Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

Doc. No. NBTC – M3 – QC – Insul – 26.0 Cont. No.: 03UT02-053

Rev. No. 0 Page 2 of 9

TITLE PROCEDURES FOR HOT INSULATION

TABLE OF CONTENTS

1. Purpose
2. Scope
3. References
4. Definitions & Abbreviation
5. Materials
6. Procedure
7. Flanges and Valves
8. QC Inspection
9. Safety

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TITLE PROCEDURES FOR HOT INSULATION

1.0 PURPOSE :

This procedure provides the minimum requirements for the application

of insulation to pipe in conformance with the contract requirements.

2.0 SCOPE :

This procedure shall be applicable for Hot Insulation and Personal

Protection work used in DOW-PIC Olefins 2 Project (OL2K) Utilities
Mechanical Works (M3) contract.

3.0 REFERENCES :

Thermal insulation General Requirements : G15S-0001-00

Hot Insulation-Polyisocyanurate : G15S-1001-00

Hot Insulation-Mineral Wool : G15S-1002-00

Aluminum Jacketing : G15S-4001-00

4.0 DEFINATIONS & ABBREVIATIONS :

Owner : Equate Petrochemical Company, K.S.C.C, Kuwait

Contract : Utilities Mechanical Works – OL2K

NBTC : Naser M. Al-Baddah & Partner General Trading & Co. W.L.L

QCI : Quality Control Inspector

5.0 MATERIALS :

5.1 Polyisocynaurate :

5.1.1 Thermal conductivity (Lambda Value) shall be maximum of

0.023 W/mK, (0.16 Btu/sq.ft-hr-degr.F) at 0C (32F).

5.1.2 Density shall be minimum of 32 kg/m3 (2pcf)

5.1.3 Foam shall be manufactured without the use of CFC’s

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TITLE PROCEDURES FOR HOT INSULATION

5.2 Mineral Wool :

5.2.1 Mineral Wool Insulation shall be rock or basalt based. Slag

or others are not acceptable

5.2.2 Thermal conductivity (Lambda Value)<0.065 W/mK, (0.45

Btu/sq.ft-hr-deg-F) at 200C (392F)

5.2.3 Density shall be minimum of 96 kg/m3 (6.0 pcf)24"-42",

128 kg/m3 (8.0 pcf) Upto 24" Dia incl., 192 kg/m3 (12.0 pcf)

5.2.4 The free chloride content shall not exceed 10 ppm.

5.2.5 Insulation shall be treated so that water absorption shall

be lell than 10% after immersion in water for 24 hours.

5.3 Metal Jacket: 0.024” thick and 3/16” Corrugated Aluminum

sheet with Poly-surlyn moisture barrier shall be used for straight pipe
and smooth finish 0.024” Thick for fitting, Valve box, etc.

5.4 0.020” thick & ½” wide SS 304 band and 1 mm SS wire seals.

5.5 Owner Approved Metal Sealant Foster 95-44 based on surface

temperature.

6.0 PROCEDURE :

6.1 General Requirements :

6.1.1 Insulation shall be applied over the pipe lines as per the
applicable Engineering specifications / approved drawings /
Standard insulation details.

6.1.2 It shall be ensured before start of job, that surfaces are

ready for insulation and cleared by Owner.

6.1.3 Insulation shall not be applied until hydrostatic and or /

other testing has been completed and the item approved by the
Owner. If it is authorized to apply insulation prior to completion
of testing, all joints, including welds, shall be left un insulated
and exposed during the test.

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TITLE PROCEDURES FOR HOT INSULATION

6.1.4 Insulation shall be installed after the application of all

required coatings and approved by Owner.

6.2 Insulation application :

6.2.1 Insulation shall be applied only to clean, dry, frost free

surfaces.

6.2.2 Only new and undamaged insulation shall be used. All

Insulation and accessory materials shall be stored in an area
protected from weather before and during application.

6.2.3 Both the insulation materials and surfaces to be insulated

shall be kept dry during application. The jacketing shall be
applied as soon as possible. All work not jacketed at the end of
the shift shall be covered to protect from the element.

6.2.4 Insulation shall be applied using the staggered joint

method. In multiple layers the joints of each succeeding layer
shall be staggered.

6.2.5 Insulation shall be installed in such a way that the gap

between insulated surface and insulation is less than 1/8”.

6.2.6 The insulation for piping shall be single layer for process
temperature up to 3150C and multiple layers shall be applied
above 3150C.

6.2.7 Polyisocynaurate :

Piping size less than 24” – Two Piece Preformed Pipe Insulation.

Piping size less above 24” (up to 144”) – Performer curved

segments

Fittings Flanges and Valves – Fabricated in minimum number of

pieces so as to minimize void space and number of joints.

6.2.8 Mineral Wool :

Piping size less than 24” – Preformed Pipe Insulation.

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TITLE PROCEDURES FOR HOT INSULATION

Piping size above 24” – Medium strength Board

(plates) or multiple curved
segments.

Vessel Heads and Bottoms – High Strength Boards

Fittings Flanges and Valves – Preformed or molded sections if

available or mitered sectional pipe or board (plates). For Valve
boxes insulation blankets shall be used.

6.3 Securements of insulation :

6.3.1 All bands and other attachments shall be type 302 or 304
material. The band width shall be of ½” and thickness of 0.020”.

6.3.2 In multi layer sections inner layer shall be secured

separately with 9” (250 mm) spacing, For Polyisocynaurate – fiber
glass reinforced tape up to an insulation dia of 36” for Mineral
wool – SS wire of size Gauge 18 or 0.051” OD up to an insulation
dia of 36”.

6.3.3 Outer layer shall be secured with bands ½” and thickness of

0.020” with 9”
(250 mm) spacing.

6.3.4 The insulations shall be securely held in place with bands.

Bands shall be placed no closer than 1” or farther than 4.5” from
the end of section. All pipe section shall have at least 2 bands.
Where more than one bridle band is used, head band connections
spacing shall not be exceeding 9”.

6.3.5 Bands shall tighten with a mechanical tightening tool and

secured with a wing type or crimp type seal. Seals shall be buried
flush with the Insulation.

6.3.6 After the Insulation is applied, all unfilled joints greater than
1/16”, and chipped edges shall be filled with piece of
polyisocynaurate foam cut to fit so as to leave a smooth and even
surface.

6.4 Securement of Jacketing :

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TITLE PROCEDURES FOR HOT INSULATION

6.4.1 Aluminum jacketing (sheeting) and components shall be of

type 3105-H14 alloys conforming to ASTM B-2009.

6.4.2 Pre manufactured Aluminum components in site shall be

installed in accordance with the manufacturer’s
recommendations. Field or site fabricated components shall be
fabricated and installed in accordance with the job specifications.

6.4.3 Jacketing shall be installed with overlaps oriented to

ensure the system sheds water.

6.4.4 Longitudinal laps shall face away from the view of

roadways and frequently traveled areas. Overlap of longitudinal
and circumferential joints shall be 50mm.

6.4.5 Jackets on piping shall be banded with ½” x 0.020” bands

on maximum of 11-1/3” (287.9mm) centers. Each
circumferential overlap shall be banded.

6.4.6 Jacked on hot pipe shall be secured with screws on

maximum of 150 mm centers.

6.4.7 The heads of the screws used for fastening the jackets
shall be sealed by using a neoprene washer under the screw.

6.4.8 All burrs or sharp areas on exposed edges shall be

removed prior to application.

6.4.9 On vertical pipe, S clips shall be placed on the perimeter of

each sheet before the next higher sheet is applied. A minimum
of two clips shall be used up to 24” diameter. Above 24”, clips
shall be equally spaced a maximum of 30” apart. Only one clip is
required up to 6” insulated diameter.

6.4.10 To prevent the bands from slipping, bands on vertical pipe

shall be secured by attaching “J clips” to the jacket with the
screws.

6.5 Sealant :

6.5.1 The approved sealant shall be selected based on the

maximum temperature of the surface to which it is applied.

6.5.2 Silicon sealant shall be applied to all voids, entrance holes,

protrusions etc.

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TITLE PROCEDURES FOR HOT INSULATION

7.0 Fittings, Flanges & Valves :

7.1 Piping adjacent to flanged connections to be insulated shall be

totally finished, water proofed and sealed regardless of whether
flanges are insulated or not.

7.2 Flanges, valves shall be insulated with same type of insulation as

the pipe, with easily removable, reusable covers, unless noted
otherwise.

7.3 Insulation adjacent to equipment items specified to have

removable insulation covers shall have a waterproofed, sealed,
termination, so that water can not enter the insulation when the
removable cover is removed.

7.4 Covers shall be fabricated in minimum number of pieces to

provide full insulation coverage to all area.

7.5 Covers for flanges and valves shall include space left un
insulated on pipe for bolt removal.

7.6 Jacketing shall be provided with permanently attached straps

with adjustable release fasteners and draw strings on wind flaps.

7.7 Jacketing shall be constructed in a manner to prevent

penetration of rain, moisture etc. A three fold binding shall be
used on all edges. Pleated corners creating a boxed edge to hold
insulation in place without compressing shall be used. Sewn bar
tacks shall be used to reinforce the seam ends for draw string
closures. Sewn retainers shall be provided to prevent movement
of the insulation inside the cover.

8.0 QC INSPECTION :

8.1 Material Inspection for owner approved products.

8.2 Ensure clearance for insulation – All mechanical, Tracing Paint

touchup works finished.

8.3 Ensure General condition of insulation lagging before cladding.

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TITLE PROCEDURES FOR HOT INSULATION

8.4 The Insulation metal jacketing shall be visually inspected for

voids, cracked segments, open joints etc. to ensure compliance
with the requirements with this procedure.

8.5 Inspection shall be done as per approved ITP and relevant check
lists shall be signed off.

9.0 SAFETY :

9.1 Removal and or disturbance of existing insulation shall not

proceed with out Owner’s approval.

9.2 PPE compliance shall be adhered as per the Owner Standard.

Safety harness used for higher elevated wroks more than 1.8
meters shall confirm ANSI Z 359 and 100% tie off shall be
ensured.

9.3 Induction training and periodical specific training shall be

imparted to all the employees working at site.

9.4 The Equipments used for insulations works will be inspected by

Safety Supervisor and color coding as per the Owner
recommendations shall be adhered.

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