Insulation of Piping and Equipment ES-14-102-14

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: Number: Owner: Authoriser: Reasons for Creating or Amending Document Actual Change Details:

INSULATION OF PIPING AND EQUIPMENT ES-14-102-14

Harish Chopra David Zacher

Full Review of Existing Document

Reviwed no changes to content.

TABLE OF CONTENTS
1. 2. 3. 4. 5. 5.1 5.2 5.3 5.4 5.5 6. 7. 7.1 7.2 8. 9. 9.1 9.2 9.3 9.4 10. SCOPE ....................................................................................................................................... 4 DEFINITIONS OF TERMS..................................................................................................... 4 APPLICABLE STANDARDS.................................................................................................. 4 INSULATION LIMITS ............................................................................................................ 6 INSULATION MATERIAL..................................................................................................... 7 TYPE AND PURPOSE OF INSULATION.......................................................................... 7 INSULATION IDENTIFICATION CODES ........................................................................ 7 INSULATION PROPERTIES .............................................................................................. 8 INSULATION THICKNESSES ........................................................................................... 9 CONSTRUCTION ................................................................................................................ 9 CLADDING MATERIAL ...................................................................................................... 10 INSULATION ACCESSORIES ............................................................................................ 11 MATERIALS ...................................................................................................................... 11 SUPPORT RINGS, LUGS AND STUDS ........................................................................... 12 PREPARATION AND PROTECTION ................................................................................ 12 APPLICATION....................................................................................................................... 12 GENERAL REQUIREMENTS........................................................................................... 12 INSULATED PIPEWORK ................................................................................................. 15 INSULATED EQUIPMENT............................................................................................... 15 STORAGE TANKS ............................................................................................................ 16 INSPECTION AND TESTING.............................................................................................. 17

Version No. 6.0

Page 1 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

10.1 10.2 11.

QUALITY CONTROL ....................................................................................................... 17 INSPECTION...................................................................................................................... 17

REPAIRS ................................................................................................................................. 17

Version No. 6.0

Page 2 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

APPENDIX 1 - HOT SERVICE - INSULATION TYPES A AND B THICKNESS IN mm 18 APPENDIX 2 - HOT SERVICE - INSULATION TYPE D THICKNESS IN mm ................. 19 APPENDIX 3 - COLD SERVICE - INSULATION TYPE G THICKNESS IN mm .............. 20 APPENDIX 4 - PERSONNEL PROTECTION - INSULATION TYPE P THICKNESS IN mm 21 APPENDIX 5 - INSULATION CLIPS - HORIZONTAL VESSELS ............................................ 22 APPENDIX 6 - INSULATION CLIPS - VERTICAL VESSELS .................................................. 23 APPENDIX 7 - INSULATION ON PIPING DN400 .................................................................... 24 APPENDIX 8 - RIGID INSULATION ON VERTICAL TANKS, VESSELS & PIPING OVER 400mm NOMINAL SIZE ................................................................................................................................ 25 APPENDIX 9 - EXPANSION JOINT IN RIGID INSULATION ON PIPING ............................ 26 APPENDIX 10 - REMOVABLE FLANGE BOX............................................................................ 27 APPENDIX 11 - INSULATION OF INSPECTION COVERS USING REMOVABLE COVER BOXES 28 APPENDIX 12 - INSULATION DETAILS ON EXTERNALLY TRACED PIPES .................... 29 APPENDIX 13 - TYPICAL HANGER FOR COLD INSULATED PIPES................................... 30 APPENDIX 14 - TYPICAL VALVE BOX COLD INSULATED PIPES...................................... 31

TABLES Table 1 Table 2 Insulation Limits ............................................................................................................... 6 Insulating Material Heat Transmission Coefficients ........................................................ 8

Version No. 6.0

Page 3 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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 at CSBPs 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 Superintendent. Manufacturer The Company that manufacturers Insulating Material. Superintendent Wesfarmers CSBP Limited, or authorised representative. For internal works the Superintendent shall be the Responsible Officer. 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 Superintendent in writing. The Superintendents decision regarding resolution of conflict shall be final. Australian Standards AS1449 AS1530.1 AS1594 AS2461 AS2464 AS3742 Wrought Alloy Steels - Stainless & Heat Resisting Steel Plate, Sheet & Strip Methods for Fire Tests on Building Materials, Components and Structures Combustibility Test for Materials Hot-Rolled Steel Flat Products Mineral Wool Thermal Insulation - Loose Fill Methods of Testing Thermal Insulation Mineral Wool Thermal Insulation - Batt and Blanket

Version No. 6.0

Page 4 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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 Methods for Determining Thermal Insulating Properties Steel Plate, Sheet and Strip Part 1: Part 2: BS2972 BS3958 Carbon and Carbon-Manganese Plate and Strip Specification for Stainless & Heat Resisting Steel Plate, Sheet & Strip

BS874 BS1449

Methods of Test for Inorganic Thermal Insulating Materials Thermal Insulating Materials Part 3: Part 4: Part 5: Metal Mesh Faced Man Made Mineral Fibre Bonded Performance Man Made Mineral Fibre Pipe Sections Specification for Bonded Man Made Mineral Fibre Slabs

BS5422 BS5970

Method for Specifying Thermal Insulating Materials on Pipes, Ductwork and Equipment (In the temperature range -40 C to +700C) Code of Practice for Thermal Insulation of Pipework & Equipment (In the temperature range -100C to +870C)

American Standards ASTM C533 ASTM B209 NACE RP0198-98 EEMUA Pub. 142 Calcium Silicate, Preformed Pipe, Fittings Covers and Block Insulation Aluminium Alloy Sheet and Plate The Control of Corrosion under Thermal Insulation and Fireproofing Materials - A Systems Approach Acoustic Insulation of Pipework and Flanges

CSBP Engineering Standards ES-14-102-12 ES-14-603-14 Protective Coatings Steam Tracing

Version No. 6.0

Page 5 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

4.

INSULATION LIMITS

EQUIPMENT INSULATED PARTS Vessels Columns Boilers Cylindrical section and Heads

NON INSULATED PARTS Nozzle necks and flanges Man-hole, hand-hole Name Plate Skirt and supports Internally Insulated equipment Flanges Skirts and supports Flanges, Bellows

REMARKS Except for Steam Service, or other specified applications

Reactors Exchangers

Cylindrical section and Heads Shell Heads - Bonnets or Channels 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

Unless otherwise noted on drawings Unless otherwise noted on drawings

Pipes

Flanges and Valves (product service)

On nitric acid, process gas lines and ammonium nitrate lines, all dead legs and instrument connections Expansion bellows shall be fully insulated (Unless otherwise noted on with a removable box and drawings) all nozzles also insulated including instrument nozzles. Steam Traps and Unions Pipe supports

Centrifugal Pumps Control Instruments Note:

Body, Flange

Unless otherwise noted on drawings According to instrument list

All temperatures referenced in this Standard are piping and equipment skin temperatures within the range -50C and +500C. Table 1 Insulation Limits

Version No. 6.0

Page 6 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

5.
5.1
5.1.1

INSULATION MATERIAL
TYPE AND PURPOSE OF INSULATION
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 Superintendent. It has to be sufficiently clear of the pipe or equipment, such that the temperature of the perforated sheet remains in the range 0C to 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 case of adverse atmospheric conditions.

5.2
A B C D F G H J K L N P S T U V W X Y

INSULATION IDENTIFICATION CODES

= = = = = = = = = = = = = = = = = = = Heat Insulation, Glass Fibre Heat Insulation, Mineral Wool Heat Insulation, Calcium Silicate Heat Insulation, Foam Glass Cold Insulation, Polyurethane or Polystyrene formed in place Cold Insulation, preformed Polyurethane or Polystyrene Cold Insulation, Foam Glass Acoustic Insulation - Light Acoustic Insulation Medium Anti Condensing Insulation Acoustic Insulation Heavy Personnel Protection at Locations of Possible Contact Steam Tracing Electric Tracing Steam Jacket Water Jacket Wrapping, Underground Lines Acoustic Insulation with Impedance Layer Thermal and Acoustic Insulation

Version No. 6.0

Page 7 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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 the Prilling 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 <0C and glass fibre or mineral wool 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 Code A, B, C, F,G, P D Note: Temperature t C -50 0 50
0.0401 0.0577

100
0.0448

150

200
0.0546 0.0692

300
0.0639

400
0.0756

500
0.0872

0.0308 0.0355

0.0613 0.0663

t C is the insulated equipment skin temperature. Table 2 Insulating Material Heat Transmission Coefficients

Version No. 6.0

Page 8 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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
5.4.1

INSULATION THICKNESSES
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
5.5.1

CONSTRUCTION
Heat Insulation - Semi-rigid boards/mattresses or blankets - Preformed shells to suit nominal size - Pieces cut in semi-rigid board, blankets for small valves. Cold Insulation

Cylindrical shells and heads Piping up to 400mm nominal size Valves 5.5.2

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

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

Version No. 6.0

Page 9 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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 1.0mm Flat - Pipes & Horizontal Vessels up to and including 150mm nominal pipe size - Pipes & Horizontal Vessels 200mm nominal pipe size and above

1.0mm Corrugated - Vertical Vessels and Tanks 1.0mm Flat Note: - Removable Covers

In areas where cladding is exposed to caustic attack, stainless steel cladding of thickness as follows shall be used in lieu of aluminium: - Pipes & Horizontal Vessels up to and including 150mm nominal pipe size - Pipes & Horizontal Vessels 200mm nominal pipe size and above

0.55mm Flat 0.7mm Flat

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 seam shall 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. b. Piping and equipment up to 1200mm diameter: Piping and equipment above 1200mm diameter: 150mm 300mm

Version No. 6.0

Page 10 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

7.
7.1
7.1.1

INSULATION ACCESSORIES
MATERIALS
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 to BS1449 Part 2, Grade 316 S33 sized as follows: 7.1.2.1 a. b. 7.1.2.2 a. b. c. 7.1.3 Banding Over Insulation Sections 0.6mm x 13mm 0.8mm x 20mm - For piping and equipment up to 1200mm diameter. - For piping and equipment above 1200mm diameter.

Banding Over Cladding 0.6mm x 13mm 0.6mm x 20mm 0.6mm x 50mm Fasteners - For piping up to DN 150 - For piping DN 200 and above - For vessels and tanks

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. b. Coverage: Solids content: 35.4 metres per litre at 6mm bead Average 55% by volume

Version No. 6.0

Page 11 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

c. d. e. f.

Drying time: Service temperature limits: Solvent: Flammability (dry):

Touch - hour, thorough - 3 days - 40 to 200 Celsius White Spirit 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 after application. 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 vapoursealing 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 Superintendent shall approve the duration and extent of protection. Permanent terminations shall be fully vapour-sealed, waterproofed and metal clad.

9.
9.1
9.1.1

APPLICATION
GENERAL REQUIREMENTS
Scope

The extent of work shall be as detailed on the Data Sheets/Line Designation Lists/ Insulation Schedule and other documents.

Version No. 6.0

Page 12 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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. Insulated piping and equipment surfaces, which have an operating temperature of less than 100C shall be primer coated only to System B. Layering

b.

9.1.3

For mineral wool insulation single layers shall be used for temperatures up to and including 350C and 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 after hydrotesting 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.

Version No. 6.0

Page 13 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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 9.1.5.1 Fastening Insulation Piping and Equipment PIPING <DN150 DN200 - 600 0.6 x 13mm banding strap c/w flat buckle max. centres 450 mm N/A PIPING & EQUIPMENT 650 - 1200 DIA 0.6 x 13mm banding strap c/w flat buckle max. centres 300 mm N/A >1200 DIA 0.8 x 20mm banding strap c/w flat buckle max. centres 300 mm N/A

DESCRIPTION

Adjoining sections of Binding wire insulation material shall maximum be firmly butted centres 150 mm together and secured. Ends of binding wire loops shall be twisted together and embedded into insulation 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.

Version No. 6.0

Page 14 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

9.2
9.2.1

INSULATED PIPEWORK
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. 9.2.2 Cold Insulation

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
9.3.1

INSULATED EQUIPMENT
Hot Insulation

Equipment shall be insulated with rigid slabs/boards, or flexible mattresses (rigid slabs only on tops of 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.

Version No. 6.0

Page 15 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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 minimum distance of 600 mm below their point of contact with the shell, or to within 150mm of the horizontal support, as applicable. 9.3.2 Cold Insulation

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
9.4.1

STORAGE TANKS
Hot Insulation

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.

Version No. 6.0

Page 16 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

10.
10.1

INSPECTION AND TESTING

QUALITY CONTROL

Quality control and testing procedures for all manufactured materials/components shall be submitted to the Superintendent 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 Superintendent for approval.

10.2

INSPECTION

Inspection will be carried out by the Superintendent 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. b. c. d. e. f. Note: Visual inspection of surface to be insulated and insulation materials being used. Recording of temperatures and humidity during application. Visual inspection of the insulation prior to the application of cladding. Visual inspection after the application of cladding. Visual inspection prior to, and after repairs. Final inspection of the completed works. 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 Superintendent 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.

Version No. 6.0

Page 17 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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

NOMINAL PIPE SIZE (mm) 15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 > 500 & shells 100 30 30 30 30 30 30 40 50 50 50 60 60 60 60 70 70 150 30 30 30 30 40 40 50 60 60 60 70 70 70 70 70 70

TEMPERATURE IN DEGREES CELSIUS 200 30 30 40 40 40 50 60 70 70 70 80 80 80 80 80 80 250 30 30 40 40 50 60 60 70 70 80 80 100 100 100 120 120 300 30 30 40 40 50 60 60 70 70 80 80 100 100 100 120 150 350 40 40 50 50 60 80 100 100 100 100 120 120 120 120 150 150 400 40 40 50 50 60 80 100 100 100 100 120 120 120 120 150 150 450 40 40 50 50 60 80 100 100 100 100 120 120 120 120 150 150 500 50 50 60 60 80 100 100 100 100 110 120 120 120 150 150 150

Note: Note: Note:

Type A insulation is Glass Fibre, Type B is Mineral Wool. Piping which is traced may be covered with oversize insulation to include the tracing line(s). Refer to APPENDIX 12 for details. Insulation for Jacketed piping shall be in accordance with the Jacket Size and the respective temperature. Insulation thickness for equipment and piping operating above 500C shall be as indicated in the respective piping and instrumentation diagrams/equipment drawings.

Note:

Version No. 6.0

Page 18 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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

NOMINAL PIPE SIZE (mm) 40 50 80 100 150 200 100 30 30 30 30 30 40

TEMPERATURE IN DEGREES CELSIUS 150 40 40 40 40 40 50 200 40 50 50 50 65 65

Note:

Type D insulation is Foam Glass.

Version No. 6.0

Page 19 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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

NOMINAL PIPE SIZE (mm) 15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 > 500 and shells +5 25 25 25 40 40 40 40 40 40 40 40 40 40 40 50 50 -5 40 40 40 40 40 50 50 50 50 50 50 50 50 50 65 65

TEMPERATURE IN DEGREES CELSIUS -15 40 40 40 50 50 50 50 65 65 65 65 65 65 65 75 75 -25 40 50 50 50 50 65 65 65 65 75 75 75 75 75 75 75 -40 50 50 50 50 50 65 65 75 75 75 90 90 90 90 90 90 -55 50 50 50 65 65 75 75 75 75 90 90 100 100 100 100 100 -75 65 65 65 65 75 90 90 90 90 100 100 115 115 115 115 115 -100 65 65 75 90 90 90 100 115 115 115 115 125 125 125 125 140 -130 75 75 90 90 90 100 115 115 125 125 125 140 140 140 150 150 -160 75 90 90 90 100 115 115 125 140 140 140 150 150 150 150 165 -185 90 90 90 100 115 115 125 150 150 150 150 165 165 165 165 180

Note:

Type G insulation is preformed Polyurethane or Polystyrene.

Version No. 6.0

Page 20 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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

(FOR SURFACES OF POSSIBLE CONTACT WITH TEMPERATURE > 500C OR < 00C)

NOMINAL PIPE SIZE (mm) 15 20 25 40 50 80 100 150 200 250 300 350 400 450 500 500 and shells 100 30 30 30 30 30 30 30 30 30 30 40 40 40 40 40 40 150 30 30 30 30 30 30 30 30 30 40 40 40 40 40 40 40

TEMPERATURE IN DEGREES CELSIUS 200 30 30 30 30 30 30 30 30 40 40 40 40 40 40 40 40 250 30 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50 300 30 30 30 30 30 40 40 40 40 40 50 50 50 50 50 50 350 40 40 40 40 40 40 40 40 50 50 50 60 60 60 60 60 400 40 40 40 50 50 50 50 60 60 60 60 60 70 70 70 70 450 50 50 50 50 60 60 60 60 60 70 70 70 80 80 80 80 500 50 50 60 60 60 60 70 70 80 80 80 80 80 90 90 90

Note: Note:

For > 50C use Glass Fibre type A or Mineral Wool type B insulation. For < 0C use Polystyrene with thickness based on APPENDIX 3 .

Version No. 6.0

Page 21 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

APPENDIX 5 - INSULATION CLIPS - HORIZONTAL VESSELS

Note: 1. 2. 3. 4.

Clip to be provided at approximately 500mm Circumferential pitch. Clip material to be compatible with part to which it is attached. Horizontal vessels to have insulation rings at each tan line. Insulation supports provided by vessel fabricator.

Version No. 6.0

Page 22 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

APPENDIX 6 - INSULATION CLIPS - VERTICAL VESSELS

Version No. 6.0

Page 23 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

APPENDIX 7 - INSULATION ON PIPING DN400

Version No. 6.0

Page 24 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

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

Version No. 6.0

Page 25 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

APPENDIX 9 - EXPANSION JOINT IN RIGID INSULATION ON PIPING

Version No. 6.0

Page 26 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

APPENDIX 10 - REMOVABLE FLANGE BOX

Version No. 6.0

Page 27 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

APPENDIX 11 - INSULATION OF INSPECTION COVERS USING REMOVABLE COVER BOXES

Version No. 6.0

Page 28 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

APPENDIX 12 - INSULATION DETAILS ON EXTERNALLY TRACED PIPES

Version No. 6.0

Page 29 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

APPENDIX 13 - TYPICAL HANGER FOR COLD INSULATED PIPES

Version No. 6.0

Page 30 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.

Insulation of Piping and Equipment ES-14-102-14

APPENDIX 14 - TYPICAL VALVE BOX COLD INSULATED PIPES

Version No. 6.0

Page 31 of 31

Document last modified: 29 November 2011. PDF created: 08 December 2011.