PTS Thermal Insulation

PETRONAS TECHNICAL STANDARDS
Thermal Insulation (Amendments/Supplements to the

Cini Manual)
PTS 15.13.01
November 2015
PTS 15.13.01
THERMAL INSULATION (AMENDMENTS/SUPPLEMENTS TO THE CINI
November 2015
MANUAL)
Page 2 of 44
FOREWORD
PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.
Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.
Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
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specific requirements are not covered in the PTS, it is the responsibility of the
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Contractors/manufacturers/suppliers to propose other proven or internationally established
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standards or practices of the same level of quality and integrity as reflected in the PTS.
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In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
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completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
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ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
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codes and technical standards before start of any work.

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PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
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in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
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consent of PETRONAS.
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The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
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PETRONAS that this requirement is met.

PTS 15.13.01
November 2015
MANUAL)
Page 3 of 44
ANNOUNCEMENT
Please be informed that the entire PTS inventory is currently undergoing transformation exercise from
2013 - 2015 which includes revision to numbering system, format and content. As part of this change,
the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition
to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and where required
make reference to other PTS in its revised numbering to ensure consistency. Users are requested to
refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For
further inquiries, contact PTS administrator at ptshelpdesk@petronas.com.my
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PTS 15.13.01
November 2015
MANUAL)
Page 4 of 44
Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
1.1 SCOPE .............................................................................................................................. 5
1.2 GLOSSARY OF TERMS ...................................................................................................... 5
1.3 SUMMARY OF CHANGES ................................................................................................. 8
2.0 AMENDMENTS / SUPPLEMENTS TO THE CINI MANUAL .......................................... 9
3.0 INSPECTION AND MAINTENANCE OF EXISTING INSULATION SYSTEMS.................. 32
3.1 INSPECTION ................................................................................................................... 32
3.2 MAINTENANCE .............................................................................................................. 35
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4.0 BIBLIOGRAPHY .................................................................................................... 37
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APPENDIX 1: INSPECTION CHECKLIST OF THERMAL INSULATION SYSTEMS ................... 39
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APPENDIX 2: GUIDELINE ON CINI MANUAL VIA DVD ACCESS ........................................... 43
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PTS 15.13.01
November 2015
MANUAL)
Page 5 of 44
1.0 INTRODUCTION
This PTS specifies the minimum requirements and gives recommendations for the external
thermal insulation of above ground surfaces of equipment and piping.
This PTS adopts Commissie Isolatie Nederlandse Industrie (CINI) Manual ‘Insulation for
Industries', with additional requirements as an amendment and supplement based on
PETRONAS lessons learnt and best practices.
1.1 SCOPE
1.1.1 This PTS covers both hot and cold insulation for indoor and outdoor facilities, upstream and
downstream operations.
1.1.2 This PTS is divided into five parts:
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i. Section 1.0 provides the introduction, the scope, outlines the relationship
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between this PTS and the CINI Manual and explain the other parts;
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ii. Section 2.0 gives amendments and supplements to the CINI Manual. For ease of
reference, the clause numbering of the CINI Manual has been used. Clauses of
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the CINI Manual that are not mentioned shall apply as written. Wherever
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reference is made to the CINI Manual it shall be understood to mean the CINI
Manual as amended/supplemented by this PTS;
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iii. Section 3.0 specifies requirements and gives recommendations for inspection
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and maintenance of existing insulation systems that are not covered in the CINI
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Manual;
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iv. Section 4.0 lists the publications referenced in this PTS;

v. Section 5.0 contains the appendices with diagrams, table and drawings.
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1.1.3 This PTS does not cover acoustic insulation. Please refer to PTS 15.13.02 Acoustic Insulation
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for Piping
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1.2 GLOSSARY OF TERMS
1.2.1 General Definition of Terms & Abbreviations
Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS
00.01.03 for General Definition of Terms & Abbreviations.
PTS 15.13.01
November 2015
MANUAL)
Page 6 of 44
1.2.2 Specific Definition of Terms
No Term Definition
1 Acoustic Insulation Insulation installed to reduce the amount of

noise radiated from a surface. Acoustic
insulation is often used in conjunction with hot
and cold insulation.
2 Cold Insulation Insulation used to avoid condensation at the

outer surface and to reduce heat gain for
economic reasons.
3 Condensation Moisture forming at the surface of uninsulated
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or insufficiently insulated piping/equipment
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when the process temperature is below
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ambient. The rate of condensation depends on
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ambient temperature, relative humidity, and
emissivity of bare surface or insulation
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jacketing, wind velocity and process
temperature.
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4 Dual Process Temperature Process temperature cycling between -20oC and

320°C (or lower). Insulation material for this
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duty is normally cellular glass.

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5 Heat Gain Heat ingress from the outside in cold insulation

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systems or heat loss from the inside in hot

insulation systems.
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6 Hot Insulation Insulation used to save energy for economic

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reasons; typically applied for process

temperatures between 70°C and 600°C.
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7 Insulation System Combination of insulation materials and

jacketing designed to achieve the most
economical solution and service life.
8 Metallic Jacketing Jacketing which consists of aluminum,

aluminized steel cladding Type 2 or stainless
steel SS316. The emissivity of these materials is
typically 0.4.
9 Non-Contact Insulation Insulation system in which spacers are used to

avoid contact between bare surfaces of
piping/equipment and the insulation material.
The annular space between insulation material
and bare surface is a non-ventilated space in
PTS 15.13.01
November 2015
MANUAL)
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No Term Definition
which openings or drains are always located at
the lowest point of the piping or equipment.
10 Non-Metallic Jacketing Jacketing consisting of GRE, GRP, polymeric

compound or modified EPDM; often used in
conjunction with a multiplex primary vapour
barrier.
11 Personnel Protection Barrier system consisting of insulation material

or metal screens, to prevent people from
touching hot surfaces (or exceptionally very cold
surfaces) of piping or equipment
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12 Process Insulation Insulation required to avoid freezing, internal
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condensation or solidification, or to control
product viscosity. This type of insulation is often
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used in conjunction with heat tracing
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13 Thermal Insulation Generic term covering hot, cold, process and
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personnel protection insulation.

Table 1: Specific Definition of Terms
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1.2.3 Specific Abbreviations

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No Abbreviation Description
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1 CFC Chlorofluorocarbon
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2 CG Cellular Glass
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3 CUI Corrosion Under Insulation. Five (5) categories

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of CUI are recognized, indicating the severity of

problem; further described in CINI 1.2.04
4 EPDM Flexible Elastomeric Foam EPDM Type
5 ESCC External Stress Corrosion Cracking
6 FEF Flexible Elastomeric Foam
7 GRE Glass-fibre Reinforced Epoxy
8 GRP Glass-fibre Reinforced Polyester
9 GW Glass Wool
10 HFC Hydrofluorocarbon
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MANUAL)
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No Abbreviation Description
11 HT-GF High Temperature Glass Fiber
12 ITP Inspection Test Plan
13 MPS Microporous Silica
14 NDT Non Destructive Testing
15 PEC Pulsed Eddy Current
16 PIR Polyisocyanurate
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17 PL Perlite
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18 PUR Polyurethane
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19 RBI Risk-Based Inspection
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20 RW Rock Wool
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21 S Silica
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22 SS Stainless Steel
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23 UV Ultraviolet
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24 VC Vermiculite
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25 VDI Verbund Deutscher Ingenieure (Association of

German Engineers)
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26 XPS Extruded Polystyrene Foam

Table 2: Specific Abbreviations
1.3 SUMMARY OF CHANGES

This PTS 15.13.01 replaces PTS 30.46.00.31 (December, 2010).
PTS 15.13.01
November 2015
MANUAL)
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2.0 AMENDMENTS / SUPPLEMENTS TO THE CINI MANUAL
In this section, the reference clauses of CINI are amended or supplemented, existing clause is
deleted or new sections are added as mentioned. Clauses of CINI that are not mentioned in
this PTS shall apply and remain valid.
On guidance on accessing the CINI Manual via DVD access, please refer Appendix 2.
CINI 1.2.01 Heat Insulation Diagram

Diagram 1 Add to this clause:
The Heat Insulation Diagram/schematic which provides overview on Insulation

Material, Maximum Temperature, Material Specification, Installation
Specification and Finishing Material and Specifications may be used as
guidance.
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CINI 1.2.02 Cold Insulation Diagram
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Diagram 1 Add to this clause:
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The Cold Insulation Diagram/schematic which provides overview on Insulation
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Material, Minimum Temperature, Material Specification, Installation
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Specification, Finishing Material and Finishing Specifications may be used as

guidance.
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CINI 1.2.04 Operation-temperature versus Corrosion Under Insulation (CUI) risk

Add New Add new clause:
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Clause 2
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The following table summarizes vulnerabilities of CUI from Clause 1:

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Category Vulnerability to CUI* Process Temperature

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1 Extreme Cyclic process temperature between

-20°C to 320°C
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2 High Process temperature between

50°C to 175°C
3 Medium Process temperature between
-5°C to 50°C
4 Low All process temperature > 175°C
5 Low All process temperature < -5°C
Based on the table of vulnerabilities to CUI above, the recommended thermal

insulation systems for piping/equipment/tanks are as follows:
Category System and Material Guidance

1 Two layers of cellular glass shall be applied as minimum.
PTS 15.13.01
November 2015
MANUAL)
Page 10 of 44
A high temperature anti-abrasive compound (based on a

mixture of calcium sulphate hemihydrates and Portland
cement for temperatures up to +320 oC) for the inner side of
the inner layer.
Other suitable compounds may be used for temperatures up

to 250 °C.
The application and system of cellular glass shall be in

accordance with the recommendations of the
Supplier/Manufacturer.
As long as an RBI analysis and/or CUI risk assessment has been

carried out, other insulation systems and materials may be
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used.
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2 As long as an RBI analysis and/or CUI risk assessment has been
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carried out, other insulation systems and materials may be
used. UV curable GRP or aluminised steel or stainless steel
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jacketing are allowed for finishing, as long as they are provided
with sufficient drain holes.
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The use of Calcium Silicate shall be with Owner’s approval.

Compliance to requirements of ASTM documents shall be met
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prior to use:
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ASTM C533 Specification for Calcium Silicate Block and Pipe

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Thermal Insulation.
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ASTM C795 Specification for Thermal Insulation for Use in

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Contact with Austenitic Stainless Steels.

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3 Selection of materials to be used shall be in accordance to

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following criteria:
 Temperature range
 Economics (related pipe diameter)
 Materials life time
 Sufficient drain holes (for aluminised or stainless steel
jacketing)
 Metal jacketing is not recommended to be used for
pipes or tubes with smaller diameters (outside
diameter < 25 mm). In cases where metallic jacketing
is selected, Contractor shall demonstrate that the
jacketing forming and sealing works can be performed
satisfactorily for Owner’s approval.
 Primary vapour barrier is recommended to be used for
temperature lower than the maximum ambient
temperature
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4 Recommended to use rock wool with aluminised steel or

stainless steel jacketing.
5 Recommended to use PUR/PIR with heavy-duty multiplex foil

(20/50/25µ) primary vapour and non-metallic finishing (e.g. UV
curable GRP or weather-proof jacketing). Owner’s approval is
required for other primary vapour barriers.
Based on table of vulnerabilities to CUI, recommended acoustic insulation

systems are as follows:
Category Generic Acoustic Insulation System Description
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1 Not applicable.
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2 As indicated in PTS 15.13.02 (Acoustic Insulation for Piping).
Recommended to use non-contact insulation system and
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aluminized steel or stainless steel jacketing.
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Recommended to use aluminized steel or stainless steel

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jacketing.
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Recommended to use aluminized steel or stainless steel

jacketing.
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5 Recommended to use PUR/PIR system (including primary

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vapour barrier) and remainder as indicated in PTS 15.13.02

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(Acoustic Insulation for Piping).

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A vapour barrier that includes a heavy duty multiplex foil,

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covered with a UV curable GRP shall be provided in between the

acoustic insulation and the jacketing.
CINI 1.3.01 General Requirements for The Thermal Insulation of “Hot” Pipelines and
equipment
1.3 Replace this clause with:
For the corrosion protection of insulated metal surfaces, PTS 15.20.03

Protective Coatings and Linings shall apply.

Clause 1.6
In special situations where a combination of insulation and fireproofing is
required, a combined PUR/PIR with cellular glass insulation system shall be
PTS 15.13.01
November 2015
MANUAL)
Page 12 of 44
applied. In this combination, the cellular glass shall be used as the outer layer
and provided with a vapour barrier.
If justified economically (based on life cycle costs and service life), this
combination may also be used for normal insulation systems.

Clause 1.7
Reference to appropriate clauses in CINI (according to insulation materials
used) should be made for insulated small bore pipes/instrument tubing of
equipment.
Typical suitable insulation materials include glass, rock wool and flexible
elastomeric foam.
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2.1.1 Add to this clause:
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If there is no heat recovery at the end of the line, no insulation shall be applied
to piping or equipment that has been designed to emit heat or where cooling
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is required or acceptable by the process (e.g. piping to air coolers, blow down
systems and condensate return lines).
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The following documentations shall be prepared by Main Contractor and

approved by Owner:
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 Detailed Specification
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 Isometric Drawings
 Line Designation Tables for the Insulation Contractor
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Main Contractor shall make the following information available in the Line
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Designation Table:
 Operating temperature
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 Type of insulation
 Economic insulation thickness
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For items that are not covered in CINI Manual and this PTS, a detailed design
of insulation system shall be carried out by the Main Contractor and approved
by the Owner.
For new construction and maintenance project, the Insulation Contractor shall
supply the following items unless otherwise specified by the Owner:
 Insulation materials
 Jacketing materials
 Fastening materials
All insulation system and materials selected shall comply with this PTS. Any
deviation or alternative system proposed by Insulation Contractor shall be
subjected to Owner’s approval. The applications shall be supported by
references (e.g. track records) and qualified laboratory’s test certificates
and/or test report.
PTS 15.13.01
November 2015
MANUAL)
Page 13 of 44
Insulation Contractor shall also submit the following documentations for the
execution of work:
 Execution Plan
 Materials List
 Manpower’s Skills Record
 QA/QC procedure
An ITP (Inspection Test Plan) indicating all phases for test and inspection
activities of the insulation system shall be submitted and approved by the
Owner.

Clause
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2.1.6 All items such as valves, flanges and nozzle shall be insulated, unless other
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requirements are overruling such as:
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 Flanges in hydrogen service shall not be insulated;
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 Flanges in system containing hydrocarbons above their auto-ignition
temperature shall not be insulated;
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 Uninsulated components in accordance with ASME B31.3 Section
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301.3.2 or PTS 18.54.09 Fire-Fighting Vehicles And Fire Stations

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Removable insulation covers shall be provided for valves and flanges in piping
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system.
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2.2.1 Replace this clause with:

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Each line should be insulated separately; a common insulation cover should

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not enclose adjacent lines in accordance with the installation instructions and
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finishing details. Any deviations shall be shown on the piping drawings and
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approved by the Owner.

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Following are the additional methods that may be applied if insulation is

necessary e.g. for steam and gas turbine and boiler feed water pumps or
electric traced cooling system:
 Insulating blankets applied over the housing, stitched together with
binding wire and covered with aluminised steel cladding.
 Removable insulation mats or mattresses with glass fibre fabric finish,
tailor made over the housing and fixed by lacing.
 A removable metal box reinforced with angle iron and filled with loose
insulation materials. Refer to CINI 4.6.01 for a typical removable
insulation cover for pumps.
 Insulation with e.g. sealed rope or flexible cell rubber (e.g. FEF or EPDM
foam) around small-bore tubing.
No insulation shall be applied on pump handling liquid hydrocarbon products.

PTS 15.13.01
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MANUAL)
Page 14 of 44
Non-contact insulation is also used for acoustic insulation system, if hot

insulation is not required.
Requirements of the CINI 1.3.22, CINI 4.1.34 and CINI 4.2.18 shall be complied
with for Non-contact insulation.
2.3.3.1 Add to this clause:
Bellows insulation design shall be submitted by the Main Contractor for

approval by the Owner.
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A minimum number of layers based on commercially available thickness shall
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be applied to hot insulation. The total thickness shall be as close as possible to
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the economic insulation thickness. The thickness shall be rounded off to the
upper commercially available thickness.
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3.1 Add to this clause:
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The following materials shall be applied for hot insulation(1):

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Materials for CINI Temperature and Category

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Hot Insulation Specifications

Tab 2
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Rock Wool Tab 2 Application for product temperatures

Products(2) CINI 2.2.01 to
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between 80°C and 600°C and

CINI 2.2.06 prefabricated section or slabs should
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be used. If not available, blankets may

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be used. Approval shall in this case be

obtained from the Owner. Rock wool
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shall also be used in conjunction with

non-contact insulation systems and
acoustic insulation systems. Suitable
insulation material for categories 2, 4
and 5.
Cellular Glass Tab 2 Application for product temperatures <
CINI 2.9.01 427 °C, as fire protection in conjunction
with other insulation materials and as
collars to avoid water/product ingress
and capillary action. Suitable for
categories 1, 3 (in conjunction with
electrical tracing), 4 and 6 (for passive fire
protection)
Flexible Tab 2 In general for insulation of small bore
Elastomeric CINI 2.3.01 piping and appendages of
Foam pump/compressor skids and the like,
PTS 15.13.01
November 2015
MANUAL)
Page 15 of 44
but also for larger pipe diameters.

Subject to economic considerations.
Limited temperature range.
Application shall be considered for
category 3 and part of category 2.
Note:
(1) Other insulation materials from CINI Manual may be used, as long as they do not increase corrosion
rate and potential in piping and/or equipment. Approval from the Owner shall be obtained prior to
usage of these materials.
(2) Depending on the type of resin used as binder in rock wool materials, an initial temperature increase
rate during the start-up of the unit shall not be more than 50°C/h, in order to avoid auto-ignition
reactions of the resin. During the design, the start-up conditions shall be verified to avoid breaching
this limit.
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Galvanised (per CINI 3.1.04) or aluzinc sheeting (per CINI 3.1.03) shall not be
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used.
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For aluminum sheeting CINI 3.1.01 shall apply.
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In areas with potential fire hazards and passive fire protection is required, only
aluminised steel type II or stainless steel sheeting shall be used.
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No combustible materials shall be applied on the metal jacketing.

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Removable covers for flanges, valves etc. shall be made of 1.0 mm thick sheets,
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irrespective of the type of material. For covers smaller than diameter 600mm,
0.8 mm thick sheet shall be used.
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The choice of the cladding material shall be based on a design life of 20 years,
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taking into account environmental and climate conditions.

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For SS 316 the following minimum thickness may be adopted:

 Outside diameter insulation < 140 mm: 0.4 mm
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 Outside diameter insulation 140 - 300 mm: 0.5 mm

 Outside diameter insulation in > 300mm: 0.6 mm
CINI 3.2.01 and CINI 3.2.11 only shall apply.

Clarification: Other cited specifications may be omitted as they are seldom
used.
Nameplates, identification plates, stampings, reference and measuring points

shall remain visible and clear of insulation or shall be fitted on the outside of
the jacketing at all time. Discharge and air relief valves shall remain operable.
The edges of the recesses shall have a weatherproof finish, as per CINI 4.2.16
and CINI 4.3.04. Alternatively, Main Contractor shall propose other designs
PTS 15.13.01
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which prevents condensation and heat losses. Such design shall be approved
by the Owner.
Minimum spacing shall be 50 mm between the thermal and/or acoustic

insulation finishing (e.g. cladding) and the adjacent surfaces (see also CINI
1.3.01 paragraph 2.3.1.2).
The covers/boxes shall be made in halves from metal sheets, provided with
rigid insulation slabs or proper fixed blankets and secured by hinges and quick-
release toggles, self-tapping screws or removable strapping bands.
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The rigid insulating material shall be fixed by clips or metal strips riveted to the
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inside of the metal cover. Blankets shall be properly fixed with straps or wires.
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Overlapping edges of the box shall be furrowed and be installed so as to shed
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rainwater. The thickness of insulation over the flanges should be of the same
thickness as the insulation over the pipe, with a minimum of 25 mm.
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Alternatively, Cellular Glass shall be applied near flanges in order to prevent

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flammable product from entering the insulation system. For special cases,
alternative solutions shall be submitted for Owner approval e.g. welded collars
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or insulation cement applications.

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Clause 4.1.11
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All covers subject to frequent removal e.g. inspection ports on heat

exchangers, pressure vessels, tanks, manholes, shall be provided with a box
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made of metal sheets, lined with insulation slabs having the same thickness as
of that of the vessel insulation.
Each box shall be made of one or more pieces, each piece being of such size
and shape that two persons can easily handle it. Securing in position shall be
done by quick-release toggles, see Tab 4, CINI 4.4.02.
4.4.1 Change this clause with:
Delete “For hot dip galvanized cladding, hot dip galvanized self-tapping screw
or blind rivets shall be used.”
Please refer to CINI 3.1.01 (with addition to the clause provided by this PTS)
for prohibition of aluminum sheets as finishing materials for Heat insulation in
fire protection conditions and CINI 9.2.02 supplemented by clause 3.3.5 (new
clause added by this PTS) for acoustic insulation on SS Piping.
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In order to reduce heat losses, insulation shall be applied in two or more layers
with staggered joints. For pre-formed rigid insulation, circumferential joints
shall be in staggered in between segments of the adjacent lengths.
4.4.8 Change this clause with:
Delete: “a cord of flexible elastomeric or silicone compound.”, and add:

“sufficient UV curable GRP wrapping material (see Tab 3 - CINI 3.2.11)”.
(Example: Especially horizontal elbows are vulnerable. Often they will be
damaged and water can easily penetrate. The topside should therefore always
be covered by UV curable GRP or similar non-metallic material.
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Prefabricated sections/segments of insulation material, provided with UV
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curable GRP are allowed. Special UV curable GRP tape shall be used to seal the
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joints. The application shall be as described for the finishing of UV curable GRP
sheets (see CINI 1.3.60).
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CINI 1.3.02.1 General Requirements for The Thermal Insulation of “Cold” Pipeline and
Equipment
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1.4 Replace this clause with:

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For the corrosion protection of insulated metal surfaces, PTS 15.20.03

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Protective Coatings and Linings shall apply.

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…the latest edition of the CINI Manual and the latest edition of this PTS shall
be available.
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Clause 1.7
In special situations where a combination of insulation and fireproofing is
required, a combined PUR/PIR with cellular glass insulation system shall be
applied. In this combination, the cellular glass shall be used as the outer layer
and provided with a vapour barrier.
If justified economically (based on life cycle costs and service life), this
combination may also be used for normal insulation systems.

Clause 1.8
Reference to appropriate clauses in CINI (according to insulation materials
used) shall be made for insulated small bore pipes/instrument tubing of
equipment.
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Typical materials for cold insulation may include cellular glass and flexible
elastomeric foam.
The following documentations shall be prepared by the Main Contractor and

approved by the Owner:
 Detailed Specification
 Isometric Drawings
 Line Designation Tables for the Insulation Contractor
The Main Contractor shall make the following information available in the Line
Designation Table:
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 Operating temperature
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 Type of insulation
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 Economic insulation thickness
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For items that are not covered in CINI Manual and this PTS, a detailed design
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of insulation system shall be carried out by the Main Contractor and approved
by the Owner.
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For new construction and maintenance project, the Insulation Contractor shall
supply the following items unless otherwise specified by the Owner:
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 Insulation materials
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 Jacketing materials
 Fastening materials
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All insulation system and materials selected shall comply with this PTS. Any
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deviation or alternatives system proposed by the Insulation Contractor shall

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be subjected to Owner’s approval. The applications shall be supported by

references (e.g. track records) and qualified laboratory’s test certificates
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and/or test report.
Insulation Contractor shall also submit the following documentations for the
execution of the work:
 Execution Plan
 Materials List
 Manpower’s Skills Record
 QA/QC procedure
An ITP (Inspection Test Plan) indicating all phases for test and inspection
activities of the insulation system shall be submitted and approved by the
Owner.
2.2.1 Add to this section:
For cold services, the following insulation materials shall be applied:

 Polyisocyanurate (PIR) Foam (see Tab 2 - CINI 2.7.01) or Polyurethane
PTS 15.13.01
November 2015
MANUAL)
Page 19 of 44
(PUR) Foam (see Tab 2 – CINI 2.7.02)

 Cellular Glass (see Tab 2 - CINI 2.9.01) and only in conjunction with
PIR/PUR
 For small bore pipe FEF or EPDM foam (depending on process
temperature and related properties of FEF and EPDM foam)
Other insulation materials shall require the Owner’s approval.
Metal cladding shall only be applied if approved by the Owner. Preference

shall be given for the application of UV curable GRP. If metal cladding is
allowed, a space of 25 mm between primary vapour barrier and cladding shall
y
be provided with sufficient drain holes (diameter 20 mm). For spacers, FEF or
nl
EPDM foam or “polyethylene burls foil” material shall be used.
O
se
lU
The supports shall also be designed to withstand all service loads as follows:
 Thermal stress from differential contraction of the foam and the pipe
na
 Thermal stress from temperature gradient through insulation

er
thickness, clamping forces, mechanical loads from the piping system

 Other loading that may be present at the support
nt
-I
Vertical and horizontal loads (mechanical loads) can be obtained from pipe
support drawing (e.g. isometric drawings).
AS

N
O
Fire-retardant vapour barrier mastic shall be used to coat all exposed cut
TR
surfaces of the PUR/PIR in order to protect the foam during the period of
installation and line insulation application. Refer to CINI Manual 5.1.09 for
PE
typical pipe support finishing details.

Clause
2.3.2.10 The Main Contractor shall submit a proposal which covers all related
requirement such as thermal conductivity, mechanical properties, stresses,
tolerances, etc.; supported by following documentations for Owner’s
approval:
 Data sheets
 Test certificates
 Calculations
 Methods statements of installation
The test results of mechanical and corrosion properties shall be submitted to

PTS 15.13.01
November 2015
MANUAL)
Page 20 of 44
Owner to verify the suitability of service loads, the thermal stresses, and
compatibility with other materials and the environment.
3.2.1 Delete this clause.

Clause 3.2.4
CINI clauses 3.2.2 and 3.2.3 shall be used for repair and/or maintenance of
existing cold insulation system only. For new cold insulation systems the
primary vapour barrier shall consist of multiplex foil, factory applied and
complies with the material specification of CINI 3.3.10 (Tab 3). The field
seams shall be tapped together with a minimum overlap of 50mm in
accordance with the material specification of CINI 3.3.11 (Tab 3). The non-
metallic jacketing finishing shall fully encompass and protect the primary
y
vapour barrier.
nl
O
se
Metal jacketing shall only be used if indicated by the Owner and if passive fire
lU
protection is required.
na
The design life of the jacketing shall be 20 years.

er
nt
The composition of Stainless Steel 316 cladding shall be in accordance with

ASTM A 240/A 240M.
-I
AS
Claddings in Aluzinc (CINI 3.1.03) and Hot Dip Galvanized Steel (CINI 3.1.04)
shall not be applied.
N
O
If metal finishing is to be applied, the following shall be applicable:

 Removable covers for flanges, valves etc. shall be made of 0.8 mm thick
TR
sheets.
PE
 Corrugated (wave type) SS 316 shall be used with a pitch between 75

and 85 mm, and a height between 18 and 30 mm for equipment/large
vertical piping (> 24”).
If passive fire protection (fireproofing) is required, stainless steel 316 metal

finishing shall be used in conjunction with PIR/PUR and Cellular Glass, as
indicated in clause 1.7 above (new clause added by this PTS).
Galvanised cladding shall not be used.
Nameplates, identification plates, stampings, reference and measuring points

PTS 15.13.01
November 2015
MANUAL)
Page 21 of 44
shall remain visible and clear of insulation or shall be fitted on the outside of
the jacketing at all time. Discharge and air relief valves shall remain operable.
The edges of the recesses shall have a weatherproof finish, as per CINI 4.2.16
and CINI 4.3.04. Alternatively, Main Contractor shall propose other designs
which prevents condensation and heat losses. Such design shall be approved
by the Owner.
The Insulation Contractor shall make detail drawings for the application of
non-metallic jacketing systems combined with contraction joints.

Clause
y
4.4.3 CINI clauses 4.4.1 and 4.4.2 shall be used for repair and/or maintenance of
nl
existing cold insulation systems only. For new cold insulation systems, the
O
primary vapour barrier shall consist of factory-applied multiplex foil and
se
comply with the material specification of CINI 3.3.10 (Tab 3). The field seams
shall be tapped together with a minimum overlap of 50 mm in accordance
lU
with the material specification of CINI 3.3.11. The non-metallic jacketing
finishing shall fully encompass and protect the primary vapour barrier.
na
er
General requirements for the thermal insulation of “hot” pipelines, fittings and
CINI 1.3.03
equipment with mattresses.
nt

-I
The use of mattresses shall require Owner’s approval.

AS

N
O
The use of glass wool shall require Owner’s approval.

TR
CINI 1.3.04 General requirements for the thermal insulation of “hot” storage tanks
PE
If special structures are required, the Main Contractor shall be responsible for
the design of such special structures.
Approval of the commercially available tank insulation systems shall require

Owner’s approval.
Insulation on tank roofs are not usually provided for temperatures up to 120°C.
At this temperature, they are vulnerable to water ingress and CUI. Requirement
for insulation may be due to process reasons.
PTS 15.13.01
November 2015
MANUAL)
Page 22 of 44
For insulated tank roofs, the mechanical design shall anticipate all insulation
requirements as in CINI and this PTS.
Personnel protection shall be installed on accessible areas tank roofs where the
calculated metal temperature is greater than 70°C.

Clause 2.2.2.4
Sprayed rigid polyurethane foam (PUR/PIR) for tanks
Sprayed PUR/PIR is for use on tank shells with operating temperatures

between ambient and 90°C. The insulation shall be sprayed on a painted
surface that is compatible with the sprayed PUR/PIR.
y
At the time of application, the temperature of the liquid foam components
nl
shall be between 15°C and 25°C. During spraying, the surface temperature to
O
be insulated shall be between 20°C and 40°C.
se
No application of the insulation shall be performed during rain or when the
lU
wind speed is above 5 m/s.
na
PUR/PIR shall not be applied if the weather conditions are outside the limits
er
specified by the supplier. Temporary weather protection and a heater shall be

nt
used, if necessary. Over-spray shall be minimized.

-I
The thickness requirements for PUR/PIR are as follows:

AS
 Each layer of PUR/PIR shall be 15mm thick maximum until the

specified thickness is obtained.
N
O
 The minimum final insulation thickness of PUR/PIR shall be 25 mm.

TR
 The average thickness the PUR/PIR layer on the tank surface shall
PE
be between 5 and 10 mm above the specified final thickness. The

final thickness shall be measured using a non-destructive
instrument.
The insulation shall end at a sufficient height above the tank base to prevent
contact between ground water and insulation, e.g. after rainfall.
Provisions shall be made to enable the removal of the insulation from parts
which have to remain accessible or remain free of contamination, e.g.
staircases, railings, manholes, gauge glasses or other accessories which shall
temporarily be covered with plastic foil.
The insulation shall be made smooth and properly sealed, including the seams
where supports, nozzles, stair steps, etc. protrude through the insulation.
Junctions between permanent and removable insulation shall be properly
sealed against ingress of moisture.
PTS 15.13.01
November 2015
MANUAL)
Page 23 of 44
PUR/PIR used on tank roofs and shells shall be protected against ultraviolet
radiation and weather conditions by applying an elastomeric coating of
acrylate polymers.
Sprayed PUR/PIR without metal sheet covering shall not be used on roofs of
tanks since damage to the PUR/PIR will cause severe corrosion of the roof
plates. However, special “proprietary tank roof insulation systems” containing
PUR/PIR that are free from these effects may be acceptable. Owner’s approval
shall be obtained prior to use.
CINI 1.3.05 Quality Control of Insulation Systems

Section 2 Amend first sentence of this section as follows:
y
Change ISO 9000 to ISO 9001.
nl
O
Add to this section:
se
Facilities for the inspection of all materials and application procedures shall be
lU
provided by the Main Contractor before, during the insulation work and up to
the contractual completion date.
na
er

nt
Test of materials shall be performed at both the supplier’s works and at arrival
-I
on site.
AS
Should the material be delivered in multiple production batches, one

laboratory test shall be performed at both the Manufacturer’s works and at
N
arrival on site. The test results shall be submitted to Owner for approval.
O
TR
For all other batches a “Compliance Certificate” shall be submitted certifying

that the materials are in accordance with the project technical specifications.
PE
Each batch used on site shall be clearly marked to allow rapid tracing of the
origin of the supply should discrepancies be detected.
3.1.2 Replace the final paragraph of this clause with the following:
The insulation shall not be installed prior to receiving Owner’s approval,

including:
 Surfaces: Surfaces have been applied with specified coating, is

clean and dry. In coastal areas, the surfaces should be washed
with fresh water to remove salt deposits and shall be dried.
 Hangers/Supports: The hangers and supports are of the correct

size and properly located according to the specifications. All
PTS 15.13.01
November 2015
MANUAL)
Page 24 of 44
supports, anchors, guides or hangers on low temperature piping

shall be free from obstructions to allow sufficient space for
support insulation application and condensation control
treatment, and normal expansion and contraction of the system.
 Expansion/Contraction joints: All positions for installation of the

expansion/contraction joints in the insulation clearly defined and
marked.
 Clearances: Sufficient accessibility and clearance are provided for

both the insulation thickness to be applied and the space
necessary for workmen to apply it.
y
nl
 Electrical tracing stations/hangers: Sufficient protection against
O
water ingress are provided (e.g. water deflectors, etc.).
se
lU
Clause 3.1.3.1
3.1.3.1 Inspection procedure for in-situ moulded / dispensed PUR
na
er
Foam injection shall be done only after the application procedure for each unit
to be insulated has been reviewed and approved by the Owner.
nt
-I
The Main Contractor shall draw up the ITP and the inspection procedure shall
AS
be established for each pipe/spool in order to assess the step-by-step

inspection status on a continuous basis.
N
O
The inspection procedure shall include but not limited to the following tests,
documented in appropriate data sheets and performed daily:
TR
 For each machine and before the start of dispensing work, a sample
PE
shall be made in a closed mould to simulate conditions in practice.

Each sample shall be examined for density, closed cell content,
thermal conductivity and visual appearance. Samples shall be
tested in accordance with clause 3.1.5 (new clause) of this PTS.
 Machine foaming test in free expansion to ensure compliance to

specifications.
 Measuring and recording of all data such as:

 Ambient temperature;
 Relative humidity;
 Operating and re-circulation pressures for the pouring machines.
 Inspection of the cavities to be injected for the following:

PTS 15.13.01
November 2015
MANUAL)
Page 25 of 44
 Temperature;
 Humidity / water pockets;
 Accessibility;
 Properly placed pouring and vent holes.
 Inspection of the foamed cavities by examination of the quantity

and quality of the foam escaping from the de-aeration, drain and
injection holes.
 Daily checks by taking samples. On these samples the compressive

strength shall also be tested.
Injection control data sheets shall be maintained for all insulated pipes/spools
y
nl
to record all operating and material data for easy cross-reference in case of
failure.
O
se
All samples shall be numbered to ensure full traceability and shall be stored by
the Insulation Contractor under such conditions that they remain suitable for
lU
further testing if necessary, until all dispensing work has been completed.
na
Test results shall be submitted weekly.

er
nt

Clause 3.1.5
-I
Requirements of the CINI Manual and in particular CINI 1.3.05 shall be

AS
complied with by the Insulation Contractor.

N
During detailed design, a validation scheme of test certificates shall be

O
determined which shall be part of the Inspection Test Plan (ITP).

TR
The Insulation Contractor shall comply with the requirements of the CINI
PE
Manual for In-Situ Moulded/Dispensed PUR or sprayed PUR.
All defective materials shall be replaced in case of non-conformance and

removed from the worksite.
Add New Add new section:

Section 5
Section 5: Removal and Disposal of Insulation Materials
Insulation materials (including auxiliary/ancillary materials), their application

and the disposal of waste or surplus materials and containers shall comply with
applicable national and local regulations for health, safety and environment.
Materials that can be re-used shall be removed carefully and stored in a proper
place. Reuse of materials shall require Owner’s approval.
Past insulation materials may contain asbestos. Where presence of asbestos is

PTS 15.13.01
November 2015
MANUAL)
Page 26 of 44
suspected, material tests shall be performed to confirm presence of asbestos

prior to stripping of insulation. PETRONAS HSE Guide "Asbestos" and any
national or local regulations shall be consulted.
For the disposal of waste materials, including asbestos, reference shall also be
made to the PETRONAS HSE Guide “Waste Management" and any national or
local regulations.
CINI 1.3.10 Mineral Wool (GW) (RW)

Use of glass wool shall require Owner’s approval.
y
nl
The blankets shall be installed with the wire mesh on the outside.
O
se
lU
If there are two or more layers of different thickness, the thicker layer shall be
applied on the inside.
na
er

nt
Removable insulation covers with insulation wool on the inside fastened with
-I
clips shall be provided to hot insulation for the following items:

 Valves
AS
 Flanges
N
 Fittings
O
 Equipment dome heads

TR
If frequent removal is required, covers with locked quick-release toggles shall

PE
be provided. Quick-release toggles shall not be installed on overhead lines

above walkways.
Alternatively, for any complicated configurations, the use of mattresses may

be suitable if sufficient control to prevent water ingress has been performed.
Owner may consider to use proprietary designed mattress jackets with quick
release toggles. Refer to CINI 4.2.1 for insulation mattress production drawings
set up.
Provision for drainage outlets shall be made to give visible indication of

possible valve or flange leakage.
Galvanizing wire and hooks shall not be used. Only stainless steel or aluminised
PTS 15.13.01
November 2015
MANUAL)
Page 27 of 44
steel wire and hooks shall be used.
The bands shall be equipped with expansion elements (springs) to compensate

for equipment expansion.
CINI 1.3.11 Flexible Elastomeric Foam (FEF+EPDM)

…and shall be used for small-bore piping. For normal piping/equipment,

approval from Owner shall be required.
CINI 1.3.14 Vermiculite (VC)
y
1 Add to this clause:
nl
O
Approval from the Owner shall be required prior to usage of this material.
se
CINI 1.3.15 High Temperature Glass Fiber (HT-GF)
lU
na
er
CINI 1.3.18 Perlite (PL)

nt

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AS
CINI 1.3.19 Personnel Protection

N

O
TR
Metal screens or fencing for cold service shall be designed and provided by the
Main Contractor for Owner’s approval and record.
PE
CINI 1.3.20 Microporous Silica (MPS)

CINI 1.3.21 Silica (S)

CINI 1.3.52 Extruded Polystyrene Foam (XPS)

General Delete this section.
CINI 1.3.53 Polyisocyanurate Foam (PIR)

1 Change this clause with:
PTS 15.13.01
November 2015
MANUAL)
Page 28 of 44
Delete “CINI Spec. No. 3.2.02, 3.2.03, 3.3.06 and 0” and replace with “CINI
3.3.10, 3.3.11 and 3.2.11”.
Note: The above change concerns the primary vapour barrier and finishing
jacketing. This vapour barrier shall be made of multiplex foil of which the
seams are tapped with multiplex foil. The finishing shall be UV curable GRP.
Other non-metallic finishing systems shall have the approval of Owner.

Clause
2.1.15 All CS parts shall be coated per PTS 15.20.03 (Protective Coating and Linings).
Synthetic membrane shall be used to avoid potential of galvanic corrosion due
y
to any contact of different metals.
nl
O
se
Preference shall be given to system 1. For system 2, approval from the Owner
lU
shall be required.
na
CINI 1.3.54 Cellular Glass (CG)

er
1 Change this clause with:

nt
Delete “CINI Spec. No. 0 – Weather resistant mastic” and replace with “CINI
-I
3.2.11”.
AS
Note: The above change concerns the finishing jacketing of CG passive fire
protection. The finishing shall be UV curable GRP or a polymeric compound,
N
covered by corrugated or flat stainless steel 316 cladding.

O
TR
CINI 2.7.01 Polyisocyanurate (PIR) Slabs, Sections and Segments for Thermal Insulation
of Piping and Equipment
PE
All insulation materials shall comply with PETRONAS HSE requirements; it shall
be free from asbestos. In reference to PTS 18.72.10, no CFCs or HFC C141-b
shall be used in the production of PUR/PIR foam materials.
CINI 2.7.02 Polyurethane (PUR) rigid spray/pour foam for injection and in situ foaming
in thermal insulation systems on piping and equipment
1 GENERAL Add this clause:
Reference is made to EN 13941 and EN 253 on In-Situ Moulded/Dispensed

PUR/PIR and Shop Application of Sprayed PUR/PIR Pre-Insulated Pipe.
Longitudinal contraction joints and fixed point shall be designed to avoid gaps
due to contraction differential between pipe/equipment and PUR/PIR.
PTS 15.13.01
November 2015
MANUAL)
Page 29 of 44
CINI 2.25.01 Auxiliary materials for the application of hot insulating materials
2.7 For Self-tapping screws, change this clause as follows:
Delete the words: ”aluminum or galvanized steel”
2.8 For Blind rivets, change this clause as follows:
Delete the words: ”aluminum or galvanized steel”
CINI 3.1.01 Aluminum Sheet / Bands

Add to this clause:
Aluminum sheets shall not be used as metallic jacketing for passive fire
protection of piping/equipment.
y
nl
For Thermal Insulation on “cold” pipelines and equipment requiring passive
O
fire protection or near potential fire hazard, refer to CINI 1.3.02.1 paragraph
se
2.2.1.6 and 3.5.2 (supplemented by this PTS) for allowed metallic jacketing in
fire protection zone. lU
CINI 3.1.05 Stainless steel sheet
na
2 Change the clause as follows:

er
SS 304 may be used for onshore application while SS 316 shall be used for
nt
offshore applications.
-I
CINI 3.2.11 Weather resistant UV-curing glass-fibre reinforced polyester (GRP)

AS

N
The material may also be used as tape. The adhesive properties shall be similar
O
to or better than the properties given in CINI 3.3.11.

TR
CINI 6.1.01 Thermal Insulation Calculations

PE
Computer software programs shall be used to determine the economic

insulation thickness for new construction projects and major
rejuvenation/maintenance works. Other standards, if specified by Owner such
as VDI 2055, shall be used to calculate the contribution of convection.
Following shall be the basis to calculate thickness of hot insulation:

 Local data on insulation
 Energy costs
 Capital charge factor
If the allowable temperature drop is limited, e.g. to avoid condensation,

PTS 15.13.01
November 2015
MANUAL)
Page 30 of 44
solidification, etc., due to process reasons; the required insulation thickness

shall be calculated separately. Nevertheless, the thickness should not be less
than the economic insulation thickness.
Following shall be the basis to calculate thickness of cold insulation:

 The heat gain (heat ingress) for piping in off-plot areas shall be
determined by the Owner. If information is not available the heat gain
(heat ingress) shall be assumed not to exceed 25 W/m2. Solar radiation
shall be taken into account.
 Parameters such as ambient temperature, wind velocity and relative
humidity shall be determined from historical local weather data to
avoid surface condensation.
y
nl
A report shall be made available demonstrating the design parameters
O
necessary to arrive at an economically and technically acceptable design. The
se
report shall be subjected to the Owner’s approval.
lU
na
The following input data shall be used in conjunction with software

er
calculations and shall be subjected to the Owner’s approval.

nt
8.1 Add the following note below the table:

-I
Note: The Economic Insulation Thickness is applicable with the agreement

AS
between the manufacturer and purchaser.

N
O
CINI 7.2.01 Corrosion Protection Under Insulation

TR
3 Replace this clause with:

PE
All steel surface shall be suitably painted with a paint system in accordance
with PTS 15.20.03 (Protective Coatings and Lining) as applicable.
CINI 9.2.02 General Requirement for Acoustic Insulation of Hot and Cold Piping and
Equipment
For all thermal and acoustic insulation systems, detailed designs shall be
produced to cover the following areas:
 Prevention of Corrosion Under Insulation (CUI)
 Economic Insulation Thickness (minimum heat ingress or loss)
 Compliance with safety requirements (Personnel Protection)
 Compliance with process conditions
 Design life of 20 years (or shorter if indicated by the Owner). Life cycle
cost calculations shall be carried out until the lowest cost; based on the
design life of 20 years
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November 2015
MANUAL)
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 Acoustic insulation system shall comply with PTS 15.13.02 (Acoustic

Insulation for Piping)
The thermal insulation and acoustic insulation systems for piping, tanks and
equipment shall be minimized and able to cope with thermal expansion or
contraction. The insulation and jacketing shall be designed to allow expansion
or contraction. Finishing of an expansion-/contraction joints shall be enclosed
like a flange box.
Aluminum sheet shall not be used for acoustic insulation on SS piping.
y
nl
Galvanized and Aluzinc steels shall not be used.
O
se
Usage of aluminized steel sheet Type 1 shall be subjected to Owner’s approval.
lU
na
er
nt
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AS
N
O
TR
PE
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MANUAL)
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3.0 INSPECTION AND MAINTENANCE OF EXISTING INSULATION SYSTEMS
This part specifies the requirements and gives the recommendations for inspection and
maintenance of existing insulation system that are not covered in the CINI Manual.
3.1 INSPECTION
3.1.1 Purpose of Inspection
To detect shortcomings at the earliest possible time in order to prevent uncontrolled

deterioration of the insulation system which leads to CUI and External Stress Corrosion
Cracking (ESCC).
3.1.2 Inspection Techniques
y
nl
Refer to CINI 1.3.05 Section 4.3 Inspection Techniques.
O
Visual inspection is an important method in detecting damage on insulation systems, although
se
only full insulation removal can give the highest level of certainty. Removal of insulation for
visual inspection of CUI can be effective if supplemented by other methods such as infrared
lU
thermography, pulsed eddy current (PEC), conventional gamma radiography, flash
na
radiography (X-ray), real time radiography and neutron backscatter.

er
Thermography using an infrared camera can reveal hot or cold spots on the insulation. This
nt
method is a useful for screening suspect locations through inference of moisture presence in
insulation due to damage to insulation materials and jacketing. The technique can also be used
-I
when the insulation materials is suspected to have experienced wetting. However, this
AS
technique shall be performed under approved guidelines and by qualified and experienced
personnel.
N
O
PEC can be used for screening of corrosion under insulation (CUI) via measurement of the
TR
average remaining wall thickness of ferromagnetic materials under the insulation. Direct
current is sent through an induction coil system (transmitter), which causes stable magnetic
PE
field in pipe or equipment wall. When current is switched off, magnetic field drops to zero
consequently inducing eddy current within the material. The duration of eddy current is
directly related to the remaining wall thickness of the material. However, PEC method has the
following restrictions:
i. The method is not suitable at or close to protrusions/nozzles of piping and

equipment.
ii. Only suitable for insulated systems installed with non-ferromagnetic metal
cladding (such as aluminum) and non-metallic jacketing.
iii. Not suitable for insulation materials installed with wire mesh.
For piping (particularly long straight portions) and small diameter vessels, guided wave
ultrasonic technique may be applied for detection of wall loss. A probe ring is used to transmit
guided waves through the pipe in both directions.
PTS 15.13.01
November 2015
MANUAL)
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Flash radiography has proven to be a quick and effective method of assessing the external
condition of piping under insulation.
Neutron Backscatter method can be used for moisture detection. A radioactive source emits
high-energy neutrons into the insulation. The hydrogen nuclei from the moisture present in
the insulation will attenuate the energy of the neutrons and detected by the instrument. The
count displayed by the instrument is proportional to the amount of water in the insulation
where high counts per time period indicate higher moisture presence.
Moisture in insulation may also be checked by means of drilling a hole in the jacketing and the
use of a moisture-measuring probe.
ESCC may be detected by performing screening of locations followed by stripping of insulation

and performance of dye penetrant or eddy current testing. With presence of chlorides,
suspected locations as crack initiation points include welds and bottom of pitting. Any relevant
y
indications shall be further inspected using UT method.
nl
O
3.1.3 Inspection Methods and Frequency
se
Refer to CINI 1.3.05 Section 4.5 Inspection Methods and Section 4.6 Inspection Frequency.
lU
In summary, insulation inspection can be performed through the following methods:
na
No. Inspection Method Performed by Frequency

er
1 Survey: Inspector, operations Daily or during each time

nt
Visual checks during daily technicians, maintenance personnel enters plant

-I
walkabouts in the plant technicians or contractors

2 Visual/Physical Inspector, maintenance  After every maintenance
AS
Inspection: supervisor or contractors activity

More thorough checks
 Before shutdowns for
N
against indications of
repair workscoping
O
leaks and damage,

TR
visually or with aid of NDT  After shutdowns for

per 3.1.2 surveillance to ensure
PE
proper reinstallation and

no damage from work at
adjacent areas
3 Detail Inspection and Inspector, maintenance As required after performing
Repair: supervisor and Visual/Physical Inspection
As required after possible contractors.
CUI or damage locations
are identified from
Visual/Physical Inspection
Appendix 1 provides a sample of insulation inspection checklist and an example of recorded

data for thermal insulation inspection.
3.1.4 Inspection Programme

Refer CINI 1.3.05 Section 4.5 Inspection Methods and 7.2.01 Section 4 CUI Inspection Strategy.
PTS 15.13.01
November 2015
MANUAL)
Page 34 of 44
The insulation inspection programme shall be driven by the Risk Based Inspection (RBI)
analysis and planned in the maintenance management system. For PETRONAS RBI, refer PTS
15.40.01 PETRONAS Risk-Based Inspection (PRBI).
3.1.5 Items to be Inspected

The integrity of the weather protection and vapour barrier and the thickness of the insulating
material are of prime importance and inspection is therefore required.
In addition to CINI 1.3.05 the following are considered:

i. CUI susceptibility is for equipment and piping operating within temperature range
of:
a) -20°C and +175°C (-5°F and +350°F) for carbon and low alloy steels
y
(CINI)
nl
b) 140oF (60°C) and 400oF (205°C) for austenitic stainless steels and duplex
O
stainless steels (API 571)
se
c) -20°C and + 320°C (-5°F and +610°F) for cyclic process (CINI)
lU
ii. ESCC susceptibility is for equipment and piping which is unprotected under the
insulation, made of austenitic or duplex stainless steel and operates in the
na
temperature range of 50°C – 175°C (120°F – 350°F) (CINI).

er
iii. Checks required for the following locations and instances:

nt
-I
a) Sagging and settling of insulation materials at horizontal pipe or vessels

as well as adjacent areas to a change in direction from vertical to
AS
horizontal piping.
N
b) Condensation or frost on cold surfaces: Moisture on the surface of cold

O
insulation finishes (e.g. cladding) indicates either insufficient insulation

TR
thickness or a wet insulation system (usually indicating total deterioration

of the insulation material beneath it, due to ice build-up).
PE
c) Areas exposed to external wetting from sources such as mist over spray
from cooling water towers, sea water splashes, salt sprays, steam vents,
deluge systems, process spills, ingress of moisture, or acid vapours.
d) Protrusions through the insulation which includes dead legs and
attachments which operate at a temperature different than the main
insulated line. The seals shall be inspected at regular intervals to see if
they are free from cracks/holes, disintegration of sealant, etc.
e) Piping subjected to vibrations that increases the tendencies for the
insulation jacketing damage and creates gaps for water ingress.
f) Lines equipped with steam tracing to be checked for leaks at fittings and
at tracer tubing penetrations through the insulation.
g) Piping systems with suspected damage to the protective coatings and/or
wrappings underneath the insulation.
PTS 15.13.01
November 2015
MANUAL)
Page 35 of 44
h) Piping subjected to insulation removals for maintenance access and

isolation/spading, pipes removed for maintenance (including pipe left in
the plant) as well as those located adjacent maintenance or operations
activities which may be damaged due to human traffic. This include
locations where insulation of valves/flanges has been removed to permit
spading.
iv. Immediate rectification is required on:
a) Damaged jacketing, vapour barrier, coating or wrappings

Gaps are to be closed and sealed to prevent further water ingress.
The presence of gaps may indicate the need for expansion/contraction
y
joints. If so, gaps shall then be constructed as contraction/expansion
nl
joints and shall as such be incorporated into the insulation system.
O
Patching of broken cracked vapour barriers shall include the use of the
se
reinforcing fabrics with weather/vapour barrier mastics in accordance
lU
with the Manufacturer’s requirements.
na
b) Leaks or spills.
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Leaks shall be repaired, the insulation shall be removed and replaced as

nt
required and consideration shall be given to installation of protective

-I
covers or the use of non-absorbent materials at these locations.

AS
3.2 MAINTENANCE
N
O
3.2.1 Preventive Maintenance

TR
At the conclusion of every inspection survey, damage found and reported should be translated
into a plan of action for next remedial and preventive maintenance. The damage should be
PE
monitored in next surveys. Modifications may be required to prevent future recurrence to the
insulation and its underlying surfaces.
Technical shortcomings in design should be rectified, for example:

i. Repositioning of supports and brackets to eliminate water ingress;
ii. The installation of rainwater shields;
Damage caused by personnel or equipment can be prevented by:

i. Installation of a walkway and/or platforms over insulated pipes in a pipe track or
at piping manifolds;
ii. Re-routing of pedestrians by putting up hand railings;
iii. Avoidance of firewater spraying during fire drills on insulated tanks or equipment;
iv. Instruction and monitoring of third parties, such as painters, cleaners and
scaffolders.
PTS 15.13.01
November 2015
MANUAL)
Page 36 of 44
Damaged or saturated insulation should be discarded and the insulated metal surfaces
cleaned, de-rusted and painted before installing the new insulating material.
3.2.2 Programmed Maintenance

Based on the results of inspection surveys, the scope of long-term insulation maintenance can
be aligned with the inspection plan produced by PETRONAS Risk Based Inspection.
During any corrective actions on the insulation, opportunities should be taken to perform
coating maintenance underneath the replacement scope.
3.2.3 Execution of Maintenance Work

During performance of the maintenance work, care shall be taken so that the insulation
materials such as slabs, pipe sections and pre-formed covers are removed carefully and
properly stored so that it can be reused.
Temporary protection shall be provided to prevent water ingress during mechanical

maintenance work. For hot insulation, the jacketing and its vicinity shall be checked for proper
weather protection while for cold insulation, the vapour barrier shall be applied with sufficient
overlap over the existing undamaged portion.
Prior to acceptance by Owner of any maintenance work, checks on work completion and
cleanliness shall be carried out. This include confirmation of complete reinstatement of
removable boxes and safe removal of construction debris from the site.
PTS 15.13.01
November 2015
MANUAL)
Page 37 of 44
4.0 BIBLIOGRAPHY
In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:
PETRONAS STANDARDS
Index to PTS PTS 00.01.01
Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide
Fire Fighting Vehicles and Fire Stations PTS 18.54.09
Acoustic Insulation for Piping PTS 15.13.02
Protective Coatings and Linings PTS 15.20.03
PETRONAS Risk-Based Inspection (PRBI) PTS 15.40.01
Environmentally Hazardous Substance Guide PTS 18.72.10
AMERICAN STANDARDS
Damage Mechanisms Affecting Fixed Equipment in the Refining API RP 571
nd
Industry, 2 Ed. Apr. 2011
Risk-Based Inspection Technology API RP 581

nd
2 Ed. Sept. 2008
Issued by:
American Petroleum Institute
Publication and Distribution Section
1220 L Street Northwest
Washington DC 20005
USA
Process Piping, ASME Code for Pressure Piping, B31 ASME B31.3-2012
Jan. 2013
Issued by:
The American Society of Mechanical Engineers,
Three Park Avenue,
New York NY 10016
USA
Standard Specification for Chromium and Chromium-Nickel ASTM A240/A240M

Stainless Steel Plate, Sheet, and Strip for Pressure Vessels and for 2015
General Applications
Specification for Calcium Silicate Block and Pipe Thermal Insulation ASTM C533
PTS 15.13.01
November 2015
MANUAL)
Page 38 of 44
Specification for Thermal Insulation for Use in Contact with ASTM C795
Austenitic Stainless Steels
Issued by:
ASTM International
100 Barr Harbor Drive, PO Box C700
West Conshohocken, PA 19428-2959
United States
INTERNATIONAL STANDARDS
CINI Manual ‘Insulation for Industries’ 2014
CINI Foundation
Hofweg 1
3208 Le Spijkenisse
The Netherlands
Quality Management Systems - Requirements ISO 9001:2008

4th Ed. Nov. 2008
Issued by:
International Organization for Standardization
1, Rue de Varembé
CH – 1211 Geneva 20
Switzerland
District heating pipes. Preinsulated bonded pipe systems for EN 253:2009

directly buried hot water networks. Pipe assembly of steel service +A1:2013
pipe, polyurethane thermal insulation and outer casing of Apr. 2013
polyethylene
Design and installation of preinsulated bonded pipe systems for EN 13941:2009+A1
district heating July 2010
Issued by:
European Committee for Standardization
Avenue Marnix 17, B-1000 Brussels
Belgium
PTS 15.13.01
November 2015
MANUAL)
Page 39 of 44
APPENDIX 1: INSPECTION CHECKLIST OF THERMAL INSULATION SYSTEMS

The following table shows the inspection checklist for thermal insulation systems.
The table overleaf lists the recommended details to be recorded when performing thermal insulation
inspections.
Areas Findings
A. Damaged insulation areas:
Missing insulation jacketing (removed but not reinstalled)

Loose jacketing
Caulking/Sealant that has hardened, separated and cracked
Missing self-tapping screws, rivets or bands
Damaged or unsatisfactory termination in a vertical pipe or
equipment
Bulges of insulation cladding
Sagging insulation cladding
Rust staining as evident of coating damage and active
corrosion
Damaged or unsatisfactory termination at flanges
Open gaps at bends
Damage due to foot traffic or access to adjacent items for
maintenance
Gaps due to uncontrolled expansions/contractions
Hot/Cold spots detected via infrared thermography
Damaged vapour barrier
Icing/condensation on jacketing surface
Visible fungal growth
B. Penetrations:
Penetrations through the insulation jacketing such as hangers,
supports, valves, fittings, lifting lugs and dead legs.
Steam tracer tubing penetrations
Poorly designed insulation support rings
Stiffener rings
C. Other considered areas:
Carbon or low alloy components under insulation in a high
alloy piping system
Inspection ports used for Thickness Measurement Locations
PTS 15.13.01
November 2015
MANUAL)
Page 40 of 44
Areas Findings
Areas subject to external wetting from cooling tower mist
overspray
Areas exposed to steam vents
Areas exposed to firefighting deluge systems
Areas with substandard thermal performance
Recommended Record Details of Thermal Insulation Inspection
Record types Description of record

Inspection ID Enter unique reference number
Date of Inspection Input inspection date
Insulation Unit Number Process unit
Insulation Tag Number Line or equipment number
Hot, Cold, Hot+Acoustic, Cold+Acoustic, Personnel Protection
Type of Thermal Insulation
(PP) or Others
Year Installed Input year of installation
P&ID Number Input or hyperlink P&ID number
Isometric Drawing Number Input or hyperlink isometric drawing number
From process supervisory systems e.g. DCS, from PFD or
Operating Temperature
similar.
Constant temperature (input operating temperature/range);
OR
Operation Type
Cyclic temperatures (input operating range e.g. Ambient to
100oC, Minus to Ambient etc.)
Note any operation aspects e.g. intermittent service, start-up
Remarks on Operation
lines, long down time periods/mothball etc.
Marine/Cooling Tower Drift Area; Temperate; Arid/Dry; or
Severe. The appropriate corrosion rate e.g. per API 581 to be
Climate
assigned in alignment to the climate types in absence of
actual NDE measurements.
Notes on moisture exposure in the local environment, such as:
Conditions of local - Cooling Tower mist over spray
- Steam vents.
environment
- Deluge systems.
- Spills from process, moisture ingress or acidic vapours.
Carbon Steels; Low Temperature Carbon Steel; Austenitic
Material of Construction
Stainless Steel etc.
PTS 15.13.01
November 2015
MANUAL)
Page 41 of 44

Rock Wool; Calcium Silicate; Polyurethane (PUR);
Type of Insulation Material
Polyisocyanurate (PIR); Cellular Glass etc.
Description of layers used in the system e.g. Hot insulation
Insulation System
using rock wool over thermal spray aluminum coating with
Description
stainless steel jacketing.
Number of detected Specify on isometric drawings accompanied by a summary
damage at penetrations sheet
Damage at penetrations
Describe damage nature e.g. sealant failure, bulges, dents etc.
descriptions
Damage at penetrations Workmanship or design of substandard quality, aged
possible/apparent causes materials or third party caused damage.
Size of missing cladding (if If applicable, indicate size of missing insulation in length of
2
applicable) pipe (meters) or area of equipment (m ).
Missing cladding
Indicate cladding type
description
Workmanship or design of substandard quality, aged
Missing cladding
materials or not re-installed after removal for
possible/apparent causes
shutdown/maintenance etc.
Missing terminations (if Indicate number of missing terminations on isometric
applicable) drawings
Missing terminations Further details such as material not reinstalled after
description modifications etc.
Workmanship, design or usage of substandard quality, not re-
Missing terminations
installed after removal for shutdown/maintenance, third party
caused damage etc.
Number of missing
insulation at Indicate the detected number on isometric drawings
Valves/Flanges
Missing insulation at Further details such as material not reinstalled after
Valves/Flanges description modifications etc.
Missing insulation at
Workmanship, design or usage of substandard quality, aged
Valves/Flanges
materials or third party caused damage
Other deficiencies/defects
and descriptions (as Description of other found defects
applicable)
Insulation General
Substandard/Poor; Moderate/Average; or Good
Condition
Comments on Inspector’s comments with regard to CUI possibility, thermal
consequential damage losses etc. based on current inspection findings
PTS 15.13.01
November 2015
MANUAL)
Page 42 of 44

Require corrective actions? Yes or No
Timeframe of required Next available opportunity; Next planned shutdown; Within X
corrective actions years etc.
Suggested subsequent For example 6 monthly from last corrective action and/or after
inspection interval every shutdown
Suggested date for next inspection. This date can be aligned
Date of next inspection?
with inspection plan produced by PRBI analysis
Units of material Estimate of the number of insulation material units required for
replacement required and replacement/repair and its costs (cost estimate with reference
Replacement/repairs to previous insulation related maintenance activities and
costs? relevant procurement records).
Total estimated costs Calculate total estimate
PTS 15.13.01
November 2015
MANUAL)
Page 43 of 44
APPENDIX 2: GUIDELINE ON CINI MANUAL VIA DVD ACCESS

Guidelines on accessing the CINI Manual; accessed from a DVD, are as follows:
This CINI Manual consists of 11 Main Tabs as shown in the following figure:
Each tab contains individual table of content which provides access to specific CINI specification. The
numbers shown on the right side of this table of content (e.g. 1.1.01) indicate the specification’s
number.
The specification numbering is defined as follows:

1 3 02 1
st nd rd
CINI Main Tab 1 level of Sub Tab 2 level of Sub Tab 3 level of Sub Tab
PTS 15.13.01
November 2015
MANUAL)
Page 44 of 44
The search function provides another alternative to users in accessing the CINI specification. When
using the search function, one keyword should be entered. The following is a sample of the search
results:
Users may obtain a PDF copy of any page of interest by clicking on the PDF icon located at the top of
the respective pages as shown below:

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PETRONAS TECHNICAL STANDARDS

Thermal Insulation (Amendments/Supplements to the

codes and technical standards before start of any work.

PETRONAS that this requirement is met.

1.1.2 This PTS is divided into five parts:

iv. Section 4.0 lists the publications referenced in this PTS;

1.2 GLOSSARY OF TERMS

1.2.1 General Definition of Terms & Abbreviations

1.2.2 Specific Definition of Terms

1 Acoustic Insulation Insulation installed to reduce the amount of

2 Cold Insulation Insulation used to avoid condensation at the

3 Condensation Moisture forming at the surface of uninsulated

4 Dual Process Temperature Process temperature cycling between -20oC and

duty is normally cellular glass.

5 Heat Gain Heat ingress from the outside in cold insulation

systems or heat loss from the inside in hot

6 Hot Insulation Insulation used to save energy for economic

reasons; typically applied for process

7 Insulation System Combination of insulation materials and

8 Metallic Jacketing Jacketing which consists of aluminum,

9 Non-Contact Insulation Insulation system in which spacers are used to

10 Non-Metallic Jacketing Jacketing consisting of GRE, GRP, polymeric

11 Personnel Protection Barrier system consisting of insulation material

personnel protection insulation.

1.2.3 Specific Abbreviations

3 CUI Corrosion Under Insulation. Five (5) categories

of CUI are recognized, indicating the severity of

4 EPDM Flexible Elastomeric Foam EPDM Type

5 ESCC External Stress Corrosion Cracking

6 FEF Flexible Elastomeric Foam

7 GRE Glass-fibre Reinforced Epoxy

8 GRP Glass-fibre Reinforced Polyester

11 HT-GF High Temperature Glass Fiber

12 ITP Inspection Test Plan

13 MPS Microporous Silica

14 NDT Non Destructive Testing

15 PEC Pulsed Eddy Current

25 VDI Verbund Deutscher Ingenieure (Association of

26 XPS Extruded Polystyrene Foam

1.3 SUMMARY OF CHANGES

2.0 AMENDMENTS / SUPPLEMENTS TO THE CINI MANUAL

CINI 1.2.01 Heat Insulation Diagram

The Heat Insulation Diagram/schematic which provides overview on Insulation

Specification, Finishing Material and Finishing Specifications may be used as

CINI 1.2.04 Operation-temperature versus Corrosion Under Insulation (CUI) risk

The following table summarizes vulnerabilities of CUI from Clause 1:

Category Vulnerability to CUI* Process Temperature

1 Extreme Cyclic process temperature between

2 High Process temperature between

5 Low All process temperature < -5°C

Based on the table of vulnerabilities to CUI above, the recommended thermal

Category System and Material Guidance

A high temperature anti-abrasive compound (based on a

Other suitable compounds may be used for temperatures up

The application and system of cellular glass shall be in

As long as an RBI analysis and/or CUI risk assessment has been

The use of Calcium Silicate shall be with Owner’s approval.

ASTM C533 Specification for Calcium Silicate Block and Pipe

ASTM C795 Specification for Thermal Insulation for Use in

Contact with Austenitic Stainless Steels.

3 Selection of materials to be used shall be in accordance to

4 Recommended to use rock wool with aluminised steel or

5 Recommended to use PUR/PIR with heavy-duty multiplex foil

Based on table of vulnerabilities to CUI, recommended acoustic insulation