SCAFFOLDER

INSULATOR

Personal Protective Equipment (PPE)

 v

Ear Protection

Respiratory Protection

Safety Harness (Fall Arrest Equip. ANSI Z359.1)

SCAFFOLDING PLAN:
TEMPORARY FACILITIES PLAN
 MATERIAL SAFETY DATA SHEET
Revision :3-2015

SECTION 1 — PRODUCT AND COMPANY IDENTIFICATION

Manufacturer’s Name : Saudi Rockwool Factory

P.O. Box 145, Riyadh – 11383, K.S.A

Tel: +966 1 2650034

Fax: +966 1 2650089

www.saudirockwool.com

Address:

K.S.A / Riyadh / third industrial Zone

Postal Code:

P.O. Box 145, Riyadh – 11383

Emergency Telephone: +96612650034

Date MSDS Prepared: 8/5 /2013

SECTION 2 — COMPOSITION/INFORMATION ON INGREDIENTS:

Synonyms: Mineral wool, Rockwool, Manmade Vitreous Fiber , Manmade Vitreous mineral Fiber.

Ingredients WT % CAS Number TLV PEL

3 3
Mineral Rockwool fiber 95 - RN 65997-17-3 TOTAL 10 MG/M TOTAL 15 MG/M
(amorphous, non-crystalline, 99.5 RESPIRABLE 1 RESPIRABLE 1
bio-soluble.
FIBER/CC FIBER/CC
Heat-cured resin (fiber binding 0.5 - 5 25104-55-6 NONE NONE
agent)
3 3
Emulsion Oil <1 8012-95-1 5 MG/M 5 MG/M

Mineral wool has been classified by EU as locally irritating (irritate the skin),

High levels may irritate nose, mouth, throat, and eyes.

This product is not asbestos product free from freeformaldehyde and Environment friendly with CFC
and HCFC free , ,and chemically inert, with Zero ODP Ozone Depletion Potential &Zero GWP Global
Warming Potential .

SECTION 3 — HAZARDS IDENTIFICATION

Skin Contact : Flush with clean water, If discomfort persists, seek medical attention.

Eye Contact: Flush with clean water, If discomfort persists, seek medical attention.

Inhalation: Remove to fresh air, If symptoms persist, seek medical attention.

Advice to Doctor: Any symptoms and signs of ill-health are likely to be due to other causes. Can be
slightly itchy on prolonged contact with skin. Does not produce any acute

or chronic health effects. Treatment should be directed toward cleansing the skin and symptomatic
treatment as necessary.

SECTION 5 FIRE FIGHTING MEASURES

Flammability: Non flammable, will not burn.

Suitable extinguishing media: As needed for surrounding fire conditions. Any extinguishing media may
be used as required. Water fog may be used to cool intact containers and nearby storage areas.

Hazards from combustion products: Saudi Rockwool Insulation is non-flammable, but the plastic
wrapping, resin binder, and some facings may decompose, or burn in a fire or when heated above
300ºC.
Fire Fighting Procedures: As needed for surrounding fire conditions, If required evacuate area and
contact emergency services, remain upwind and notify those downwind of fire hazard, and wear
protective equipment including Self-Contained Breathing Apparatus (SCBA).

SECTION 6 — ACCIDENTAL RELEASE MEASURES

Containment Procedure: If product is torn or loose, cover or reseal to minimize fiber release. Reuse
where possible or place in a sealable plastic bag for disposal according to local authority guidelines.

Clean Up Procedure: Personnel directly involved in clean-up of loose material should wear personal
protective equipment, clean area so as to avoid dispersion

of loose material or fibbers using wet sweep methods or vacuum cleaner.

SECTION 7 — HANDLING AND STORAGE

Handling: These products are safe in use. Once installed, the product does not release dust or fibers.
Handling, installing or removing the product may result in some dust and airborne fiber. Minimize eye or
skin contact and inhalation during handling, installation and removal, Observe good personal hygiene,
including washing hands before eating. Remove personal protective equipment before entering eating
areas

Storage: Store in sealed container in cool, dry area, removed from foodstuffs. Ensure packages area
adequately labeled, protected from physical damage, and sealed when not in use. Avoid packaging being
stored under UV light (direct sunlight) for long periods.

Incompatibilities: None.

SECTION 8 — EXPOSURE CONTROL / PERSONAL PROTECTION

Exposure Control : During most applications and installation no special ventilation

will be required. However, if installing in dusty or poorly-ventilated areas, or during the first heat up
cycle in high-temperature industrial applications, local exhaust ventilation should be considered. Work
practices should aim to minimize the release of, and exposure to, fibers and/or dust. Hand tools
generate the least amount of dust and fibers. If power tools are used directly on the product
appropriate dust collection systems are recommended.

Personal Hygiene: Washing of exposed skin with soap and water at the end of a shift or as required is
recommended as a comfort measure.

Skin Protection: Direct skin contact can be minimized by wearing long-sleeved shirts and long trousers, a
cap or hat, and standard duty gloves .Work clothes should be washed regularly and separately from
other clothes. Comfort sleeve gloves are recommended for improved comfort when handling and
installing Rockwool Insulation

Eye Protection: When handling these products, particularly overhead or in enclosed or poorly ventilated
areas such as ceiling spaces or risers, eye contact with dust or fiber can be avoided by wearing ventilated
non-fogging dust resistant goggles.

Respiratory Protection: None normally required. If dust is generated in enclosed or poorly-ventilated

areas use respiratory protection at least class P2 respiratory protection.

SECTION 9 — PHYSICAL AND CHEMICAL PROPERTIES

Appearance: Brown or grayish/ yellowish fibrous material resembling wool. It is

supplied in different shapes and sizes wrapped in plastic. It may be rigid or
flexible. Facings such as aluminum foil, , wire mesh, and synthetic tissues
are applied to meet specific purposes.
Odor: odorless
pH: 7 -9
Vapor Pressure/Density: N/A
Melting Point: > 1100 ⁰C
Solubility in water: Insoluble
Flammable (Explosive) Limit: N/A ( none- Flammable )
Physical State : solid
Auto-ignition Temperature: N/A
Flash Point: N/A
3
Relative density for fiber : Approx. 2.9 g/cm
3
Product Density : 30 -180 kg/m
Boiling Point: N/A

SECTION 10 — STABILITY AND REACTIVITY

Chemical Stability: Stable. The cured resin is stable and will remain intact for the life of the
product under normal atmospheric conditions
Incompatible Materials: None . No reported incompatibilities. Acids, alkalis or organic solvents
may cause degradation of resin binder.

SECTION 11 — TOXICOLOGICAL INFORMATION

Effects of Acute Exposure : Unprotected exposure to high levels of dust of these products (during
installation or removal) may cause discomfort of the nose, throat, and upper and lower respiratory tract,
especially in persons suffering from upper respiratory or chest complaints such as hay fever, asthma or
bronchitis Handling repeatedly during installation may cause temporary itching of exposed skin. This is
not an allergy and usually disappears quickly, may cause eye discomfort resulting in watering and
redness.

Effects of chronic exposure: There are no known long-term health effects.

In October 2001, IARC completed a re-evaluation of respirable mineral wool fibers and classified them in
Group 3 (not classifiable as to their carcinogenicity to humans).

SECTION 12 — ECOLOGICAL INFORMATION

Eco-toxicity: This product is not classified as a hazardous air pollutant. No specific data is available on
ecotoxicity, but estimations based on toxicity information suggest that the materials in these products
are not toxic to fish, birds insects or organisms in the environment. No harm to fish or wildlife would be
caused by this product.

Persistence and Degradability: Rockwool Insulation is bio-soluble and in most ecosystems it would be
expected to solubilise over a period of weeks to months. Binder-coated insulation wool is hydrophobic,
and no adverse environmental effects would be expected if accidentally released in water or soil.

Ozone Depleting Potential: No Ozone Depleting Substances are involved in either the manufacture
or composition of this product & therefore has an ozone depletion potential of zero.

SECTION 13 — DISPOSAL CONSIDERATIONS

This product is not toxic to animal and plants or fish , Place in plastic bags or containers and close or
seal for disposal in accordance with local authority guidelines. Label as NON-HAZARDOUS insulation
wool or as general building waste (non-hazardous), as appropriate to assist local authorities waste
disposal sites, and local authorities will usually advise any local handling arrangements at their disposal
sites.
SECTION 14 — TRANSPORT INFORMATION

Transport Rockwool Insulation products are not classified as Dangerous Goods and have
Requirements: no special transport requirements.
HAZCHEM code: None allocated

SECTION 15 — REGULATORY INFORMATION

Poisons Schedule: Not scheduled. No specific regulatory requirements are applicable regarding
occupational health and safety, consumer protection or environmental
protection measures.

SECTION 16 — OTHER INFORMATION

For further information on this product, please contact:

Saudi Rockwool Factory

Prepared By Eng. Marwan Lobani /Chemical Engineer

P.O. Box 145, Riyadh – 11383, K.S.A

Tel: +966 1 2650034

Fax: +966 1 2650089

www.saudirockwool.com
 DOCUMENT NO.
METHOD STATEMENT CN-100-7001-MST
(Thermal Insulation and Cladding Works on
Piping and Equipment) PAGE 1 of 21 REV.B
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METHOD STATEMENT FOR

THERMAL INSULATION AND CLADDING
WORKS ON PIPING AND EQUIPMENT

APOC PDH/UTOS PROJECT

B 04-SEP-2022 Issue for Approval J.Y LEE (G.SI) J.H KIM S.J LEE

A 18-AUG-2022 Issue for Approval J.Y LEE (G.SI) J.H KIM S.J LEE

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

No part of this document or the information it contains may be reproduced or transmitted in any form or by any means electronic or mechanical, including
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REVISION MODIFICATION LOG

Revisi
Section Description
on

A - First Issue
Add: "The materials shall be stored manufactured under recommended Temperature"
B 6.4
//Replacement of material after exposure to high temperature is the last step
All such gaps shall be refitted and not refilled - as per APOC specification - AES-S-
7.3.3. d
006- 25.1.5
7.3.3.m Mitered - Metered

7.3.3. n Add: "or Minimum 305mm from the surface"

7.8 Include: Vapor barrier mastic shall be applied in a minimum of two coats

7.13 Metal Joint Sealing - As the section describes the process & not the material to be used

9 the Topic is "Tools" any description to be laid out lower in the paragraph

No part of this document or the information it contains may be reproduced or transmitted in any form or by any means electronic or mechanical, including
photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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TABLE OF CONTENTS

PAGES

1.0 Purpose 4

2.0 Scope 4

3.0 References 4

4.0 Materials 4

5.0 Responsibility 5

6.0 Storage and Handling 5

7.0 Hot and Cold Insulation Procedure 6

8.0 Acoustic Insulation 16

9.0 Tools 18

10.0 Quality Assurance and Control 19

11.0 Safety Precaution 20

12.0 Attachments 21

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1.0 PURPOSE
To describe the insulation materials, sequence, and method of application in Hot, Cold and
Acoustic insulation for piping and equipment.

2.0 SCOPE
This procedure covers the requirement of installation for all Hot, Cold and Acoustic
insulation being carried out by BINZAGR FACTORY FOR INSULATION MATERIALS
LTD.

3.0 REFERENCES

➢ 01_AES-S-0006 Insulation Specifications for Piping and Equipment Rev.01

➢ INSH2000 - Installation of Hot Service Insulation Systems
➢ INSH1000 - Hot Service Insulation Materials and Installation Application
➢ INSC2000 - Installation of Cold Service Insulation Systems
➢ INSC1000 - Cold Service Insulation Materials and Installation Application
➢ INIH1000 - Hot Insulation Installation Details
➢ INIC1000 - Cold Insulation Installation Details
➢ INSA1000 - Acoustic Insulation Systems Specification

4.0 MATERIALS:

4.1 INSULATION MATERIAL

a. Hot Insulation (by Contractor/EPC)
i.
Mineral Wool (100 kg/m3)
b. Cold Insulation
i. Polyisocyanurate Foam (PIR)
ii. ASTM C591, type 2, 40 kg/m3
c. Acoustic Insulation
i. Absorption Barrier – Mineral wool
ii. Barrier – Loaded Vinyl (5 kg/m2)

4.2 METAL JACKETING

a. Aluminum smooth sheet shall be used as jacket material up to 593 C
i. 0.6 mm thick for equipment and piping up to 1066 mm OD (42”)
ii. 0.8 mm thick for above (42”)1066 mm
b. Stainless steel Jacketing for fire hazardous location
i. 0.5mm thick for piping and Equipment

4.3 ACCESSORIES MATERIALS:

a. Unless otherwise specified, all wire, bands or other attachment hardware shall be
Type 304 stainless steel. SS Bands, Seals, Screws, Rivets, Toggle Clip, Wires,
b. Reinforced fiber glass tape.

4.4 METAL SEALANTS/CAULKING COMPOUNDS:

a. Silicone Sealant for sealing open and cut joints in metal jacketing

No part of this document or the information it contains may be reproduced or transmitted in any form or by any means electronic or mechanical, including
photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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4.5 JOINT SEALANT

a. Foster 95-50
b. SHC107-84

4.6 INSULATION TERMINATION

a. Foster 65-05
b. Foster 42-24 - Mast-A-Fab
c. SHC 107-66+SHC740-100

4.7 CAVITY FILL and CONTRACTION JOINT

a. Afico wool – Arabian Fiberglass

4.8 VAPOR BARRIER

a. Bituseal – Bitumat

4.9 SOUND BARRIER

a. Loaded Vinyl

5.0 RESPONSIBILITY:
5.1 Project Manager / Construction Manager are responsible for the
implementation of this procedure. He shall ensure that all engineers, supervisors,
foremen and craftsmen associated with this job will comply with this procedure
and shall ensure availability of required tools and equipment for the job described
in this procedure.

5.2 QC Manager / Engineer / Inspectors Shall ensure full implementation of

required quality requirements and maintain the required documentation as per
Inspection Test Plan for final acceptance and hand over package.

5.3 Safety Engineer / Supervisor / inspector will ensure safety regulations and
rules as required by the project.

5.4 Insulation Supervisor is responsible to provide his site team with appropriate
resources to ensure that works based on the approved procedures, Project
requirements and specification including safety compliance. Confirm the
availability of the materials, tools and required personnel who will carry out the
work.

6.0 STORAGE AND HANDLING

6.1 Ensure that all material receiving has been approved and inspected prior to application.

6.2 Insulation material shall be transported and stored vertically with care and as per
manufacturer recommendation.

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6.3 From delivery up to site storage area, materials shall be at all times be protected from all
elements such as:

a. Flammable materials shall be stored safely away from probale ignition sources.
b. All materials shall be stored in a well ventilated area to avoid contamination from
humid air.
c. All materials shall be stored in a manner that prevents contamination by water,
process chemicals and even physical damage.
d. Materials stored shall be on pallets, covered with tarpaulin and have adequate
drainage.

B 6.4 Mastics, adhesives and sealers shall be stored properly and materials exposed to
temperatures beyond the manufacturers recommended temperature range during storage
must be removed and replaced. All should stored at cold container. The materials shall
be stored manufactured under recommended Temperature

6.5 Materials that exceed their shell life must be removed and replaced with new items.

6.6 Appropriate safety equipments are present and used as follows.

a. Personnel protection safety equipment for safe handling of insulation and hazardous
b. Fire protection equipment
c. Hazardous materials disposal area (damage insulation, containers).

6.7 Material handling and storage instructions from manufacturers are available at site.

6.8 Appropriate MSDS is available to detail hazards (insulation handling, chemicals).

6.9 Materials package in cans or tubes shall be in original sealed containers. All insulation
and accessory materials shall be stored in area protected from the weather before and
during the application.

7.0 HOT and COLD INSULATION METHODS / PROCEDURES

7.1 GENERAL
a. The piping shall have been tested and inspected as required by relevant specification
prior to installation of insulation.

b. An approval clearance sheet allowing insulation contractor to proceed with

insulation shall be turned over by the respective department.

c. All surfaces to be insulated shall be clean and dry. All loose scale and foreign matter
shall be removed from surfaces before applying insulation. Insulation shall not be
applied over wet surface.

d. All insulation materials shall be protected from rain and moisture and keep it dry.

No part of this document or the information it contains may be reproduced or transmitted in any form or by any means electronic or mechanical, including
photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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e. Insulation sections shall be trimmed as required to achieve close fit to avoid major
voids and gaps.
f. All joints of multi-layer insulation shall be staggered as possible.

g. SS Wire and Bands used to secure the insulation shall be installed straight and in
proper tension without crushing the insulation. Filament tape shall be used for
securing pipe insulation.

h. Sound barrier / Vapor barrier shall be applied on top of insulation.

i. All external surfaces of insulation shall be weather jacketed to keep insulation dry
and provide mechanical protection to the system.

j. A minimum clearance of 50mm (2") shall be maintained between the outer surface
of insulation and any adjacent piping, equipment or structural member under all
temperature conditions of operation.

k. Stages of inspection and verification, characteristics to be checked, acceptance

criteria and inspection / verification authority for cold insulation shall be as per
Inspection and Test Plan (ITP) for Acoustic, Hot and Cold Insulation for Equipment
and Piping.

l. Inspection and test records of insulation shall be as per Insulation Inspection

Checklist.

7.2 HOT INSULATION USING MINERAL WOOL PIPE SECTION OR MINERAL

FIBER BLANKET

7.2.1 INSULATION THICKNESS:

a. Insulation thickness for Heat Conservation and Personnel Protection shall
be in accordance with the approved design isometric drawing otherwise
noted by the contractor or Refer to applicable project specifications.

7.2.2 INSTALLATION
a. Insulation thickness having greater than 80mm shall be applied with
multilayer application.

b. Where piping is supported on structural steel without shoes, the insulation

shall be notched for the width of the support +50mm or as required for
thermal movement, or as otherwise specified. Notched edges shall be
weather proofed.

c. When multiple layers are required, the staggered joint method shall be
used. The second layer shall be applied so that both the circumferential and
longitudinal joints are staggered. On multiple layer construction, each layer
shall be wired or banded separately.

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d. The circumferential joints on straight piping shall be staggered by

approximately 150mm from the joints of the preceding layer.
e. The circumferential and the longitudinal joints in the second layer and
succeeding layer of multiple layered piping shall be staggered by
approximately 150mm.

f. The ends of the upper and lower layers shall not be apart less than 100mm.

g. All joints shall be tight fitting. Any void or gap larger than 1/8" (3 mm)
shall be filled. Fill material shall be same as the insulation material used.

h. Insulation shall be installed in such a way that the gap between insulated
surface and insulation is less than 1/8" (3 mm) unless oversized insulation
is required to the accommodate heat tracer.

7.3 COLD INSULATION USING POLYISOCYANURATE

7.3.1 MATERIALS:
a. Polyisocyanurate with Density shall be minimum of 40 kg/m3 as per
ASTM C ASTM C591, type 2.

7.3.2 INSULATION THICKNESS:

a. Insulation thickness shall be in accordance with the approved design isometric
drawing otherwise noted by the contractor or applicable project specification.

7.3.3 INSTALLATION
a. Insulation pieces shall be sized to ensure the space between the insulated
surface and the inner layer or joint gaps between insulation is approximately
less than 1/8”(3mm).

b. The joint sealer shall be applied to the face side and all edge surface single
layer of insulation and the outer layer only for multiple layer insulation. The
joint sealer shall be applied in a thickness sufficient to fill the joints.

c. Joints between the insulation pieces shall be “tight” over their entire length. To
reduce voids or gaps the installer shall pre-fit each insulation piece and trim as
required.

B d. When voids or gaps greater than 1/16” (3 mm) exist they shall not be filled. All
such gaps shall be refitted and not refilled

e. Filling of voids or gaps using adhesive or joint sealant is unacceptable.

f. When a single layer insulation system is specified the staggered joint method
shall be utilized. Joints shall be staggered approximately 1/3” of the insulation
length.

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photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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g. When a multiply layer insulation system is specified the staggered joint method
shall be utilized. The circumferential and longitudinal joints of the outer layer
shall be staggered vs the joints of the inner layer. Joints shall be staggered
approximately 1/3 of the insulation length.

h. If the insulated item is heat traced the insulation shall be “oversized” to the
nearest standard size which still accommodates the tracing.

i. Temporary elastomeric or metal bands shall be utilized when pre-fitting the

insulation pieces.

j. Temporary bands shall be mechanical tightened to ensure the insulation pieces

are tightly butted together prior to installing the permanent bands.

k. Permanent bands shall be mechanically tightened using a “Band Tensioning”

tool. During closing of the seal precautions shall be taken to prevent cracking
of the insulation.

l. All insulation pieces shall be securely held in place, a minimum of two bands is
required per full length insulation section.

B m. When metered sections or small insulation pieces are required each piece shall
be secured with a band. Bands shall be spaced evenly whenever possible and no
closer than 1”/25mm from the ends of an insulation piece.

B n. Metal parts such as equipment skirts and legs, pipe supports, saddles and
bracket, Insulated connections in piping and other miscellaneous attachments
which protrude through the insulation shall be insulated for approximately four
(4) times the insulation thickness from the outer surface of equipment or piping
or minimum of 305mm from the surface.

7.4 INSULATION SECUREMENT

MATERIALS INSULATION OUTSIDE DIAMETER

Insulation up to ≤ 12"
ROCK WOOL Insulation 12” to 42” OD Over 42” Insulation OD
OD
single/inner
16 gauge SS tie wire 13x0.5mm (1/2")SS band 19x0.5mm (3/4")SS band
layer

outer layer 16 gauge SS tie wire 13x0.5mm (1/2")SS band 19x0.5mm (3/4")SS band

spacing 300mm ( 12") 300mm (12") 300mm (12")

No part of this document or the information it contains may be reproduced or transmitted in any form or by any means electronic or mechanical, including
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Insulation up to ≤ 12"
PIR Insulation 12” to 42” OD Over 42” Insulation OD
OD
single/inner Filament 13x0.5mm(1/2”)SS band
19x0.5mm (3/4")SS band
layer Tape / Filament Tape
13x0.5mm(1/2”) ss
outer layer 13x0.5mm(1/2”)SS band 19x0.5mm (3/4")SS band
band
spacing 300mm ( 12") 300mm (12") 300mm (12")

7.5 SUPPORT RING

a. For vertical piping, insulation shall be supported by insulation support rings

installed directly above all elbows, flanges or flanged valves provided as
follows

i. insulation support ring has to be installed at base of vertical piping over

6" (150 mm) diameter
ii. Additional supports are required at maximum of 7.3m of un interrupted
length.
iii. Support ring shall be provided above elbows and tees if the vertical pipe
is equal or greater than the expansion/contraction joints.

7.6 PIPING VALVES AND FLANGES

7.6.1 Hot Insulation

a. It shall be mineral wool blanket to the pre-fabricated box.
b. Insulation thickness of valves and flanges shall be the same thickness as
the insulation over the adjacent pipe.

7.6.2 Cold Insulation

a. Insulation materials shall be same as pipe/shell insulation or else
otherwise noted for col.
b. Insulation thickness of valves and flanges shall be the same thickness as
the insulation over the adjacent pipe.
c. Valves in insulated line shall be insulated up to packing gland.
d. Fittings and flanges shall be insulated

7.6.3 Weather Jacketing

a. Pre-fabricated Aluminum or SS Jacketing shall be used. It shall be
removable type using clips and quick released toggles, so that it can be
removed and replaced to allow maintenance without damage to insulation
or to cladding. The metal box shall cover minimum 150mm of the
adjacent pipe.
b. Observe bolt clearance from the face of the flange with bolt length plus
1” in both sides.
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7.7 INSULATION OF EQUIPMENT

7.7.1 Insulation Application using Mineral Wool

a. Vertical equipment shell

i. Mineral wool shall rest on to support rings with wire mesh facing outward.

b. Vertical Equipment - top head and bottom head.

i. The blanket shall be supported with SS bands hooked from floating ring to
bands stretch on to the shell.

c. Horizontal Equipment shell

i. Blanket insulation applied to horizontal equipment shell shall be secured
in place using SS Bands.

d. All voids found at joints on both directions shall fill with the same material as
the insulation.

7.7.2 Materials Using PIR

a. PIR Min Density 40 kg/m3

i. Slabs/Block – Top/Bottom Head of Vessel/Tanks or Flat Head
ii. Preformed or curve segment for Vessel/Equipment or tank shell

7.7.3 Insulation Application

a. Flat block curve segments or small slab of PIR shall be applied for the
equipment or tank. Insulation section shall be fabricated in accordance to the
manufacturer and tightly butted to eliminate voids, gaps or open joints. The
insulation shall be refitted to achieve the tight fit. Insulation shall fit the
curvature of the surface to be insulated.
b. Each Insulation segment should be fitted to the surface or item to be insulated
and adjacent segments so that the joints form a tight barrier.
c. Joints of insulation shall be staggered as far as possible.
d. Temporary bands shall be utilized when pre-fitting the insulation pieces and
ensure the insulation pieces are tightly butted together prior to installing the
permanent bands.

7.7.4 Securement of Insulation

a. Insulating cover at body of equipment and tank shall be secured and fastened
in place using SS bands for a close fit to surface.
b. Heads of horizontal and head of vertical equipment a floating ring made of
6mm diameter rod (SS rod for SS equipment and CS rod for CS equipment)
shall be placed at the center where bands shall be hooked to hold the
insulation in place.

No part of this document or the information it contains may be reproduced or transmitted in any form or by any means electronic or mechanical, including
photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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c. Man ways, nozzle, vessel clips or other attachment may interfere with the
band spacing. As an option a ring may be fabricated by inter weaving strands
of stainless-steel wire. 2 strand rings shall be used to support 6 or less bands
and 3 or more strand is required when multiply bands are necessary.

d. See Table below for band size and spacing

MATERIALS INSULATION OUTSIDE DIAMETER

ROCK WOOL Insulation up to 42” OD Over 42” Insulation OD

single/inner layer 13x0.5mm (1/2")SS band 19x0.5mm (3/4")SS band

outer layer 13x0.5mm (1/2")SS band 19x0.5mm (3/4")SS band

spacing 300mm (12") 300mm (12")

PIR Insulation up to 42” OD Over 42” Insulation OD

13x0.5mm(1/2”)SS band
single/inner layer 19x0.5mm (3/4")SS band
/ Filament Tape
outer layer 13x0.5mm(1/2”)SS band 19x0.5mm (3/4")SS band
spacing 300mm (12") 300mm (12")

7.8 VAPOR BARRIER

a. Material to be used shall be Bituseal 1000 / 1200 Membrane type.
b. Before the application of weather jacketing, all surfaces shall be sealed with vapor
barrier.
c. Seams shall be overlapped minimum of 50mm (2inches) at all joints.
d. All seams shall be tightly bonded with no gaps. Any gaps shall be repaired by
applying a strap around entire area. Any perforation in the vapor barrier shall be
repaired.
e. Vapor barrier overlap shall be arranged to shed water.
f. Stagger each section so that longitudinal joints do not line up.
B g. Vapor barrier mastic shall be applied in a minimum of two coats

7.9 VAPOR STOP

a. Materials to be used shall be vapor barrier mastic with glass cloth.

b. All attachments which protrude beyond the insulation, (Ex: pipe shoes or supports,
instrumentation points, name plates ladder/platform clips, man ways, dummy legs)
c. All insulation termination points, (Ex: support legs, vessel saddles, tower skirts)
d. A vapor stop requires joint sealant to be applied to the surface of the item being
insulated, to the inside bore, outside bore and all edges of the inner and subsequent
insulation layers.
e. Vapor stop shall be extend min of 50mm from the insulation termination.
f. The vapor stop when applied at a flanged connection shall initiate one bolt length
plus 2 inches/50 mm beyond the flange.

No part of this document or the information it contains may be reproduced or transmitted in any form or by any means electronic or mechanical, including
photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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7.10 JOINT SEALER

a. Joint sealer shall be applied to all joints of single layer and outer layer for multiple
layer insulation.

7.11 EXPANSION AND CONTRACTION JOINTS FOR PIPING AND EQIUPMENT

a. The expansion joint shall be used for rigid insulation on the piping and equipment.
b. Each expansion/contraction joint shall be filled up with fiber glass wool insulation
material for compression and or extension.
c. In the case of vertical piping and equipment with support ring / stiffener ring a
expansion and contraction joint shall be provided under each ring.

d. Refer to table below for contraction joints spacing

WEATHER JACKETING
7.8.1 Metal Jacketing Thickness

Thickness and type of Thickness and type of

Insulation Outside
Aluminum Jacketing Stainless Steel Jacketing
Diameter
(Non-Firehazardous) (Fire Hazardous)

0.6 mm tks, smooth with 0.5 mm tks, smooth

Up to 42” OD
moisture barrier without moisture barrier

0.8 mm tks, smooth with 0.5 mm tks, smooth with

Above 42” OD
moisture barrier without barrier

Acoustic Services – SS 0.6mm thick Inside fire hazardous zone

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photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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7.8.2 SECURING OF WEATHER JACKETING

a. Jackets shall be secured with screws and/or bands. (Screw shall not be
used in cold insulation

b. All bands, seals, screw clips, rivet and springs shall be type 304/302
stainless steel

c. On hot piping shall be secured with screw with neoprene washer on

maximum of 150mm centers.

d. On cold pipe / vessel and tracing line shall be secured with bands on
maximum of 300 mm on center and rivet as required.

e. If Insulation diameter <= 42” Ø, 13.0 x 0.5mm ss band type 304

Securement shall be used space at 300 mm OC.

f. If Insulation diameter > 42” Ø), 19.0 x 0.5mm ss band type 304
Securement shall be used space at 300 mm OC.

g. On Hot Vessel jacketing shall be secured with screws on maximum 150

mm on centers for vertical seams and 300mm for horizontal seams.

h. On vertical storage tanks with corrugated sheeting, use only 3 bands

(bottom, middle and top each sheet)

i. Top head of the cold vessels and tanks shall be secured with ss type 304
rivets and where the head remains the rivet to avoid water entrance.

j. On vertical pipe, tanks, vessel, and equipment S clip shall be placed on the
perimeter of each sheet with minimum two clips and J-clips shall be used
for the bands.

7.8.3 Weather Jacket overlapping

a. Weather jacket shall be overlapped 50mm (2”) longitudinally and

circumferentially.

b. All laps shall be turned downwards to avoid accumulation of water at

joints.

c. Longitudinal overlaps shall be oriented at a position to shed water or else

otherwise noted by the contractor.

d. Where Tee’s or support is located, Longitudinal and circumferential seam

to be oriented as Tee’s and support.

No part of this document or the information it contains may be reproduced or transmitted in any form or by any means electronic or mechanical, including
photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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7.8.4 Weather jacketing for Elbows and Bends

a. Elbows cover for 3” Ø and below, 90º & 45 º elbows shall be pre-fabricated in
a maximum of two precision formed sections. Pipe elbows 4” diameter and
over shall be mitered type.

b. Insulation shall be cut into sections sufficiently to form a close fit with the
bend.

c. The sections of insulation shall be installed with SS wire around so as to be

held in place tightly.

7.12 EQUIPMENT FLANGES AND VALVES

a. All flanges on the equipment body shall be covered with rock wool or else
otherwise specified by the client and flat aluminum sheet/SS Sheet as metal
jacketing.

b. Valve covers shall be flange-shaped casing line with line with the insulation.

c. Flange covers having an outside diameter approximately 500mm or greater,

the insulation shall be wired tightly in place over the flange.

d. The clearance between the flanges and insulation covers shall be long
enough to facilitate the removal of bolts in all direction prior to any repair.

e. Bolt clearance may vary from bolt length plus 1” inch on both sides from the
face of the flange.

B 7.13 METAL JOINT SEALING

a. Cut joints in weather jacket shall be caulked with sealant to prevent entry of
water.
b. Seal longitudinal joints of vertical pipe, and circumferential joints of
horizontal pipe.

7.14 REMOVABLE INSULATED

a. Removable insulated covers shall be provided for man way, designed in

such a way that they can be removed without disturbing the surrounding
fixed insulation. It shall be secured with clips and quick released toggles for
easy removal maintenance.

b. Pre-fabricated Aluminum covers shall be flat Aluminum sheet or stainless

steel sheet. It shall be removable type using clips and quick released toggles,
so that it can be removed and replaced to allow maintenance without
damage to insulation or cladding.

No part of this document or the information it contains may be reproduced or transmitted in any form or by any means electronic or mechanical, including
photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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c. Metal joint sealant shall be applied on all cut joints of removable covers to
prevent entry of water.

7.15 REMOVABLE INSULATION PLUG/INSPECTION PLUG (TML, CML)

a. Removable insulation plugs shall be provided to permit on-stream ultra-sonic

inspection on both piping and equipment when required by the operating
Company Representative.
b. Plugs shall be vapor tight, ultrasonic resistant or prefabricated SS/AL Plug
and be opened and re-closed without disturbing the adjacent insulation.
c. Contractor shall provide location where inspection plugs to be installed.
d. Inspection window diameter shall be 125mm (Depend on the size and
thickness)

7.16 PROTECTION OF INSTALLED INSULATION AND REPAIR OF DAMAGED

INSULATION:

a. Installed insulation shall have the permanent protection or temporary

protection applied before conclusion of that day’s work.
b. Installed insulation shall have temporary protection applied if the insulation
can be damaged by rain or other form of atmospheric moisture.
c. Any item found to have been damaged adversely due to improper installation
or due to the manufacturing defect of the insulation material shall be removed
and reinstalled.

8.0 ACOUSTIC INSULATION

8.1 General
a. This is to reduce the noise during the operation of the system.
b. Normally consist of a resilient sound-absorptive layer and outer-
barrier layer applied to noise-radiation surfaces.

8.2 Type of Acoustic Insulation as per 01_AES-S-0006 PP 28/44

Type ACOUTIC INSULATION TREATMENT

S1 50 mm mineral wool covered by outside jacket

Two 50 mm layers of mineral wool covered with outside jacket.

S2
For S2 Insul CODE (RV2, RV4, V2, V4) – Vapor Barrier for Cold Service and Mass Vinyl to be applied
50 mm mineral wool with 5 kg/m2 Mass Loaded Vinyl covered
S3
with outside jacket
Two 50 mm layers of mineral wool covered with 5 kg/m2. Mass Loaded Vinyl and an outside jacket
S4
For S4 Insul CODE (RV2, RV4, V2, V4) – Vapor Barrier for Cold Service and Mass Vinyl to be applied

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8.3 Materials
a. Absorptive Layer
i. Sound absorbing material shall be fibrous glass 96-128 kg/m3 (6-8
lb/ft3)
b. Sound barrier material shall be lead sheet with a minimum mass of 5kg/m2
i. Vinyl Sheet

8.4 Acoustic Insulation Design

a. Large Equipment Acoustic Blanket insulation

i. Acoustic insulation shall be applied to the piping / equipment whose
noise level shall be greater than 85 dBA at a distance of one meter
from the piping/ equipment
ii. Service
1. Acoustical insulation shall be used on equipment with surface
temperatures not exceeding 230 C.
2. For higher temperature service, a fiberglass mat enclosed in
knitted stainless steel wire mesh should be used under the
acoustical insulation.
iii. Design Component
3. Outer Jacket: 0.6 kg/m (17 oz./yard ) Teflon impregnated
fiberglass cloth
4. Noise Barrier: 3.7 kg/m (0.75 lb/ft ) loaded vinyl faced with
tightly woven fiberglass
5. Insulation: 175 kg/m (11 lb/ft ) fiberglass needled mat, 25 cm
or 50 cm thick cloth.

b. Acoustic Insulation for Cold Service (CS)

i. The thermal insulation for cold service shall be applied first to the
pipe/equipment and the acoustic insulation shall be applied on top or
outside.
ii. To prevent condensation at interface between the two layers a second
vapor barrier shall be applied outside the acoustic insulation layer.
c. Acoustic Insulation for Hot Acoustic Insulation (IC)
i. Where acoustic insulation is applied in conjunction with the thermal
insulation for hot service, the material for acoustic insulation shall be
preferred and the thickness of the insulation layer shall be determined
by the more stringent of the two requirements.

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photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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8.5 Absorptive Layer Application

a. Material for absorptive layer shall be fibrous glass or mineral fiber/mineral
wool.
b. Thickness will be 80mm and shall be applied in single layer. When thickness
is 100mm, two 50mm shall be used.
c. For Dual Temperature Installation.
i. For dual-temperature installations [-73 to +177 C (-100 to +351 F)]
and cold service [- 73 to +1.7 C (-100 to +35 F)],
ii. the complete thermal system (basic insulation material, coverings)
shall be applied before acoustical absorptive material is applied.
d. All joints and interruptions of outer-barrier material at protrusions such as
valve bonnets, hangers, etc., shall be sealed
e. Unless otherwise specified, all surfaces shall be covered, including valve
bodies, flanges, fittings, supports, etc., on the piping or equipment to be
acoustic proof.

8.6 Barrier Layer Application

a. Material shall be an impervious, dense sheet material (loaded Vinyl or loaded
Mastic)
b. Sheet- metal screws shall not be used on vinyl, elastomer, or plain sheet lead
barrier layer materials.

8.7 Weather Jacketing

a. Refer to Section 7.12 of this Method Statement

B 9.0 TOOLS
a. These are the following to be used while performing the insulation and metal
jacketing activity.
b. Ensure that all the tools are inspected prior to use.
c. Any damage tools shall not be used.

9.1 Tools to be use for mineral wool, PIR and Cellular Glass insulation
a. Wool Cutter
b. Wire Cutter
c. Hand Saw
d. Scrapper
e. Masonry Trowel
f. Measuring tape
g. Band Tighter

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photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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Note: Personnel carrying out the application of insulation shall be wearing Kevlar or similar suitable
hand gloves, including other required PPE’s. If any cutter shall be used for Mineral wool, PIR, and
CG.

9.2 Use for Cladding Installation

a. Battery operated drill
b. Sheet cutter
c. Measuring tape
d. Hammer
e. Divider
f. Wise Grip
g. Rivet Gun
h. Rubber Hammer
i. Screwdriver
j. Band Tighter

Note: Any protrusion sharp edges will be bent and rendered safe to avoid injury and personnel
carrying out the application of cladding shall be wearing Kevlar or similar suitable hand gloves,
including other required PPE’s.

10.0 QUALITY ASSURANCE AND QUALITY CONTROL:

10.1 Quality Plan

a. For an application of insulation system, a quality plan-based ISO 9001 shall be

provided. The Quality Plan shall be included:

i. The delegated responsibilities of the several sections of the works and all
procedure, method statements and inspection test plan (ITP).

ii. The method statement shall be described, the execution plan, materials, trade
and quality procedure.

iii. In the ITP, all the test procedures shall be described such as the number of
samples, hold/witness points, test frequencies, acceptance/rejection criteria
etc. of all the application insulation system.

iv. Inspection shall be carried out prior, during and after completion of any stage
of the work, beginning with the material checks and ending with final
performance checks.

v. The quality plan shall be clearly indicated and in which stages material test
reports shall be available and how it is documented.

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photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
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10.2 Quality Control

a. Inspection of materials

i. All materials shall be complying with the minimum requirements and approved
by the client.
ii. All materials shall be inspected at the workshop and upon arrival on site.
iii. Prior to commencement of the work, data sheet, safety data sheet and method
statement of the various materials shall be submitted together with test
certificate.

b. Before Applying Insulation Application:

i. Prior to release for insulation, ensure that the following that had been check as
required.
ii. The relevant documents are signed from all required parties.
iii. Verify Surface to be insulated is dry, clean and free from dust, dirt etc.
iv. QC Inspector shall coordinate with the other inspector to conduct inspection as
required.
v. Stages of Inspection and verification, characteristics to be checked, acceptance
criteria and inspection / verification authority for hot/cold insulation shall be as
per Inspection and Test Plan for Thermal Insulation.

c. During Insulation Application

i. Make sufficient check to verify that the materials being applied are the same as
the specified or approved materials.
ii. Verify the insulated items, insulation code, thickness and weathering.
iii. Verify that the insulation surface is uniform without gaps and voids.
iv. Inspect tightness of joints and fasteners
v. Inspect the location of bands.
vi. Verify that the insulation segments are properly staggered.

d. During Weatherproofing Jacketing Installation

i. Verify that the insulation is completely dry and free from gaps.
ii. Inspect for proper overlap of metal flashing
iii. Verify the application of sealant at the circumferential overlap of metal jacketing
on horizontal pipe.
iv. Verify the location of bands, screw, s-clips and j-clips are specified.
v. Ensure that the moisture protection and weatherproofing at cut outs, protrusions
and locations where possible entry of moisture are properly applied.

11.0 SAFETY PRECAUTION:

11.1 Approved Work Permit shall be obtained prior to start any Insulation Works.

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11.2 The insulation supervisor with the assistance of the safety department will
carry-out a safety risk assessment identifying the actual hazard and possible
precaution to be taken to eliminate or lessen the risk prior to start of any
activities.

11.3 The necessary manpower inclusive of Supervisory Staff, tools, equipment,

materials and other resources required must be made available and ready to
use.

11.4 Workers shall always wear their Personnel Protective Equipment (PPE’s)
required for the work.

11.5 Certified Permit Receiver, in case of any confined space work a hole watcher
trained by CONTRACTOR Training Department and Work in-charge should
be at worksite during the execution of the work.

11.6 Tools to be secured with a restrainer string at open areas during working time
to prevent possibility of injury due to falling objects.

11.7 After the day works a good housekeeping shall be maintained.

11.8 House Keeping and Waste Disposal

11.9 The scrap of the cellular Glass/PIR/Mineral Wool materials will be keep in a
trash bag and sending to BFIM temporary facility area and place it in waste
container to be collected by waste disposal company as per Environmental
Company.

12.0 ATTACHEMENTS
12.1 Attachment 1 – Job Safety Analysis

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photocopying, recording, or by any information storage and retrieval system, without permission in writing from APOC and Samsung Engineering
 1.2.1. Involved personnel must attend Safety Induction and
necessary trainings
1.2.2. TBT meeting to be conducted by concerned supervisor and EHSS Supervisor
discuss the hazards which can expect while performing the Site supervisor/ EHSS
1.2. Untrained personnel
work, its reduction method and Preventive action to be known Officer
to each employee. PTW Receiver
1.2.3. Only trained and authorized personnel are allowed to perform
the work.

1.3.1. Ensure the accesses are free from obstruction.

1.3.2. Provide safe access, do not use shortcuts
Site supervisor
1.3.3. Removed unwanted materials, practice proper stacking of
1.3. Slip, trip and fall EHSS Officer
materials
Flagman
1.3.4. Barricade the working area, post appropriate signage and
restrict entry to authorized personnel only

1.4.1. Hand tools shall be inspected and color coded only by

authorized trained Personnel.
1.4.2. Power Tools shall be inspected only by authorized
Site supervisor
1.4. Damaged Hand Tools electrician and project monthly color code to be affixed.
Authorized Electrician
and Power Tools 1.4.3. All rejected tools and equipment shall be removed from site
EHSS Officer
immediately.
1.4.4. Full body harness and components shall be inspected and
color code by authorized personnel only.
2.1.1. Proper manual handling technique to be used.
2.1.2. Manual lifting, maximum of 20 KGs of weight shall be
allowed; ensure enough workers are assigned for carrying
Transportation and storing of Site supervisor
bulk and large materials and use of non-mechanical lifting
2 insulation materials at site (manual 2.1. Ergonomics EHSS Officer
devices, when required.
and by vehicle) Working crew
2.1.3. Proper body posture and positioning shall be maintained.
2.1.4. Regular housekeeping must be carried out in the working
area.
 2.2.1. Ensure vehicle is inspected by SSA 3rd Party certified
Equipment inspector and monthly inspection sticker affixed
2.2.2. Daily equipment checklist to be updated by driver/operator
2.2.3. Working Back up alarm and beacon lamp provided on
Site supervisor
2.2. Man/machine interface heavy equipment (e.g., dyna-truck, boom truck)
EHSS Officer
2.2.4. Pre-planning and clear instruction given to driver/operator
on where materials shall be delivered
2.2.5. Vehicle movement certificate with attached route plot plan
shall be available and secured.
2.3.1. Follow project site speed limit and traffic signs. Maintain
speed of <= to 20 kph in the main road and 10 kph inside
process area.
Site supervisor
2.3. Falling of materials 2.3.2. Pre-hauling checklist to be filled up.
EHSS Officer
2.3.3. Avoid over stacking. Materials should be tied properly with
rope to prevent from falling while bringing and storing to
work site.
3.1.1. Proper working table and/or bench to be provided while
cutting Rockwool for fitting
3.1.2. Work Area to be barricaded and signage’s to be provided.
3.1.3. Ensure that only self-retractable (spring type) knife shall be
Site supervisor
3.1. Hand Injury / Pinch point used.
EHSS Officer
3.1.4. Keep away fingers and hands from pinch point.
3.1.5. Wear rubber coated hand gloves.
3.1.6. Involved personnel shall be trained in Hand & Power Tools
Safety Training
Cutting and trimming of Rockwool
3 3.2.1. Use only rock wool with intact fiber; deteriorating fiber shall
(insulation material)
not be used.
3.2.2. Wear clear safety glasses at all times when handling rock
wool
3.2.3. Use appropriate PPE as per SDS such as disposable cover Site supervisor
3.2. Health hazard
all, rubber coated gloves and N95 respirator. EHSS Officer
3.2.4. Discuss the potential hazards and PPES required for the
work in TBT prior to starting the activity
3.2.5. SDS shall be at site and hazard to be discussed to work
crew by the Supervisor.
 3.3.1. Proper manual handling technique to be followed.
Personnel shall be trained in the Safe Manual Handling
Technique.
3.3.2. Manual lifting, maximum of 20 KGs of weight shall be
allowed; ensure enough workers are assigned for carrying Site supervisor
3.3. Ergonomics
bulk and large materials and use of non-mechanical lifting EHSS Officer
devices, when required.
3.3.3. Proper work position to be maintained.
3.3.4. Regular housekeeping must be carried out in the working
area.
4.1.1. Face shield to be provided over the safety glass.
4.1.2. Use mandatory PPEs such as rubber coated gloves, face Site supervisor
4.1. Personal injury
mask, face shield and EHSS Officer
Safety goggles.
4.2.1. Use suitable drill bits, Check the bits for cracks / damage
prior to use.
4.2.2. Dull bits shall not be used, only sharp and inspected bits
shall be available on the activity area.
4.2.3. Avoid overheating the drill bit and drill at high speeds. Start Working crew
4.2. Drill bits shattering/broken into pieces
at low drill speeds, and only increase the speed if the drill Site supervisor
Overhead drilling using Drilling isn't moving smoothly.
4
machine 4.2.4. If the drill bit gets stuck in the material, don't try to force it
out by running the drill. Unplug the drill, separate the bit and
the chuck, and remove the bit using manual tools.

4.3.1. Proper work position and posture to be maintained.

4.3.2. Regular housekeeping must be carried out in the working
Working crew
area.
4.3. Ergonomics Site supervisor
4.3.3. Work rotation to be implemented.
EHSS Officer
4.3.4. Personnel shall be trained and adhere to the Safe Manual
Handling Technique.
 4.4.1. Power Tools shall be inspected only by authorized
electrician and project monthly color code to be affixed.
4.4.2. Supervisors shall ensure the safe working condition of the Site supervisor/ EHSS
4.4. Defective tools
tools before the starting of daily activity. Officer
4.4.3. Tools must be checked and inspected prior to every use as
per the tool inspection checklist.

4.5.1. Check Dead man’s switch of power tools and ensure that it
is functioning properly; electrical tools shall stop running
when finger is released from the trigger.
4.5.2. All power tools to be used are connected to electrical panel
Site supervisor/ EHSS
4.5. Electrical shock board that area provided with RCCB/ELCB.
Officer
4.5.3. Panels and electrical tools/equipment must be checked as
per the checklist
4.5.4. Ensure that proper hand gloves are provided and worn.
E.g., Rubber coated gloves and/or leather gloves

4.6.1. Provide barricade and signage in the working area Site supervisor/ EHSS
4.6. Unauthorized personnel entry
4.6.2. Constant supervision shall be ensured and in place. Officer

5.1.1. Proper manual handling technique to be used.

Insulation and Cladding Works on
5.1.2. Manual lifting, maximum of 20 KGs of weight shall be
pipes & equipment
allowed; ensure enough workers are assigned for carrying
- Lifting of cladding materials Site supervisor/ EHSS
bulk and large materials and use of non-mechanical lifting
5 - Secure cladding with 5.1. Ergonomics Officer
devices, when required.
fastener / Joint sealed with Working crew
5.1.3. Proper work position to be maintained.
Aluminum tape using
5.1.4. Regular housekeeping must be carried out in the working
scaffolding
area.
 5.2.1. Wear appropriate & approved PPE’s (safety glass,
disposable cover-all, dusts mask design for nuisance dust,
hand gloves, etc.)
5.2. Health hazards – skin, eye, throat and Site supervisor/ EHSS
5.2.2. Proper and mandatory PPES shall be provided and worn as
respiratory irritation Officer
per SDS. Adhere and comply with requirements as per
SDS.
5.2.3. Ensure eye wash station is available near work area.

5.3.1. Provide barricade in the working area and signage’s to be

posted.
5.3.2. Buddy system to be implemented. Co-worker will assist
during installation activity.
5.3.3. Tools shall be secured with tool lanyard or lashing
5.3.4. Only Required quantity of insulation and cladding materials
Working Crew
5.3. Falling of Rockwool to be placed on the man lift platform and loose materials
Site supervisor/ EHSS
and Cladding Materials shall be removed and placed on proper container
Officer
5.3.5. Ensure materials are manually hoisted at work area by 3rd
party approved gin wheel with at least 18 mm nylon rope.
5.3.6. Constant supervision shall be in place and ensured
5.3.7. Do not overload platform capacity, materials that were not
used before lunch/evening/morning break shall be lowered
down to grade level.
5.4.1. All personnel involved in working at heights have attended
Working at Heights training and other required safety
trainings.
5.4.2. Full Body Harness shall be worn and shall be hooked on
suitable and designated anchorage on the man lift. 100% tie
Site supervisor/ EHSS
off policy to be complied.
Officer
5.4.3. Ensure chin strap provided and used when working at
5.4. Fall from height SSA 3rd party certified
height.
Scaffolding Inspector /Site
5.4.4. Work shall be conducted in the constant presence of work
supervisor/ EHSS Officer
supervisor
5.4.5. Ensure scaffolding is erected by 3rd party certified
scaffolders/erectors and is checked, inspected and provided
with Scaff. tag by SSA 3rd party certified Scaffolding
Inspector
 5.5.1. Refrain from placing fingers and hands from pinch point
area and sharp edges.
5.5.2. Wear proper hand gloves. Personnel shall be provided and Work crew
5.5. Hand Injury / pinch point / cut must wore rubber coated or leather gloves Site Supervisor
5.5.3. Involved personnel shall be trained in Hand & Power Tools EHSS Officer
Safety
5.5.4. Good housekeeping shall be conducted and maintained

5.6.1. Work area shall be barricaded and provided with

5.6. Man/machine interface
appropriate signage
Work crew/Site
5.6.2. Assign Dedicated Trained Flagman to control and direct
Supervisor/EHSS Officer
traffic and pedestrian access.
5.6.3. Constant supervision shall be in place and ensured

6.1.1. Work rotation to be considered to minimize exposure time

6.1.2. Hazards and risks associated with task at hand shall be
6.1. Health hazards
discussed and shared to work force Work crew/Site
6 Application of sealant (silicone) - Skin/eye irritation
6.1.3. Ensure eye wash station is available near work area. Supervisor/EHSS Officer
- Excessive inhalation
6.1.4. Proper and mandatory PPES shall be provided and worn as
per SDS.
7.1.1. Manlift shall only be operated on plain and leveled ground;
ground shall be leveled and compacted
7.1.2. Work area shall be barricaded and provided with
appropriate signage
7.1.3. Trained flagman shall be provided to assist and guide man
PI/PR/Site supervisor/
7.1. Manlift toppling lift operator
EHSS Officer
7.1.4. Ensure valid Vehicle movement certificate with route plot
plan available with operator and/or attached on the work
permit.
7.1.5. Only 3rd party approved Man lift operator to perform the
7 Installation of insulation using man lift
activity
7.2.1. Man lift equipment must have valid 3rd party certification
7.2.2. Manlift must be checked, inspected by SSA 3rd party
certified Equipment Inspector and project monthly sticker to
be affixed.
PI/PR/Site supervisor/
7.2. Equipment failure 7.2.3. Daily man lift checklist to be filled up and updated by
EHSS Officer
operator
7.2.4. Maintain maintenance record. Ensure to adhere and follow
preventive maintenance schedule as per manufacturer’s
manual.
 7.3.1. All personnel involved in working at heights including
working on (MEWP) man elevated working platform such as
man lift is has attended Working at Heights training and
other required safety trainings.
7.3.2. Full Body Harness shall be worn and shall be hooked on
PI/PR/Site supervisor/
7.3. Fall from height suitable and designated anchorage on the man lift. 100% tie
EHSS Officer
off policy to be complied.
7.3.3. Ensure chin strap provided and used when working at
height.
7.3.4. Work shall be conducted in the constant presence of work
supervisor
7.4.1. Barricade the working area and provide signage.
7.4.2. Tools shall be secured with tool lanyard or lashing
7.4.3. Only Required quantity of insulation materials to be placed
on the man lift platform and loose materials shall be
PI/PR/Site supervisor/
removed and placed on proper container
7.4. Fall of material EHSS Officer
7.4.4. Constant monitoring of designated trained flag man shall be
carried out
7.4.5. Do not overload platform capacity, materials that were not
used before lunch/evening/morning break shall be lowered
down to grade level.
7.5.1. Use mandatory PPEs such as but not limited to rubber
coated gloves, face mask and safety goggles.
7.5.2. SDS to be always available at site. Instructions and Site supervisor/ EHSS
7.5. Health hazards
information on SDS to be communicated and discussed to Officer
all work crew.
7.5.3. Adhere and comply with safety requirements as per SDS

8.1. Heat related Illness
Working in extreme/ hot weather
8 and carried out.
condition
8.2. Adverse weather conditions. (High winds,
hail storm and heavy rain)
8.1.1. Pay attention to environmental board details and heat
stress flagging system
8.1.2. Ensure to apply and implement work/rest rotation
8.1.3. In case anyone is affected with heat stress, shift that victim
to a shaded area, immediately inform Project ERT via
Project Hotline number: 050-892-7264
8.1.4. Implement Buddy system, Ensure that no one is allowed to
Site supervisor/ EHSS
work alone
Officer
8.1.5. Provide sufficient cold drinking water at all times and heat
stress shelter with complete requirements including
informative signage, mist fan, etc. on work area. Put into
consideration that no water, no work since it is essential for
the workers to be hydrated as always to continue their work
8.1.6. Constant monitoring and supervision shall be implemented
8.2.1. Do not work at height if wind speed is more than 40.2 kph /
25 mph and in adverse weather conditions. Refrain from
lifting if the wind speed is more than 32 kph/20 mph/9 m/s
8.2.2. Halt lifting activity if there is heavy rain, lighting and
thunderstorm.
8.2.3. Wear appropriate clothing for various weather condition Supervisor/ EHSS
including weather protection clothing. Personnel
8.2.4. Supervisor to check weather conditions each day prior to
work commencing and throughout the job.
8.2.5. Ensure rest shelters are provided in the work area
8.2.6. Supervisor should direct the workers to solid roof shaded
area during heavy rain.

8.1.1. Remove all the debris from work area on a daily basis
8.1.2. Stack the materials properly, provide access in between
8.1. Slip trip and fall. stacked materials. Site supervisor/Foreman
8.1.3. Ensure good housekeeping conducted before, during and
8 Post cleaning of work area prior to leaving the area
8.1.4. Ensure materials are lowered to the ground prior to leaving
the work area. Supervisor/ EHSS
8.2 Fall from heights, falling object
8.1.5. Adhere to proper and safe manual handling/lifting Personnel
technique.
 8.1.6. Use correct tools and equipment when lowering materials
such as manila rope 18 mm min., duffle bag, canvas bag
with SWL and pulley.
8.1.7. Manual lifting area to be barricaded and provided with
appropriate signs
8.1.8. Ensure all personnel involved in elevated areas are
provided and wearing full body harness and maintaining
100% tie-off.
Personal Protective Equipment (PPE):- Safety Helmet, Safety Shoes, Safety Glass, Visible Safety Vest, gloves and Face Mask.
NOTE: Ensure all safety requirements in this JSA are met and provided. If there are emergency hazards identified as per site condition, stop and re-assess work activity and provide mitigating
measures. Conduct 360° assessment of the work area prior to start of activity. Share and discuss JSA with work crew.
 Date:
APOC PDH/UTOS PROJECT
Illumination Plan September 20, 2022

1.0 Title

Illumination Plan

2.0 Purpose

To establish lighting procedure in APOC PDH/UTOS Project in order to achieve a

safe and healthy illuminated workplace area at heights and confined spaces.

3.0 Requirements

Each facility-Lighting shall be designed for safe and efficient operation and
maintenance of the site (project).

Lighting systems shall be in accordance with applicable local regulations / standards.

In absence of any applicable local regulation / standard, Samsung Engineering
standard shall be followed.

4.0 Temporary Electrical Connections

4.1 Temporary Electrical Connections shall be provided only by authorized

personnel (Electrician).
4.2 Damaged Flexible cords shall not be used. Cords should be inspectedbefore
each use. Flexible cords shall be used only in continuous lengths without
splice or tape.
4.3 Flexible cords shall not be passed through doorways, along the floor, in water,
or in any other area where it might become damaged.
4.4 Kinking or excessive bending of extension and power cords shall be avoided.
4.5 The extension cord and socket box shall be made of insulating materials.

5.0 General Requirements for Temporary Wiring

Feeder shall originate in a distribution center. The conductors shall be run as multi
conductor cord or cable assemblies or where not subject to physical damage, they
may be run as open conductors or insulators no less than 3.3 m (10.8 ft ) apart.

Branch circuits shall originate in a power outlet or panel board. Conductors shall be
run as Multi conductor cord or cable assemblies or open conductors, or shall be
run in raceways.
All conductors shall be protected by over current devices at their capacity. Runs of
open Conductors shall be located where the conductors will not be subject to
physical damage
 Date:
APOC PDH/UTOS PROJECT
Illumination Plan September 20, 2022

And the conductors shall be fastened at intervals not exceeding 3.3 m (10.8 ft). No
branch Circuit conductors shall be laid on the floor. Each branch circuit that supplies
receptacles or fixed equipment shall contain a separate equipment grounding
conductor if the branch Circuit is run as open conductors.

Receptacles shall be of the grounding type. Unless installed in a complete metallic

raceway, each branch circuit shall contain separate equipment grounding conductor
and all Receptacles shall be electrically connected to the grounding conductor.
Receptacles for Uses other than temporary lighting shall not be installed on branch
circuits, which supply Temporary lighting. Receptacles shall not be connected to the
same ungrounded conductor of multi wire circuits, which supply temporary lighting.

• Disconnecting switches or plug connectors shall be installed to permit the

disconnection of all underground conductors of each temporary circuit.
• All lamps for general illumination shall be protected from accidental contact or
breakage. Metal-case sockets shall be grounded.
• Temporary lights shall not be suspended by their electric cords unless cords and
lights are designed for this means of suspension.
• Portable electric lighting used in wet and/or other conductive locations, for
example, drums, tanks and vessels shall be operated at 24 volts or less.
• A box shall be used wherever a change is made to a raceway system or a cable
system, which is metal, clad or metal sheathed.
• Flexible cords and cables shall be protected from damage. Sharp corners and
Projections shall be avoided. Flexible cords and cables may pass through
doorways or other pinch points if protection is provided to avoid damage.
• Temporary Site electrical cable line shall be protected and hang not less than 2
meters (above) with “S” type insulated cable line (electrical) holder.
• Extension cord sets used with portable electric tools and appliances shall be of
three-wire type and shall be designed for hard or extra hard usage. Flexible
cords used with temporary and portable lights shall be designed for hard or extra-
hard usage.
• Temporary wiring shall be removed in its entirety immediately upon completion of
construction or the purpose for which the wiring was installed. In isolated cases,
where removal is impractical and with management approval, temporary wiring
may be abandoned in place. In such cases, ends of wires or cables shall be
disconnected from the power source, taped and tagged as abandoned.
• Additional fixtures should be added in case of and to make sure that it could give
a sufficient lighting inside the equipment.
• Back up light (Emergency light) is required and to be installed in both entrance
(confined space) in order to give an emergency lighting in-case of power failure.
 Date:
APOC PDH/UTOS PROJECT
Illumination Plan September 20, 2022

6.0 Authorized Personnel (APOC PDH/UTOS Project)

Name Designation Badge No. (I.D.) Mobile Number

Ramakant Electrician 2241804919 0503826186

7.0 Temporary electrical components and lighting fixtures:

PARTICULARS SPECIFICATIONS

Main Breaker 100 Amps / 3 phase / 220v

Circuit Breaker (equipment) 30 amps
Circuit Breaker (outside lighting) 20 amps
Circuit Breaker (inside lighting except 15 amps
confined space lighting)
Electrical Cable (Main) 3 phase / 50Amps
Electrical cable (distribution) 3 phase / 20 amps
Power connector (electrical) “Y” type 16 amps / 110v – 2220 v
Halogen Lamp 400 watts / 220 v.
Tube lighting (offices, mess hall, 40 watts / 110 v.
storage room, etc.)
Bulb type (confined space) / bump 40 watts / 24 v
protected
Power converter 110 v (input) / 24 v. (output)
For confined space lightings.
Emergency light 110v (input) / 24v. bulb lighting