ERECTION AND INSTALLATION MANUAL DOC.

No:
STC INSULATION AND LAGGING STC-IN-P0001

CONTENTS
PAGE
1. General 2
2. Design Conditions and Technical Requirement 2
3. Materials 2
4. Pipe Insulation 3
5. Valve and Fittings Insulation 4
6. Equipment Insulation 4
7. Pumps 5
8 Pipe work and Equipment Lagging 5
9. Storage of Insulation Materials

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 ERECTION AND INSTALLATION MANUAL DOC.No:
STC INSULATION AND LAGGING STC-IN-P0001

1 General. This Standard Specification covers the standard technical requirements for the
supply and installation of thermal insulation, lagging, jacket, and accessory material.

2 Design Conditions and Technical Requirement. All thermal insulation, lagging, jacket, and
accessory material necessary for heat conservation, personnel protection, and antisweat
protection on all equipment items and piping systems within his scope of supply.

The insulation shall be fireproof and waterproof and shall be compatible with the surface to
which it is applied.

The insulation shall maintain its properties for the plant lifetime, and shall be applied
according to good and acceptable insulation practice for the particular service and
temperature involved.

Surfaces to be insulated shall be clean of dirt, scale, rust, grease, or moisture before any
insulation is applied. Insulation materials shall be dept dry and shall not be applied when it is
wet. If the materials become wet after application, they shall be allowed to dry before
proceeding with the application of metal jacket or weatherproof compounds.

Removable sections of insulation shall be provided over removable plates, lifting lugs,
access doors, or areas on pressure vessels where code inspection data appear, and where
otherwise specified. Insulation shall be applied in a manner which will allow withdrawal of
removable sections without damage to such sections or to adjacent insulation.

Welded joints in pipes and equipment shall not be covered with insulation until hydrostatic
tests have been satisfactorily performed on the pipes and equipment.

3 Materials. The materials to be supplied shall conform to the latest issues of the designated
ASTM Standards. Equivalent internationally recognized standards may be accepted, subject
to approval of the Engineer.

Thermal insulation, lagging materials, and hardware called for in subsequent sections of this
specification shall conform to the following requirements:

(1) Thermal insulation for hot equipment (temperatures up to 600 oC):

Mineral wool blankets per ASTM C592, 48 kg/m3 minimum density (except as
otherwise specified), reinforced on both sides with galvanized hexagonal wire
mesh

(2) Thermal insulation for hot piping systems (temperatures up to 600 oC):

Molded calcium silicate block per ASTM C533

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 ERECTION AND INSTALLATION MANUAL DOC.No:
STC INSULATION AND LAGGING STC-IN-P0001

(3) Metal lagging and jacket for all insulated surfaces):

Aluminum sheet, as per ASTM B209 surface as a moisture barrier; ribs, corrugations,
and thickness shall be as specified in subsequent sections of this specification

(4) Insulating and finishing cement:

As per ASTM C449, blended with hydraulic setting binders and corrosion inhibitors
to provide smooth, hard, monolithic finish when dry

4 Pipe Insulation. For hot pipes, performed segmental pipe insulation as per section 3,
Materials shall be used.

Piping insulation shall allow for radial expansion and contraction of the pipe, and shall permit
the pipe to move longitudinally. It shall accommodate all normal movements of the pipe due
to changing thermal conditions without opening up the joints between sections of insulation.

Insulation for service below 400oC shall be applied in single layers with staggered
longitudinal joints. Insulation for service at higher temperatures shall be applied in double
layers with staggered circumferential and longitudinal joints.

Insulation joints shall be tightly butted and gaps shall be filled with insulating cement.
Insulation diameters under 500 mm size shall be fastened with wires as specified in, section
3, Materials Larger insulation diameters shall be fastened with bands specified in section 3,
Materials Wires or bands shall be placed on 230 mm centers.

The number and spacing of expansion joints shall be such that the expansion in any joint is
limited to 20 mm. The design of the expansion joints in single layer insulations shall be of
double-wall construction. On multilayer insulations, the locations of the expansion joints
shall be staggered. The joints shall be filled with resilient material.

Projections on clod piping such as pipe hangers shall be sealed with mastic where they join
the pipe insulation to prevent vapor penetrating into the insulation material.

All pipes shall have adequate insulation support rings and/or attachments to support
insulation.

5 Valve and Fittings Insulation. Valves and fittings shall be insulated with segments of pipe
insulation carefully cut to fit and then firmly wired in place.

Molded or shop-fabricated insulation shall be used with preference.

Voids shall be filled with high temperature insulating cement. Two coats of finishing cement
each 6 mm thick shall be finally applied, bringing the total insulation thickness on fittings to

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 ERECTION AND INSTALLATION MANUAL DOC.No:
STC INSULATION AND LAGGING STC-IN-P0001

that of the adjacent pipe insulation. The finishing cement shall be reinforced on fittings of
dia 200 mm nominal size and larger with wire mesh.

Where pipe is provided with flanges, the pipe insulation shall be tapered adjacent to the
flange to permit removal of the flange bolts without damaging the insulation.

Where flanges are uninsulated, the jacket shall end flush with the insulation and finish at 45
degree with insulating cement and weatherproof mastic.

Where flanges are insulated, the jacket shall be fabricated to fit neatly around the flange
insulation.

6 Equipment Insulation. Equipment items shall be insulated with mineral wool blankets as
specified in section 3, Materials.

Lagging shall be in intimate contact with the insulation. In areas where it is not convenient
to have the lagging in intimate contact with the insulation (in air space between insulation
and lagging), galvanized steel plaster lath shall be applied to the cold surface of the
insulation for support.

Insulation for service below 400 oC shall be applied in a single layer. Insulation for service at
higher temperatures shall be applied in double layers.

Insulation shall be fitted to the equipment and provided with an adequate number of
expansion joints. All joints shall be staggered and tightly butted. Adjacent edges shall be
laced with lacing wire. Gaps shall be filled with insulating cement and reinforced with wire
mesh.

7 Pumps. Insulation shall be cut and fitted to the shape of the pump body. Pump body shall
be coated with core coating before insulating. If straps cannot be used to secure insulation
due to irregularities of the; body, insulation shall be secured in place with insulation wire.

Insulation may be formed into a box around the unit, in lieu of being formed to fit the shape
of the pump body. All void spaces shall be filled with fibrous insulation. Core coating of the
pump body is not required.

8 Pipework and Equipment Lagging. All pipes and equipment which is insulated shall be
lagged or jacketed with aluminum as follows:

Aluminum lagging shall be fabricated from corrugated sheets of smooth, embossed aluminum
alloy as per section 3, Materials. The thickness shall be 0.4 mm for application to piping
systems dia 600 mm and smaller, and shall be 0.8 mm thick for larger size piping systems
and for all equipment.

Lagging shall not be applied until insulating cement is dry.

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 ERECTION AND INSTALLATION MANUAL DOC.No:
STC INSULATION AND LAGGING STC-IN-P0001

Aluminum jacket shall be applied with all joints lapped. Longitudinal overlaps shall be 50
mm; circumferential overlaps shall be 75 mm.

Aluminum jacket shall be applied with bands and screw as specified in section 3, Materials. All
joints or screws shall be placed where they are least visible.

Elbows with an insulated outside diameter less than 330 mm shall be covered with formed
aluminum elbow jackets. Piping elbows with larger insulated outside diameter shall be
covered using mitered segment aluminum elbow jackets constructed with rolled interlocking
edge joints. Mitered segments shall have included angles not greater than 15 degrees.

Insulated long radius bends shall be jacketed using spiral wrapped aluminum straps or
individual metered segments.

The jacket shall be applied directly over the blanket insulation and neatly fitted into place. All
joints shall be arranged so as to shed water; and suitable flashing or weatherproofing shall
be provided at all nozzles, manholes, and other projections to prevent the entrance of water.
Insulated flanges shall be lagged; the lagging shall be fabricated to fit neatly around the
flange and shall be removable.

9 Storage of Insulation Materials. All insulation materials shall be supplied with adequate
protection to withstand damage during transportation and storage . Where applicable, the
materials shall be supplied in waterproof containers which can be satisfactorily resealed after
partial using of content.

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