4wpi Ins007

GLOBAL ENGINEERING SPECIFICATION
Installation of Multi-Layer Thermal Insulation of 4WPI-INS007*

Cryogenic Piping With PIR (Polyisocyanurate foam) Revision 1
22 September 2005
Symbol P1 Page 1 of 38
RESPONSIBLE GROUP: Mechanical Systems Engineering *Formerly N03.1 and 660.101
Denotes Revision
Table of Contents
Section Title Page
1. Purpose 3
2. Scope 3
3. Related Documents 3
4. Definitions 3
5. Waivers 3
6. Warranty 4
7. Materials 4
8. Material References 4
9. Insulation Thickness and Limits 4
10. Site Establishment and Preparation 5
11. General Application 6
11.1 Cavities 6
11.2 Vapor Barrier System 6
11.3 Protective Metal Jackets 7
12. Application of Insulation 8
12.1 Straight Piping 8
12.2 Insulation Support Rings 10
12.3 Contraction Joints 11
12.4 Fittings 12
12.5 Flanges 18
12.6 Valves and In-line Items 20
12.7 Termination of Insulation 23
12.8 Pipe Supports 25
12.9 Cellular Glass/PIR Joints 30
12.10 Equipment 30
12.11 Vacuum Jacket Piping Joints 31
12.12 Terminations With Equipment 32
Figure 1 Straight Piping 9

Figure 2 Insulation Support Rings 10
Figure 3 Contraction Joints 11
Figure 4 Elbows and Bends 13
Figure 5 External View of Typical Elbow With Miter Segments 14
Figure 6 Equal Tees 14
Figure 7 External View of Tees or Branches 15
Figure 8 Branches 15
Figure 9 End Caps or Vessel Heads 16
Figure 10 Reducers 17
Figure 11 Flanges 19
Figure 12 Valves (Preformed Insulation) 20
Figure 13 Valves (Fabricated Insulation) 21
Figure 14 Mechanical Flexible Joints or Bellows 22
Authorization for this document is on file in the GEO Standards Department.

All information herein is the confidential property of Air Products and Chemicals, Inc., unless another source is shown.
This information is subject to return on demand and must not be disclosed or reproduced without prior written consent.
© Air Products and Chemicals, Inc., 2005
4WPI-INS007, Rev. 1, Page 2 of 38
Table of Contents (continued)
Section Title Page
Figure 15 Termination of Insulation on Pipes 23

Figure 16 Small Metal or Pipe Projections 24
Figure 17 Pipe Support Saddles 25
Figure 18 Pipe Support Rests 25
Figure 19 Hanger Pipe Supports 26
Figure 20 Shoe Pipe Support A 27
Figure 21 Shoe Pipe Support B 28
Figure 22 Trunnion or Duck-foot Pipe Supports 29
Figure 23 Double Layer PIR/Double Layer Cellular Glass 30
Figure 24 Double Layer PIR/Triple Layer Cellular Glass 30
Figure 25 Vacuum Jacket to Insulated Pipe Termination 31
Figure 26 Vacuum Jacket Pipe Insulated Field Joint 31
Figure 27 Storage Tank Nozzle With Termination Plate 32
Figure 28 Cold Box Piping Penetration – Can 32
Figure 29 Cold Box Piping Penetration – Ring 33
Appendix A Installation Quality Assurance Report 34

Appendix B Photographic Examples 35
1. PURPOSE
1.1 This global engineering specification defines and describes the minimum requirements for the
installation of multi-layer thermal insulation using polyisocyanurate (PIR) foam of cryogenic
piping.
2. SCOPE
2.1 This specification covers all preformed and slab polyisocyanurate insulation materials including
adhesives, sealers, mastics, and jackets.
2.2 This insulation material is identified on drawings with the symbol P1 (see 4WPI-INS006).
3. RELATED DOCUMENTS
3.1 Air Products Engineering Documents
⊕ 3PI99002 Thermal and Acoustic Insulation Standard

4WPI-INS001 Cellular Glass Thermal Insulation System for Cold and Cryogenic Piping and
Equipment Material Symbol C
4WPI-INS006 PIR (Polyisocyanurate Foam) Thermal Insulation System for Cold and Cryogenic
Piping and Equipment – Material Symbol P
⊕ Provided for background information only (not referenced in the text)
3.2 American Society for Testing and Materials (ASTM)
C 585 Standard Practice for Inner and Outer Diameters of Rigid Thermal Insulation for
Nominal Sizes of Pipe and Tubing (NPS System)
3.3 All standards and documents referred to herein shall be the latest issue, unless otherwise stated.
4. DEFINITIONS
4.1 Air Products and Chemicals, Inc. and its subsidiary and associated companies will be referred to
herein as Air Products.
4.2 The insulation contractor who supplies and installs the insulation will be referred to herein as the
contractor.
4.3 Approved equal in this specification means "approved in writing by Air Products."
4.4 All temperatures and dimensions in the text of this document are given in metric units with US
customary units in parenthesis. In the figures dimensions are only given in mm for clarity (divide
by 25.4 to convert mm to inches).
5. WAIVERS
5.1 Applications for waivers of the requirements contained in this specification shall be made in writing to
the Air Products representative, who will obtain approval and written authorization from the relevant
Air Products manager prior to order, supply, or installation by the contractor.
5.2 In order that any request by the contractor may be evaluated, the contractor shall submit
complete and full details of the recommended alternative.
6. WARRANTY
6.1 The contractor shall provide a warranty guaranteeing the installation's mechanical integrity
against wind, weather, and normal operating conditions, and also the vapor barrier's integrity
against the ingress of moisture, all for a period after acceptance by Air Products of the insulation
installation's completion to be agreed in writing prior to start of installation.
6.2 The contractor will be required to provide sample installations of insulation on the piping at the
start of the contract. These will be inspected by Air Products and might be destroyed in the
process of examination. The contractor will be judged on the quality of the workmanship and only
if satisfactory will be allowed to start the contract. All work on the insulation shall then be
guaranteed by the contractor to be to the same quality of workmanship and will be judged to the
same standard as the accepted sample. The contractor shall remove all damaged insulation and
re-insulate as required.
7. MATERIALS
7.1 All insulating materials and accessory materials to be used with this installation specification are
defined in the Insulation System Specification 4WPI-INS006.
7.2 The contractor shall supply all insulating materials and accessory materials unless otherwise
stated in the contract. The material shall be strictly according to the Insulation System
Specification, which provides full names and addresses of suppliers.
8. MATERIAL REFERENCES
8.1 All materials are indicated in the text and figures of this specification by the numbers shown in
square brackets, thus [0], that refer to the materials in Sections 7, and are identified in the
following list.
[1] Pipe Insulating Material

[2] Equipment Insulating Material
[3] Cavity Fill Material
[4] Vapor Barrier Jacket
[5] Vapor Barrier Jacket Adhesive
[6] Insulation Adhesive
[7] Insulation Joint Sealer
[8] Vapor Barrier Mastic
[9] Insulation Banding Tape
[10] Metal Jacket
[11] Metal Bands
[12] Pipe Clamp Insulation Support
[13] Sheet Metal Insulation Support
[14] Removable Insulation Boxes
[15] Contraction Joint Cover
[16] Contraction Joint Cover Adhesive
[17] Sheet Metal
9. INSULATION THICKNESS AND LIMITS
9.1 The insulation nominal thickness and the extent to which the insulation shall be provided and
installed on piping and equipment shall be as stated on the Insulation Summary and/or isometrics
and drawings provided by Air Products. Refer also to 4WPI-INS006. The actual insulation
dimensions shall be according to ASTM C 585.
10. SITE ESTABLISHMENT AND PREPARATION
10.1 All insulation installation shall be performed strictly according to this specification, the Insulation
Summary, piping isometrics, and drawings provided by Air Products.
10.2 The contractor shall comply with all local and national regulations and safety rules.
10.3 The contractor shall comply with Air Products site and safety rules.
10.4 The contractor shall supply all materiel, tools, transport, and supervision required for satisfactory
completion of the insulation contract.
10.5 All materials shall be new and shall be applied by competent personnel according to the
manufacturer's instructions, unless otherwise specified herein.
10.6 All materials and all installation of insulation shall be available for inspection by Air Products.
Material having defects shall be replaced, and any defects found in the installation shall be
corrected by the contractor at their expense.
10.7 Before starting work on site, the contractor shall prepare and obtain the agreement of the
Air Products representative regarding their detailed program for the work. They shall also obtain
agreement for the site establishment and for the location of working areas.
10.8 All pressure testing shall be satisfactorily completed before application of any insulating materials.
10.9 Insulating materials shall only be applied to a completely dry surface that might have been
painted by others. All surfaces shall be free of dirt, rust, and any foreign matter.
10.10 Insulating and accessory materials shall only be applied to surfaces that are clean, dry, and frost-
free, and when the ambient temperature is above +2°C (36°F). Great care shall be taken to
prevent damage to the paint system, especially on stainless steel piping or equipment as this paint
does not fully harden until it has reached the system's operating temperature for the first time.
10.11 The contractor shall verify with the Air Products representative, before commencing work on a
pipe system or item of equipment, that the system is ready for insulation installation and shall also
confirm the requirements for any special conditions such as cleanliness or internal purge.
10.12 The contractor shall cover all openings in the equipment to prevent the ingress of insulation or
foreign materials.
10.13 Welding or drilling on equipment, piping, and structures is prohibited.
10.14 All insulating material shall be kept dry and shall be protected from inclement weather and
contact with water at all times. Any evidence of moisture in the insulation or its accessories, either
before or after application, shall be sufficient cause for rejection.
10.15 All insulation applied in one day shall be weatherproofed overnight or before rain by either the
final coating or a temporary weatherproof covering.
10.16 All insulation shall be fabricated using a minimum number of pieces, and all surfaces between
adjacent pieces of insulation shall be tightly butted together so that no voids or gaps occur at any
joint, except where specifically indicated.
10.17 Cutting and fitting of any insulation at tie-ins, valve handwheels, steel gratings, steelwork, conduit,
cable tray, tubing, pipe supports, or other interference shall be considered part of the insulation
contract.
10.18 Repair and/or replacement in kind of any existing insulation at tie-in points shall be considered as
part of the insulation contract.
10.19 When piping or equipment is electrically or steam traced by others, insulation shall only be
applied when the tracing has been completed and approved by Air Products. The contractor shall
provide and install "electric traced" signs on the outside surface of the insulation over electric
traced lines at 3 m (10 ft) intervals on both sides of the pipe. All gland plates on electrical tracing
cables shall be banded to the metal jacket [10] and adequately sealed with [7].
10.20 Insulation on piping and equipment specified as personal protection on the Insulation Summary
and/or isometrics shall be installed only within the limits shown therein.
10.21 All moving parts shall be free of mastics and cements.
10.22 The contractor shall remove all waste or surplus material.
11. GENERAL APPLICATION
11.1 Cavities
11.1.1 All cavities within the preformed insulation for pipes or equipment shall be completely filled by
hand with cavity fill material [3] to a firm, resilient consistency.
11.2 Vapor Barrier System
11.2.1 It is essential that all insulation to this specification shall be completely covered by the contractor as
it is installed using a vapor barrier system that is totally watertight. The protective metal jacket shall
not be considered as providing any sort of watertight vapor barrier.
11.2.2 The contractor shall install a factory- or site-applied vapor barrier jacket [4] with vapor barrier
jacket adhesive [5].
11.2.3 On irregular surfaces, at the ends of insulation, or anywhere that it is not possible to use the
vapor barrier jacket material [4], use the vapor barrier mastic system. The mastic system shall
extend a minimum of 75 mm (3 in) on to the vapor barrier jacket [4] of the adjacent pipe or
equipment insulation.
11.2.4 At flanges, valves, heat exchanger heads, and other bolted joints, there shall be insulation that is
removable to allow maintenance of the equipment. The vapor barrier shall be installed over the
outer layer of fixed insulation, on to the inner layers of insulation and on to the pipe or equipment.
It shall be applied such that when the removable insulation is either taken off or is applied later,
the fixed insulation is fully sealed.
11.2.5 The vapor barrier jacket system shall be installed as follows:
11.2.5.1 All outer surfaces of all piping and equipment insulation shall be completely sealed with
weather-resistant vapor barrier jacket [4]. The jacket and longitudinal flaps shall be sealed with
vapor barrier jacket adhesive [5]. Circumferential butt joints shall be covered using a 75 mm
(3 in) [or 100 mm (4 in) for equipment] wide strip of vapor barrier jacket material [4] and shall be
sealed with adhesive [5] or self-adhesive tape [5] centered on the joint.
11.2.5.2 When installing insulation banding tape [9] to secure the outer layer, care shall be exercised in
order not to damage or puncture the vapor barrier. Any damage or puncture shall be repaired
with a piece of vapor barrier jacket [4] and adhesive [5] or self-adhesive tape [5].
11.2.5.3 When there is a slip joint provided in the insulation of equipment, the vapor barrier jacket shall
be stopped short of the joint, and the joint shall be adequately sealed with the vapor barrier
mastic only.
11.2.6 The vapor barrier mastic system shall be installed as follows:
11.2.6.1 All outer surfaces of all piping and equipment insulation shall be completely sealed with
weather-resistant vapor barrier mastic reinforced with glass cloth [8] applied according to the
manufacturer's instructions. The glass cloth shall be embedded in the first coat of mastic while it
is still wet, then the second (top coat) shall be applied.
11.2.6.2 The coating shall be carefully examined after drying to ensure that there are no cracks, holes,
thin spots, bare reinforcement, or open joints of any sort. If there are any defects of this type, an
additional coating of mastic shall be applied at these locations until there are no further defects.
11.2.6.3 When the vapor barrier mastic [8] terminates onto a metal surface, the surface shall be cleaned
of all dirt, grease, oil, and other foreign matter by wire brushing and solvent washing before the
application of mastic.
11.2.6.4 When there is a slip joint provided in the insulation of equipment, the reinforcement cloth shall
be stopped short of the joint, and the joint shall be adequately sealed with the vapor barrier
mastic only.
11.3 Protective Metal Jackets
11.3.1 All insulation shall be protected with a metal jacket applied with minimum longitudinal and
circumferential overlaps of 50 mm (2 in).
11.3.2 Longitudinal overlaps shall be located on or below the horizontal centerline, not on the top of piping
or equipment, but installed to shed water. Adjacent longitudinal overlaps shall be installed at
180 degrees from one another to avoid double circumferential lap areas.
11.3.3 Metal jackets shall be secured with metal bands [11] spaced at 250 mm (10 in) maximum and at
each end of the jacket section as indicated in the drawings in Section 12, stretched and clamped
under tension with seals. This shall not crush or crack the insulation. Any cracked or broken
insulation shall be replaced. On vertical equipment, metal jackets shall be supported with 's' clips on
300 mm maximum centers and with a minimum of two per jacket section.
11.3.4 All exposed edges and sharp corners of insulation jacketing shall be rounded off to prevent a
safety hazard. Metal band ends shall be cut close to the seal [12 mm (0.5 in) minimum], folded
under, and flattened.
11.3.5 All flanges, valves, expansion bellows, flexible hoses, strainers, pump casings, vessel manways,
and other frequently maintained items shall be provided with prefabricated, proprietary, or
custom-made removable insulation boxes secured to allow easy access. All items that do not
have their labels or tag numbers visible after completion of the insulation shall have labels
provided and installed by the contractor on the outside of the insulation.
11.3.6 Self-tapping screws or any other sharp-type fixing shall not be used under any
circumstances. Any rivets used to fabricate metal jacketing shall have a smooth face on the
insulation side of the jacket or shall be totally external to the insulation system. It must be
demonstrated to Air Products' satisfaction by the contractor prior to use, that the method
proposed for using rivets or any other similar fixing cannot under any circumstances damage the
vapor barrier.
11.3.7 All overlaps on metal jackets shall be installed to shed water and shall be sealed with insulation
joint sealer [7]. On straight seams, the metal joint sealing tape material is preferred and shall be
installed continuously along the joint such that one edge is just visible.
11.3.8 All cut-outs in metal jackets shall be cut as close as possible to achieve a tight fit, shall be
covered by a flashing of aluminum sheet, and shall be adequately sealed with insulation joint
sealer [7].
12. APPLICATION OF INSULATION
12.1 Straight Piping
12.1.1 All insulation [1] shall be applied using double- or multi-layer construction.
12.1.2 The first layer of insulation, the inner layer, shall be applied dry and without sealer or adhesive, and
all joints shall be tightly butted together. Longitudinal seams shall not be staggered relative to one
another on any one layer. Ship laps or tongue-and-groove joints are preferred.
12.1.3 All layers of insulation shall be secured with insulation banding tape [9] spaced at 230 mm (9 in)
maximum centers and at each end of the insulation section as indicated in Figure 1.
12.1.4 The longitudinal and circumferential joints shall be staggered between layers. Longitudinal joints
shall be staggered midway between longitudinal joints on adjacent layers, and circumferential
joints shall be staggered by approximately half a section, but in no case closer than 150 mm
(6 in) to the joint of the adjacent layer. There shall be no through joints. On nonvertical pipe or
equipment, the outer layer longitudinal joints shall not be installed on the top of the pipe or the
equipment.
12.1.5 Before application, insulation joint sealer [7] shall be applied to all joints of the outer layer of
insulation for the full depth of the thickness of that layer. Sealer shall be applied to both surfaces of
mating insulation to provide a thin, 1 mm (0.04 in) maximum, continuous seal for the full length and
depth of each joint. Any sealer extruding from the mated joint due to compression during installation
shall be leveled onto the joint and the adjacent insulation surfaces to eliminate high spots. Ship laps
or tongue-and-groove joints are preferred.
12.1.6 The outer layer of all insulation shall be provided with a vapor barrier according to paragraph
11.2.
12.1.7 All insulation shall be completely covered with a protective metal jacket according to paragraph
11.3.
Figure 1
Straight Piping
Metal Jacket shown Outer layer shown Inner layer(s) shown
1000 1000 1000

(minimum) (minimum) (minimum)
Min overlap 50
(typical)
25 25 25
(typical) (typical) (typical)
[10] [1] with [4] and [5] [1]
[11] Joints between layers to be [9]

Five equi-spaced per section staggered by approx. half a Five equi-spaced per section
max. 250 spacing (typical) section (150 min) max. 250 spacing (typical)
Cover external circumferential joints
with a 100 mm strip of [4] fixed with [5]
Overlap installed on
nonvertical lines to to
[7] Outer layer only shed water. To be
[10] staggered 180 on [10]
adjacent sections of
jacketing
50 min 50 min
[7] Outer layer only

Stagger joints between layers
Longitudinal joints in the outer
layer shall not be located on the
vertical centerline of the pipe
Cross-section Cross-section
Sectional Two-piece Insulation Segmental Multi-piece Insulation
12.2 Insulation Support Rings
12.2.1 Insulation support rings are required on vertical piping at the maximum spacing of 5 m (15 ft)
when there are no flanges, fittings, or valves. At flanges, fittings, or valve locations, support rings
shall be installed as close as possible above these locations. These support rings shall be
insulated as indicated in Figure 2.
Figure 2
Insulation Support Rings
[1] with [4] and [5] T1 = Thickness of inner layer of insulation

Mitered and with rounded corners T2 = Thickness of outer layer of insulation
Overlap of [8] T1 + T2 [1]

2
T2 T1 T1 +1/2T2 minimum
[1] with [4] and [5]
[10]
75 minimum
(typical)
[11]
100
minimum
[6]
40 125
minimum
[8] when [4]
and [5] not
possible Pack tightly with [3]
[7] As slip joint [12] or [13]
Fillet of [7]
[9] Apply [7] to all joints in outer layers
Do not extend [4] or reinforcement of [8] over slip joint
12.2.2 The contractor shall provide proprietary support rings or shall provide materials for and fabricate
support rings as detailed in the Insulation System Specification for [12] or [13].
12.2.3 For piping DN150 (NPS 6) and smaller, a sheet metal support [13] shall be used. For piping
larger than DN150 (NPS 6), a pipe clamp support [12] shall be used.
12.2.4 If in fabricating the pipe clamp insulation support it is not possible to cut off the arms of the clamp
so that it does not extend past half of the outer layer of the insulation, an extra layer of insulation
shall be installed over the clamp, notched to accommodate the ends of the clamp as necessary.
12.3 Contraction Joints
12.3.1 Contraction joints shall be installed in the insulation according to Figure 3. One contraction joint
shall be installed and is required for any straight piping over 2.5 m (8 ft) long, plus one
additionally for every 5 m (16 ft) of length or fraction thereof longer than 2.5 m.
Figure 3
Contraction Joints
[11] two on each side of joint [9]

[11]
25 150 25
[1] [10]
minimum
[1] with [4] and [5] 50

[7] As slip joint
minimum Pack with [3]
150 150
Slip joint in [10] minimum minimum
Seal with liberal
coating of [7] [15] and [16]
Heavy coating of [7] under [15]

[15]
[10]
[16] to lap joint
[7]
75 minimum
overlap of [15]
Cross-section through joint
12.3.2 Insulation support ring locations on vertical piping that is insulated according to paragraph 12.2
may be considered as fulfilling the requirements of a contraction joint.
12.3.3 Flange, valve, and in-line equipment locations that are insulated according to paragraph 12.5 or
12.6 (for valves with fabricated insulation or for mechanical flexible joints or bellows) may be
considered as fulfilling the requirements of a contraction joint.
12.4 Fittings
12.4.1 Fittings shall be insulated with prefabricated piping insulation [1] according to Figures 4, 5, 6, 7, 8, 9,
and 10.
12.4.2 The minimum thickness of insulation on fittings shall be equal to that required for adjacent straight
piping.
12.4.3 Fitting insulation shall have insulation adhesive [6] applied to the longitudinal joints of the half
sections of all fitting insulation. The sockets that lap the first layer of adjacent pipe insulation shall be
installed dry without sealer or adhesive, but the butt ends that mate with the outer layer of adjacent
pipe insulation shall be coated with a thin layer of insulation joint sealer [7]. All joints and miters shall
be completely sealed throughout the entire joint.
12.4.4 Small openings and voids shall be filled with cavity fill material [3].
12.4.5 The insulation shall be carefully fitted and secured in place with insulation banding tape [9]. Although
a minimum of three bands are mandatory on all fittings, it is the responsibility of the contractor to
install as many as are required to ensure that the insulation is adequately secure.
12.4.6 A weather-resistant vapor barrier shall be applied over all fitting insulation according to paragraph
11.2.
12.4.7 All fitting insulation shall be completely covered with a protective metal jacket according to paragraph
11.3. When prefabricated, proprietary metal jackets are available, they are preferred; otherwise,
jacketing shall be fabricated to suit.
Figure 4
Elbows and Bends
[1] with [4] and [5]
[1]
[10]
50 overlap [9]
20 minimum depth [11]
of socket (typical)
[7]
Keyed joint
[1] premolded or
prefabricated in
two halves and
joined with [6]
[8] when [4] and

[5] not possible
75 minimum
[9] minimum of three
per fitting Overlap of [8]
(typical)
Preformed jacket elbows or miter
segments as in Figure 5
T = total insulation thickness
Permanent keyed joints
Lapped joints
20 minimum
T/3 maximum
[6]
20 minimum
Cross-section through elbow showing joints
Figure 5
External View of Typical Elbow With Miter Segments
[11]
[10]
Figure 6
Equal Tees
[1] [1] with [4] and [5]

[8] when [4] and [5]
[1] premolded or not possible
prefabricated in Seal all round with [7]
two halves and
joined with [6] [9] minimum of three
per fitting
Seal outer layers with [7]
50 minimum overlap
[10] 75 minimum (typical)
20 minimum
overlap of [8]
[11] (typical) depth of socket (typical)
Keyed joint as elbow above
Figure 7
External View of Tees or Branches
Seal all round with [7]
[10] [11]
Figure 8
Branches
75 minimum [1]
Seal all round with overlap of [8] [1] with [4] and [5]
heavy fillet of [7]
Seal all joints in outer [11]

layers with [7]
[10] [1]
[9] [8] when [4] and [5]

not possible 50 minimum overlap
(typical) [1] with [4] and [5]
Figure 9
End Caps or Vessel Heads
Pack tightly with [3]

[1] with [4] and [5] Seal outer layer with [7]
[10] [11]
[8] when [4]

and [5] not
possible
[9] 75
[1] minimum
overlap of [8] Round off corners
(Typical)
Horizontal Vertical
Figure 10
Reducers
Concentric Reducer
150 minimum
[10] [11] Pack tightly with [3] 75 minimum
[9] [1] overlap of [8] and [10]
Matching Insulation
[9]
[1] fabricate to suit
Offset Insulation
[1] with [4] and [5]
chamfer and round off Seal all round and
corners under [8] outer layers with
[8] when [4] and [5]
not possible
Eccentric Reducer
Materials as above
Reducer in Vertical Location

Materials as above
Matching Insulation Offset Insulation
12.5 Flanges
12.5.1 All flanges shall be insulated with the same thickness of insulation as the adjacent straight piping
according to Figure 11, using the same methods as for straight piping. All voids shall be tightly
packed with cavity fill material [3].
12.5.2 The flange insulation shall overlap the pipe insulation by a minimum of 150 mm (6 in) and shall be
installed in such a manner that it may be removed to provide access to the flanges and allow removal
of the flange bolts without disturbing the adjacent piping insulation.
12.5.3 Flange insulation shall be fabricated in two halves from [1] using insulation adhesive [6]. The two
halves shall be joined with insulation joint sealer [7], and the mating surfaces between the flange
insulation and the adjacent pipe insulation shall also be sealed with [7].
12.5.4 The outer layer of flange insulation shall be completely covered with a vapor barrier according to
paragraph 11.2.
12.5.5 Flange insulation shall be protected with a removable metal insulation box [14].
12.5.6 Spectacle blinds, blanks, or spacers shall be enclosed within the insulation box that shall have a
label on the outside indicating their location.
Figure 11
Flanges
External view of flange box
[14] Removable flange box (round)

Flange insulation thickness to be at least with overlaps to shed water Heavy fillet of [7]
as thick as that on adjacent pipe
Do not overlap [4] or
reinforcement of [8]
Construction where no
at this slip joint
spacer is required 150
minimum [9]
Seal all round [7] As slip joint
with [7] [1]
Lockformed
[1]
Spacer of [1]
if required to
clear flanges
[1] with [4] and [5]
[6]
Pack void tightly with [3]
75 minimum
Seal all joints in outer layer with [7] overlap of [8]
Longitudinal joints shall not be on [11]
the vertical centerline of the pipe
Construction where
a spacer is required
[8] when [4] and
The insulation of the piping adjacent to flanges shall be [5] not possible
stopped short of the flange to allow the flange bolts to
be removed without damage to the pipe insulation
12.6 Valves and In-line Items
12.6.1 All valves and in-line items shall be insulated with the same thickness of insulation, with the
exception of extended stems, as the adjacent straight piping according to Figures 12, 13, and 14.
They shall be insulated with premolded insulation in two halves when commercially available, or
with preformed piping insulation fabricated in two halves with insulation adhesive [6] using the same
methods as for fittings and straight piping. All voids shall be packed with cavity fill material [3].
Figure 12
Valves (Preformed Insulation)
External view of valve box
Slot jacket and overlap

120 min to completely seal
50 minimum
Seal with thick layer of [7]
between metal jacket and
250 min (valves DN50 and larger)
valve stem
150 min (valves smaller than DN50) 75
[11]
Removable valve box [14] (round) Seal all round with [7]
with overlaps to shed water
75 minimum
Pack all voids tightly with [3] overlap of [8]
[11] [8] when [4] and [1] with [4] and [5]
[5] not possible
Minimum thickness round

valve body to be equal to [1] [10]
pipe insulation thickness
Keyed joint
[7] 20 minimum [1] premoulded or
depth of socket prefabricated in two
Lockformed halves and joined with [6]
[9] minimum of three
Round corners
Figure 13
Valves (Fabricated Insulation)
External view of valve box
Box to be completely sealed to

prevent ingress of moisture
50 minimum
Seal with thick layer of [7] 250 min (valves DN50 and larger)
between metal jacket [10] 150 min (valves smaller than DN50)
and valve stem
Seal all round with [7] 75
Removable valve box [14]

with toggle clips [1] with [4] and [5]
Seal outer layers with [7]
[1] with [4] and [5]
[1]
[7] As slip joints 20 minimum socket
[6]
[10]
Pack all voids [9]
[11] tightly with [3] Valve insulation thickness to be equal
to that on adjacent piping. Fabricate
The insulation of piping adjacent to valves shall be [1] with [6] in two halves seal with [7]
stopped short of the valve to allow the flange bolts and cover with [4] and [5] or [8]
to be removed without damage to the pipe
Figure 14
Mechanical Flexible Joints or Bellows

[6] Seal this side with [7] as slip joint
[1] with [4] and [5]
Round off corners
[8] when [4] and Pack voids with [3] [1]

[5] not possible [10]
[11]
Lockformed
25
T/2
[7]
75 minimum 50 min [9]
overlap of [8] 150 min
[11] (typical)
min three per box
T = Total insulation thickness
Removable box [14] (round)
with overlap to shed water
similar to paragraph 12.5
The insulation of piping adjacent to mechanical joints
shall be stopped short to allow the flange bolts to be Joint insulation thickness to be
removed without damage to the pipe insulation equal to that on adjacent piping
12.6.2 The valve or in-line item insulation shall be installed in such a manner that it may be removed to
provide access to the valves or items for their removal, including the withdrawal of bolting,
without disturbing the adjacent piping insulation.
12.6.3 Valve insulation shall have insulation joint sealer [7] applied to the longitudinal joints of the half
sections of all valve insulation. The sockets that lap the first layer of adjacent pipe insulation shall
be installed dry without sealer or adhesive, but the butt ends that mate with the outer layer of
adjacent pipe insulation shall be coated with a thin layer of insulation sealer [7].
12.6.4 Extended stems of cryogenic valves shall be insulated with a minimum of 50 mm (2 in) thick
single layer of insulation to a minimum distance from the top packing gland of 150 mm (6 in) for
valves DN40 (NPS 1 1/2) and smaller and 250 mm (10 in) for valves DN50 (NPS 2) and larger.
The insulation on the stem shall extend into the socket of the valve body insulation, and the joint
shall be sealed with insulation joint sealer [7]. The same methods of application shall be used as
for straight piping.
12.6.5 The outer layer of valve and in-line item shall be completely covered with a vapor barrier
according to paragraph 11.2.
12.6.6 Valve and in-line item insulation shall be protected with a removable metal insulation box [14].
12.6.7 All valve packing glands shall be accessible for adjustment or repacking.
12.7 Termination of Insulation
12.7.1 When insulation terminates on a pipe, the insulation shall be installed according to Figure 15 and
shall be adequately sealed with vapor barrier mastic [8] according to paragraph 11.2.
Figure 15
Termination of Insulation on Pipes
[1] with [4] and [5] [8] when [4] and

[5] not possible
[10] [11] [9]
75
minimum
[1]
[11]
Horizontal Pipe Seal all round

with [7]
75
minimum Seal with thick layer of [7]
between metal jacket [10]
and pipe
[10]
75 minimum
overlap of [8]
[1]
[9]
[1] with [4] and [5]
[11]
Vertical Pipe
12.7.2 Small branch connections from cryogenic lines, such as pressure taps, safety valve connections,
drains, and vents, shall be insulated for a distance (when possible) of four times (minimum two
times) the insulation thickness required for the cryogenic line according to Figure 16 and shall be
adequately sealed with vapor barrier mastic [8] according to paragraph 11.2.
12.7.3 When insulation terminates on a small metal projection, the insulation shall be installed according
to Figure 16 and shall be adequately sealed with vapor barrier mastic [8] according to
paragraph 11.2.
Figure 16
Small Metal or Pipe Projections
Seal with thick layer of [7] between

metal jacket [10] and pipe Metal or pipe projection
[8] when [4] and [5]

not possible
Chamfer insulation and

round off corners T/2 (50 minimum)
[11]
[9]
100 minimum
75 minimum
[10] overlap of [8]
4T when
[11]
possible, [1] with [4] and [5]
2T minimum
[7]
T
[10]
T = total insulation thickness

[1] [1] with [4] and [5]
12.8 Pipe Supports
12.8.1 When insulation is supported by a saddle or cradle support provided by others, it shall be sealed
to the outside of the metal jacket [10] with a liberal coating of insulation joint sealer [7] as shown
in Figure 17.
Figure 17
Pipe Support Saddles

[1] with [4] and [5]
[10]
[1]
[7]
Liberal coating of [7] Metal saddle support

by others
12.8.2 When insulation bears onto a pipe support or structural steel provided by others, the insulation
shall be wrapped with sheet metal [17] that is 200 mm (8 in) wider than the support steel. The
sheet shall be sealed to the outside of the metal jacket [10] with a liberal coating of insulation
joint sealer [7] and secured with metal bands [11], one at each end as shown in Figure 18.
Figure 18
Pipe Support Rests

[11]
[17]
A Liberal coating of [7] [10]
[10]
[1] with [4] and [5]
[1]
[17]
[7]
A
100 100
minimum minimum
Pipe support by others
Section A-A
12.8.3 When there are hanger supports provided by others, the insulation shall be wrapped with sheet
metal [17] that is 300 mm (12 in) wide. The sheet shall be sealed to the outside of the metal
jacket [10] with a liberal coating of insulation joint sealer [7] and secured with metal bands [11],
one at each end as shown in Figure 19.
Figure 19
Hanger Pipe Supports
Hanger support by others
Liberal coating of [7]

[10]
[1]
[17]
[7]
[1] with [4] and [5]
[11]
Hanger support by others
[1] with [4] and [5] [10]
[1]
Liberal coating of [7]
[17]
300
minimum
12.8.4 Shoe supports provided by others shall be insulated as shown in Figures 20 and 21.
Figure 20
Shoe Pipe Support A
[10]
[1]
[1] [7]
[11] Seal all round with [7]
[1] with [4] and [5]

Non-metallic spacer
by others
4T Pack tightly with [3]

if possible
75 minimum
ovelap of [8]
(typical) [6]
[8] when [4] and [1] with [4] and [5]
[5] not possible
Pipe shoe by others Seal all round with [7]
[1] with [4] and [5] [9] [10]
[1]
Joints at corners to be
[11]
staggered between layers
(no straight through joints)
[8] when [4]
and [5] not Round off corners
possible
All metal parts to be covered
Pipe shoe by others with minimum half insulation
thickness T
Figure 21
Shoe Pipe Support B
[10] T = Total insulation thickness
[1]
[7]
[11]

75 minimum
overlap of [8] [1] with [4] and [5]

4T if possible
75 if possible Joints at corners to be

staggered between layers
(no straight through joints)
[7] All metal parts to be
Fix [1] to shoe with [6]
covered with minimum half
and seal with [8]
insulation thickness T
[8] when [4] and [5] Round off corners
not possible
[9] [11]
[1] with [4] and [5]
[10]
[1]
Nonmetallic spacer
by others [1] with [4] and [5]
Pipe support by others
12.8.5 Trunnion or duck-foot supports provided by others shall be insulated as shown in Figure 22.
Figure 22
Trunnion or Duck-foot Pipe Supports

[10]
[1]
T
[7]
[9] Seal all round with [7]

All metal parts to be
covered with minimum
half insulation [1] with [4] and [5]
thickness T
100
if possible 2T minimum
75 minimum
overlap of [8]
Round off corners
T/2 T [8] when [4] and

[7] [5] not possible
minimum minimum
[9]
[1]
[1] with [4] and [5]
Nonmetallic spacer by others [11]
[10]
Pipe support by others [8]
12.8.6 All pipe supports, guides, and anchors shall be insulated in a manner generally according to
Figure 17, 18, 19, 20, 21, or 22.
12.9 Cellular Glass/PIR Joints
12.9.1 When a pipe has an interface between insulation systems of polyisocyanurate foam (PIR) to this
specification, and cellular glass to 4WPI-INS001, the interface joint shall be insulated as shown in
Figure 23 or 24.
Figure 23
Double Layer PIR/Double Layer Cellular Glass

[8] when [4] and [5] Cellular glass insulation
Chamfer and round off corners not possible
[1]
[9]
150
minimum
[11] [10
[7] 75 minimum overlap of [8]
Figure 24
Double Layer PIR/Triple Layer Cellular Glass
Materials as above
12.10 Equipment
12.10.1 Cryogenic equipment is normally designed with integral insulation. However, when equipment or
large piping greater than DN900 (NPS 36) is to be insulated, it shall be insulated in the same
manner as for the piping shown in paragraphs 12.1 to 12.9 using equipment insulation slabs [2].
12.11 Vacuum Jacket Piping Joints
Figure 25
Vacuum Jacket to Insulated Pipe Termination

Seal with thick layer of [1] Thickness as required
[7] between metal to match insulation O.D.
jacket [10] and VJ
75 150 150
[10]
Minimum
Vacuum [11]
Jacket (VJ)
[8]
[7]
[7] Inner Insulation's O.D.
less than VJ O.D.
[7]
Inner Insulation's O.D.

greater than VJ O>D>
Seal with thick layer of [11] Field piping

[7] between m etal jacket
[10] and VJ 75
Minimum 150
[8] when [4] and [10]
Seal with thick layer of [7] [5] not possible
[9]
between pipe insulation [1] [1] Filler - thickness [9]
and VJ as required
Figure 26
Vacuum Jacket Pipe Insulated Field Joint (Alternate for Non VJ Joint)
Thickness required by
process line size “D”
75 150 Varies 150 75
VJ
[11]
"D"
Seal with thick layer of

[7] between insulation [1]
and VJ (typical)
[7] (typical)

[8] when [4] and [5] [10]
[7] between metal jacket
not possible
[10] and VJ (typical)
12.12 Terminations With Equipment
Figure 27
Storage Tank Nozzle With Termination Plate
[8] when [4] and Thickness to

[7]
[5] not possible match plate
50 Min
150 [11]
[7]
Tank Insulation O.D. less

than termination
Filler plate O.D.
Sleeve
Nozzle
Filler Insulation O.D

greater than or equal
to termination plate
O.D.
Termination
plate supplied Field Piping
with tank
[10] [11]
250 230 [8] when [4]
[7] and [5] not
(Ref.) (Ref.) possible
Figure 28
Cold Box Piping Penetration - Can

[7]
Existing cold box [11]

sleeve [8] when [4] and
[10] [5] not possible
[7]
Diameter
varies with
pipe size
[10] [11]

[7] between insulation
and cold box sleeve Seal with thick layer
end of [7] between metal
jacket and cold box
sleeve
Jacket panel 315 300

(Ref.) Min.
Figure 29
Cold Box Piping Penetration - Ring
300
[11] [8] when [4] and [5]
minimum not possible
[10]
Seal with thick layer of [7]
between metal jacket [10] [11]
and cold box sleeve
[7]
Extra [1] only if gap
between normal insulation
and cold box sleeve is over Non-Flexible
20 mm. If gap is less seal penetration
with [7]
Flexible
penetration
[1] with casing
seal
[10] [11]
[8] when [4] and
[5] not possible
Casing seal with hose
Jacket panel clips by others
300 minimum
INS007AppA.doc
Appendix A
Installation Quality Assurance Report
Contract Reference Report No.
Description of work inspected to Air Products Engineering Specification 4WPI-INS007

Area Description of
Location Equipment Line Number Insulation System Applied
Yes/No
1. Pre-application inspection Pipe/equipment ready for insulation
Erection and assembly complete
System successfully pressure tested
Painting complete, dry, and accepted
Surface clean and dry
2. Insulation materials Correct insulation supplied

Correct accessory materials supplied
Metal jacket and banding correct
No self-tapping screws supplied
3. Insulation application Inner layer banded in position

All voids filled
Outer layer banded in position
Vapor barrier jacket complete and sealed
All other areas sealed with vapor barrier mastic
All pipe supports and projections sealed
4. Metal jacket All insulation covered with metal jacket

All jackets banded securely in position
No self-tapping screws used
Overlaps installed to shed water
Horizontal overlaps staggered
All joints and openings sealed
5. Finishing Labels installed on outside of jackets

Site cleaned and rubbish removed
Report by Date
Appendix B
Photographic Examples
Photograph 1
DO provide removable valve and flange boxes.

DO allow for bolt removal within valve and flange boxes.
DO NOT insulate valves, flanges, or other maintenance items in fixed
insulation systems.
Photograph 2
DO install expansion/contraction joints at correct intervals.

DO support insulation adequately on vertical equipment or piping.
Note:
This specification when issued must contain this appendix. This appendix contains color images of
photographs. Color printing or copying is preferred for paper distribution. Color copies of this appendix
can also be obtained from Air Products, Engineering Standards upon request.
Appendix B (continued)
Photograph 3
DO protect insulation from rain during and after installation.

DO NOT install insulation during inclement weather.
Photograph 4
DO cover ALL insulation with metal jacketing.
DO NOT leave glass cloth reinforcement without mastic covering.
DO NOT leave sharp edges of jacket or banding protruding.

Note:
Photograph 5
DO NOT use self-tapping screws to secure insulation.
Photograph 6
DO NOT leave ledges for water to collect.

DO NOT leave partially sealed areas.
Note:
Photograph 7
DO use bands to secure metal jacket.
DO arrange joints in jackets to shed water.

DO seal all surfaces of insulation and seal jacket joints.
Photograph 8
DO NOT leave gaps in the metal jacket or seams at the top that allow
the ingress of water.
Note:

4wpi Ins007

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GLOBAL ENGINEERING SPECIFICATION

Installation of Multi-Layer Thermal Insulation of 4WPI-INS007*

RESPONSIBLE GROUP: Mechanical Systems Engineering *Formerly N03.1 and 660.101

Section Title Page

Figure 1 Straight Piping 9

Authorization for this document is on file in the GEO Standards Department.

Section Title Page

Figure 15 Termination of Insulation on Pipes 23

Appendix A Installation Quality Assurance Report 34

3.1 Air Products Engineering Documents

⊕ 3PI99002 Thermal and Acoustic Insulation Standard

⊕ Provided for background information only (not referenced in the text)

3.2 American Society for Testing and Materials (ASTM)

[1] Pipe Insulating Material

9. INSULATION THICKNESS AND LIMITS

10.13 Welding or drilling on equipment, piping, and structures is prohibited.

10.21 All moving parts shall be free of mastics and cements.

10.22 The contractor shall remove all waste or surplus material.

11. GENERAL APPLICATION

11.2 Vapor Barrier System

11.2.5 The vapor barrier jacket system shall be installed as follows:

11.3 Protective Metal Jackets

12.1 Straight Piping

Metal Jacket shown Outer layer shown Inner layer(s) shown

1000 1000 1000

[10] [1] with [4] and [5] [1]

[11] Joints between layers to be [9]

[7] Outer layer only

12.2 Insulation Support Rings

Insulation Support Rings

[1] with [4] and [5] T1 = Thickness of inner layer of insulation

Overlap of [8] T1 + T2 [1]

[7] As slip joint [12] or [13]

[9] Apply [7] to all joints in outer layers

Do not extend [4] or reinforcement of [8] over slip joint

[11] two on each side of joint [9]

[1] with [4] and [5] 50

Heavy coating of [7] under [15]

[16] to lap joint

Cross-section through joint

Elbows and Bends

[1] with [4] and [5]

[8] when [4] and

Cross-section through elbow showing joints

External View of Typical Elbow With Miter Segments

[1] [1] with [4] and [5]

Keyed joint as elbow above

External View of Tees or Branches

Seal all round with [7]

Seal all joints in outer [11]

[9] [8] when [4] and [5]

End Caps or Vessel Heads

Pack tightly with [3]

[8] when [4]

Reducer in Vertical Location

Matching Insulation Offset Insulation

External view of flange box

[14] Removable flange box (round)

Valves (Preformed Insulation)

External view of valve box

Slot jacket and overlap

Minimum thickness round

Valves (Fabricated Insulation)