Ref GLT.ENG.ME.ST.

03
SABMiller - Group Technical
Page : 1 of 9
Version. : 0
Version Date : 9 Oct 2007
Scheduled
Title: Insulation - Hot Stainless Steel Vessels
Owner: Group Engineering Review : 01 Oct 2010

Contents PAGE

1. Version & Revision History 2

2. Scope 2
3. References 2
4. Mandatory Requirements 3
4.1. INSULATION MATERIALS 3
4.2. INSULATION SYSTEM 3
4.3. FITTINGS 4
5. Guidelines for Insulation of Vessels 4
6. Quality Assurance and Quality Control 5
7. Inspection and Handover 5
APPENDIX A - Examples of correct and incorrect insulation 6
details for fittings

POSITION NAME DATE

ORIGINATOR Consultant John Cluett 30 May 07

REVIEW Global Engineering Community 30 May 07

APPROVAL Head of Engineering Rod Milne 09 Oct 07

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1. Version and Revision History

Version 0 is the original version.

2. Scope
This document covers the general guidelines on specific mandatory requirements for the
insulation of hot vessels and lists recommendations on workmanship and application of
insulation of hot vessels operating at temperatures greater than 50°C, or where heat loss may
affect the process or be dangerous to personnel.

3. References
This specification refers to the latest revision and amendments of the following standard.
3.1. SABMiller
ENG-STD 001 Insulation – Hot Stainless Steel Vessels
3.2. National Standards
OHS Act No. 085 : Occupation Health & Safety Act No. 085 of 1993
3.3. International Standards
Where references are made to “internationals standards’ these shall be specified by
the Contractor and approved for use by SABMiller
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4. Mandatory Requirements
4.1. INSULATION MATERIALS
Hot vessels operating at 50°C or higher shall be insulated with one of the four materials
defined below to limit heat losses which may affect the process, or to conserve heat
energy, or for personnel protection. Saturated steam pressures at 3.1 bar (45psi) =
temperature 135 deg C and at 5.17 bar (75psi) = temperature 153 deg C. The
insulation shall be designed in accordance with internationally recognised standards.
The thickness of insulation shall be in accordance with internationally recognised
standards that define "Economic thickness of insulation for process pipework and
equipment" as defined in the following table.

Material Thickness at shell Upper temperature

(mm) of insulation
Polyisocyanurate – (PIR – PIC) 80 140°C
Modified Phenolic 80 120°C
Glass Fiber 100 450°C
Mineral Wool 100 900°C
The above materials have been tested to SANS 10177 Part 3 “Surface Fire Index of
Finishing Materials” in a composite panel that includes the complete insulation system
as defined in this guideline document. This test defines spread of flame index, heat
contribution index and smoke emission index of each material, resulting in a Surface
Fire Index and Classification as follows
Sample Identification Results
Heat Smoke
Spread of contribution emission Surface fire
Insulation material flame index index index index Class
Polyisocyanurate 1.15 1.12 1.74 1.34 3
Phenolic 0.88 0.68 0.45 0.56 3
Glass Fibre 0.12 0.75 4.32 1.54 5
Mineral Fibre (wool) Nil 0.77 0.01 0.26 2
Forbidden insulation materials
Polyurethane 2.08 1.05 9.4 4.18 >5
Polystyrene 2.76 1.09 14.96 6.28 >5

4.2. INSULATION SYSTEM

Stainless Steel Vessels
Stainless steel vessels shall be insulated with the following system:
4.2.1. Two layers of anti-stress-corrosion barrier coating; Lacquer or suitable paint for
the operating temperature specified shall be used (e.g. Dulux Anti-Stress-Corrosion
Lacquer D126-2864 for operating temperatures below 150°C, or Fosters 57-73 for
temperatures above 150°C, or equal and approved).
4.2.2. Aluminum foil shall be of thickness not less than 30 µm to be applied over the last
layer of ant-stress corrosion lacquer or paint.
4.2.3. Insulation material chosen from the list defined in 3.1 above These materials
must have a maximum 5 ppm chlorides
4.2.4. Outer aluminum foil layer over the isolation materials to prevent moisture ingress.
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4.2.5. Stainless steel cladding will be secured with screws or rivets and sealed at all
circumferential and longitudinal joints with sealant or as a totally welded outer shell.
4.2.6. Piping associated with the vessels shall have a similar insulation system
.
4.3. FITTINGS
4.3.1. Where man-ways, instruments, piping etc. protrude through the insulation, a
shroud shall be provided around the protrusion. This also applies on piping related to
the vessels.
4.3.2. See Appendix A for photos of examples of good and bad examples.
4.3.3. The insulation and flashing shall be neatly finished off and sealed to prevent the
ingress of water at such points.

5. Guidelines for insulation vessels

These guidelines shall serve to assist in the final agreement between the SABMiller
engineer and the Contractor as to how the work should be carried out.
5.1. The method of application to be in accordance with accepted engineering practices that
should include the following:
5.1.1. All insulating materials, however fixed, to be in close contact with the surfaces to
which they are applied unless an air space is specifically required.
5.1.2. Before any section of the insulation work on a vessel is commenced, all hangers,
brackets, pipe clips etc. to be in position and the required acceptance tests for
pressure/vacuum etc. shall have been carried out.
5.1.3. The Contractor shall do NO WELDING on the vessel shell, unless prior
permission in writing has been obtained from the SABMiller Engineer responsible.
5.1.4. No insulation may be applied to any vessel that is wet, or that is at or below dew
point at the time of application.
5.1.5. Insulation to be installed on clean, dry surfaces.
5.1.6. Insulation shall be applied in accordance with the manufacturer’s instructions in a
neat and workmanlike manner so as to give a smooth and even surface.
5.1.7. Cladding for vessels situated outside buildings must be weatherproof.
Longitudinal lap joints shall be seamed, grooved and lapped.
The lap shall be manufactured, so as to shed water / moisture without entering the
muff. Joints between adjoining muffs shall also be seamed and grooved.
5.1.8. The details of cladding finish to be agreed with SABMiller to ensure that openings
for maintenance work, etc, are provided. Where shrouds are provided the cladding
must be secured to the shroud by overlapping the shroud.
5.1.9. Each vessel to be insulated will be inspected by SABMiller before being handed
over to the insulation contractor to ensure that the following requirements have been
met:
5.1.10. All surfaces of the vessel requiring insulation are clean, dry, free from grease, dirt
or scale. All heat affected zones after welding have been fully pickled and passivated.
5.1.11. The entire insulation system shall be totally completed before any operation is
allowed in or around the vessels to prevent any moisture to ingress into the insulation
system from water, steam or product spillage.
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5.1.12. The final appearance of the insulation must be aesthetically pleasing and of a
high standard.
5.1.13. The Contractor shall provide detailed drawings and samples of the proposed final
finish for approval by SABMiller before any work starts on the work. Alternatively the
Contractor may request SABMiller to provide examples of acceptable finishes. These
samples will be used as acceptance criteria for the completed work.

6. Quality Assurance and Quality Control

6.1. The requirements for Quality Assurance Plans shall be developed by the contractor and
submitted to SABMiller for approval before any work starts on the vessel
6.2. Vapour permeance tests shall be carried out in accordance with international standards.
6.3. SABMiller shall have the right to call for site tests with respect to insulation bulk density
and thickness.
6.4. SABMiller may further arrange for a thermal conductivity test to be carried out in
accordance with international standards...
6.5. Tests shall be carried out on selected vessels by the approved laboratory, and the cost
shall be borne by the Contractor.
6.6. SABMiller shall have the right to call for tests in respect of the chemical suitability of the
lagged materials in accordance with international standards.

7. Final Inspection and Handover

7.1. All work is to be done to the complete satisfaction of the SABMiller Inspector
7.2. A complete schedule of insulation details per vessel and components, with reference to
the applicable drawings shall be provided as part of the documentation to be handed over
to SABMiller during the design phase of the project. SABMiller shall define the timing of
this information. .
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Appendix 1 Examples of correct and incorrect insulation details for fittings

Correct insulation detail of fittings on vessels

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Fittings up against insulation makes insulation &

cladding difficult and cause damage to system
during maintenance .Shrouds are required.

Man way is at lower level to cladding.Damage

to cladding will be excessive during access to
vessel
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Valve and actuator up against

insulation makes maintenance
difficult. This requires shroud

Pipe & fittings welded to vessel to be

shrouded and flanges to be further
from insulation to prevent damage to
insulation during maintenance

Shroud to be lipped to allow for

effective sealing of cladding.
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Pipe & fittings welded to vessel to be shrouded

and flanges to be further from insulation to
prevent damage to insulation during maintenance

Profiled cladding is difficult

to seal at penetrations
fittings, pipe supports, and
man ways

Vessel sitting on plinth.

What material is under the
vessel and is there a coating
between the vessel and
material?