Professional Documents
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Installation of Hot Service
Installation of Hot Service
PIP INSH2000
Installation of Hot Service
Insulation Systems
PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES
In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these technical
requirements into a single set of Practices, administrative, application, and engineering
costs to both the purchaser and the manufacturer should be reduced. While this Practice
is expected to incorporate the majority of requirements of most users, individual
applications may involve requirements that will be appended to and take precedence over
this Practice. Determinations concerning fitness for purpose and particular matters or
application of the Practice to particular project or engineering situations should not be
made solely on information contained in these materials. The use of trade names from
time to time should not be viewed as an expression of preference but rather recognized as
normal usage in the trade. Other brands having the same specifications are equally
correct and may be substituted for those named. All practices or guidelines are intended
to be consistent with applicable laws and regulations including OSHA requirements. To
the extent these practices or guidelines should conflict with OSHA or other applicable
laws or regulations, such laws or regulations must be followed. Consult an appropriate
professional before applying or acting on any material contained in or suggested by the
Practice.
PIP INSH2000
Installation of Hot Service
Insulation Systems
Table of Contents
5.10 Protection of Installed Insulation ....... 7
1. Introduction ..................................2 5.11 Damage Considerations ................... 7
1.1 Purpose ............................................2 5.12 General Housekeeping ..................... 7
1.2 Scope ...............................................2
1.3 Insulation Systems............................2 6. Extent of Insulation...................... 8
1.4 Supporting Documents......................2
7. Documentation............................. 8
2. References....................................2
2.1 Process Industry Practices (PIP) .......2
2.2 Industry Code and Standards ............2 Data Sheets
1. Introduction
1.1 Purpose
The purpose of this Practice is to provide requirements for installation of hot service
insulation systems, ambient to 1200°F (649°C).
1.2 Scope
This Practice covers requirements for storage and handling of insulation materials,
application of insulation, extent of insulation, and documentation.
2. References
When adopted in this specification or in the contract document, the latest edition of the
following codes, standards, specifications and references in effect on the date of contract award
shall be used, except as otherwise specified. Short titles will be used herein when appropriate.
3. Definitions
Contractor: Party responsible for furnishing and/or installing the insulation system
4.1 From delivery to installed finished product, insulation materials shall at all times be
protected from the elements and have adequate drainage.
4.2 Insulation materials shall be handled and stored per manufacturer’s printed
recommendations.
4.3 Mastics, adhesives, and sealers that are exposed to temperatures outside the
recommended temperature ranges during storage shall be removed from the site and
replaced with new material.
4.4 Materials with expired shelf life and dates shall be removed from the site and replaced
with new material.
5. Application of Insulation
5.1 General
5.1.1 All materials shall be stored, mixed, thinned, and applied in accordance with
the manufacturer’s printed instructions. All conflicts between this
specification and the manufacturer’s instructions shall be brought to the
attention of the Purchaser for resolution.
5.1.2 Authorization to proceed with application of insulation shall be obtained in
writing from the Purchaser.
5.1.3 Unless otherwise specified, insulation shall not be applied until completion of
the following has been verified:
a. Required hydrostatic and/or pneumatic pressure testing
b. Application of required substrate protective coating systems, including
touch-up of previously applied coatings
c. Installation and testing of required tracing systems
d. Cleaning of surfaces that are to receive insulation
5.1.4 If required by the Purchaser, application of insulation may proceed before
pressure testing is complete, provided that all welds and flanged and threaded
connections are left exposed until the pressure testing is complete. Temporary
terminations of installed insulation shall be adequately protected at all times.
5.1.5 Where insulation has been specified on piping or equipment flanges that are to
be hot bolted, the insulation shall not be installed until hot bolting has been
accomplished and the flange determined to be leak-free.
5.1.6 Unless otherwise specified, all insulation materials shall be installed in a single
layer when the total thickness does not exceed 3 in. (75 mm).
5.1.7 When applying single layer insulation, other then hinged pipe covering, the
circumferential butt joints of each half section shall be staggered.
5.1.8 Thicknesses 3-1/2 in. (90 mm) and greater shall be applied in multi-layers
with staggered joints. Consideration shall be given to multi-layer insulation for
operating temperatures over 600°F (316°C).
5.1.9 When applying double or multi-layer insulation, each succeeding layer shall
be staggered to the longitudinal and circumferential joint of the layer beneath.
All joints of all layers shall be staggered.
5.1.10 Each layer of double layer or multi-layer insulation shall be held in place
separately.
5.1.11 All insulation shall be smooth and free from cracks, voids, gaps and
depressions greater than 1/8 in. (3 mm). All cracks, voids, gaps and
depressions in the insulation greater than 1/8 in. (3 mm) shall be refitted not
filled.
5.2 Securement
5.2.1 Insulation up to 12 in. (300 mm) outside diameter (O.D.) shall be held in place
with 16 gauge Type 304 stainless steel tie wire, except cellular glass and
polyisocyanurate foam insulation, which may be held in place with fiberglass
reinforced pressure-sensitive tape or stainless steel tie wires applied over the
tape.
5.2.2 Insulation 12 in. (300 mm) O.D. to 24 in. (610 mm) O.D. shall be held in
place with 1/2 in. (13 mm) wide by 0.020 in. (0.51 mm) thick Type 304
stainless steel bands and wing seals. Above 24 in. (610 mm) O.D., use 3/4 in.
(19 mm) wide by 0.020 in. (0.51 mm) thick bands and wing seals.
5.2.3 Metal jacketing 12 in. (300 mm) O.D. to 24 in. (610 mm) O.D. shall be held
in place with 1/2 in. (13 mm) wide by 0.020 in. (0.51 mm) thick Type 304
stainless steel bands and wing seals. Above 24 in. (610 mm) O.D., use 3/4 in.
(19 mm) wide by 0.020 in. (0.51 mm) thick bands and wing seals.
5.2.4 All cut ends of wire shall be embedded into the insulation.
5.3.2 Metal jacketing on horizontal equipment 48 in. (1219 mm) and larger in
diameter shall be aluminum 0.024 in. (0.61 mm) thick. Finish shall be
specified by purchaser, (i.e., smooth, corrugated, cross-crimped, embossed,
coated, etc.)
5.3.3 Metal jacketing on all vessels, and piping, less than 48 in. (1219 mm) in
diameter shall be aluminum, 0.016 in. (0.406 mm) thick and machine-rolled
for circumferential fit. Finish shall be specified by the Purchaser, (i.e.,
smooth, corrugated, crossed crimped, embossed, coated, etc.).
5.3.4 Vessel head segments, fittings, valves, etc., shall be fabricated from smooth
metal.
5.3.5 Stainless steel jacketing 0.010 in. (0.254 mm) or zinc-aluminum alloy coated
steel 0.016 in. (0.406 mm) thick shall be used on equipment and piping when
fire protection is required, to comply with API 521.
5.3.6 When aluminum jacket is used on lines with an operating temperature
exceeding 750°F (400°C), 0.010 in. (0.254 mm) thick stainless steel shall be
used at points of contact.
5.3.7 Exposed edges of metal jacketing shall be machine-bent or rolled to eliminate
sharp edges.
5.4 Screws
Screws shall be self-drilling No. 8 by 1/2 in. (13 mm) stainless steel, with elastromeric
washer. Heads may be hex, Phillips recessed round, round, or hex-slotted or pan type.
5.6.2 Insulation expansion joints shall be a minimum of 1 in. (25 mm) wide, packed
tightly with mineral fiber blanket insulation compressed a minimum of 50%.
5.6.3 Insulation expansion joints shall be installed in all layers of multiple layer
insulation. Joints shall be staggered between layers.
5.6.4 Insulation expansion joints shall also be installed below insulation support
clips or rings on equipment and piping
the mesh to obtain a good bond. Care shall be taken to completely fill and seal
the mesh openings.
5.9.3 The combined thickness of the weatherproofing mastic and reinforcing shall be
in accordance with the manufacturer’s recommendation.
5.9.4 Mastic weatherproofing shall overlap adjoining metal surfaces to provide a
weather-tight joint.
5.10.1 Insulation systems must be caulked and/or sealed at all possible points of
moisture entry. Do not feather edge of caulk.
5.10.2 Installed insulation shall have the required permanent protection or temporary
protection applied before the conclusion of that day’s work.
5.10.3 Installed insulation shall have temporary protection applied if the insulation
can be damaged by rain or other forms of atmospheric moisture.
6. Extent of Insulation
7. Documentation
Documents required to define the scope of the work shall be listed on Data Sheet PIP
INSH2002.
Comments:
Installation of Hot Service
Insulation Systems PIP INSH2002
Data Sheet for PAGE 1 OF 3
Documentation Requirements JAN 97
PROJECT____________________________________________________ DATE______________________
NUMBER TITLE REV DATE NOTES
INIH0009 YES ¨ NO ¨ Removable and Reusable Insulation -
Flexible
INIH0010 YES ¨ NO ¨ Valve Cover
INIH0011 YES ¨ NO ¨ Pipe Supports
INIH0012 YES ¨ NO ¨ Hanger Rod Rain Shield
INIH0013 YES ¨ NO ¨ Spacer Blocks for Typical Tracer
Arrangements
INIH0050 YES ¨ NO ¨ Vertical Vessels with Outside
Diameters over 36" (915)
INIH0051 YES ¨ NO ¨ Vertical Vessels with Outside
Diameters 36" (915) and Less
INIH0052 YES ¨ NO ¨ Vessel Composite Type 1
INIH0053 YES ¨ NO ¨ Vessel Composite Type 2
INIH0054 YES ¨ NO ¨ Vertical Vessel Bottom Head
Insulation
INIH0055 YES ¨ NO ¨ Top/Horizontal Head Nozzles
INIH0056 YES ¨ NO ¨ Vessel Stiffener Insulation Detail
INIH0057 YES ¨ NO ¨ Insulated Manhole Cover
INIH0058 YES ¨ NO ¨ Rigid, Removable and Reusable
Insulated Manhole Cover
INIH0059 YES ¨ NO ¨ Typical Clip Details
INIH0060 YES ¨ NO ¨ Nozzle Flashing
INIH0061 YES ¨ NO ¨ Lap Seam Details
INIH0062 YES ¨ NO ¨ Horizontal Vessels
INIH0063 YES ¨ NO ¨ Application of Metal Gores on
Horizontal Vessel Heads
INIH0064 YES ¨ NO ¨ Horizontal Heat Exchangers
SELECTED MATERIALS SYSTEM DATA SHEETS
INSH1001 YES ¨ NO ¨ Hot Service Insulation System for
Project Specific Requirements
INSH1002 YES ¨ NO ¨ Calcium Silicate Insulation System for
Pipe and Equipment
INSH1003 YES ¨ NO ¨ Expanded Perlite Insulation System
for Pipe and Equipment
INSH1004 YES ¨ NO ¨ Mineral Wool Performed Pipe
Sections Insulation System
INSH1005 YES ¨ NO ¨ Mineral Wool Board Insulation
System for Equipment
INSH1006 YES ¨ NO ¨ Mineral Wool Blanket Insulation
System for Pipe and Equipment
INSH1007 YES ¨ NO ¨ Glass Fiber Performed Pipe Sections
Insulation System
INSH1008 YES ¨ NO ¨ Glass Fiber Block and Board
Insulation System
INSH1009 YES ¨ NO ¨ Glass Fiber Blanket Insulation
System
INSH1010 YES ¨ NO ¨ Cellular Glass Block and Fabricated
Sections Insulation System
Installation of Hot Service
Insulation Systems PIP INSH2002
Data Sheet for PAGE 3 OF 3
Documentation Requirements JAN 97
PROJECT____________________________________________________ DATE______________________
NUMBER TITLE REV DATE NOTES
INSH1011 YES ¨ NO ¨ Polyisocyanurate Insulation System
INSH1012 YES ¨ NO ¨ Ceramic Fiber Blanket Insulation
System
INSH1013 YES ¨ NO ¨ Glass Fiber Needled Blanket
Insulation System
OTHER