THICKNESS IN mm 19

APPENDIX 2 - HOT SERVICE - INSULATION TYPE D THICKNESS IN mm ................. 20

APPENDIX 3 - COLD SERVICE - INSULATION TYPE G THICKNESS IN mm .............. 21

APPENDIX 4 - PERSONNEL PROTECTION - INSULATION TYPE P THICKNESS IN mm

22

APPENDIX 5 - INSULATION CLIPS - HORIZONTAL VESSELS ............................................ 23

APPENDIX 6 - INSULATION CLIPS - VERTICAL VESSELS .................................................. 24

APPENDIX 7 - INSULATION ON PIPING DN400 .................................................................... 25

APPENDIX 8 - RIGID INSULATION ON VERTICAL TANKS, VESSELS & PIPING OVER 400mm

NOMINAL SIZE ................................................................................................................................ 26

APPENDIX 9 - EXPANSION JOINT IN RIGID INSULATION ON PIPING ............................ 27

APPENDIX 10 - REMOVABLE FLANGE BOX ............................................................................ 28

APPENDIX 11 - INSULATION OF INSPECTION COVERS USING REMOVABLE COVER BOXES

29

APPENDIX 12 - INSULATION DETAILS ON EXTERNALLY TRACED PIPES .................... 30

APPENDIX 13 - TYPICAL HANGER FOR COLD INSULATED PIPES................................... 31

APPENDIX 14 - TYPICAL VALVE BOX COLD INSULATED PIPES ...................................... 32

TABLES

Table 1 Insulation Limits ............................................................................................................... 7

Table 2 Insulating Material Heat Transmission Coefficients ........................................................ 9


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1. SCOPE

This Standard covers the minimum technical requirements for design, selection of materials and

methods of application of Hot and Cold Insulation applied to process pipework and equipment atCSBPs facilities.

2.

DEFINITIONS OF TERMS

Contractor/Vendor

The Company that provides the equipment and services needed.

Sub-Contractor

A third party to be employed by the Contractor/Vendor who has been approved by the Responsible

Officer.

Manufacturer

The Company that manufacturers Insulating Material.

Responsible Officer

Wesfarmers CSBP Limited, or authorised representative.

CSBP

Wesfarmers CSBP Limited.

3.

APPLICABLE STANDARDS

The Contractor shall perform the Works in accordance with the most recent issue of the following

Standards.

Where conflict arises between the requirements of this Standard, referenced documents and codes,

such conflict shall be brought immediately to the attention of the Responsible Officer in writing.

The Responsible Officers decision regarding resolution of conflict shall be final.

Australian Standards

AS1530.1 Methods for Fire Tests on Building Materials, Components and Structures -

Combustibility Test for Materials

AS/NZ1594 Hot-Rolled Steel Flat Products

AS/NZ4859 Materials for the thermal Insulation of Buildings General Criteria and

Technical Provisions


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British Standards

BS476 Fire Tests on Building Materials and Structures

Part 4: Non-Combustibility Test for Material

Part 7: Method for Classification of the Surface Spread of Flame of Product

BS EN12664 Thermal performance of building materials and products. Determination of

thermal resistance by means of guarded hot plate and heat flow meter methods.

Dry and moist products of medium and low thermal resistance



Products of high and medium thermal resistance



Thick products of high and medium thermal resistance

BS EN ISO8990 Thermal insulation. Determination of steady-state thermal transmissionproperties . Calibrated and guarded hot box

BS1449 Steel Plate, Sheet and Strip

Part 1: Carbon and Carbon-Manganese Plate and Strip

BS EN 10029 Hot-rolled steel plates 3 mm thick or above. Tolerances on dimensions and

shape

BS EN 10048 Hot rolled narrow steel strip. Tolerances on dimensions and shape

BS EN 10051 Continuously hot-rolled strip and plate/sheet cut from wide strip of non-alloy

and alloy steels. Tolerances on dimensions and shape

BS EN 10095 Heat resisting steels and nickel alloysBS EN ISO9445 Continuously cold-rolled stainless steel narrow strip, wide strip, plate/sheet and

cut lengths. Tolerances on dimensions and form

BS2972 Methods of Test for Inorganic Thermal Insulating Materials

BS3958 Thermal Insulating Materials

Part 3: Metal Mesh Faced Man Made Mineral Fibre

Part 4: Bonded Performance Man Made Mineral Fibre Pipe Sections

Part 5: Specification for Bonded Man Made Mineral Fibre Slabs

BS5422 Method for Specifying Thermal Insulating Materials on Pipes, Ductwork and

Equipment (In the temperature range -40 C to +700C)

BS5970 Code of Practice for Thermal Insulation of Pipework & Equipment (In the

temperature range -100C to +870C)

American Standards

ASTM C533 Calcium Silicate, Preformed Pipe, Fittings Covers and Block Insulation

ASTM B209 Aluminium Alloy Sheet and Plate

NACE RP0198-98 The Control of Corrosion under Thermal Insulation and Fireproofing


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Materials - A Systems Approach

EEMUA Pub. 142 Acoustic Insulation of Pipework and Flanges

CSBP Engineering Standards

ES-14-102-12 Protective Coatings

ES-14-603-14 Steam Tracing


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4. INSULATION LIMITS

EQUIPMENT INSULATED PARTSNON INSULATED

PARTSREMARKS

Vessels

Columns

Boilers

Cylindrical section and

Heads

Nozzle necks and flanges

Man-hole, hand-hole

Name Plate

Skirt and supports

Internally Insulated

equipment

Except for Steam Service,

or other specified

applications

Reactors Cylindrical section and

Heads

Flanges

Skirts and supports

Unless otherwise noted on

drawings

Exchangers Shell

Heads - Bonnets or

Channels

Flanges, Bellows Unless otherwise noted on

drawings

Pipes Flanges and Valves

(steam service)

Semi removable for

flanges, removable for

valves.

Flanges and Valves of

traced pipes as steam

service.

Purge and Vent

connections including

first block valve.

Jacketed lines

Flanges and Valves

(product service)

Expansion bellows

(Unless otherwise noted on

drawings)

Steam Traps and Unions

Pipe supports

On nitric acid, process gas

lines and ammonium

nitrate lines, all dead legs

and instrument connections

shall be fully insulated

with a removable box and

all nozzles also insulated

including instrument

nozzles.

CentrifugalPumps

Body, Flange Unless otherwise noted ondrawings

Control

Instruments

According to instrument

list

Note: All temperatures referenced in this Standard are piping and equipment skin temperatures

within the range -50C and +500C.

Table 1 Insulation Limits


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5. INSULATION MATERIAL

5.1 TYPE AND PURPOSE OF INSULATION

5.1.1

Heat Conservation

Insulation is to be provided to limit the loss of heat for process reasons and steam traced lines

where the temperature is to be kept either constant or higher than ambient.

5.1.2 Personnel protection

Personnel protection insulation to be provided on uninsulated piping operating in excess of 50C or

less than 0C, at locations of possible contact, where insulation is not required for process reasons.

As an alternative to insulation for personal protection, perforated stainless steel sheet may be

installed in lieu of insulation if approved by the Responsible Officer. It has to be sufficiently clear

of the pipe or equipment, such that the temperature of the perforated sheet remains in the range 0Cto 50C, when the pipe or equipment is in service and has reached maximum or minimum

operating temperature.

5.1.3 Cold Conservation

Insulation to be provided for minimisation of heat gain and cold conservation, for protection from

condensation and in case of icing on the surface.

5.1.4 Heat Tracing (Electric or Steam Tracing/Steam Jacketing)

Insulation to be provided primarily for stabilisation of process temperatures, or in certain cases for

protection of equipment and piping not normally used in continuous operation and at times, in caseof adverse atmospheric conditions.

5.2 INSULATION IDENTIFICATION CODES

A = Heat Insulation, Glass Fibre

B = Heat Insulation, Mineral Wool

C = Heat Insulation, Calcium Silicate

D = Heat Insulation, Foam Glass

F = Cold Insulation, Polyurethane or Polystyrene formed in place

G = Cold Insulation, preformed Polyurethane or Polystyrene

H = Cold Insulation, Foam Glass

J = Acoustic Insulation - LightK = Acoustic Insulation Medium

L = Anti Condensing Insulation

N = Acoustic Insulation Heavy

P = Personnel Protection at Locations of Possible Contact

S = Steam Tracing

T = Electric Tracing

U = Steam Jacket

V = Water Jacket

W = Wrapping, Underground Lines

X = Acoustic Insulation with Impedance Layer

Y = Thermal and Acoustic Insulation


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Note: Insulation in areas where ammonium nitrate solution or dust plus an organic agent could

infiltrate hot insulation, shall be closed cell insulation type (Type D) and substantially

free from organic bonding agents and substances which may catalyse ammonium nitrate

decomposition. An example of such an area is the amine mixing and storage area of thePrilling Plant.

5.3 INSULATION PROPERTIES

All insulation applied for heat conservation shall be mineral wool, glass fibre, foam glass or

calcium silicate or any approved equivalent material, which meets the requirements specified.

Insulation applied for personnel protection (P) shall be polystyrene for temperatures 50C, or any approved equivalent material, which meets

the requirements specified. Refer also to Section 5.1.2.

For Stainless Steels, thermal insulation materials and ancillary products with a low total leachable

halide concentration shall be used. These shall be less than 10ppm chlorides, and less than 10ppm

fluorides individually, with the combined total being less than 15ppm, when tested in accordance

with BS2972.

All fixing, banding, wire mesh, etc. shall be Type 316 Stainless Steel.

Any materials liable to be in contact with the surfaces concerned shall not cause corrosion or

support corrosion. Insulation materials shall have a pH value between 7 and 8.

The insulating material physical properties shall remain within the tolerances allowed in BS3958,

Parts 3, 4 and 5.

The insulating materials, including fixing and finishing materials shall be non-combustible to the

requirements of BS476 Part 4.

The material used for any applications shall be in accordance with the requirements of BS5422 and

BS3958.

Heat transmission coefficient of the insulating material shall be as low as possible, and less than the

maximum values specified in Table 2.

THERMAL CONDUCTIVITY W/mK

Insulation CodeTemperature t C

-50 0 50 100 150 200 300 400 500

A, B, C, F,G, P 0.0308 0.0355 0.0401 0.0448 0.0546 0.0639 0.0756 0.0872

D 0.0577 0.0613 0.0663 0.0692

Note: t C is the insulated equipment skin temperature.

Table 2 Insulating Material Heat Transmission Coefficients


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For normal operating temperature, the insulation maximum outside surface temperature shall be

50C.

Ammonium nitrate piping could be jacketed with the maximum outer pipe (carbon steel)

temperature of 200C and this temperature shall be used to determine insulation thickness.

5.4 INSULATION THICKNESSES

5.4.1 Heat Insulation

Insulation thickness for types A and B (including use with Steam/Electrical Tracer / Jacketed lines)

shall be in accordance with APPENDIX 1.

Insulation thickness for type C, Calcium Silicate, shall be in accordance with manufacturers

recommendations, based on thermal conductivity.

Insulation thickness for type D shall be in accordance with APPENDIX 2 .

5.4.2 Cold Insulation

Insulation thickness for type G shall be in accordance with APPENDIX 3

5.4.3 Personnel Protection

Insulation thickness for type P shall be in accordance with APPENDIX 4.

Personnel protection insulation shall not extend more than 2,100mm above grade, floors or

platforms, nor more than 600mm outside platforms. Refer also to Section 5.1.2.

5.4.4 Acoustic Insulation

Requirements to be determined on a case by case basis that is based on the properties of the

insulating material.

5.5 CONSTRUCTION

5.5.1 Heat Insulation

Cylindrical shells and heads - Semi-rigid boards/mattresses or blankets

Piping up to 400mm nominal size - Preformed shells to suit nominal size

Piping 450mm nominal size and larger - Mitred blocks or semi-rigid board

Valves - Pieces cut in semi-rigid board, blankets for small valves.


Shaped blocks, or foamed in place if approved by the Responsible Officer.

Insulating material shall be chemically neutral (contain no soluble sulphur compounds or free ions

of chlorine) to avoid corrosion of the insulated surfaces.

Insulating material shall be suitable for the service temperature, rot proof, odourless and fire proof.


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5.5.3 Mattresses

Mattresses shall be faced on one side with 1.0mm gauge 25mm hexagonal Type 316 stainless steel

wire mesh with 0.4mm Type 316 stainless steel stitching.

5.5.4

Loose Packing

Loose mineral wool used for packing voids shall have a density of approximately 60kg/m3.

6.

CLADDING MATERIAL

Insulation shall be protected from the weather, oil spillage, mechanical wear or other damage by

marine grade aluminium sheet cladding and installed such that all seams are weather repellent.

Thickness of aluminium sheet cladding shall be as follows:

0.8mm Flat - Pipes & Horizontal Vessels up to and including 150mm nominal pipe size

1.0mm Flat - Pipes & Horizontal Vessels 200mm nominal pipe size and above

1.0mm Corrugated - Vertical Vessels and Tanks

1.0mm Flat - Removable Covers

Note: In areas where cladding is exposed to caustic attack, stainless steel cladding of thickness

as follows shall be used in lieu of aluminium:

0.55mm Flat - Pipes & Horizontal Vessels up to and including 150mm nominal pipe size

0.7mm Flat - Pipes & Horizontal Vessels 200mm nominal pipe size and above

0.7mm Corrugated - Vertical Vessels and Tanks

0.7mm Flat - Removable Covers

Overlapping shall be 60mm minimum for vertical seams and 50mm minimum for horizontal seams.

Sections of aluminium sheet shall be beaded on two sides. The beaded side of the horizontal seamshall cover the non-beaded side of the following section. Seams on horizontal piping cladding shall

be watertight.

Up to 250mm nominal size piping, the circumference of the cladding shall be made of only one

piece. Above 250mm and for equipment, circumference of the cladding shall be made up of

several pieces. Adjoining sections of cladding shall be held together by self-tapping screws.

Maximum screw spacing shall be as follows:

a. Piping and equipment up to 1200mm diameter: 150mm

b. Piping and equipment above 1200mm diameter: 300mm


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7. INSULATION ACCESSORIES

7.1 MATERIALS

7.1.1

Binding Wire

Binding wire shall be 1.5mm minimum diameter stainless steel wire.

7.1.2 Banding Strap

Banding strap materials shall be stainless steel, Grade 316 S33 sized as follows:

7.1.2.1 Banding Over Insulation Sections

a. 0.6mm x 13mm - For piping and equipment up to 1200mm diameter.

b. 0.8mm x 20mm - For piping and equipment above 1200mm diameter.

7.1.2.2 Banding Over Cladding

a. 0.6mm x 13mm - For piping up to DN 150

b. 0.6mm x 20mm - For piping DN 200 and above

c. 0.6mm x 50mm - For vessels and tanks

7.1.3 Fasteners

Self-tapping screws, rivets, nuts, bolts and other fastenings shall be stainless steel. S clips shall

be fabricated from stainless steel.

7.1.4

Adhesives

Adhesives used for bonding insulation sections together or to metal surfaces, shall not contain

ketones of methylated hydrocarbon solvents and be as recommended by the Insulation

Manufacturer. Adhesives shall be fire resistant.

7.1.5 Anti-Abrasion Compound

Where a non-flammable anti-abrasion compound that is suitable for temperatures down to -100C

is required it shall be used as recommended by the Insulation Manufacturer.

7.1.6 Sealant

A metal sealant, suitable for gun extrusion to a minimum diameter of 6mm shall be used for sealing

joints overlaps and screw holes in the protective cladding.

It shall comprise of polymeric vapour sealant of butyl rubber and hydrocarbon resin dissolved in

white spirit/xylol blend and pigmented with neutral fillers and aluminium paste. The material shall

have the following properties:

a. Coverage: 35.4 metres per litre at 6mm bead

b. Solids content: Average 55% by volume


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c. Drying time: Touch - hour, thorough - 3 days

d. Service temperature limits: - 40to 200Celsius

e. Solvent: White Spirit

f. Flammability (dry): Low flame spread

7.2 SUPPORT RINGS, LUGS AND STUDS

The vessel fabricator will provide support rings on horizontal vessels. They will comply as a

minimum with Appendix 5.

The vessel fabricator will provide lugs or loops on the bottom heads of vertical columns and

vessels. They will comply as a minimum with

Similarly, the vessel fabricator will provide support rings on vertical vessels and columns generally

in accordance with APPENDIX 6 and APPENDIX 8.

On vertical or inclined lines at more than 45 from horizontal, an insulation support shall be

provided at the bottom and every 3m thereafter, where straight runs exceed three metres.

If any additional holding rings are required, sizing and fastening them shall be the responsibility of

the contractor.

8.

PREPARATION AND PROTECTION

Insulation must be protected against damage and kept dry both in storage, during and afterapplication.

Insulation is only to be applied to clean dry surfaces in dry weather conditions and when the metal

surface temperature is at least 3C above the ambient dew point. Any runs of insulation which are

not completed by the end of the working day are to have all exposed surfaces sealed with vapour-

sealing tape and polythene sheet.

After completion of application of insulation, if the insulation can be exposed to rain, dripping

water or any other cause that may result in damage of the insulation material, it shall be protected

with weatherproof sheeting. The Responsible Officer shall approve the duration and extent of

protection. Permanent terminations shall be fully vapour-sealed, waterproofed and metal clad.

9. APPLICATION

9.1 GENERAL REQUIREMENTS

9.1.1 Scope

The extent of work shall be as detailed on the Data Sheets/Line Designation Lists/ Insulation

Schedule and other documents.


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In no case shall insulation be applied before successful completion of hydrotesting of all piping and

equipment.

The working locations shall be kept in a tidy condition and all waste and surplus material shall be

removed from the site at the completion of the job. All insulation materials and accessories shall

be delivered to the job site in the original, marked, unopened containers as supplied by the

manufacturers.

All statutory health and safety requirements shall be complied with for all operations. In particular,

all materials used shall be of a low-toxicity type and non-flammable. Asbestos-based insulation

shall not be permitted.

9.1.2 Surface Preparation

All surfaces to be insulated shall be cleaned and dried, and must be free from mud, rust, loose

scale, oil, and grease.

Surface protection shall be in accordance with CSBP Engineering Standard Protective Coatings

(ES-14-102-12)as follows:

a. No primer coating required for insulated pipework and equipment which have an operating

temperature of over 100C, except where specified.

b. Insulated piping and equipment surfaces, which have an operating temperature of less than

100C shall be primer coated only to System B.

9.1.3 Layering

For mineral wool insulation single layers shall be used for temperatures up to and including 350 Cand for thicknesses up to 100mm. If the temperatures exceed 350C or the required thickness

exceeds 100mm, multiple layers shall be used.

If the total thickness of Cold Insulation is more than 60mm, insulation shall be applied in several

layers, except for protection against freezing for which maximum layer thickness shall be 30mm.

All joints between successive layers and also between adjacent sections of insulation shall be

staggered.

9.1.4 Installation Requirements

Field welding of any insulation supports on piping and/or equipment is strictly prohibited afterhydrotesting has been completed. Where post-weld heat treatment is needed for equipment or

piping, then insulation supports shall also be heat-treated. Adequate insulation supports shall be

supplied and welded by the fabricator of the piping and/or equipment in accordance with the

drawings and standards.

Removable insulating hoods for flanges, valves and instrument when required shall be made in

sections and attached with quick fastening, cadmium plated or stainless steel clips. This also

applies to removable parts of vessel insulation and process piping where inspection is required

(such as removable bundle tubular heat exchanger).

Piping and/or Equipment supports (skirt, lugs, legs, saddle, etc) shall not be insulated.


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Expansion contraction joints shall be provided in the insulation as required.

Insulation shall be bevelled at the neck of all flanges leaving adequate free space for mounting and

dismounting of bolting.

Elbows shall be insulated with mitred sections of same insulating material as the straight runs.

The application of the insulation shall be carried out in accordance with BS5422 and as required by

this Standard.

Finished surface of the insulation shall allow nameplates and code inspection plate mounting

brackets to remain visible outside the insulation. The insulation shall be finished and properly

sealed against bad weather.

9.1.5 Fastening Insulation

9.1.5.1 Piping and Equipment

DESCRIPTIONPIPING PIPING & EQUIPMENT

1200 DIA

Adjoining sections of

insulation material shall

be firmly butted

together and secured.

Binding wire

maximum

centres 150 mm

0.6 x 13mm

banding strap

c/w flat buckle

max. centres

450 mm

0.6 x 13mm

banding strap c/w

flat buckle max.

centres 300 mm

0.8 x 20mm

banding strap c/w

flat buckle max.

centres 300 mm

Ends of binding wire

loops shall be twisted

together and embedded

into insulation

N/A N/A N/A

Joints shall be staggered

9.1.5.2 Heads

The wire shall be attached to the insulation support lugs and arranged in a diamond pattern so as to

hold firmly the insulation material against the surface of the head.

9.1.6 Sealing

Voids between the insulated surfaces and the insulating material shall be minimised.

Sections of insulation shall fit closely to the surface to be insulated and to adjacent sections. Any

gaps shall be filled with loose insulation material to give a continuous uniform surface.

All insulation shall be weatherproofed and shall be capable of withstanding firewater impingement.

All cracks and voids at the joints of the insulation material shall be filled with insulating cement.

All interruptions in continuity of the cladding shall be made watertight by caulking/sealant.


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9.2 INSULATED PIPEWORK

9.2.1 Hot Insulation

Insulation of pipework shall be carried out with rigid preformed sectional materials or semi rigid

boards. Where the pipe diameter is too large for moulded pipe sections, bevelled blocks shall be

used. All bends, tees and elbows shall be insulated with mitred sections of the same material and

thickness as that for the straight piping.

Insulation assembled to pipework shall be to manufacturers standard lengths as far as possible, but

shall not exceed one metre in length.

Each insulation layer shall be secured with binding wire.

Longitudinal expansion joints where necessary shall consist of 50mm spun mineral wool

compressed to 25mm thickness.

Stainless Steel bands shall be provided as Flange Guards in AN Service clamped at the 6 oclock

position.

Details of insulation assembled to pipework are shown in APPENDIX 7 and APPENDIX 9.


Insulation of pipework shall be carried out using pre-formed material. In-situ foam /sprayed foam

may be used for larger sizes. A Vapour seal shall be an integral part of the Insulation.

Where normal operating temperature is less than 0C and where more than one layer is applied,

each layer shall be sealed.

Pipe supports shall not be attached to the Pipe to avoid difficulties of sealing the support shoe,

instead, load bearing insulation shall be provided at the support at a hanger (see APPENDIX 13) or

a clamped-on type of shoe or directly supported if on a structural beam/pipe sleeper.

Valves and Flanges shall be insulated with moulded or pre-fabricated flange/valve boxes. Refer to

APPENDIX 14 .

9.3 INSULATED EQUIPMENT


Equipment shall be insulated with rigid slabs/boards, or flexible mattresses (rigid slabs only on topsof equipment). Standard preformed pipe sections and mitred blocks shall be used where diameter

permits. Flat slabs shall only be used for flat surfaces or diameters greater than five metres. Pumps

shall not be insulated.

Flexible mattresses shall only be used when it is not possible to apply standard preformed pipe

sections or rigid slabs.

Rigid slab insulation shall be laid with staggered joints and secured with banding at 300mm

centres. When the bands are in position there shall be no cracks, open joints or bruises. Expansion

joints shall be used as required for expansion. Refer to APPENDIX 8.


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Flexible mattress insulation shall be wrapped around the surface and laced to the support rings with

binding wire. Adjacent mattresses shall be laced together with binding wire. The whole insulation

shall then be secured with banding at 300mm centres and tensioned so that the insulation is

compressed about 3mm.

Rigid slab insulation for heads of vessels/heat exchangers shall be segmental in shape. They shall

be held together with binding wire and finally secured by radial bands attached at their inner ends,

to a floating ring of 10mm diameter type 316 stainless steel bar, and at their outer ends to the

support ring on the vessel shell.

Suitably tensioned type 316 stainless steel spring buckles which allow for expansion shall be used

on equipment where required.

For the purpose of taking shell or pipe thickness measurements a removable self-sealing section of

insulation shall be provided.

Skirts, saddles, and supports of insulated equipment shall be insulated externally to a minimumdistance of 600 mm below their point of contact with the shell, or to within 150mm of the

horizontal support, as applicable.


Equipment shall be insulated with pre-formed slabs to ensure an accurate fit. A Vapour Seal shall

be an integral part of the insulation. Expansion/Contraction joints shall be used as required to cover

for differential movement between the vessel and the insulating material.

If normal operating temperature is less than 0C, if applied in more than one layer, each layer shall

be sealed.

9.4 STORAGE TANKS


Insulation on Storage Tanks shall terminate 150mm from the top of the floor plate to keep the

insulation clear of standing liquids. A weather shield flashing shall be installed such that it supports

the insulation and directs the run off from the cladding away from the tank floor/ring beam. A

weatherproof flashing shall also be provided around the perimeter of the tank roof. Where the

storage tank roof is not to be insulated, a suitable flashing shall be fitted over the corrugated sheets

and sealed watertight against the underside of the top curb angle of the tank.

9.4.2

Cold Insulation

The tank base, side walls, roof and appurtenances shall be insulated such that there is a continuous

vapour barrier over the outer surface of the insulation. The vapour seal over the manholes and

nozzles shall be integrated with the shell and roof.

Floor insulation shall be load bearing type and shall be as foam glass, with a vapour barrier.


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10. INSPECTION AND TESTING

10.1 QUALITY CONTROL

Quality control and testing procedures for all manufactured materials/components shall besubmitted to the Responsible Officer for approval.

Tests to be undertaken shall include physical properties of materials, uniformity and thickness of

Aluminium sheets, etc.

The quality control procedure shall be in the form of an inspection and test plan that references all

test procedures, witness points, acceptance and rejection criteria, frequency of testing and how

control of quality is measured and maintained.

Manufacturers of all materials shall supply certificates indicating all results of the applicable tests

required by this Standard.

Proposed quality control and testing procedures shall be submitted to Responsible Officer for

approval.

10.2

INSPECTION

Inspection will be carried out by the Responsible Officer to ensure that the insulation, installation

and equipment comply with the design requirements of this Standard.

Inspection shall include but not be limited to the following:

a. Visual inspection of surface to be insulated and insulation materials being used.

b. Recording of temperatures and humidity during application.

c. Visual inspection of the insulation prior to the application of cladding.

d. Visual inspection after the application of cladding.

e. Visual inspection prior to, and after repairs.

f. Final inspection of the completed works.

Note: The Contractor shall replace any materials that has been improperly installed or damaged.

11.

REPAIRS

Before any repair work is commenced, a repair procedure shall be submitted to the Responsible

Officer for approval, giving details of location, cause of damage and type of repair proposed.

Where paint work and insulation is damaged or removed due to temporary bracing/supports,

temporary attachments, lifting attachments, tie-down operations, etc, the damaged insulation shall

be removed, the paintwork made good and the insulation re-applied in accordance with this

Standard.

Each plant area shall keep a log specifying where all repairs are made and when and how the

repairs were affected.


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APPENDIX 1 - HOT SERVICE - INSULATION TYPES A AND B

THICKNESS IN mm

NOMINAL

PIPE SIZETEMPERATURE IN DEGREES CELSIUS

(mm) 100 150 200 250 300 350 400 450 500

15 30 30 30 30 30 40 40 40 50

20 30 30 30 30 30 40 40 40 50

25 30 30 40 40 40 50 50 50 60

40 30 30 40 40 40 50 50 50 60

50 30 40 40 50 50 60 60 60 80

80 30 40 50 60 60 80 80 80 100

100 40 50 60 60 60 100 100 100 100

150 50 60 70 70 70 100 100 100 100

200 50 60 70 70 70 100 100 100 100

250 50 60 70 80 80 100 100 100 110

300 60 70 80 80 80 120 120 120 120

350 60 70 80 100 100 120 120 120 120

400 60 70 80 100 100 120 120 120 120

450 60 70 80 100 100 120 120 120 150

500 70 70 80 120 120 150 150 150 150

> 500

& shells

70 70 80 120 150 150 150 150 150

Note: Type A insulation is Glass Fibre, Type B is Mineral Wool.

Note:

Piping which is traced may be covered with oversize insulation to include the tracingline(s). Refer to APPENDIX 12 for details.

Note: Insulation for Jacketed piping shall be in accordance with the Jacket Size and the

respective temperature.

Note: Insulation thickness for equipment and piping operating above 500C shall be as

indicated in the respective piping and instrumentation diagrams/equipment drawings.


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APPENDIX 2 - HOT SERVICE - INSULATION TYPE D

THICKNESS IN mm

NOMINAL PIPE

SIZETEMPERATURE IN DEGREES CELSIUS

(mm) 100 150 200

40 30 40 40

50 30 40 50

80 30 40 50

100 30 40 50

150 30 40 65

200 40 50 65

Note: Type D insulation is Foam Glass.


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APPENDIX 3 - COLD SERVICE - INSULATION TYPE G

THICKNESS IN mm

NOMINAL


(mm) +5 -5 -15 -25 -40 -55 -75 -100 -130 -160 -185

15 25 40 40 40 50 50 65 65 75 75 90

20 25 40 40 50 50 50 65 65 75 90 90

25 25 40 40 50 50 50 65 75 90 90 90

40 40 40 50 50 50 65 65 90 90 90 100

50 40 40 50 50 50 65 75 90 90 100 115

80 40 50 50 65 65 75 90 90 100 115 115

100 40 50 50 65 65 75 90 100 115 115 125

150 40 50 65 65 75 75 90 115 115 125 150

200 40 50 65 65 75 75 90 115 125 140 150

250 40 50 65 75 75 90 100 115 125 140 150

300 40 50 65 75 90 90 100 115 125 140 150

350 40 50 65 75 90 100 115 125 140 150 165

400 40 50 65 75 90 100 115 125 140 150 165

450 40 50 65 75 90 100 115 125 140 150 165

500 50 65 75 75 90 100 115 125 150 150 165

> 500

and shells

50 65 75 75 90 100 115 140 150 165 180

Note: Type G insulation is preformed Polyurethane or Polystyrene.


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APPENDIX 4 - PERSONNEL PROTECTION - INSULATION TYPE

P THICKNESS IN mm

(FOR SURFACES OF POSSIBLE CONTACT WITH TEMPERATURE > 500

C OR < 00

C)

NOMINAL


(mm) 100 150 200 250 300 350 400 450 500

15 30 30 30 30 30 40 40 50 50

20 30 30 30 30 30 40 40 50 50

25 30 30 30 30 30 40 40 50 60

40 30 30 30 30 30 40 50 50 60

50 30 30 30 30 30 40 50 60 60

80 30 30 30 30 40 40 50 60 60

100 30 30 30 40 40 40 50 60 70

150 30 30 30 40 40 40 60 60 70

200 30 30 40 40 40 50 60 60 80

250 30 40 40 40 40 50 60 70 80

300 40 40 40 40 50 50 60 70 80

350 40 40 40 50 50 60 60 70 80

400 40 40 40 50 50 60 70 80 80

450 40 40 40 50 50 60 70 80 90

500 40 40 40 50 50 60 70 80 90

500 and

shells

40 40 40 50 50 60 70 80 90

Note: For > 50C use Glass Fibre type A or Mineral Wool type B insulation.

Note: For < 0C use Polystyrene with thickness based on APPENDIX 3 .


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APPENDIX 5 - INSULATION CLIPS - HORIZONTAL VESSELS

Note:

1. Clip to be provided at approximately 500mm Circumferential pitch.

2. Clip material to be compatible with part to which it is attached.

3. Horizontal vessels to have insulation rings at each tan line.

4. Insulation supports provided by vessel fabricator.


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APPENDIX 6 - INSULATION CLIPS - VERTICAL VESSELS


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APPENDIX 7 - INSULATION ON PIPING DN400


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APPENDIX 8 - RIGID INSULATION ON VERTICAL TANKS,

VESSELS & PIPING OVER 400mm NOMINAL SIZE


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APPENDIX 9 - EXPANSION JOINT IN RIGID INSULATION ON

PIPING


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APPENDIX 10 - REMOVABLE FLANGE BOX


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APPENDIX 11 - INSULATION OF INSPECTION COVERS USING

REMOVABLE COVER BOXES


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APPENDIX 12 - INSULATION DETAILS ON EXTERNALLY

TRACED PIPES


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APPENDIX 13 - TYPICAL HANGER FOR COLD INSULATED PIPES


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APPENDIX 14 - TYPICAL VALVE BOX COLD INSULATED PIPES

insulation of piping and equipment

Documents