HALFAYA PROJECT SURFACE FACILITY

Petrochina (Halfaya)

DETAIL DESIGN DOC. NO.: HFY-PIP-SP-00008 REV.: X PAGE 2 OF 13

CONTENT

1.0 SCOPE .......................................................................................................................3

2.0 CODES AND STANDARDS........................................................................................3

3. 0 DESIGN REQUIREMENTS .........................................................................................4

4.0 INSULATION DESIGN................................................................................................5

5.0 MATERIAL REQUIREMENTS ....................................................................................8

6.0 GENERAL INFORMATION ABOUT INSULATION APPLICATION............................9

7.0 APPLICATION OF HOT SERVICE INSULATION.......................................................9

8.0 SAFETY PROTECTION............................................................................................11

9.0 GUARANTEE ...........................................................................................................12

10.0 PACKAGING AND MARKING.................................................................................12

11.0 STORAGE ...............................................................................................................13

12.0 DRAWINGS .............................................................................................................13

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Petrochina (Halfaya)

DETAIL DESIGN DOC. NO.: HFY-PIP-SP-00008 REV.: X PAGE 3 OF 13

1.0 SCOPE

This specification covers the minimum requirements for the supply and installation of
insulation on piping, vessels, and equipment operating in hot and cold service for
HALFAYA PROJECT SURFACE FACILITY.

2.0 CODES AND STANDARDS

2.1 General
The Contractor shall meet or exceed the requirements of the latest edition of the
following codes, regulations and standards, except as superseded herein. In cases
where more than one code, regulation or standard is applied to the same condition, the
most stringent one shall be followed. In the event of a conflict between this specification
and other specifications or correspondence, the OWNER shall be consulted and a
written rule shall be obtained before any work is started.
2.2 Codes and Standards
2.2.1 American Society for Testing and Materials (ASTM):
BS 5970 "Code of Practice for Thermal Insulation of Pipework and Equipment (in
℃
theTemperature Range -100 to +870 ) ℃
ASTM A 167 Stainless and Heat Resistant Chromium Nickel Steel Plate, Sheet and
Strip
ASTM A 653 Specification for Steel sheet, Zinc coated (Galvanised) or Zinc-Iron alloy
Coated (Galvannealed) by the Hot dip process.
ASTM B 209 Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate
ASTM C 168 Standard Terminology Relating to Thermal Insulating Materials
ASTM C 449 Standard Specification for Mineral Fiber Hydraulic-Setting Thermal
Insulating and Finishing Cement
ASTM C 612 Standard Specification for Mineral Fiber Block and Board Thermal
Insulation
ASTM C 795 Standard Specification for Thermal Insulation for Use in Contact with
Austenitic Stainless Steel
ASTM C 1055 Contact Burn Injuries
ASTM C 547 Standard Specification for Mineral Fiber Pipe Insulation
ASTM C 592 Standard Specification for Mineral Fiber Blanket Insulation and Blanket-
Type Pipe Insulation (Metal-Mesh Covered) (Industrial Type)
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DETAIL DESIGN DOC. NO.: HFY-PIP-SP-00008 REV.: X PAGE 4 OF 13

2.2.2 Occupational Health and Safety Act

2.3 The General Specifications HFY-CP-SP-00002 ”Specification for External Coating of
Equipment and Piping” shall be used in conjunction with this specification where
applicable.
2.4 Some requirements in this specification may be modified by specific requirements in the
Purchase Specification. In case of conflict, the specific requirements supersede this
specification.

3.0 DESIGN REQUIREMENTS

3.1 General Requirements

3.1.1 Insulation shall be supplied and installed to meet the following requirements:

Saving of energy by reducing the rate of heat transfer

Maintenance of process temperature

Prevention of freezing, condensation, vaporization or formation of undesirable
compounds such as hydrates

Protection of personnel from injury through contact with equipment

To prevent condensation on surface of equipment conveying fluids at low temperature
3.1.2 The insulation Manufacturer’s instructions and recommendations as to the selection and
methods of application of the insulation shall supplement this specification. In the event
of a conflict, the OWNER shall make the final decision.
3.2 Personnel Protection
3.2.1 Insulation for personnel protection shall be provided as follows on all piping and
equipment adjacent to the work platforms or other operating areas where the maximum
operating bare metal temperature exceeds 60 : ℃

Horizontal piping where the bottom of the pipe elevation is less than 2.5 meters above
grade or a working platform;

Portions of the vertical piping, which are less than 2.5 meters above grade or a working
platform;

Piping adjacent to and within 750 mm of a working platform;

Where specified by the OWNER.
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DETAIL DESIGN DOC. NO.: HFY-PIP-SP-00008 REV.: X PAGE 5 OF 13

3.2.2 The piping insulation for personnel protection shall be limited to the pipe and pipe fittings,
excluding the flanges and valves.
3.2.3 Where required, insulation for personnel protection shall be installed from 150 mm to 2.5
meters above grade or working platform.
3.2.4 Insulation for personnel protection is not required where screens are to be installed for
this purpose.
3.2.5 If alternate personnel protection measures are considered to be economical, details
shall be submitted to the OWNER for approval.
3.3 Where insulation is required on the outside of piping, vessels or equipment extending
through an exterior building wall or roof, the insulation shall not be stopped at the
exterior of the building, but shall be extended for 300 mm inside the building.
3.4 ℃
Piping operation above 55 and within 150 mm of electrical conduit or Teck cable shall
be insulated for a distance of 300 mm on either side of the conduit or Teck cable.

4.0 INSULATION DESIGN

4.1 General
4.1.1 The insulation structure consists of an insulation layer, damp proof layer and protective
layer.
4.1.2 Use fixed insulation structure for the parts that do not need to be tested, and use the
dismountable insulation structure for the parts needing dismantling and overhaul, such
as flanges, valves, manholes, and so on.
4.1.3 The insulation structure must be fixed firmly on the pipe and its accessories, and must
have close waterproof measures. The parts such as the equipment opening, the
connection between pipe and equipment, etc., shall be locally treated to prevent moist
air and rainwater penetration.
4.1.4 The insulation structure shall have a certain mechanical strength and rigidity, and shall
not be destroyed by deadweight or occasional exogenic action.
4.1.5 The insulation supporting of the equipment needing heat treatment shall be welded in
the factory beforehand. The angle steel supporting ring connected with bolts shall be
installed on the site, if the equipment doesn’t have an insulation support.
4.1.6 For the insulation application, Please refer to the P& IDs
4.2 Insulation Layer Thickness
4.2.1 Heat insulation
a. The thickness of heat insulation for pipes except Heat Medium pipes, Insulation Material is
Centrifugal Glass Wool Shell (with aluminum foil), Mineral Fiber ASTM C547 Type I.
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DETAIL DESIGN DOC. NO.: HFY-PIP-SP-00008 REV.: X PAGE 6 OF 13

PIPE Thickness (mm) PIPE Thickness (mm)

NPS OD(mm) 60~90 ℃ NPS OD(mm) 60~90 ℃

1/2 21.3 40 8 219.1 60
3/4 26.7 40 10 273.0 60
1 33.4 40 12 323.8 60
1-1/2 48.3 40 14 355.6 60
2 60.3 40 16 406.4 80
3 88.9 40 18 457 80
4 114.3 40 20 508 80
6 168.3 50 24 610 80

b. The thickness of heat insulation for Heat Medium pipes, Insulation Material is Centrifugal
Glass Wool Shell(with aluminum foil), Mineral Fiber ASTM C547 Type I.

PIPE Thickness (mm) PIPE Thickness (mm)

NPS OD(mm) 91~150 ℃ 151~230 ℃ NPS OD(mm) 91~150 ℃ 151~230 ℃

1/2 21.3 40 60 4 114.3 50 90
3/4 26.7 40 60 6 168.3 50 90
1 33.4 40 70 8 219.1 60 100
1-1/2 48.3 50 70 10 273.0 60 100
2 60.3 50 80 12 323.8 60 100
3 88.9 50 90

c. The thickness of heat insulation for equipments except Heat Medium equipments,
Insulation Material is Centrifugal Glass Wool (with aluminum foil), Mineral Fiber ASTM C612
Type IA.
The thickness of insulating layer for equipments is 80mm.
d. The thickness of heat insulation for Heat Medium equipments, Insulation Material is
Centrifugal Glass Wool (with aluminum foil), Mineral Fiber ASTM C612 Type II.
The thickness of insulating layer for Heat Medium equipments is 140mm.
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DETAIL DESIGN DOC. NO.: HFY-PIP-SP-00008 REV.: X PAGE 7 OF 13

4.2.2 Personnel protective

a. The thickness of personnel protective for pipes, Insulation Material is Centrifugal Glass
Wool Shell (with aluminum foil), Mineral Fiber ASTM C547 Type I.
b. The thickness of personnel protective for equipments
The thickness of personnel protective for equipments which temperature is equal to and less
than 150 ℃
is 30mm, Insulation material is Centrifugal Glass Wool (with aluminum foil),
Mineral Fiber ASTM C612 Type IA, when the temperature is from 151 ℃
to 250 , the℃
thickness is 60mm, Insulation Material is Centrifugal Glass Wool (with aluminum foil), Mineral
Fiber ASTM C612 Type II. The equipments not have insulation, but to avoid the possibility of
accident caused by touching it, warning signs shall be provided in a visible position.

PIPE Thickness (mm) PIPE Thickness (mm)

NPS OD(mm) 60~90 ℃ 91~230 ℃ NPS OD(mm) 60~90 ℃ 91~230 ℃
1/2 21.3 30 30 8 219.1 30 40
3/4 26.7 30 40 10 273.0 30 50
1 33.4 30 40 12 323.8 30 50
1-1/2 48.3 30 40 14 355.6 30 50
2 60.3 30 40 16 406.4 30 50
3 88.9 30 40 18 457 30 50
4 114.3 30 40 20 508 30 50
6 168.3 30 40 24 610 30 60
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Petrochina (Halfaya)

DETAIL DESIGN DOC. NO.: HFY-PIP-SP-00008 REV.: X PAGE 8 OF 13

5.0 MATERIAL REQUIREMENTS

5.1 General
5.1.1 Use of materials other than those specified uses requires the OWNER’s approval.
5.1.2 All the supplied materials shall be new and undamaged. All insulation materials shall be
properly stored and protected from moisture. Insulation that is damp or wet shall be
properly dried to the satisfaction of the OWNER or be replaced at Contractor’s expense.
Also all material shall be of high quality and good appearance.
5.1.3 All insulation shall be rigid and self-supporting.
5.1.4 The insulation materials including asbestos shall not be used. All the selected insulation
materials shall conform to the latest edition of the Occupational Health and Safety Act,
and all other applicable standards.
5.1.5 Insulation materials applied to the austenitic stainless steel shall meet the requirements
of ASTM C-795. The material manufacturer shall furnish test certificate.
5.1.6 All metal primers, adhesives, insulating cement, moisture barrier sealers, and weather-
proofing must meet the insulation Manufacturer’s recommendations, and shall be
compatible with the insulation in use.
5.1.7 The permissible temperature of the insulation material and its produce shall be higher
than the design temperature of the pipe and equipment.
5.1.8 The adhesive agent, sealant, etc. shall not corrode the metal wall, shall have a short
curing time and sealing property, and shall not craze within the design life.
5.1.9 The Owner shall have right to inspect any or all the test conducted on insulation material
by manufacturer at his shop or any laboratory.
5.2 Hot Insulation
5.2.1 Glass wool shell / plate shall be used for hot service. The properties requirements are as
per relevant ASTM standard specification.
5.2.2 Weight Loss by Tumbling
Maximum loss in weight when tested in accordance with ASTM Test Method C421 shall
be as following:
Duration Weight Loss(%)
After first 10 min 30.0
After second 10 min 50.0
5.3 Protective Layer
For piping, heat exchanger, separator, and horizontal vessel provide 0.5mm thick,
stucco embossed pattern finish, Type 1100 aluminum jacket, ASTM B209.
For tank, and vertical vessel provide 0.5mm thick, stucco embossed pattern finish
in a corrugation form, Type 1100 aluminum jacket, ASTM B209.
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DETAIL DESIGN DOC. NO.: HFY-PIP-SP-00008 REV.: X PAGE 9 OF 13

5.4 Bands
Provide 20mm wide, 0.5mm thick, fully annealed 316 type stainless steel for
banding.

6.0 NERAL INFORMATION ABOUT INSULATION APPLICATION

6.1 The Contractor shall perform all the work with the highest quality workmanship to
provide a neat, uniform appearance with no sharp edges exposed.
6.2 Insulation shall not be applied until all testing such as hydrostatic, X-ray (with X-ray
numbers indicated on the isometric piping drawings), etc. have been completed on all
the involved piping and equipment and all leaks have been repaired or made tight.
6.3 All surfaces to be insulated shall be thoroughly cleaned of dirt, grease, rust, scale, etc.,
and shall be perfectly dried before the insulation is applied.
6.4 Insulation shall not be installed in a weather which might cause the pipe or insulation to
become wet. Insulation to be installed over an extended period must be protected to
ensure that it remains dry until it has been properly sealed.
6.5 Insulation shall be installed such that the shrinkage is held to a minimum. Any cracks or
openings in the insulation or weather-proofing are to be filled in with additional insulation
or weather-proofing to provide a smooth sealed surface.
6.6 Insulation shall neither involve the face of gauge glasses, equipment nameplates, data
plates or tags, nor shall be applied so as to interfere with the dynamic parts of the
instruments or equipment.
6.7 All openings in the metal jacketing for the manways, nozzles, nipples, pipe supports, etc.,
are to be neatly cut to provide a snug fit, and shall be thoroughly sealed and weather-
proofed to prevent the moisture from penetrating the jacket. The openings shall be fitted
with a metal collar or suitable flashing embedded in sealant and screwed firmly in place.
6.8 At all flanges, unions, and pipe terminations, the pipe insulation shall be bevelled at a
45° angle to facilitate removal of flange bolts and union collars without damaging the
main pipe insulation and metal jacketing. A screwed and sealed metal cover shall be
installed.
6.9 The thickness of the basic insulation on pipe fittings shall be the same as that of the
insulation on the adjoining pipe.
6.10 All insulation shall be clad with metal jacketing as far as is reasonably practical.
Jacketing shall be installed so as to shed water and protect against wind and blowing
rain.

7.0 APPLICATION OF HOT SERVICE INSULATION

7.1 General
Provision for the expansion of hot equipment shall include the installation of expansion
springs in circumferential banding securing insulation and jacketing.
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DETAIL DESIGN DOC. NO.: HFY-PIP-SP-00008 REV.: X PAGE 10 OF 13

7.2 Piping
7.2.1 The factory fabricated sectional pipe insulation shall be applied by staggered joint
construction and shall be secured with stainless steel wire on 225 mm centers. During
multiple layer construction, all joints shall be lapped one-half of each section between
layers. Each layer shall be secured separately. All joints shall be securely butted. All
cracks, joints, etc., shall be appropriately filled with insulating cement or glass fiber.
7.2.2 The mastic sealer shall be used around the pipe supports where the insulation is
punctured by the support.
7.2.3 Insulation shall be covered with metal jacketing lapped a minimum of 50 mm on all
seams and shall be secured with screws and bands, with one band at each lap joint and
spaced a maximum of 450 mm on center. Vertical jacketing shall be supported with “S”
clips.
7.3 Fittings, Flanges and Valves
7.3.1 The valves, flanges and unions shall not be normally insulated, unless it is specified by
the OWNER. All other fittings are to be insulated.
7.3.2 Fittings shall be insulated with the standard factory fabricated insulation, and shall be
secured with bands, minimum two per section. All joints shall be appropriately filled with
insulating cement or glass fiber. Insulation shall be covered with factory fabricated
standard metal jacketing.
7.3.3 Insulation and jacketing on valves, flanges and unions shall be installed so as to be
removable without damaging the main pipe insulation. Valves where insulated shall be
insulated with prefabricated removable stucco embossed pattern finish Type 1100
aluminum sheets lined & filled with insulation material ; However insulation shall be cut
and shaped around the valve stem & kept clear of the stuffing box & gland. All cutouts in
the enclosure shall be sealed with mastic sealer.
7.4 Vessels and Equipment
7.4.1 Vessels
7.4.1.1 Vessel shells shall be insulated with factory fabricated insulation that is curved or
grooved to fit the vessel shell contour. If additional layers are required, insulation shall
be installed with staggered joints. Each layer shall be secured with bands, and shall be
machine stretched and fastened on 300 mm centers. All cracks or voids shall be filled
with insulating cement. The insulation shall be covered with the metal jacketing lapped a
minimum 75 mm on all seams. The jacketing shall be secured with metal screws on 150
mm centers on longitudinal seams and with bands, located at lap and spaced on a
maximum of 450 mm on center.
7.4.1.2 Vessel heads shall be insulated in the same manner as the shell. The insulation shall be
covered with metal jacketing in a pie shaped or segmented arrangement.
7.4.1.3 The corrugated jacketing on vertical vessels shall be installed using the “S” clip method,
and shall be lapped a minimum of two (2) corrugations on vertical seams.
7.4.1.4 For vessels up to and including 900 mm O.D., the jacketing shall be secured with plain
bands. For vessels with the O.D larger than 900 mm, the banding shall be sealed.
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7.4.1.5 Expansion joints shall be provided under each insulation support ring. A 25 mm space
between the top of the insulation and the underside of the support ring shall be filled with
class wool shell/plate insulation.
7.4.1.6 A band shall be placed adjacent to heads of horizontal vessels and at the top sheet on
vertical vessels, in order to secure flashing between the head and the shell jackets.
7.4.1.7 Vessel skirts, saddle supports, bottom heads, and flanged connections shall not be
normally insulated unless specified by the OWNER.
7.4.2 Insulation and jacketing (soft material) on the exchanger flanges and heads shall be
installed so as to be removable without damaging the main shell insulation.
7.4.3 Equipment
7.4.3.1 Whenever possible, for equipment in irregular shape, the insulation shall be of the same
type and thickness as specified for the vessels. Insulation and metal jacketing shall be
installed so as to be removable.
7.4.3.2 Where it is required, the insulating cement shall be applied in layers 20 to 25 mm thick.
Every layer shall be reinforced with steel mesh. The outer surface of the insulating
cement shall be finished with a smooth layer of finish cement.

8.0 SAFETY PROTECTION

8.1 The major safety requirements may be separated into the following divisions:

Safe surface temperature for personnel protection or ignition

Safety from radioactivity or chemical reaction

Safety from toxic conditions

Fire protection

8.2 When hot equipment or piping is located where its insulation may be touched by
personnel, the insulation shall be so designed that its thermal resistance, surface
emittance, and jacket conductivity together create a condition which will not produce skin
burns when its outer surface is accidentally touched.
8.3 Where combustible materials are present and changes of leakage or spillage prevail, a
suitable low surface temperature of insulated vessels and piping may be very important
in preventing the ignition of these materials. When this condition prevails, it becomes
necessary that all hot surfaces, such as valves, flanges, and metal projections, be
insulated so as to maintain all exposed surfaces below the maximum allowable surface
temperature. Some areas which cannot be insulate, such as valve bonnets and stuffing
boxes, may require shielding to prevent contact with the chemical.
8.4 As previously mentioned, non-combustible but absorptive insulation may be a fire hazard
in two ways. First, in the case of combustible material leaks, the insulation’s tremendous
internal surface area can assist in causing rapid oxidation which will result in
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DETAIL DESIGN DOC. NO.: HFY-PIP-SP-00008 REV.: X PAGE 12 OF 13

spontaneous combustion. Second, also in the case of leaks, any absorbent can hold
large quantities of combustibles and, if an accidental fire occurs, the saturated insulation
will feed and spread it. However, properly used insulation can be used as fire protection.
An installation on equipment and piping must first, the combustibility of the insulation
must be considered, including the speed at which the insulation will spread the fire, or
the amount of heat and smoke it will contribute. Second, the time rate at which
temperature will pass through the insulation from the fire side to the vessel or pipe must
be thought of.
8.5 The operator shall wear the normal protective appliances such as work clothes, footwear
and so on before insulation construction.
8.6 Set the fire fighting equipment on the construction site.
8.7 Clean out the tools and site after the construction is completed or temporarily paused.
Transfer the inflammable and poisonous articles to the specified place.
8.8 The falsework shall be dismantled only after the fixture has been firmly fixed.
8.9 While screwing down and seizing the iron wire, the operator shall not use too much force,
and embed the end of the iron wire into the insulation layer.

9.0 GUARANTEE

The Contractor shall guarantee the installation to be free from material defect,
misapplication, or poor workmanship for a period of one (1) year after the date of
acceptance. Any unsatisfactory work or defects shall be repaired at Contractor’s
expense and at a time acceptable to the OWNER.

10.0 PACKAGING AND MARKING

10.1 Packaging
Unless otherwise specified by the Purchaser, the class wool shell/plate insulation
material shall be packaged in manufacturer’s standard commercial container approved
by the Purchaser and considering the following:
10.1.1 Overseas consignments shall be packed in double-corrugated cartons incorporating
weather & water proof material because of greater handling involved and possibly of
exposure to wet conditions. If the size of sections exceeds the practical size for cartons,
wooden or strong mesh crates may be used.
10.1.2 The insulation materials shall not be unpacked at site until is required for use.
10.1.3 Stacking of packed class wool shell/plate insulation (including soft material) during
transportation shall be in accordance with the manufacturer’s recommendation. It should
be noted that for the Contractor shall take full considerations on the transportation
protection of insulation material especially during the offshore transportation. Any
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impairment, corrosions or other unsatisfactory work or defects may be rejected by the

COMPANY at Contractor’s expense and at a time acceptable to the COMPANY.
10.2 Marking
Unless otherwise agreed between purchaser and manufacturer and/or supplier,
containers shall be marked as follows:

purchase order No.;

name and type of material;

sizes of thermal insulation;

quantity of material in the container;

date of manufacturing;

supplier’s name;

origin of manufacturing;

destination.

11.0 STORAGE

11.1 The insulation shall be stored in a dry atmosphere under cover and inspected at interval
not exceeding three months.
11.2 Cartons shall be stored end up and be stacked no more than three meters high.

12.0 DRAWINGS

When specific details preclude the use of general insulating practices, the Contractor
shall submit the drawings complete with full details to the OWNER for approval,
indicating the proposed insulation details for piping, vessels, equipment, support rings,
insulation expansion joints, insulation termination points and flashing, and
pipe/equipment supports.