LKT-PROC-6-04

PT. LANGGENG KARYA TEKNIK

REV: A

PROCEDURE
FOR INSULATION

FABRICATION & INSTALLATION OF BOP FL3B

DOCUMENT NO. LKT-PROC-6-04

Issued to:

Controlled Copy Uncontrolled Copy

A 15 April 21 FAZ NIW MIF Issued for Approval

Rev. Date Prep’d Chk’d App’d Description
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TABLE CONTENT

1. COVER 1
2. TABLE OF CONTENT 2
3. PURPOSE 3
4. RESPONSIBILITIES 3
5. PROCEDURE 4
6. INSPECTION 18
7. HSE REQUIREMENT 19
8. WORK PROCESS 20
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1. PURPOSE

This method statement covers the procedure of Insulation Installation for Insulation on
FL3B Project. The Insulation itself purposes are:
1.1. Heat Loss Prevention
To be installed to the equipment and piping for preventing heat losses, and
improving the human working environment.
1.2. Personal Protection
To be installed to the equipment and piping when the surface temperature is over
60°C, and the area where human could touch.
1.3. Freeze Prevention
Not applicable
1.4. Condensation Prevention
To be installed to equipment/piping with a possibility of condensate for preventing
condensate.
1.5. Sound Prevention
To be installed to equipment/pipe for sound reduction.

2. RESPONSIBILITY
2.1. Site Manager
Site Manager is responsible for all of the construction.
2.2. Construction Manager
Construction manager is responsible for carry out every work according to this
work procedure

2.3. Engineer
Engineer is responsible for coordinating the process of installation. Before
installation the engineer shall check all related documentation and match with the
material and working ea to avoid any mistake. During installation the engineer shall
confirm or advice if any concern raised. After installation the engineer shall
coordination with QAQC department for confirmation on quality.
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2.4. Supervisor
Supervisor is responsible for the process of Installation. Supervisor will coordinate
the manpower, equipment and material.
2.5. Quality Control Team Leader
Quality Control Team Leader is responsible for quality of overall construction until
completion and activity inspection based on ITP (Inspection and Test Plan).
2.6. Surveyor
Surveyor is responsible for determining the location before construction and to
check the quality of the work (dimension, location, distance) based on ITP
(Inspection and Test Plan),
2.7. QC inspector
QC Inspector is responsible for determining the quality of the work based on ITP
(Inspection and Test Plan) and reported to QC team leader.
2.8. HSE Engineer
2.9. HSE Engineer is responsible for :
 Being familiar with the requirements and recommendations for method statement,
JSA applicable to work place and ensure that they enforce.
 Ensure that tidy and safe working area
 Ensuring that all activities regarding HSE are carried out in accordance with the
HSE regulation.
 Inspecting the working area and correcting of unsafe.

3. PROCEDURES

3.1 Release for Insulation

Before starting the insulatoin work, the insulation engineer must make sure that the
related piping/equipment to be insulated is already on release for insulation status.
To make sure of the piping/equipment status, QC Inspector must prepare the
Release for Insulation document and submit to Construction and QC team from
Client. After the document signed by the client than the Insulation team can proceed
to start the insulation work.
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3.2. Insulation Materials

Insulation material are as below
Applicable material is classified by operating temperature
1 JIS A 9510 or ASTM C 533-I Inorganic porous thermal insulation Material ( Calcium
Silicate )

Insulation Sleeve Class 2-17 8000 Hr

Insulation Board Class 2 -17 8000 hr

2 JIS A 9504 or Thermal Insulation Material Made of Rck Wool

ASTM C612-IVB Insulation Sleeve 8000 hr

ASTM C 592 Insulation Board Class 2 8000 hr

ASTM C547

3 JIS H 4301 or ASTM B 325 Lead and Lead Alloy Sheet and Plate

Apply for sound preventive part

Thickness is 0,5mm or 1 mm basically,actual thickness

depend on installation procedure

3.3. Auxiliary Materials

Auxiliary material means adhesive, joint material,filler,waterproofing material,seal
material,etc.
Auxiliary material are able to apply under design temperatureAuxiliary materials are
selected in correct without to affect any damages to insulation materials and or
equipment / piping.Waterproofing materials and seal materials are selected with
proper thickness in accordance with the used materials and applied area.
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3.4. Lagging Material

Exterior materials are as below.
Exterior materials are used in separate for equipment and piping,basically.
1 ) JIS H 4000 or EQ ASTM B 209
2 ) JIS H 4000 or EQ ASTM B 209
3 ) JIS H 4000 or EQ ASTM B 209
Aluminum and aluminum alloy sheet and
plates,strips and coiled sheets ( Rectangular
Corrugated Sheet )
Colour : Silver
Thickness : 0,4 mm
Applied for : Boiler Parts ( Except for steam
drum and Penthouse Roof ),Bag Filter,Flue
Gas Duct ( Square Type Duct ),etc
Eq Aluminum and aluminum alloy sheet and
plates,strips and coiled sheets ( Flat Surface
Sheet )
Colour : Silver
Thickness : 0,4 mm
Applied for : Equipment except Boiler
Parts,steam drum,air dcts ( Round type duct
),etc
Aluminum and aluminum alloy sheet and
plates,strips and coiled sheets ( Flat Surface
Sheet )
Colour : Silver ( Material Colour )
Thickness : 0,4 mm
Applied for :Piping

3.5. Binding Materials

Binding materials are as below :
Binding material are used in separate per applied area.
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1) JIS G 3532 or ASTM A 641 Low Carbon steel ( Galvanized )

Insulation OD ≥ 150mm : ᴓ 1.6mm
Insulation OD ˂ 150mm : ᴓ 1.2mm
2) JIS H 4000 or EQ ASTM B 209 Aluminum and Aluminum Alloy Sheet and
Plates,Strip and Coiled Sheets
Insulation OD ≥ 1200mm : 0,4t x 19w

3) JIS G 3554 or ASTM A 975 Hexagonal Wire Netting ( Galvanized )

Netting = 26mm, Wire =ᴓ 0,9mm

3.6. Insulation Classification for Piping

Piping insulation is indicated as following system in the line number of EFD.
insulation thickness for general piping is specified by insulation code as below) and Table
1-land 1-2.

Insulation thickness til necessary, unit:

mm)

Insulation Class Temperature

(Rounded by 50°C 10°C

(Process Ter serature)

Classification of insulation (Material

Purpose of insulation)
C : Calcium Silicate
R : Rock Wool
A : Rock Wool for PersonalProtection
Insulation applied for all area of
protection

Purposes of insulation

H : Heat Loss Prevention

P : Personal protection
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F : Freeze Prevention

T : Steam Trace with Insulation

S : Sound Insulation.

Example

- HC20 Heat Loss Prevention for 200°C Fluid temperature with Calcium Silicate

- PR15 Personal protection for 150°C Fluid temperature with Rock Wool

- PP20 Personal protection for 200°C Fluid temperature with Rock Wool

- Insulation is applied only on walkway contact area.

- TR10 Steam Trace with Rock Wool for 100°C Fluid temperature

- FR Freeze Prevention with Rock Wool

3.7. Transportation, Unloading and Storage Materials

The Materials are being shipped to site by returnable containers. These materials will have
to be unloaded upon arrival of materials at job site. The arrival of client materials shall be
coordinate with ellent representative and shall be inspected together. If any materials not
according to the packing list, shortage or over and damage, the material control shall be
prepare the Over Shortage Damage Report (OSDR). Check the shipment is completed
with packing list and shipping documents:

- Check that packing and marking of each item actually exists and perfectly legible.

- Check packing for good condition so as to determine the possible damage due
improper handling

- Check identification and marking of materials.

- Check material dimension randomly.

- Check materials conformity with certificate.

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- For storage, the materials can be divided into two categories according to storage
requirements.
- Materials that must be stored in Lay down with covered sheets
- Materials that must be stored in container or ware house. Ideally all the materials should
be stored in covered area or shed.

a) Make certain that the aluminium lagging and casing is stored in dry place and
ventilated. Care shall be taken to avoid water stain to the aluminium Lagging. They
can be stored outdoor with protection of tarpaulin sheets or Plastic sheets. The cover
should be firmly secured with temporary frames.
b) Mineral fiber insulation materials are shipped with shrink wrap. It is very important that
these materials should protected from rain and water. They must be stored in covered
area. Handling time care shall be taken to avoid damage to the packing as they easily
torn. The wool materials should be stored elevated off the ground by placing them on
the wooden platform.
c) The Galvanized, aluminized, and stainless materials must be stored in warehouse.
d) All carbon steel items carbon steel metal lath, flat bars and steel plates shall be stored
indoor to prevent rusting before they are installed.
e) The items Tie wire, Insulation pins, speed clips, sewing thread, studs, sheet metal
screws,neoprene sheets etc., must be stored in containers with locking facilities.
The Material status report shall be clarifies the status of materials received, issued, and
balance stock. All materials for installation shall be requested with Material Requisition
Order (MRO) by the requester to the material controller. Any materials issued shall be
recorded in issuance note. Stocktaking of materials held by material controller and
witnessed by client representative / MC / Manufacturer will include visual count of
materials held in the warehouse and open-air storage yard.

3.8. General Requirement Insulation and Lagging

- Insulation shall be installed on piping and equipment where indicated on the construction
drawings, in line lists and equipment lists. Insulation shall only be applied over coated
piping and equipment.
- All materials shall be new, undamaged nor crushed and shall be installed prior to the
expiration date, if applicable. Sealants, mastics and adhesives shall be applied from
factory sealed containers.
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- Insulation shall be maintained dry at all times during storage and installation. Do not
install wet Insulation. If the insulation becomes wet during or after installation, remove
and replace with new dry insulation. Insulation shall be protected with plastic film, but
shall be vented to prevent condensation. If there is a work delay, seal all possible paints
of moisture penetration before work is halted.
- Insulation supports, anchor nuts, etc., will normally be welded to equipment and clamped
re piping unless otherwise note Weiding will not be permitted un piping or equipment
after stress relieving without written approval by chent or vendors
- All valves including control valves and relief valves, all flanges, including man way
flanges, vessel skirts, heat exchanger closures and connectors, expansion joints,
instruments and other similar items which require periodic access shall be insulated for
energy conservation or for personnel protection. Where hot insulation is required for
these items, the insulation shall be permanent insulation, however removable blanket
type insulation may be used where specifically indicated on the drawings.
- Hot Insulation of flanges shall be beveled to the pipe at a sufficient distance from the
flange to allow removal of bolting without damaging adjacent insulation. Cold insulation
of flange shall be a removable sealed type box assembly.
- Manufacturer's equipment nameplates and code name plates shall not be covered by
insulation, Insulation shall be cut to angle from the nameplate edges and sealed off with
mastic followed by weatherproofing compound.
- All welded and screwed fittings, except unions, in insulated lines shall be insulated.
- Make sure to protect adjacent equipment, etc. from the application of insulating
materials, for example drippings, sprayed paint, mastics, and compounds.
- Insulation shall not be applied to piping or equipment until the piping or equipment has
been pressure tested, any leaks located and repaired, and all surfaces cleaned of scale,
rust, oil and foreign matter and painted prior to application of insulation.
- Each layer of multiple layer insulation shall be held in place separately.
- Pre-placement inspection - Equipment Prior to placing the insulation the following
inspections to be performed.

a. Confirm the equipment is tested and accepted.

b. Check the proper insulation support rings have been installed, where required.
c. Confirm that all clips for piping supports, ladders, platforms, etc. have been installed.
d. Ensure that the steam tracing is completed, where required.
e. Confirm that the equipment is properly painted and inspected, if specified.
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f. Ensure the surface to be insulated is dry, clean, and free from dirt, grease, rust, loose
mill scale, etc. If required wash with clean water to remove the dirt or salt contamination
g. Confirm sufficient accessibility and clearance is provided for both the insulation be
applied and the space necessary for workmen to apply it.

3.9. Equipment, Tools and Consumable

The equipment and consumables involved are, but not limited to:

 Lifting Tools (electrical winch, wire sling, sling belt, wire rope)
 Welding Machine
 Saw
 Alloy Sheet cutterscissors Grinding Machinever
 Forming Machine
 Bolt, Nut and Washer
 Water-Resistance Sheet
 Water resistance paste
 Measurement equipments (Measuring tape)

3.10. Insulation Application

3.10.1. Insulation of Tanks/Vessels

Insulation of tanks/vessel consist of 150 mm rockwool and calcium silicate, wire mesh
and aluminum sheet. No welding for any material to the vessels. The rockwool should
be fixed by use band/wire and then install the aluminium sheet.