G3ir 1000 55 SP 9002 - R1 PDF

Client Name : BASF India Limited
Project Name : Project GIR

Project Number: G3IR

Specification
G3IR-1000-55-SP-9002
Date 31 Oct 2012
Page 1

Cold Insulation of Equipment and Pipeline
G3IR-1000-55-SP-9002_Rev 1 Page 1 of 19

Document No: G3IR-1000-55-SP-9002

Unit: General

Discipline: Mechanical

Document Type: Specification

Document Title: Cold Insulation of Equipment and Pipeline

1 31-Oct- 2012 Issued for Construction AV AA VP
0 10-J une 2012 Issued for RFQ AV AA VP
Revision Date Purpose Prepared By Checked By
Fluor BASF
Approved By

This document was prepared for BASF INDIA LIMITED by FLUOR DANIEL INDIA PVT LTD (CONTRACTOR) and based in part on
information not within the control of either owner or contractor. Neither owner not contractor have made an analysis, verified or rendered
an independent judgement of the validity of the information provided by others. While it is believed that the information contained herein
will be reliable under the conditions and subject to the limitations set forth herein, neither owner nor contractor guarantee the accuracy
thereof. Use of this report or any information contained herein shall be at users sole risk.

AV AA VP
ISSUED FOR
CONSTRUCTION
05 Nov 2012

Specification
G3IR-1000-55-SP-9002
Date 31 Oct 2012
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RecordofRevisions

This specification has been revised as indicated below and described in the revision record on the
following page. Please destroy all previous revisions.

Revision
No.
Date Description
0 10-J une-2012 Issued for RFQ ( No Change , Only G2IR is changed to G3IR)
1 31-Oct-2012 Issued for Construction ( No change)


Specification
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TABLE OF CONTENTS

GENERAL ............................................................................................................................................................ 4
2. REFERENCES ............................................................................................................................................... 5
3. PRODUCTS .................................................................................................................................................... 6
4. EXECUTION ................................................................................................................................................... 8
4.1. GENERAL............................................................................................................................................... 8
4.2. INSULATION THICKNESSES ............................................................................................................... 8
4.3. PIPING INSULATION ............................................................................................................................. 8
5. SUBMITTALS ............................................................................................................................................... 14
6. QUALIFICATIONS ....................................................................................................................................... 14
7. STORAGE AND HANDLING ....................................................................................................................... 14
TABLE 1 ............................................................................................................................................................ 15
TABLE 2 ............................................................................................................................................................ 16
TABLE 3 ............................................................................................................................................................ 16
TABLE 4 ............................................................................................................................................................ 16
TABLE 5 ............................................................................................................................................................ 17
TABLE 6 ............................................................................................................................................................ 18
ATTACHMENT 1 ............................................................................................................................................... 19

Specification
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GENERAL
1.1. Scope of Specification

Specification for scope of work, general terms and conditions, special conditions and all
instructions for insulation Contractor shall be considered as supplementing the
requirements of this specification.

1. This specification prescribes the procedures for the selection and application of field
applied, external, thermal insulation and weatherproofing to piping, vessels, and
equipment operating in the low temperature range of minus 100C to ambient.

2. Wherever a difference exists between this specification and the drawings, the
drawings shall govern. However, no deviations shall be made from this specification
without written authorization from the Owner.

1.2. Work Not Included

Intermediate and high temperature thermal insulation from ambient to 650C is covered
in G3IR-1000-55-SP-9000: Specification for Hot Insulation.

1.3. Related Specifications

The following specifications prescribe items of related Work:

G3IR-1000-55-SP-9000: Hot Insulation
G3IR-1000-55-SP-9001: Painting

Coordinate Work prescribed by this specification with Work prescribed by the above listed
specification.

1.4. Terminology

1. Concealed Area: An area not normally exposed to view of persons performing daily
tasks in a building.
2. Exposed Area: An area normally exposed to view by persons performing daily tasks
in a building.
3. Indoors: An area in which insulation is protected sufficiently by building structure.
4. Outdoors: An area in which insulation is in direct contact of sun, rain etc.
5. Insulation Codes: Piping and equipment shall be insulated wherever insulation
codes are indicated on the Engineering and Utility system Flow Diagrams, Piping
Line.

Lists, Piping Plans and Piping Isometric Drawings. The insulation code that is
applicable to this specification is defined as follows:

Specification
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Insulation Code Definition

IC Insulate to control temperature, surfaces
condensation, and conserve refrigeration (cold).

6. Block (called BOARD by some suppliers): Refers to rigid insulation having
compressive strength of at least 7 kg/cm
2
at 5 percent deformation.

2. REFERENCES

The publications listed below form part of this specification. Each publication shall be
the latest revision and addendum in effect at the time of Contract issue. Except as
modified by the requirements specified herein or the details of the drawings, thermal
insulation materials shall meet the requirements of the following specifications
applicable to the specific product.

ASTM: (American Society for Testing and Materials)

ASTM C450 Recommended Practice for Fabrication of Thermal Insulating
Fitting Covers.

ASTM C585 Recommended Practice for Inner and Outer of Rigid Thermal
Insulation for Nominal Sizes of Pipe and Tubing

ASTM C764 Specification for Mineral Fiber Loose Fill Thermal Insulation

ASTM C653 Determination of the Thermal resistance of Low Density Blanket
Type Mineral Fiber Insulation

ASTM C795 Specification for Wicking-type Thermal Insulation for Use Over
Austenitic Stainless Steel

ASTM C1094 Specification for Removable Covers

ASTM E84 Surface Burning Characteristics of Building Materials

ASTM E96 Water Vapour Transmission of Materials in Sheet Form

Other Indian Standards

IS 6911 Specification for Stainless Steel Plate Sheets and Strips

IS 9842 Performed Fibrous Pipe Section


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IS 12436 Preformed rigid Polyurethane (PUR) and Polyisocyanuarate
(PIR) foams fir Thermal Insulation

IS 14164 Industrial Application and finishing of thermal Insulation materials
for -80 deg C upto 750 deg C

IS 15402 Ceramic Fiber Blanket Insulation

IS 13205 Code of Practice for Application of Polyurethane Insulation by
Insitu pouring method

IS 3346 Method for determination of thermal conductivity of thermal
Insulation Materials

BS 5608 Specification for preformed rigid polyurethane (PUR) and
polyisocyanurate (PIR) foams for thermal insulation of pipework
and equipment

Local Code Requirements (if any)

If any local code publications, those are currently in use, exceed the requirements of
the above referenced publications than the more stringent shall be applied to this
specification section.

3. PRODUCTS
Where brand or trade names are mentioned herein, they are for the purpose of identifying
general types of acceptable materials. Products of equivalent characteristics shall be
acceptable after information regarding temperature and service limits; K factors over full
range of temperature limits, flame spread rating, physicals, and composition are submitted
to and approved by Owner or his designee.

3.1. General

A. All insulation materials and accessories shall conform to the regulations of the
Occupational Safety and Health Administration (OSHA) and local laws. Material
Safety Data Sheets (MSDS) are required for insulation and accessories, including
adhesives (if any).
B. When the insulation or use of thermal insulation materials, accessories, and
systems may pose safety or health problems, Manufacturer shall provide
appropriate current information regarding known problems associated with the
recommended use of the companys products and shall also recommend protective
measures to be employed in there safe utilization. Contractor shall establish
appropriate safety and health practices and determine the applicability of regulatory
requirements prior to use.

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C. Materials shall be new, the best quality of the respective types and suitable for the
intended service.
D. Insulation and accessory materials shall not contain asbestos in any form. The
requirement shall be maintained without exception.
E. Insulation materials for austenitic stainless steel piping vessels, and equipment
shall meet the requirements in ASTM C795 for an acceptable analysis.

3.2. Insulation Material

Insulation material shall be Polyurethane Foam (PUF/PIR) supplied in preformed
pipe cover, curved or flat block form.

3.3. Jacketed Material

J acketing material selection shall be based on the materials listed in Table 4.

A. All insulation jacketing will be Aluminium except high fire risk area. Stainless Steel
J acketing will be used in high risk of fire areas. All Stainless Steel jacketing systems
shall have a moisture barrier to prevent galvanic corrosion at the metal-to-insulation
interface of the jacket. Moisture barriers (3 mil thick Polysurlyn film) shall be factory-
applied to the underside of the Stainless Steel jacket.

3.4. Standard Accessory Material

A. Insulation Accessory Material

1. Vapour barrier mastic reinforced with glass fabric applied to total thickness
of 5mm (3/16, or a 30 mil ) rubberized bitumen adhesive laminated to a 3
mil polysurlyn film shall be applied to all insulated surfaces prior to the
application of weatherproof jacket.

2. Following adhesives and Sealant to be used:
Loidseal 39, MAS-35 or Foster 30-45 for J oint Sealant
Loidmastic 130, MAS-130 or Foster 60 35 coating for coating and
Vapour Sealmastic

B. Metal J acket Accessory Material

1. Flashing joint sealer/caulking compound shall be non-shrinking,
permanently flexible, metallic gray, 94 percent non-volatile, with a water
vapour permeability of 0.008 as specified by ASTM E96, for service from
minus 37 C to 149 C.
3.5. Removable and Reusable Covers


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All hand hole and manhole flanges, blind flanges, vessel and equipment flanges
shall be insulated.

4. EXECUTION
4.1. GENERAL

A. All applications of insulation systems shall be in strict accordance with these
specifications and Manufacturers recommendations. All installation procedures
shall follow good and acceptable insulation practices for the particular service and
temperature involved.
B. Insulation shall not be applied to any piping or equipment that has not been
released for insulation.
C. Contractor shall maintain orderly work areas free of debris at all time.
D. Insulation materials shall be protected against the elements at all times. Every
precaution should be taken to ensure that each days work is weatherproofed during
erection and before leaving for the night. Decking and covering tarp are not
considered sufficient protection from the elements for storing of materials.
E. It is the responsibility of insulation contractor to clean the surfaces by removing
loose scale and other surface contaminants such as oil, grease, dirt, moisture, ice,
or snow, prior to the insulation application.
F. Care should be taken to avoid contact between dissimilar materials, which might
cause galvanic corrosion.
G. On cold systems, vapour barrier performance is extremely important. All
penetrations of the vapour barrier and exposed insulation must be sealed to prevent
moisture incursion.

4.2. INSULATION THICKNESSES

A. Thickness of insulation for piping, vessels, and equipment coded "IC" shall be in
accordance with Table 1.
B. Insulation thickness in excess of 100mm shall be applied in a minimum of two
layers.

4.3. PIPING INSULATION

A. General

1. The following items shall not be insulated unless otherwise noted on the drawings,
or noted herein:

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a. Sight Glasses
b. Tri-Clamped connections
c. Diaphragm Valve Bonnets
d. Valve bonnets

2. Insulate attachments to the pipe that project through the insulation. Externally
insulate projections from the point where they project through the insulation for a
distance of 4 times the thickness of the base insulation, unless otherwise shown on
drawings.
3. Valves and flanges in insulated lines shall be insulated with the same thickness of
insulation as the pipe to which attached.
4. The basic insulating materials for piping 600 mm and under shall be fabricated in
cylindrical sections conforming to ASTM C585, or half sections depending upon
pipe size and commercial availability.
5. Preformed insulation shall be used on all fittings whenever commercially available,
provided the material satisfies all the specifications of the insulation for straight
pipe.
6. Where pipe saddle supports are used, high compressive strength saddle insulation
may be provided and installed with the pipe hanger and is included in the Work
prescribed by this specification. The pipe saddle insulation thickness shall be the
same as the specified pipe insulation thickness.
7. Insulation shall be sized specifically for the intended application on either NPS
pipe or OD tube.

8. For Impulse Lines (small diameter pipes of diameter less than 50.8mm) to be
insulated with Supercera Ceramic Fibre Rope to diameter 18-24mm. The rope shall
be reinforced with SS wire for tight application.

B. Insulation Application

1. Apply single thickness sectional pipe insulation in such a manner that all voids are
eliminated. Coat the butt edges with a 1.6mm thick layer of joint sealer. In cases of
double layer pipe insulation, apply the inner layer without sealer joint. Secure each
layer of insulation with wire or bands as shown in PIP drawings in Attachment.
Place bands within 13mm of the end of each section. When applying double layer
insulation, stagger or offset outer layer joints from the inner layer joints. Only the
outer layer of double layer insulation shall have a vapour barrier. Seal the
longitudinal and circumferential overlaps of the vapour barrier jacketing with an
adhesive.
2. Insulate and complete vapour seal attachments fastened to piping. Extend the
insulation a minimum distance of 4 times the pipe insulation thickness from the pipe.
3. Insulate fittings, including valve bodies, with prefabricated fitting covers or mitred
sectional pipe insulation, securely wired or banded in place.

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4. Install insulation materials with smooth and even surfaces. Insulate each continuous
run of piping with full length units of insulation, with single cut piece to complete run.
Do not use cut pieces or scraps abutting each other. Butt insulation joints firmly to
ensure complete, tight fit over all piping surfaces.
5. Maintain the integrity of factory applied vapour barrier jacketing on all pipe
insulation, protecting it against puncture, tears or other damage.
6. Extend piping insulation without interruption through walls floors ceilings, and similar
piping penetrations, except where otherwise specified.
7. All insulated surfaces, shall receive a vapour barrier per section 3.4A prior to
8. Supercera Ceramic Fibre Pad of thickness 75mm or 50mm comprising of Ceramic
Fibre Blanket of density 128 kg/m3 (25mm x 2 or 3 nos.) encased in glass cloth and
stitched with SS wire on the sides and provided with suitable fastening
arrangement, for application over Valve & Flange. The pad shall be coated with
Teflon for application of exposed areas to act as a water proof. The pad shall have
a layer of SS foil in between two layers of Ceramic Fibre Blanket in each pad.

C. Supports

1. Pipe supports shall be supplied and installed by others. Supports for insulation shall
be supplied and installed by the contractor. Field welding supports to vessels,
equipment and piping is not allowed without prior written authorization.

2. All the insulation lines shall have high density Polyurethane Pipe Supports. The pipe
supports shall be of density 250 kg/m3 for pipe diameter up to 250mm and beyond
that of density 320 kg/m3. The pipe supports shall be of length 300-450mm
depending upon the metal support and the thickness shall be same as the insulation
thickness. The pipe support shall be complete with metal clamps.

D. Contraction Joints

All insulation contraction joints shall be provided by insulation contractor.

1. Provide contraction joints in the insulation of 50mm and larger horizontal piping.
Install contraction joint in each 6.5m of straight pipe not interrupted by flanges,
valves, or fittings. Where flange fittings or valves are within these intervals, provide
for contraction in the flange cover in lieu of contraction joints.
2. Where a contraction joint is required, leave a 25mm void between butting edges of
insulation. Fill this space with fibrous insulation and vapour seal with 30 mil
rubberized bitumen.

E. Weatherproofing Application

1. Material as per Table Weatherproof jacketing material shall be used for
Weatherproofing of Insulation.

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2. All insulation applications shall have the basic insulation jacketed. Insulated fittings
and valves shall be jacketed with prefabricated fitting covers with weatherproof
seams. All joints shall be overlapped a minimum of 50mm. J acketing on horizontal
piping shall have the longitudinal seam located in the 4, 5, 7, and 8 oclock positions
only and arranged in order to shed water.
3. Metal jacketing shall be secured with bands as shown in PIP drawing in attachment.
A band shall be applied over each circumferential lap joint. J acketing on vertical
lines 150mm and smaller shall be supported by a minimum of 2 S-clips. For vertical
lines 200mm and larger, a minimum of 4 S-clips shall be used. Metal covers shall
be secured with screws on 75mm maximum centres; care shall be taken not to
penetrate the vapour barrier.
4. A watertight flashing ring shall be installed where pipe insulation terminates
regardless of service.
5. Heavy fillets of flashing compound shall be applied at all possible sources of
moisture penetration on metal jacketing.
6. Irregularly shaped surfaces that cannot be suitably weatherproofed with jacketing
shall be either finished with a 1.6mm thick tack coat of vapour barrier mastic
followed by reinforcing fabric installed wrinkle-free. Over the fabric, a 3.2mm thick
dry coat of vapour barrier mastic shall be applied with a smooth finish, or a 30 mil
rubberized bitumen adhesive laminated to a 3 mil polysurlyn film may be applied.
This finish shall extend approximately 50mm under the adjacent jacketing. No
porosity shall exist in mastic weather coating when dry.

3.4 Cold Vessel and Equipment Insulation

A. General

1. Vessels and equipment shall be insulated when indicated on the equipment list or
flow diagrams. Thicknesses shall be in accordance with the attached thickness
chart Table 1.
2. Insulation thickness in excess of 100mm shall be applied in a minimum of two
layers.
3. Insulate manhole covers, flanges, nameplates, and all other appurtenances. Where
periodic maintenance or inspection is required, such as at manholes and
nameplates, provision in design for removability and replacement without damage
to the insulation shall be made.
4. Insulate attachments secured to the vessel or equipment that project through the
insulation. Insulate projections externally from the point where they project through
the insulation for a distance of 4 times the thickness of the base insulation.
5. Insulate stiffener rings on vessels and equipment with the same thickness of
insulation as the adjacent surfaces. Box the stiffener rings with insulation.
6. Vessels and tubular equipment 600mm in diameter and smaller shall be insulated
with preformed pipe insulation.

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7. Curved or flat rigid block insulation shall be used on the shells and heads of
vessels, and equipment.

B. Insulation Application

1. Block insulation on vessels and equipment shall be applied with stagger joint
arrangement. Coat the butt edges with a 1.6mm thick layer of joint sealer. In cases
of double layer insulation, apply the inner layer without joint sealer. Secure each
layer of insulation with bands on 300mm centres. Equip each bend with one
breather spring when applying double layer insulation, stagger or offset outer layer
joints from the inner layer joints. Only the outer layer of double layer insulation
requires a vapour barrier. Shape block for heads so that sections closely fit the
contour of the head. Coat butt edges with a 1.6mm thick layer of joint sealer. Secure
insulation in place with a band in the centre of each stiffener ring.
2. Shape vessel transition block insulation so that sections closely fit the contour of the
shell. Coat butt edges with a 1.6mm thick layer of joint sealer. Secure insulation in
place with bands.
3. Enclose stiffener ring in block insulation. Coat butt edges of insulation with a 1.6
mm thick layer of joint sealer. Secure insulation in place with a band in the centre of
each stiffener ring.
4. Enclose pump and compressor casings in block insulation. Coat butt edges of
insulation with a 1.6mm thick layer of joint sealer. Secure the insulation in place with
bands.
5. Stiffener rings on vessels and equipment shall be insulated with the same thickness
of insulation as the adjacent surfaces. The stiffener rings shall be boxed with
insulation.
6. Apply vapour barrier coating at 1.6mm dry thickness to seal protrusions, joints, or
other discontinuities in the vapour barrier jacketing.
7. All insulated surfaces shall receive a vapour barrier per section 3.4A prior to

C. Supports

1. Supports for insulation shall be supplied and installed by the insulation contractor.
Field welding of supports to vessels, equipment and piping is not allowed without
prior written authorization. Contractor shall not remove or modify owner supplied
insulation supports without prior notification and approval of Owner or his designee.

2. For Stationary support, high density Polyurethane Blocks to be used of density 320
500 kg/m3 depending upon the weight of the equipments / vessels. The shape
and dimension shall also depend upon the type of equipment / vessel.

D. Contraction Joints

All insulation contraction joints shall be provided by Insulation Contractor.

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1. Insulation contraction joints shall be provided below vessel insulation support rings
and piping as required per this specification.
2. J oints shall be 40mm wide, packed with 50mm of fibrous insulation. Seal joints with
a 30 mil rubberized bitumen strip to serve as a vapour barrier.

E. Weatherproofing Application

1. Material as per Table Weatherproof jacketing material shall be used for
Weatherproofing of Insulation.

2. On vertical vessels and equipment, support metal jacketing on S-clips. Secure
metal jacketing with bands spaced on 300mm centers with one band at each
circumferential overlap. Equip each band with one breather spring.

3. On horizontal vessels and tubular equipment, secure the metal jacketing with bands
spaced on 300mm centres with one band at each circumferential overlay. Equip
each band with one breather spring.
4. J acket heads on vertical vessels and tubular equipment with a minimum of 150mm
turned down on the straight side of the vessel as an overlap. Secure metal head
cover in places at the circumferential overlap with a band equipped with a breather
spring. Make all joints weatherproof seams.

5. Finish transitions and stiffener rings with jacketing with weatherproof seams. Extend
jacketing under the upper shell jacketing a minimum of 150mm and down over the
lower shell jacketing a minimum of 150mm. Secure metal covers in place at the
circumferential overlaps with a band equipped with a breather spring.

6. Finish pumps and irregularly shaped surfaces, that cannot be suitably
weatherproofed with metal jacketing, with a 1.6mm thick tack coat of vapour barrier
mastic followed by a layer of reinforcing fabric installed wrinkle-free. Over the
reinforcing fabric, apply a 3.2mm thick dry coat of vapour barrier mastic with a
smooth finish. Extend finish approximately 150mm beyond the insulation at all metal
projections to assure a good seal.
7. Apply heavy fillets of flashing compound on metal jackets as flashing at all possible
sources of moisture penetration, such as nozzles and other protrusions.

3.5 Insulation and Weatherproofing for Aboveground Storage Tanks

Prefabricated panels for tank insulation shall comprise of factory / site fabricated
steel panels. The panels shall be made out of outer skin Standing Seam steel
profile made out of colour coated galvanized steel 0.6mm, Thermal Insulation
material Polyurethane Foam / Polyisocyanurate Foam Insulation of density 32-38
kg/m3 and thickness 50-75mm having a lamination of 0.05mm S.S. foil on the inner
side of the insulation. The prefab panels shall be fixed to the tank surface resting
on a special floating ring arrangement tied on to the tank surface. The wire rope will

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be tied on the tank surface holding special clips. The panels will be pressed on to
the special clips with overlapping longitudinal joints; it will be further seamed with a
seaming machine.

5. SUBMITTALS
Subcontractors shall submit materials, MSDS [Material Safety Data Sheet], insulation details, or
intended practices of insulation application not covered in these specifications to Owner or his designee
for approval. Omission of details from these specifications shall not relieve Subcontractor from the
obligation to supply a properly designed installation in accordance with current acceptable
construction practices at no additional cost or schedule impact to the Owner.
6. QUALIFICATIONS
Craftsmen regularly engaged in the insulation industry shall install the insulation. The quality of
workmanship shall be the best obtainable. Finished work shall be uniform and neat in
appearance.

7. STORAGE AND HANDLING
7.1. All insulation materials and accessories covered by this specification shall be delivered to
the jobsite and the contractor shall use whatever means are necessary to protect the
insulation materials and accessories before, during, and after installation. No insulation
material shall be installed that has become damaged in any way. The contractor shall also
use all means necessary to protect work and materials already installed by other trades.

7.2. Only the materials that shall be used in a given work day shall be stored in the immediate
work area. All materials shall be stored away from the work area or at designated
locations. Failure to comply with these provisions shall be cause for contract termination.


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TABLE 1

Anti-Sweat or Cold Conservation Insulation Polyurethane Foam (PUF/PIR)
for PIPING EQUIPMENT AND ENGINEERED ITEMS

Outside
dia.
(mm)

Operating Temperature in Degree C

20 10 0 -10 -20 -30 -40 -50 -60 -70 -80 -90 -100
21.3 25 25 30 35 40 40 45 50 50 55 60 65 70
26.7 25 25 30 35 40 45 50 50 55 60 65 70 70
33.4 25 25 30 35 40 45 50 55 60 65 70 70 75
42.2 25 30 35 40 45 50 55 60 65 65 70 75 80
48.3 25 30 35 40 45 50 55 60 65 70 75 80 85
60.3 25 30 35 45 50 55 60 65 70 75 80 85 90
73.0 25 30 40 45 50 55 60 65 70 75 80 85 95
88.9 25 35 40 45 55 60 65 70 75 80 85 90 100
114.3 25 35 40 50 55 60 70 75 80 85 90 95 105
141.3 25 35 45 50 60 65 70 80 85 90 95 100 110
168.3 30 35 45 55 60 70 75 80 85 95 100 105 115
219.1 30 40 50 55 65 70 80 85 90 100 105 110 120
273.1 30 40 50 60 65 75 80 90 95 105 110 120 125
323.9 30 40 50 60 70 75 85 95 100 110 115 125 130
355.6 30 40 50 60 70 75 85 95 100 110 115 125 135
406.4 30 40 55 60 70 80 90 95 105 110 120 130 135
457.2 30 40 55 60 70 80 90 95 105 110 120 130 135
508.0 30 45 55 65 75 80 90 100 105 115 120 130 140
558.8 30 45 55 65 75 80 90 100 110 115 125 135 145
609.6 35 45 55 65 75 85 90 100 110 120 125 135 145
Above
& Flat
35 45 55 65 75 85 90 100 110 120 130 140 150

NOTE!!! Right side of heavy double line requires DOUBLE LAYER application of Insulation.

NOTE!!!! Insulated thickness is based on condensation prevention at ambient conditions of 45 C still air
with wind velocity of 1m/s and 85% relative humidity. Outer surface emissivity of 0.5 (for SS)

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TABLE 2
INSULATION MATERIAL

Location Application Material
Indoor and Outdoor
All Materials
1) Piping
2) Equipment
Material Type: Polyurethane Foam (PUF/PIR)

Design Temp: (+) 120 C (Maximum)
(-) 196 C (Minimum)

Specification: IS 12436/BS 5608

K Factor: 0.021 W/m-K at 10C

Nominal Density: 36 2 kg/m3
TABLE 3
VAPOUR BARRIER MATERIAL

Location Application Material Remarks
Vapour Barrier

1) Pipe
2) Fittings
3) Equipment
Mastic and Reinforcing Cloth or 30 mil
rubberized Bitumen

Refer Section 3.4 A for detail
Material shall be
compatible with
adjoining insulation

TABLE 4
WEATHERPROOF JACKETING MATERIAL

Location Application
Material

Remarks
Indoor / Outdoor 1) Pipe
2) Fittings
3) Equipment
S.S J acketing ( Thickness Refer Table 5) /

Aluminium J acketing (Thickness Refer Table
5)
( Note 2)
Corrugated / Smooth
/ Embossed

Corrugated / Smooth
/ Embossed

Note 2: In plants with high risk of fire, metallic jackets made from aluminium are not permitted.


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TABLE 5
WEATHERPROOFING AND FASTENERS SCHEDULE
Material Description
Aluminum jacketing ( Note: In plants with high risk
of fire, metallic jackets made from aluminium are not
permitted)
ASTM B209, aluminum alloy 3003 or 5005-H14 with
factory applied moisture barrier
Thicknesses: 0.5mm (nominal)
Finish: Smooth or Stucco embossed
Corrugations: 5mm , 32 mm
Aluminum fitting and termination covers
( Note: In plants with high risk of fire, metallic jackets
made from aluminium are not permitted)
ASTM B209, aluminum alloy 3003 or 5005-H14 with
factory applied moisture barrier, 0.60mm minimum
thickness
Stainless steel jacketing ( Note 1) ASTM A167 Stainless steel jacketing 0.25mm thick,
Type 304
Bands (strapping) to be colored blue AISI Type 304 SS, annealed tempered
13mm wide by 0.4mm for insulation OD 600mm
19mm wide by 0.5mm for insulation OD> 600mm
Wire Soft annealed Type 304 SS, 16 gauge
Seals - wing type AISI Type 304 SS, hard temper, wing type 0.8mm
thick, to match the band width
Seals - closed type AISI Type 304 (18-8) hard temper stainless steel to
match band size, 0.8mm thick
S-clips AISI Type 304 SS 20mm by 0.5mm thick
Product reference: Childers S clips
Breather springs AISI Type 304 SS, 100mm long by 25mm wide by
3mm thick
Product reference: Childers Chil-Springs, RPR
Insul-Mate or Equivalent
Compression springs Compression springs shall be assembled from
components of Type 304 stainless steel and similar
to Childres MITY-SPRING compression springs
Screws AISI Type 304 SS, self tapping, slotted hex head with
neoprene backed washers, #8 by 12mm long
Flashing compound Flexible non-shrinking permeable type, resistant to
93C
Product Reference: Childers Chil-J oint CP-70
Sealant & Adhesives Non-shrinking, permanently flexible sealant
Product reference: Childers Chil-J oint CP-70
Sealant

Loidseal 39, MAS-35 or Foster 30-45 for J oint
Sealant
Loidmastic 130, MAS-130 or Foster 60-35 coating
For Coating and Vapour sealmastic
Insulation Tape Fiberglass woven flat tape, 3mm thick by 50mm wide
Product Reference: LEWCO Specialty Products
FT60
Note-1 : S.S. Sheet shall be coated with moisture barrier on inner side with 3mil polysurlyn film.


Specification
G3IR-1000-55-SP-9002
Date 31 Oct 2012
Page 18

G3IR-1000-55-SP-9002_Rev 1 Page 18 of 19
TABLE 6
TABLE: FASTENERS APPLICATION SCHEDULE
Insulated Item Insulation
Outside
Diameter
Insulation Weatherproofing
Fastener
/ Seals
Max
Spacing
Springs Fastener Max
Spacing
Springs
Pipe and
elbows
250mm Wire
As per attachment 1- PIP Drawings & Table 4, 5 >250mm
and
600mm
Bands /
wing type
Pipe fitting and
termination
covers
All sizes
As per attachment 1- PIP Drawings & Table 4, 5
Equipment
shells
(Horizontal and
Vertical)
All sizes
Equipment
heads (Top,
bottom, and
horizontal)
All sizes
Equipment -
longitudinal
overlaps of
metallic
jacketing
All sizes
Equipment -
circumferential
overlaps of
metallic
jacketing
All sizes
Equipment-
head cover
overlaps on
shell jacket
gores, flashing
rings
All sizes


Specification
G3IR-1000-55-SP-9002
Date 31 Oct 2012
Page 19

G3IR-1000-55-SP-9002_Rev 1 Page 19 of 19
ATTACHMENT 1
Data Sheets
INIC0001 General Arrangement - Piping Insulation
INIC0002 Piping - Layered Insulation
INIC0003 Piping - Vertical Insulation Support Single Layer
INIC0004 Piping - Vertical Insulation Support Multiple Layers
INIC0005 Piping - Single Layer Horizontal Contraction J oint
INIC0006 Piping - Multiple Layer Horizontal Contraction J oint
INIC0008 Piping - Flange Insulation
INIC0009 Piping - Insulation Connections
INIC0010 Valves with Extended Bonnets
INIC0011 Valves without Extended Bonnets
INIC0050 Vertical Vessels with Outside Diameters over 600
INIC0051 Vertical Vessels with Outside Diameters 600 and Less
INIC0052 Vessel Head
INIC0054 Vertical Vessel Bottom Head Insulation
INIC0055 Nozzle
INIC0056 Vessel Stiffener Insulation Detail
INIC0059 Typical Clip Details
INIC0061 Lap Seam Detail
INIC0062 Horizontal Vessels w/Outside Diameters over 2400 (96")
INIC0063 Application of Metal Gores on Horizontal Vessel Heads
INIC0064 Head Insulation Securement

600 mm

600

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