Professional Documents
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BE EXT CFL I
Eng. Phase Purpose Of Distribution (POD) Purpose Of Issue (POI) Owner's Action
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1 Rev.01 :
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Index Page
1. GENERAL 5
1.1 SCOPE 5
1.2 REFERENCES 5
1.3 DESIGN BASIS 6
1.3.1 Temperatures 6
1.7 LIMITATION 8
1.7.1 Hot Insulation 8
1.7.2 Personnel Protection Insulation 9
1.7.3 Cold Insulation 10
1.7.4 Clearances 10
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Index Page
3. INSULATION APPLICATION 13
4. STORAGE 19
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1. GENERAL
1.1 SCOPE
This engineering specification covers the general requirements of the design and materials for
external insulation of above ground piping and equipment for the purpose of heat conservation,
process stabilization, temperature maintenance, personnel protection , but excludes structural
insulation of buildings, fire proofing structures and all external underground mains for use in ZANJAN
Agricultural & Fertilizer Industries Co., IRAN
This engineering specification define the thermal insulation to be used for equipment, and piping
system including:
- Insulation types
- Insulation materials
- Thickness to be applied
- Fastening materials
- Jacketing systems for insulation protection
- Technical application methods to be used
1.2 REFERENCES
Throughout this engineering specification the latest edition of the following Codes and Standards
and Engineering Specifications shall be considered:
ASTM B209 : Standard Specification for Aluminum and Aluminum Alloy Sheet and Plate
ASTM C1055 : Standard Guide for Heated System Surface Conditions That Produce
Contact Burn Injuries
ASTM C1057 : Standard Practice for Determination of Skin Contact Temperature from
Heated Surfaces Using A Mathematical Model and Thermesthesiometer
ASTM C168 : Standard Terminology Related to Thermal Insulating Materials
ASTM C547 : Standard Specification for Mineral Fiber Pipe Insulation
ASTM C553 : Standard Specification for Mineral Fiber Blanket Thermal Insulation
for Commercial and Industrial Applications.
ASTM C591 : Standard Specification for Unfaced Preformed Rigid Cellular
Polyisocyanurate Thermal Insulation
ASTM C592 : Standard Specification for Mineral Fiber Blanket Insulation and
Blanket-type Pipe Insulation (Metal-Mesh Covered)
ASTM C612 : Standard Specification for Mineral Fiber Block and Board Thermal
Insulation
ASTM C795 : Standard Specification for Thermal Insulation for Use in Contact with
Austenitic Stainless Steel
BS5970 : Code of Practice for Thermal Insulation of Pipe Work and Equipment
(In the temperature range –100 °C to +870 °C)
BS5422 : Method of Specifying Thermal Insulating Materials on Pipes, tanks,
vessels, Ductwork and Equipment
(In the temperature range –40 °C to +700 °C)
1.3.1 Temperatures
In order to maintain a process temperature or for energy saving by reducing the calorie losses.
However, the outer surface of the insulation must be at a maximum temperature of 60 °C in normal
operation temperature, to ensure personnel protection as defined hereafter.
For protection of personnel against contact with the hot surfaces, which are operated at temperatures
above 60 °C in normal operating condition and accessible from normal working areas or access ways
and the following clearances :
(1) Within 2200 mm height from ground or floor level
(2) Within 600 mm distance beyond the edge of platform or walkway.
(3) Within 910 mm horizontally outside of normal working areas or access ways.
In some cases, the insulation may be replaced by a guard consisting of a grid or expanded metal,
use of guard is subject to OWNER approval.
In order to warm up and maintain a process temperature on equipment, piping, instrument etc.
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
In order to maintain low temperature for process control, conservation of refrigeration and avoid
surface condensation.
- Any area in the facility with ambient noise levels exceeding 90 dBA shall be classified as a
Noise Hazard Area. Acoustical insulation shall be applied to piping and equipment to comply
with noise abatement requirements. The Line List shall indicate all piping that will be fully or
partially acoustically insulated. The Equipment Insulation Summary shall indicate equipment
that is insulated for acoustical purposes.
- Piping and equipment requiring acoustic insulation shall have insulation thicknesses in
accordance with the operating temperatures and Attachment-1.
Additional insulation thickness may be necessary for specific noise problems.
- The piping erection drawings or assembly drawings will define the limits of acoustical insulation.
In some cases, piping or equipment operating in the range from ambient to 60°C (140°F) will
require insulation for process temperature stability ( if applicable ).
1.5.2 Piping, equipment, storage tanks and vessels requiring insulation shall be normally specified on the
following project documents:
1) Insulated piping systems shall have straight pipe, bends, tees and pipefittings completely
insulated.
3) Insulation around valves and instrument shall be provided so that insulation does not interfere its
operation.
4) For bucket and float type steam traps the inlet piping and trap shall be insulated.
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5) Insulation on inlet piping to thermostatic and thermodynamic steam traps shall terminate at
approximately 500 mm before the trap.
6) Steam trap outlet piping other than closed condensate recovery system shall not be insulated
except for personnel protection reasons.
7) Insulation shall be applied over all steam and electrical tracing as per relevant engineering
specification.
1) The scope of insulation for equipment shall be considered in accordance with relevant
engineering drawings or vendor drawings.
2) All equipment shall be insulated for heat conservation as given on insulation schedule and
equipment data sheet.
3) Liquid ends of pumps shall be insulated when heat traced or jacketed or when indicated on
outline drawing or on equipment data sheet.
4) Insulation on exchangers and vessels shall be stopped at a sufficient distance from each flange
to permit the removal of the flange bolts and shall be finished with a bevel of sealer and then
the flanged connection shall be insulated by means of prefabricated quick opening box.
1) Insulation around valves and instrument shall be provided so that insulation does not
interfere its operation.
2) All pipes, valves, flanges, and fittings shall be insulated.
3) Valves shall be insulated under the packing gland.
4) All equipment attachment and projections such as vessel supports, steel structures attached
to vessels, piping supports, instrumentation lines, equipment trim line and instruments
connections directly, to be cold insulated up to a distance of 4 times (minimum 300 mm) the
insulation thickness.
5) Insulation shall extend down the outside of vessel skirt for a distance 4 times (minimum 300
mm) the insulation thickness as measured from inside bottom tangent line.
6) All flanged joints, manhole covers, etc. shall be cold insulated with removable box insulation.
7) Insulation on exchangers shall be stopped at a sufficient distance from each flange to permit
the removal of the flange bolts and shall be finished with a bevel of sealer and then the
flanged connection shall be insulated by means of prefabricated quick box.
1.7 LIMITATION
The following piping components & equipment shall not be insulated unless otherwise specified.
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
(1) Visible parts such as nameplate, code inspection plates, stampings, sight glass and level
gauge.
(3) The following parts of the rotating machinery, which need heat dissipation and cooling, unless
otherwise specified.
a. Stuffing box
b. Packing ground
c. Piping and jacket for cooling water
d. Packing sealed piping
e. Bearing
f. Oil cooler
g. Gear shaft case, etc.
(4) Fans, compressors, blowers or other rotating or reciprocating equipment or machinery, unless
otherwise specified on relevant data sheet.
(6) Safety valves along with its outlet piping and down stream piping of such valves as steam blow
off valve, vent and drain valve.
(7) Steam traps and the lines down stream of them, which require no recovery of heat of the drain
and no prevention of freezing-up, unless specified in the drawing.
(8) Parts having moving element, such as expansion and swivel joint.
(11) Turbine casing to be insulated shall exclude shaft seal caps, shaft bearing housing, governors
and supports.
Note: Valve bodies, flanges, flanged fittings and unions in hydrogen service, highly corrosive fluids
and toxic materials should not be insulated.
The following piping components & equipment shall not be insulated unless otherwise specified.
(1) Visible parts such as Nameplate, code inspection plates, stampings, sight glass and level
gauge.
(3) Safety valves along with its outlet piping and down stream piping of such valves as steam blow
off valve, vent and drain valve.
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
(5) For equipment and piping with inside lining of refractory or insulationg material except for the
case where the metal temperature must be controlled.
(6) Turbine casing to be insulated shall exclude shaft seal caps, shaft bearing housing, governors
and supports.
The following piping components & equipment shall not be insulated unless otherwise specified.
(1) Visible parts such as nameplate, code inspection plates, stampings, sight glass and level
gauge.
(2) Parts having moving element, such as expansion and swivel joint.
1.7.4 Clearances
(1) Insulation shall be designed to provide an absolute minimum clearance of 25mm between the
outside surface of any insulation finishing material and adjacent surfaces.
(2) Where insulated piping is supported on steel shoes, the height of the shoe shall be such that
the underside of the insulation finishing material is clear of the supporting structure upon which
the shoe rest by 25mm minimum.
1.8.1 General
1) All material (Insulation, Jacketing and ancillary material) shall be of high quality, new, and good
appearance and shall not have any deleterious action on the surface to be insulated.
2) All insulation and finish coatings, fabrics, mastics and sealants supplied shall be certified by
manufacturer to be asbestos free.
3) Insulation materials shall be packed in a manner that ensure no moisture can enter during
transport, in transit and storage at site. Preferably, the materials shall be fixed to non-
returnable pallets.
4) As much as possible, insulation materials shall be of low chloride content, chemically inert,
non-sulfurous, rot proof, vermin proof, impervious to hot water and steam, non-injurious to
health and non-corrosive to steel and aluminum (even if soaked in water at ambient
temperature for extended periods).
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
2) When the insulation thickness is higher than 75mm, the insulating material shall be applied in multiple
layers and the joints should result offset.
♦ Insulating materials.
♦ Metal jacketing.
♦ Jacket Fastening.
(1) The insulation material shall meet the requirements of ASTM C795, when applied on austenitic
stainless steel surfaces.
(2) Preformed mineral wool pipe sections shall be used for pipes up to NPS 12".
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
2.2.2 Plates
2.2.3 Wires
Tie wire shall be annealed type 304 Stainless Steel to secure insulation. Wire gauges shall be as
follows:
- Pipe 12” and under: 1.5 mm
- Vessels and pipe over 12”: 2.0 mm
Metal strap and seals to secure insulation shall be type 304 stainless steel as follows:
Expansion spring for insertion in bands shall be 50 mm width stainless steel. The springs shall be of
the flattened type, 50mm or 100mm long according to performance requirments and shall be capable
of remaining in tension during the heating and cooling cycles.
Metal jacketing shall be aluminum as per ASTM B209 alloy 3003 H16 or approved equal, with
factory attached lamination of polyethylene 0.025 mm thick, and kraft paper 0.1 mm thick, without
adhesive, heat –sealed onto the side which is in contact with the insulation , and supplied as
follows:
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
a) 0.6 mm thickness in flat form for piping 12” diameter and smaller.
For attaching metal jackets together especially in straight pipe, strap should be used and screws are
for fittings, valve box and fixing metal jackets to insulation supports. The material of screws shall be
adapted to the material nature of the metal jacketing.
3. INSULATION APPLICATION
The following operations shall be performed on equipment and materials prior to application of
insulation:
♦ Supports installation
If insulation work proceeds in advance of hydrostatic testing and inspection, welded joints shall
be left un-insulated until hydrostatic testing is completed.
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
Generally insulation supports on equipment are installed by the Vessel fabricators and on piping by
the insulation contractor. Welding type support for piping shall be prohibited.
(1) The application methods, given in this engineering specification are general in nature. The
construction contractor is responsible for applying an insulating system that to give a
satisfactory operational performance and the requirements given herein shall be regarded as
the acceptable minimum. The construction contractor shall carryout the work in accordance
with the best practices of insulation application with the minimum of waste and debris and the
final job shall have a neat, efficient and workmanlike appearance.
(2) Insulation supports shall be provided at least 3700mm intervals on vertical lines or lines
inclined more than 45°from horizontal. Supports shall be installed above all flanges in vertical
lines and located to allow removal of flange bolts.
(3) Before applying weatherproofing, insulation shall be inspected for open joints, voids, cracks
and defacing. Open joints, voids, and cracks shall be adequately filled with insulation and
defacing made good to the satisfaction of the inspector.
(4) Special consideration shall be given to application of insulation near pipe supports. The
insulation and weatherproofing shall be applied in a manner, which does not restrict thermal
expansion or contraction of the piping at its support points.
(5) Piping insulation shall be continued at guides.
(6) Inner layers in multiple layer pipe insulation and insulation on irregular equipment surfaces
(where use of bands and seals is impractical) shall be secured, using stainless steel wire. The
wire shall be drawn taut to imbed it into the insulation. The ends shall be firmly twisted and the
excess cut off. The twisted ends shall be bent over and imbedded into the insulation.
(7) Provide expansion spring on vessels over 4500 mm in diameter and operating temperature
over 200 °C. A minimum of two springs shall be used 180°apart. For each additional 7500mm
of circumference, one additional spring shall be installed. Springs shall be equally spaced
around banding.
(8) Provide expansion springs on storage tanks for maximum of every 15m of circumference.
(9) For equipment 900mm in diameter and smaller, pipe insulation may be used, where applicable.
(10) For equipment larger than 900mm in diameter, blanket, blocks, beveled lags or curved
segments of insulation shall closely fit the contour of the equipment to be insulated.
(11) Butt and expansion joints shall be staggered for single layer insulation and in both directions
all multiple layers of insulation.
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
(12) Flash all man ways and nozzle necks and seal to prevent entry of water.
(13) Support lugs for ladders, platforms, piping, etc. shall be flashed and painted.
(15) Hydrostatic tests on pipe, vessels and equipment, if possible shall be completed before
insulation is installed. If insulation is applied before testing, all weld and thread joints shall
be exposed until completion of testing.
(16)Care shall be taken to avoid contact between dissimilar materials which might causes galvanic
corrosion.
(17)Insulation, which needs to be removed for maintenance purpose, shall be fabricated in such a
manner, that it is easily removable and can be remounted with a minimum of work. Quick
opening boxes and similar construction shall be used in this case.
(18)Single thickness sectional pipe insulation shall be applied with longitudinal joints staggered
and shall be secured with wire ties on 230mm centers. Double thickness sectional pipe
insulation shall be applied with all joints staggered and shall have inner layer secured by at
least two wires per section with the outer layer secured by wire ties on 230mm centers.
(19) For cases which thickness of insulation on pipes exceeds to be covered with one layer pipe
sections , using combination of pipe section + blanket layers could be acceptable with owner’s
approval
(20) External stiffing rings on vessel and piping shall be insulated with the same thickness as
required for vessel or piping.
(1) Only sound and dry materials having the correct dimensions and the required quality shall be
installed.
(3) Basic rules for installation of insulation components on equipment, ducts, piping, and
instruments, to prevent calorie losses through the joints, are the staggered arrangement.
(4) When more than one layer is provided, the components of each layer shall be staggered and
joints of the second layer shall be offset from those of the first layer
(5) Blanket (metal-mesh covered) shall be secured by twisting together the wire mesh or by means
of a hook or by tying them together with 1.3mm diameter wire.
(6) Any beveled or rounded edges of insulating component shall be carefully square off before
application.
(7) Each layer of insulating panels shall be impaled on welded pins held by means of quick
tightening plates.
(8) 10 pins/ m2 are required and shall be welded with staggered arrangement.
(9) Each layer of insulating blanket shall be applied on circular equipment and secured by steel
wire or adapted straps with an adequate spacing to hold components in place. (Maximum
spacing: 250 mm from center to center).
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
(10) On any sharp angles, a small alloy aluminum angle piece shall be installed to prevent the
metal strap cutting into the insulating materials.
(12) All insulation components shall be carefully cut and adjusted to follow the exact shape of
surfaces, nozzles, manholes, rings, supports, gussets …
(14) All spaces between blocks or between insulation and equipment shall be completely filled and
packed with a flock wool material.
(15) A layer of aluminum foil shall be wrapped around stainless steel equipment and piping to
eliminate chloride attack from hot insulating mineral wool.
(1) After equipment or piping insulation has been applied in a satisfactory manner the insulation
shall be immediately jacketed and water-proofed.
(2) If bare insulation cannot be jacketed before the end of the working day the system shall be
protected with plastic sheets or in shed to prevent water entering.
(3) A basic rule concerns the orientation of the metal jacket overlapping. To prevent any ingress
of water (or other liquid) under the jacket, it is essential for horizontal joints, that the top sheet
overlaps the bottom sheet (like roof tiles).
(4) In the case of vertical joints the overlap shall be in opposite direction of the prevailing wind.
(6) On equipment, ducts, piping and whenever it is possible, both horizontal and vertical laps shall
be minimum 50mm wide; otherwise, they shall be as large as possible.
(7) Metal jackets shall be fixed together by adequate screws spaced of maximum 200mm. From
center to center.
• To prevent thermal bridges, insulating fabric bands shall be provided between jacket and
support on equipment and at insulation supports.
• To allow movement due to the differential expansion between equipment or piping and
jacket, special arrangement shall be provided (Example: a circumferential lap joint located
between 2 supports shall not be fixed).
• Jacket for vessel heads shall be in section except for small diameters where they may be
either flat or Chinese hat type.
• In some cases (like for pumps) the metal jacket may be replaced by mastic coating with
wire mesh and glass cloth reinforcement (or by fiber glass reinforced epoxy coating).
• The outer surface of insulation shall have a regular and smooth finish.
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
(1) Insulation shall be applied in conformity with the recommendations of the paragraph 3.2.2.
(2) Insulation elements like blocks and slabs shall be applied with their length parallel to the
greatest length of surface being covered.
(3) The base course shall be applied with alternate length blocks so that all successive end joints
are staggered.
(4) Skirts supporting equipment shall be insulated outside as part of the equipment area.
(5) The insulation shall extend downwards, from the junction of the inside of the skirt and the
insulated equipment to a distance of three times the thickness of insulation but in no case less
than 250mm. The thickness of the insulation shall be equal to that specified for the equipment.
(6) Full insulation thickness shall be applied over all support rings, stiffeners, and other
protuberances on the surface of equipment.
Insulation shall be applied in conformity with the recommendation of the paragraph 3.2.2.
Straight Pipes
The edges of pipe insulation segments shall be cut off square leaving a distance between the
insulation segment edge and the flange bolt extremity equal to the bolt length plus 25mm.To ensure
enough clearance for bolt dismantling.
Bends
Generally, materials shall be cut into suitable segments and joints shall be carefully staggered.
When two layers (or more) of insulation are provided, joints shall be staggered as follows:
Flanged Components
For in-line instruments, level gauges and up to block valve of local instruments such as pressure
gauges, Extend and specification of insulation shall be according to this engineering specification.
For lubing impulse / analyzer line, insulation extent and specification shall be in accordant with
Engineering Specification for Control and Instrument.
Insulation shall be applied as described in paragraphs 3.2.1 to 3.2.3 for instrument pipes.
Adequate number of inspection windows on all strategic locations shall be provided for checking
metal corrosion by construction contractor, which will be specified by field engineer.
The removable window shall be of the same basic material and thickness as the rest of the insulation
and of sufficient rigidity to withstand handling.
The entire outer surface of the insulation shall receive a tack coat of vapor barrier mastic, 1.5 liters
per 1.0 m2 with a minimum thickness of 1 mm unless otherwise specified. And glass cloth
embedded into the surface while still wet, avoiding all wrinkles pockets, etc. and overlapping the
glass cloth a minimum of 50 mm. A finish coat of vapor barrier mastic shall then be applied to the
whole surface 3.0 liters per sq.m., with a minimum finished and dried thickness of 3 mm unless
otherwise specified, care shall be taken to ensure that all glass cloth and bands are completely
covered. The surface shall be then be smoothed off with a suitable solvent if metal cladding is not
to be applied.
The vapor barrier mastic and glass cloth shall extend at least 150 mm beyond the insulation at all
metal projections to ensure a good seal. Heavy fillets of mastic shall be applied to all corners and
crevices where water is likely to collect. Vapor barrier mastic shall also be used as flashing at all
possible sources of moisture penetration such as intersections of insulation, nozzles, building, walls,
valve bonnets tees and other protrusions through the surface coating.
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
The entire outer surface of the insulation shall receive a take coat of vapor barrier mastic, 1.5 liters
per 1.0 m2 with a minimum thickness of 1 mm unless otherwise specified. And glass cloth embedded
into the surface while still wet, avoiding all wrinkles pockets, etc. and overlapping the glass cloth a
minimum of 50 mm. A finish coat of vapor barrier mastic shall then be applied to the whole surface,
3.0 liters per sq.m. with a minimum finished and dried thickness of 3 mm unless otherwise specified.
Care shall be taken to ensure that all glass cloth and bands are completely covered. The surface
shall then be smoothed off with a suitable solvent if metal cladding is not to be applied.
At all metal flashing protrusions, insulation terminals, corners and cervices a sealant shall be applied
prior to the mastic and glass cloth, which shall extend 150 mm beyond the insulation to ensure a
good seal. Heavy fillets of vapor barrier mastic shall be applied to all corners and crevices where
water is likely to collect. Vapor barrier mastic shall also be used at all possible sources of moisture
penetration, such as intersections of insulation, nozzles, building walls and other protrusions through
the surface coatings.
4. STORAGE
Insulating materials shall be packed in a manner that ensures no moisture can enter during transport,
in transit, and storage at site.
Preferably, the materials shall be fixed to non-returnable pallets.
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
(ATTACHMENT NO. 1)
HEAT CONSERVATION AND TRACING
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
Attachment No.1
HOT INSULATION:
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
(ATTACHMENT NO. 2)
PERSONNEL PROTECTION
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
Attachment No.2
HOT INSULATION:
PERSONNEL PROTECTION (CODE P)
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
(ATTACHMENT NO. 3)
COLD & ANTI-SWEAT INSULATION
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EPs Contractor: ZANJAN UREA FERTILIZER PROJECT Owner:
Attachment No.3
COLD INSULATION:
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