Doc. No.

WSM-HIP-06
HOT INSULATION PROCEDURE Rev. 0 11/05/19
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PT. WISESA MANDIRI

HOT INSULATION PROCEDURE

WSM-HIP-06

11/05/19 0 Issued for Approval MKY MKY AA

Date Revision Revision Description Prepared Checked Approved

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Revision Summary

Date Revision Revision Description Prepared Checked Approved

11/05/19 0 Issued for Approval MKY MKY AA

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INDEX

1 SCOPE ......................................................................................................................................... 4
2 REFERENCE DOCUMENTS .......................................................................................................... 4
3 DEFINITIONS ............................................................................................................................... 4
4 EXTENT OF INSULATION ............................................................................................................. 4
5 MATERIALS ................................................................................................................................. 5
5.1 Insulation ........................................................................................................................... 5
5.2 Jacketing............................................................................................................................. 5
5.3 Ancillaries ........................................................................................................................... 5
5.4 Material Storage, Handling & Control................................................................................ 6
6 INSULATION THICKNESS............................................................................................................. 6
7 APPLICATION .............................................................................................................................. 6
7.1 General Requirements ....................................................................................................... 6
7.2 System-1 Cellular Glass Installation Procedure ................................................................. 7
7.3 System-2 Acoustic Installation Procedure ......................................................................... 7
7.4 System-3 Solartech PE-55 GRP Weatherproofing Application .......................................... 8
7.5 System-4 Personnel Protection.......................................................................................... 9
7.6 System-5 Solar Protection .................................................................................................. 9
8 TYPICAL APPLICATION DRAWINGS........................................................................................... 11
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1 SCOPE
This work method statement covers the installation of insulation for Mechanical & Piping
Work Inhouse Packaging project at Pangkalan Kerinci, Riau. The intent of this document is not
to supersede client’s project specification but to develop them by adding further details from
the viewpoint of the site application of insulation work. In case conflict exist among this
specification and the documents in the Paragraph 2 “Applicable Documents”, this specification
shall govern based on client’s approval.

2 REFERENCE DOCUMENTS
WSM Internal Procedure and Documents

WSM-PSP-02 Prefabrication Structural Procedure

WSM-PP-01 Painting Procedure

WSM-PSFP-01 Piping Spool Fabrication Procedure

WSM-CIP-05 Cold Insulation Procedure

3 DEFINITIONS
The definition of insulation type specified in client’s project specification as follows:

4 EXTENT OF INSULATION
1. Insulation is required for the Insulation Code “H”, “E”, “P”, “B”, & “A” in the above-
mentioned paragraph 3 of this document.
2. Name Plates, identification plates and stampings shall be left clear of insulation or shall be
fitted outside the cladding.
3. The piping to be insulated shall be indicated in the P&I diagrams and engineering detail
documents.
4. In particular, the following shall be insulated:
a. Piping which requires insulation for process reasons;
b. Piping where it is necessary to avoid solidification or increased viscosity of the fluid,
due to environmental conditions;
c. Piping which requires personnel protection (type P).
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5. Flanges, valves and accessories shall not be insulated except when specified for the
following reasons, insulation shall be provided by removable boxes:
a. When required for process reason;
b. When the insulation of the flanges and valves is envisaged for personnel
protection;
c. When heat tracing (type E) of flanges and valves is required.
6. The following items shall not be thermally insulated:
a. Vent Valves
b. Steam Traps
c. Filters
d. Pipes where a heat loss is required

5 MATERIALS
All materials to be used for the installation shall be in accordance with the project
specification and with manufacturer’s data sheets.

5.1 Insulation
1. Cellular Glass Slab – Shall be used for Heat Conservation (H) and Electrical (E) in accordance
to ASTM C552
2. Hydrocal-B11 – Shall be used as anti-abrasive coating.
3. Foster 30-45 – Shall be used as joint sealer for Cellular glass Insulation for temperature up
to 49°C.
4. PC® HI-TEMP/RTV Silicone Adhesive - Shall be used as joint sealer for Cellular glass
Insulation or temperature higher than 149°C.
5. Mineral Wool / Wired Mattress - Shall be used for acoustic insulation and GTRG exhaust
insulation and fillings. Pre-molded sectional wool shall be used for pipe diameter of 10”
and below while wired mattress shall be used for pipe diameter of more than 10”.
6. From the latest drawing with operating temperature of the pipes are low, expansion joints
shall not be required to be installed.

5.2 Jacketing
1. Solartech PE-55 GRP 1.5mmT w/ Solar Resin PE-55
2. Stainless Steel Guard Mesh- SS316L φ3mm eye 50x50mm

5.3 Ancillaries
1. Stainless Steel Bands – SS316L 13mmW x 0.5mmT, SS316L 19mmW x 0.5mmT
2. Stainless Steel Band Seals – SS316 0.8mmT both for 13mmW and 19mmW
3. Stainless Steel Flat Bar – SS316L 25mmW x 3mmT
4. Stainless Steel Bolts & Nuts – SS316L M10 x 25mmL
5. Stainless Perforated Sheet
6. Neoprene Sheet
7. Fiberglass Tape shall be installed underneath SS clamps for personnel protection (P)
8. Insulation materials, insulation covering, sealers, and other accessory materials shall be
asbestos free.
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5.4 Material Storage, Handling & Control

All materials arrived on site in containers or in lorry shall be off loaded to storage area.
Inspection shall be carried out upon receiving the materials on site. The appointed QC Inspector
shall do the inspection to determine if there are some discrepancies on the batches and
damages on the packing of the materials. Only necessary quantity of material shall be issued
during the application. All damaged material shall be set aside or quarantined.
The Insulation materials shall be kept dry and shall be stored off ground, undercover and
away from wet or damp surfaces.
Effective material control uses basic premises in its work process. Monitor material
quantities through engineering, procurement, fabrication, inspection, shipment and lastly, to
the application of these materials at the construction site. The material requirements must be
accurately identified and allocated to the correct areas, drawings and category codes. The
materials must be properly received, stored, maintained by the construction site and available
for installation in accordance with the requirements. Ensure that there will be record keeping
for all the materials received, issued to site and fabrication. Inventory shall be done every 3
months or whenever necessary to confirm its availability and ensure that the material is
sufficient for the remaining works.

6 INSULATION THICKNESS
1. The hot insulation thickness shall be in accordance with “Thickness of Insulation for
Electrical (E) & Heat Conservation (H) specified in project specification.”

2. Acoustic insulation (A) shall be of 100mm thickness.

3. Personnel protection (P) shall be of wire mesh guard.

7 APPLICATION
7.1 General Requirements
1. All insulation shall be stored in a dry place and shall be protected until such time the
weatherproofing jackets has been installed and sealed from water ingress.
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2. All pressure testing, electric trace, heating tapes have been installed where applicable and
line shall be released for insulation before application.
3. Insulation and accessory materials shall be applied only to surfaces that are clean, dry, and
frost-free.
4. All exposed edges and sharp corners on insulation shall be rounded to present a smooth
contour. Metal band ends shall be trimmed close to the seal and turned down to prevent
a safety hazard.
5. All mating surfaces between adjacent pieces of all insulation shall be tightly butted together
so that no voids or gaps occur at any joints. Gaps up to 3mm shall be acceptable.
6. Insulation systems for piping shall permit access to parts requiring maintenance without
destruction of the adjacent insulation system.
7. The clearance between the outside surface of any insulation adjacent to insulated surfaces,
pipe, equipment, or structural members (including stairways) shall not be less than 50 mm.
8. Insulation should be installed in such a manner that allows bolts to be removed on any
parts of the system without disturbing the insulated surfaces.
9. An insulation work shall be completed in a neat and good workmanship manner.
10. Cellular Glass shall be applied for piping and equipment with code “H” & ”E”. All cellular
glass surface shall be coated with anti-abrasive Hydrocal B-11 on the inner part before
installation to prevent abrasion on the pipe surface.
11. Mineral Wool shall be applied for piping and equipment with code “A”.
12. Personnel protection guards shall be applied for piping and equipment with code “P”.
Exposed surface are located within 800mm horizontally and 2.1m vertically above a normal
walkways or work area.
13. Insulations installation shall stop 500mm distance from the Pipe ends to give way for the
tie-in portions. Standard GRP end caps with internal plastic cover, to prevent water ingress,
shall be installed on termination ends to ensure the insulation is in the same condition all
throughout.

7.2 System-1 Cellular Glass Installation Procedure

1. Pre-fabricated pipe sections of roughly 0.6m shall be applied on pipes while slabs shall be
applied on tanks surfaces. Modifications or touch up shall be modified at site if required
site to fit to the pipe length, shape and size.
2. Pipe sections shall be grooved at site to insert electrical tracing cable for Type E insulation
if applicable or oversized to the next available commercial size pipe sections for electrical
tracing installed by coiling around the pipes.
3. Securing / Fastening the sections or segments of insulation shall be secured with specified
material in accordance with Hot Insulation System Table for Piping & Equipment.
4. All joints surfaces between every cellular glass shall be sealed with foster 30-45 joint sealer
as per recommended application for temperature lower than 149°C and PC® HI-TEMP/RTV
Silicone Adhesive for temperature above 149°C to prevent water ingress.
5. The Insulation thickness shall be as per mentioned in IFC drawings.
6. Valve and flanges shall be insulated with the same thickness of insulation as the adjacent
piping insulation.
7. Daily housekeeping shall be performed to ensure cleanliness in the surrounding.

7.3 System-2 Acoustic Installation Procedure

1. Pipe cover shall be applied on the pipe in order to fit the surfaces to be insulated. Pipe
cover shall be used for piping up to 10” dia. and mattress for piping greater than 10” dia.
Pipe covers and mattress shall be modified at site to fit to the pipe length, shape and size.
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2. The Insulation thickness shall be as per mentioned in IFC drawings.

3. Securing / Fastening the sections or segments of insulation shall be secured with specified
material in accordance with Hot Insulation System Table for Piping & Equipment.
4. Valve and flanges shall be insulated with the same thickness of insulation as the adjacent
piping insulation. Insulation material shall be mattress.
5. Anti-vibration seal (Neoprene sheet) shall be place at each termination where GRP
jacketing are in contact pipe or equipment surface.

7.4 System-3 Solartech PE-55 GRP Weatherproofing Application

1. Foil shall be installed onto the external surface of insulation to provide adhesion for GRP
which are recommended by Solartech. Aluminium foil of 100micron or Mylar foil of 50
micron, 12-50-12, shall be applicable.
2. Pre-cured / non-cured GRP shall be used according to circumstances. Adjustments shall be
made at site if required for both pre-cured / non-cured GRP to fit to the pipe length, shape
and size
3. For non-cured GRP, UV lighting shall be focused onto the installed GRP where UV light from
the sun is prohibited - lower region of horizontal pipe. Reflective material such as
aluminium foil may be placed near the installed GRP for better reflection of UV source.
4. Additional care shall be in place for installing non-cured GRP to prevent early curing -
wrapping around with black plastic cover which able to block UV source.
5. Drain holes shall be required for pre-cured GRP for every 6m distance with diameter of
10mm.
6. Overlap shall be arranged to shed water. Overlap shall be of 50mm lap for both
circumferential and longitudinal to prevent water ingress.
7. The longitudinal overlap on horizontal piping shall be arranged along the lower part of the
pipe if applicable.
8. Protective plastic shall be removed after curing. Time to cure GRP depends on the level of
UV light.
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9. All joints shall be sealed by applying Solar Resin PE 55 underneath the lap. All overflow shall
be removed and cleaned.

10. On vertical piping, the upper course of the GRP shall overlap the lower course.

7.5 System-4 Personnel Protection

a. Personnel protection shall be installed with wire mesh of 3mm diameter with 50mm x
50mm minimum.
b. Ring support shall be installed every 500-1000mm where applicable.

7.6 System-5 Solar Protection

a. Solar protection shall be installed with perforated sheet with 5mm diameter hole.
b. Ring support shall be installed every 500-1000mm where applicable.
c. Sheet thickness shall be of 1mm thickness.
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8 TYPICAL APPLICATION DRAWINGS

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