Job Procedure For Hot Insulation Work of Piping & Equipment1

JOB PROCEDURE FOR HOT INSULATION
WORK OF PIPING & EQUIPMENT
DOC.NO:
PR/2247/J-INS/01
CLIENT : RELIENCE
REV NO:00
AFCONS INFRASTRUCTURE LTD.

RPL, JAMNAGAR
Contract No: 3612153
PROJECT : JAMNAGAR EXPORT REFINERY
AF
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CONTRACTOR
AFCONS INFRASTRUCTURE LIMITED
JOB NO.
25194
PROJECT
J.E.R.P, R.P.L.
Page 1 of 13

RPL, JAMNAGAR

DOC.NO:
PR/2247/J-INS/01
CLIENT : RELIENCE
REV NO:00
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JAMNAGAR
NAME OF UNITS :
JETTY MODIFICATION
SECTION
JETTY
OWNER
RELIANCE
Page 2 of 13

RPL, JAMNAGAR

DOC.NO:
PR/2247/J-INS/01
CLIENT : RELIENCE
REV NO:00
AF
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Page 3 of 13

DOC.NO:
PR/2247/J-INS/01
CLIENT : RELIENCE
REV NO:00

RPL, JAMNAGAR
AF
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IN
FR
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PR/2247/J-INS/001
26.09.06
For Approval /
00
T.R.SAHA
S.MUKHERJEE
M.JAYARAM
PROC. NO.
DATE
ISSUED FOR/
REV. NO.
PREPD BY
AFCONS
CHKD BY
AFCONS
APPD BY
AFCONS
Page 4 of 13
APPD BY
CLIENT / TPI

RPL, JAMNAGAR

DOC.NO:
PR/2247/J-INS/01
CLIENT : RELIENCE
REV NO:00
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CONTENTS
1. SCOPE.
2.REFERENCE.
Page 5 of 13

RPL, JAMNAGAR

DOC.NO:
PR/2247/J-INS/01
CLIENT : RELIENCE
REV NO:00
AF
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3.MATERIALS.
4.STORAGE OF MATERIALS.
5. PROTECTION FOR PARTIALY COMPLETED JOB.
6.APPLICATIONS.
7. QC RECORDS.
Page 6 of 13

DOC.NO:
PR/2247/J-INS/01
CLIENT : RELIENCE
REV NO:00

RPL, JAMNAGAR
AF
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IN
FR
AS
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TU
RE
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PR
OJ
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T:
J.E
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ON
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UI
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8.ATTACHMENT.
Page 7 of 13
JOB PROCEDURE FOR HOT INSULATION WORK

OF PIPING & EQUIPMENT
AFCONS INFRASTRUCTURE
LTD. RPL, JAMNAGAR
CLIENT RELIENCE
PROJECT: JAMNAGAR EXPORT REFINERY
DOC.NO:
PR/2247/J-INS/01
REV NO:00
JOB PROCEDURE FOR HOT INSULATION WORK OF

PIPING & EQUIPMENT
1.
SCOPE
The scope of this procedure is to establish methods of application for various hot
insulation materials on piping & equipments
2.
REFERENCE
Project specification 22960/3PS/GAW/006
3.
MATERIALS:
Material consists of Insulation materials, cladding materials & ancillary materials. All
materials shall conform to above 22960/3PS/GAW/006 specification. .
4.
STORAGE OF MATERIALS:
Insulation materials shall be stored in such a place that should be protected against
weather. It must be ensured that insulation material shall not be stacked directly on
ground.
5.
PROTECTION FOR PARTIALY COMPLETED JOB:

Every precaution should be taken to ensure that each days of work is weather proofed
immediately after laying & before the days work is over to prevent exposure & entry
of water into the materials.
6.
APPLICATIONS:
a.
Prior to Insulation:
Before using insulation material, receiving inspection shall be done. All items to be
insulated shall be mechanically cleared, pressure tested including steam tracing. The
surfaces shall be cleaned manually for dust, rust, foreign particles, etc. All insulation
material must be free from corrosive agents & presence of water.
Page 8 of 13

LTD. RPL, JAMNAGAR
CLIENT RELIENCE
DOC.NO:
PR/2247/J-INS/01
REV NO:00
Heat resistant aluminum paint shall be applied on carbon steel & low alloy steel
surfaces for operating temperature unto 1250C. For operating temperature above
4500C, stainless steel surface shall be painted with two coats of Heat Resistant
Silicone Aluminum paint. Stainless steel surfaces shall be covered with 0.19mm thick
aluminum foil for operating temperature unto 4500C prior to insulation
b.
During Insulation:
Insulation thickness & type of insulation to be applied shall be as per
equipment data sheet/ line schedule (for piping) & standard specification
Double layer insulation shall be done for insulation thickness greater than
75mm. exposed surfaces operating temperature above 650C & located within
600mm horizontally on 2100mm vertically of a normal access way/ walkway
on work area shall be insulated for personnel protecting only where heat loss
is desired
For securing insulation, aluminum bands/ wires shall be applied as per ASTMB209 alloy 3003 H16 or IS: 737 designation 3100 (Old NS3) condition H3.
For securing fibrous insulation on piping, 24SWG x 12 wide, aluminum bands
shall be used.
For securing fibrous insulation on equipment, 24SWG x 20 wide, aluminum
bands shall be used.
For securing fibrous material on vertical storage tank, galvanized steel 40mm
wide x 3mm thick flat shall be used.
For securing cladding on insulation on piping, aluminum band 12mm(min) x
24 SWG thick shall be used.
For securing cladding on insulation on equipment, aluminum band 20mm
wide x 24 SWG shall be used.
For securing cladding on insulation for vertical storage tanks stainless steel
band 25mm wide x 24SWG shall be used.
Preformed pipe sections shall be used pipe dia. unto 8 for insulation thickness
maximum 100mm, otherwise blankets to be used.
Page 9 of 13

LTD. RPL, JAMNAGAR
CLIENT RELIENCE
DOC.NO:
PR/2247/J-INS/01
REV NO:00
Rivets required for metal jacket securement shall be the expanding aluminum
POP blind eye type, 9.5mm Lg., 5mm dial.
Screw required for metal Jacket securement shall be cadmium plated steel self
tapping screw type A No. 8, 12mm Lg. with neoprene washer.
All projection, such as lifting lugs, trunion, support lugs, support cleats shall
be insulated to the same extent that of equipment or piping.
Inspection windows shall be provided at critical locations on equipment and
piping for future inspection.
Cleats used for supporting of insulation shall not project outside insulation.
Insulation shall not be applied to the following unless specifically asked otherwise:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
Valves, including control valves, flanges in process lines (Safety insulation shall be
provided wherein required).
Pipe union fittings.
Steam traps, sight flow indicators.
Pumps with operating temp below 2000 C.
Fans, compressors, blower or other rotating or reciprocating equipment.
Internally insulated or refractory line equipment.
Turbine seal caps, shaft bearing housing, throttle valves, governors and supports.
Exchanger channel and covers, shell and channel flanges and expansion joints.
Nozzles, manholes and handholds and flanges of equipment.
Surfaces of coolers and condensers.
Thermo well bosses and pressure tapping.
a) Support skirts of vertical vessels and columns 1200mm dia. & above shall be
insulated both from inside and outside to a minimum distance of 600mm from bottom
tangent line. The insulation must terminate at minimum 300mm above support
concrete or steel work. For below 1200mm dia. support skirts shall be insulated
externally only.
b) Spacer strip with the help of Z stays shall be provided for supporting of cladding
material. The height shall be same of insulation thickness. Blanket shall be secured
with wide steel strapping not more than 300mm equal distance.
c) Vapor barrier shall be applied on all the vessels and equipment for services upto
1250C.
Page 10 of 13

LTD. RPL, JAMNAGAR
CLIENT RELIENCE
DOC.NO:
PR/2247/J-INS/01
REV NO:00
d) Expansion joints shall be provided in all direction wherever required. For expansion
joints, gap shall be filled with loose insulation material of same density.
e) Valve & flange pairs, manhole, if necessary, shall be insulated with removable covers
& it should terminated in such a way that during maintenance bolts can be easily
removed without affecting insulation.
c.
Finishing After Insulation:

a) All insulated items shall be finished with metal jacketing as per specification. But
before installation of metal sheet one coat of bituminous anti corrosive paints to be
used.
b) The sheeting shall be fixed with self tapping screws of size No. 8 @ 150mm
distance.
c) Jacketing over valves & flanges shall be prefabricated in half section & shall be
secured in place by means of bands with quick release clips. Before fixing of boxes,
in inside, the same insulation shall be fixed with the help of strips & rivets.
d) For vessel heads with a large dia. shall be made in segmental form.
e) To ensure perfect water proofing, all cladding joints shall be packed with sealing
materials (Silicon Sealant). Minimum overlap in sheet metal at joints shall be 50mm
both circumferentially & longitudinally.
7.
QC RECORD
8. ATTACHMENT.
ATTACHMENT -1
Page 11 of 13
DOC.NO:

LTD. RPL, JAMNAGAR
CLIENT RELIENCE
PR/2247/J-INS/01
REV NO:00
Insulation thickness (in mm) for hot insulation

Pipe Size
N.B (mm)
Up to 100
15
25
20
25
25
25
32
25
40
25
50
25
65
25
80
25
100
25
125
25
150
25
200
25
250
25
300
25
350
25
400
25
450
25
500
25
550
25
600
25
>600& Equipment
25
flat surface
Temperature (Deg. C)
101 to 150
151 to 200
201 to 250
25
40
50
25
40
50
25
40
50
30
40
60
30
40
60
30
50
60
30
50
60
40
50
70
40
50
70
40
60
70
40
60
80
40
60
80
40
60
80
40
60
90
40
60
90
40
70
90
40
70
90
40
70
90
50
70
90
50
70
90
50
70
90
251 to 310
60
60
70
70
70
80
80
80
90
90
100
100
110
110
110
120
120
120
120
120
120
Insulation thickness given in above table has been calculated based on the following
parameters.
Ambient Temperature
Surface temperature
Wind velocity
Emissive
material
Page 12 of 13
35C
50C
0 m/s
0.60(for GI cladding)
Mineral wool Mats. 150 Kg/m

LTD. RPL, JAMNAGAR
CLIENT RELIENCE
Page 13 of 13
DOC.NO:
PR/2247/J-INS/01
REV NO:00

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JOB PROCEDURE FOR HOT INSULATION

WORK OF PIPING & EQUIPMENT

AFCONS INFRASTRUCTURE LTD.

PROJECT : JAMNAGAR EXPORT REFINERY

AFCONS INFRASTRUCTURE LIMITED

AFCONS INFRASTRUCTURE LTD.