SAUDI BUTANOL COMPANY

Job No.:120167 Document No.: 120167-PI-TS-0008

SPECIFICATION FOR COLD INSULATION

Butanol & Syngas Project

SAUDI BUTANOL COMPANY

At
Madinat Al-Jubail Al-Sinaiyah,
Kingdom of Saudi Arabia

2 11 August 2015 As-Built Mike E. Y.S. Yang M.Y. Lee

Sign Sign Sign
1 19 March 2013 Issue for Construction Mike E. Y.S. Yang Y.G. Jung
0 19 Feb 2013 Issue for Approval Mike E. Y.S. Yang Y.G. Jung
Issue Date Description Prepared Reviewed Approved

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

TABLE OF CONTENTS

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

2.0 GENERAL .................................................................................................................3

3.0 INSULATION CODES ...............................................................................................3

4.0 MATERIALS ..............................................................................................................4

5.0 APPLICATION OF INSULATION ...............................................................................6

6.0 PROTECTION ...........................................................................................................8

APPENDIX 1 - INSULATION THICKNESS FOR CELLULAR (FOAM) GLASS ......................9

APPENDIX 2 - INSULATION DETAILS – GENERAL ARRANGEMENT ............................... 10

APPENDIX 3 - DETAILS FOR SECURING SINGLE & MULTI LAYER INSULATION .......... 11

APPENDIX 4 - INSULATION DETAILS FOR FLANGES ......................................................12

APPENDIX 5 - INSULATION DETAILS – INSULATION CONNECTIONS ............................ 13

APPENDIX 6 - INSULATION DETAILS FOR VALVES.........................................................14

APPENDIX 7 - SINGLE LAYER INSULATION CONTRACTION JOINT DETAILS ............... 15

APPENDIX 8 - MULTI-LAYER INSULATION CONTRACTION JOINT DETAILS ................. 16

APPENDIX 9 - INSULATION SUPPORTS ON VERTICAL PIPING...................................... 17

APPENDIX 9A - INSULATION SUPPORTS ON VERTICAL PIPING DETAILS ...................... 18

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

1.0 SCOPE

This specification indicates the requirements for material, fabrication, installation and
application of insulation on piping and equipment to be used for Cold Service.

2.0 GENERAL

This specification covers requirements for engineering and installation of cold insulation of
piping and equipment and must conform to the following:

a) Only proven stress-corrosion safe insulation material shall be applied on stainless steel.
Insulation materials to be used on austenitic stainless steel shall be low Chloride / Low
Sodium as per ASTM C 795 specifications for safe use over stainless steel.

b) Insulation materials shall be asbestos-free

c) Insulation materials shall be chemically inert, rot-proof, vermin-proof and not injurious
to health.

d) Material shall be new and shall be used prior to the expiration date. Sealants, mastics,
and adhesive shall be supplies in factory-sealed containers.

e) Insulation jacketing shall be provided with factory applied moisture barrier.

3.0 INSULATION CODES

The insulation codes which are covered in this specification are as follows:

C Cold Conservation Insulation

AS Anti-Sweat Insulation

3.1 Cold Conservation Insulation (C)

Cold Insulation shall be applied to prevent heat gain and / or to conserve refrigeration.
Temperature rangers form +25 °C to -196 °C

3.2 Anti-Sweat Insulation (AS)

Anti-Sweat Insulation shall be applied to prevent condensation from forming on the surface or
any other place in the insulation.

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

4.0 MATERIALS

4.1 Insulation Materials

Cellular (Foam) Glass: General Piping and Equipment

Conformance: ASTM C552
Conductivity
0.043
(W/m°K at 10°C)
Density
115 kg/m3
approx.(kg/m3)
Flammability Non combustible ASTM E 136 and E84

4.1.1 Cellular (Foam) Glass is the basic insulation material to be applied to Cold and Anti Sweat
Service unless otherwise specified for specific reason in this specification and other document
and drawings.

4.1.2 Multi-layer insulation is required for cellular glass thicknesses greater than 90 mm in
accordance with the following table:

Total Thickness Thickness Inner Layer Thickness Outer

(mm) (mm) Layer(s)
(mm)
90 40 50
100 50 50
115 50 65
125 60 65
140 65 75
150 75 75
165 75 90
175 50 60 plus 65
190 60 65 plus 65
200 65 65 plus 70
215 65 75 plus 75
225 75 75 plus 75
240 75 75 plus 90

4.1.3 For Pipe / Equipment Supports, High Density Urethane Foam Blocks (500 kg/m3) shall be
used. Further information about cold supports are demonstrated on Doc. 120167-PI-SD-0002,
Piping Supports Standards Drawings.

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

4.2 Insulation Jacketing

4.2.1 General insulation jacketing material shall be aluminum, thickness and finish shall be as per
the following table:

Aluminum, Smooth jacketing, with heat sealed moisture barrier

Thickness:
For pipe less than 760mm OD.
0.4mm
Thickness:
For equipment, and piping more than 760mm OD.
0.48mm

4.2.2 For piping and equipments with fire proofing insulation, the jacketing material shall be
Stainless Steel type 304. Thickness shall be as per the following table:

Stainless steel Types 304, smooth jacketing with heat sealed moisture
barrier.
Thickness:
For all pipe, and equipment sizes
0.3mm

4.3 Sealants

Sealants shall contain 90 percent or greater solids, must be butyl or silicone rubber based.
Material shall remain flexible without cracking or shrinkage at specified environmental
conditions. Shall be resistant to solar radiation and have a water vapor permeability of 0.03
perm-in or less as specified in ASTM E 96, Procedure E. Material shall conform to flame
spread classification of 25 or less as defined in ASTM E 84.

4.4 Means of Securing

4.4.1 Insulation up to 300mm O.D. shall be held in place with 16 gauge Type 304 stainless steel tie
wire. All cut of wire shall be embedded into the insulation.

4.4.2 Insulation 300mm ~ 610mm O.D. shall be held in place with 13mm X 0.5mm thick Type 304
stainless steel bands and seals. Above 610mm O.D., use 19mm X 0.5mm thick bands and
seals.

4.4.3 Metal jacketing shall be held in place with 19mm X 0.5mm Type 304 stainless steel bands and
seals. The maximum tape or band spacing shall be 300mm centers, however, for the piping
NPS 12 and larger, the maximum tape or band spacing shall be 225mm centers.

4.4.4 See Appendix 3 for wire and bands Installation details.

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

5.0 APPLICATION OF INSULATION

5.1 General

5.1.1 Unless otherwise specified, insulation shall not be applied until completion of the followings:

a. Required hydrostatic and/or pneumatic pressure testing. For exclusion, refer to

Paragraph 5.1.2.

b. Application of required substrate protective coating systems, including touch-up of

previously applied coatings.

c. Installation and testing of required tracing systems.

d. Cleaning of surfaces that are to receive insulation.

5.1.2 If required, application of insulation may proceed before pressure testing is complete,
provided that all welds and flanged and threaded connections are left exposed until the
pressure testing is complete. Temporary terminations of installed insulation shall be
adequately protected at all times.

5.1.3 Mastics shall not be applied within 24 hours of ambient air temperature falling below 4.4°C.

5.1.4 Surface to be insulated shall be dry, free from frost and condensation and hand-cleaned by
the insulation applicator to the extent of removing loose rust, loose paint film, salt, dirt, grease,
oil, moisture, or other foreign matter prior to application of insulation materials. Stainless steel
items shall be brushed with stainless steel brushes only.

5.1.5 When applying multi-layer insulation, each succeeding layer shall be staggered to the
longitudinal and circumferential joint of the layer beneath. All joints of all layers shall be
staggered.

5.1.6 Each layer of multi-layer insulation shall be held in place separately. See Appendix 3 for
details.

5.1.7 All insulation sections shall be trimmed and tightly butted to eliminate voids, gaps, or open
joints.

5.1.8 The open end of all insulation shall be neatly finished either by beveling the insulation or by
using cement.

5.1.9 All openings in the jacket for nozzles, brackets, etc. shall be cut as close as possible to
achieve a tight fit.

5.1.10 A seal shall be provided around protrusions, brackets, nozzles, terminal ends, fitting, and
valves to be provided with fully weatherproof finish.

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

5.2 Insulation Contraction Joints

5.2.1 Contraction joints shall be installed with maximum distance between joints as specified in the
table below. Contraction joints shall also be provided in uninterrupted straight pipe insulation
when the run length is equal to or greater than 1/2 the maximum allowed distance.

Maximum Contraction Joint Spacing (m)

Operating
Carbon Steel Stainless Steel
Temperature (°C)
To -18 61 34.4
-19 to -46 36 20.1
-47 to -73 N/A 14.3
-74 to -101 N/A 11
-102 to -129 N/A 9.1
-130 to -157 N/A 7.9
-158 to -184 N/A 7

5.3 Insulation Supports for Vertical Piping

Vertical pipe insulation shall be supported by a pipe insulation support located directly above
all elbows, flanges, or flanged valves. Additional supports are required at a maximum spacing
of 7.3 m of uninterrupted length, but not less than spacing required for contraction joints.

5.4 Vapor Barriers

5.4.1 Before the application of weatherproof jacketing, all surfaces shall be sealed with a vapor
barrier mastic or membrane type vapor barrier sheet.

5.4.2 Membrane type vapor barrier sheet shall be installed without fish mouthing gaps or folds and
shall have a minimum 50 mm overlap at all joints

5.4.3 Vapor barrier mastic shall be applied in a minimum of two coats. A tack coat followed by a
minimum of one finish coat after installation of reinforcing fabric. Care shall be taken to
completely fill and seal the fabric openings.

5.5 Attachments

5.5.1 Thickness of insulation on attachments and projections shall be the same as the adjoining
insulation and will extend along the projection a minimum of four times the insulation thickness.

5.5.2 Attachments and projections fastened to cold piping shall be insulated. Examples of such
attachments or projections are vessel supports, pipe hanger supports, instrument connections,
thermocouple assemblies, platform steel attached to vessels, vents, drains, or pressure taps.

5.5.3 Branch connections shall be insulated a distance of four times the adjoining insulation
thickness or a minimum of 300mm beyond the first block valve

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

5.5.4 A vapor barrier shall be applied over the insulation, and it shall extend a minimum of 150mm
on to the uninsulated portion.

5.5.5 Code inspection plates, stampings, nameplates, data plates, etc. on piping shall be covered
with removable vapor-sealed insulation plugs.

6.0 PROTECTION

6.1 Sharp outside edges of insulation are especially vulnerable to breakage and abuse and shall
be well rounded for maximum protection.

6.2 Insulation systems must be caulked and/or sealed at all possible points of moisture entry.

6.2 The insulation contractor shall apply the finish covering as soon as practical after the
insulation has been secured to assure protection from inclement weather.

6.3 If bare insulation cannot be finished before the end of the working day, the insulation must be
protected against the elements.

6.4 Insulation must be thoroughly dry at the time of weatherproofing.

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

APPENDIX 1 - INSULATION THICKNESS FOR CELLULAR (FOAM) GLASS

Insulation Codes: Cold Conservation (C), Anti-Sweat (AS)

Nominal Operating Temperature (°C)

Pipe 25 1 -19 -30 -41 -52 -74 -91 -108 -139 -150 -171
Size or To To To To To To To To To To to to
Vessel 2 -18 -29 -40 -51 -73 -90 -107 -138 -149 -170 -196
Dia. (“)
1/2 40 40 50 50 65 75 90 90 90 100 115 115

3/4 40 50 50 50 65 75 90 100 100 115 115 115

1 40 50 65 65 65 75 90 100 115 115 125 125

1 1/2 40 50 65 65 75 90 100 115 115 125 125 125

2 40 50 65 65 75 90 115 115 125 125 140 140

3 40 50 75 75 90 100 115 125 125 140 150 150

4 40 65 75 75 90 100 125 125 140 150 165 165

6 50 65 75 75 100 115 125 140 150 165 175 175

8 50 65 75 75 100 125 140 150 165 165 175 190

10 50 65 90 90 100 125 140 150 165 175 175 200

12 50 65 90 90 115 140 150 165 175 175 190 215

14 75 75 100 100 115 140 150 165 175 190 190 215

16 75 75 100 100 115 140 150 165 190 190 200 225

18 75 75 100 100 115 150 150 175 190 190 215 225

20 75 75 100 100 115 150 165 175 190 200 225 225

24 75 75 100 100 115 150 165 175 200 215 240 240

>24 75 75 100 100 115 165 185 215 215 225 250 250

Notes: 1. Insulation thickness which is greater than 90mm shall be installed in

staggered layers. See paragraph: 4.1.2.

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

APPENDIX 2 - INSULATION DETAILS – GENERAL ARRANGEMENT

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

APPENDIX 3 - DETAILS FOR SECURING SINGLE & MULTI LAYER INSULATION

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

APPENDIX 4 - INSULATION DETAILS FOR FLANGES

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

APPENDIX 5 - INSULATION DETAILS – INSULATION CONNECTIONS

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

APPENDIX 6 - INSULATION DETAILS FOR VALVES

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

APPENDIX 7 - SINGLE LAYER INSULATION CONTRACTION JOINT DETAILS

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

APPENDIX 8 - MULTI-LAYER INSULATION CONTRACTION JOINT DETAILS

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

APPENDIX 9 - INSULATION SUPPORTS ON VERTICAL PIPING

Note: 1. Where insulation expansion joints are required, they shall be provided at each insulation
support or stiffener ring.
2. Insulation supports shall be provided at intervals as noted in paragraph 5.3.
3. All insulation support material shall be the same as pipes to be insulated.
4. For support dimensions, see Appendix 9A.

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SAUDI BUTANOL COMPANY Specification for Cold Insulation
Butanol/Syngas Project Document No.: 120167-PI-TS-0008
Al Jubail, Kingdom of Saudi Arabia Rev. No. : 2 Date: 11 August 2015

APPENDIX 9A - INSULATION SUPPORTS ON VERTICAL PIPING DETAILS

PIPE I.D. SUPPORT DIMENSIONS (mm)

SIZE RING
(inch) (mm) A B C D E F
1/2 21.4 13 3 3 6 25 10

3/4 26.7 13 3 3 6 25 10

1 33.4 13 3 3 6 25 10

1-1/2 48.3 13 3 3 6 25 10

2 60.4 19 5 5 10 32 13

3 88.9 19 5 5 10 32 13

4 114.3 19 5 5 10 32 13

6 168.3 19 5 5 10 32 13

8 219.1 25 6 6 13 38 16

10 273.1 25 6 6 13 38 16

12 323.9 25 6 6 13 38 16

14 355.6 25 6 6 13 38 16

16 406.4 25 6 6 13 38 16

18 457.2 25 6 6 13 38 16

20 508.0 25 6 6 13 38 16

24 609.6 25 6 6 13 38 16

30 760.2 25 6 6 13 38 16

36 914.4 25 6 6 13 38 16

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