JOB SPECIFICATION FOR HOT INSULATION OF VESSELS, PIPING AND EQUIPMENTS

JOB SPECIFICATION No.

4935-6-44-0002 Rev. 0
Page 1 of 51

JOB SPECIFICATION FOR HOT INSULATION OF VESSELS, PIPING AND EQUIPMENTS FOR OFFSITES (PX/PTA), IOCL,PANIPAT

0 Rev. No

24.10.03 Date

Issued as Job Specification Purpose

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JOB SPECIFICATION FOR HOT INSULATION OF VESSELS, PIPING AND EQUIPMENT

JOB SPECIFICATION No.

4935-6-44-0002 Rev. 0
Page 2 of 51

Abbreviations: Ih It Ie Is Ia Ij : : : : : : Insulation for heat conservation Insulation for steam traced surfaces Insulation for electrically traced surfaces Insulation for personal safety Acoustic Insulation Insulation for steam jacketed surfaces

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JOB SPECIFICATION FOR HOT INSULATION OF VESSELS, PIPING AND EQUIPMENT

JOB SPECIFICATION No.

4935-6-44-0002 Rev. 0
Page 3 of 51

CONTENTS NO. 1. 1.1 2. 2.1 2.2 2.3 3. 3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.3 3.4 3.4.1 3.4.2 3.4.3 3.4.4 4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 5. 5.1 5.2 5.3 5.4 5.5 6. TITLE PAGE

GENERAL....................................................................................................................5 Scope.............................................................................................................................5 DESIGN BASIS ...........................................................................................................5 Criteria ..........................................................................................................................5 Extent of Insulation on Piping Systems ........................................................................6 Extent of Insulation on Equipments..............................................................................7 MATERIALS ...............................................................................................................8 General..........................................................................................................................8 Insulation Materials ......................................................................................................9 Fibrous Material (Rockwool & Glasswool)..................................................................9 Rigid Materials(Calcium Silicate, Expanded Perlite, Polyisocyanurate, Polyurethane Foam(PUF) Blocks, Sprayed Cast-in-situ PUF, Cellular Glass .................................10 High Temperature Insulation Materials(Above 550ºC)..............................................14 Insulation Material for Impulse lines..........................................................................15 Additional tests/checks for Materials .........................................................................15 Weather Protection Jacket ..........................................................................................15 Ancilliary Material......................................................................................................16 Securement Bands ......................................................................................................16 Rivets ..........................................................................................................................17 Screws.........................................................................................................................17 ‘S’ & ‘J’ Clips.............................................................................................................17 APPLICATION ..........................................................................................................17 General........................................................................................................................17 Piping..........................................................................................................................18 Horizontal Equipments ...............................................................................................22 Vertical Equipments ...................................................................................................24 Flange, Nozzle, Channel Cover, Manway and Handhole Flanged Cover ..................24 Irregular Surfaces such as Pump, Compressor, Turbine etc. ......................................24 Vertical Storage Tanks................................................................................................25 Horton Spheres ...........................................................................................................26 Inspection Windows ...................................................................................................27 Impulse lines...............................................................................................................27 INSULATION FINISH ..............................................................................................27 General........................................................................................................................27 Piping..........................................................................................................................28 Equipments .................................................................................................................29 Vertical Storage Tanks................................................................................................30 Horton Sphere.............................................................................................................31 GUARANTEE............................................................................................................31

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9. 12. 1. 6. 3. 15.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. 18. 11. 4935-6-44-0002 Rev. PIPING AND EQUIPMENT JOB SPECIFICATION No. 8-00-0001-F1 Rev. 10. 7. Detail of Spacer Rings for Cladding Support Detail of Spacer Ring Fibrous Insulation (Mattress) Bolted Insulation Support for Vertical Pipe Insulation Details for Bends / Elbows Insulation Details: Pipe Bends & Elbows Insulation Details: Pipe Branched & Reducers Insulated Removable Cover: Valves Insulation Removable Cover: Flanged Joints Insulation Details: Pipe Supports Insulation for Steam Traced Piping Horizontal Equipment Insulation Horizontal Equipment Heads Use of Flexible Insulation in combination with Rigid Insulation to compensate for Vessel Expansion Insulation details: Vertical Vessel Insulation Details: Vertical Vessel Heads Insulation Details: Vertical Vessels Insulation Details: Vertical Storage Tank Insulation Details: Sphere Format No. 2. 19. 0 Page 4 of 51 FIGURES NO. 4. 14. 13. 20. DESCRIPTION Pipe Insulation Details (Fibrous & Rigid Insulation) Pipe Insulations: Method of staggering of sections Rigid & Fibrous Insulation (Preformed Pipe Sections only) Horizontal Pipe: Fibrous Mattress Insulation. 17. 5. 8. 0 Copyright EIL – All rights reserved . 16.

6 km/hr) : 0.0 2.1.5 1.1. Alternative designs and materials would be specified if necessary for corrosive atmosphere or potential leaks and spills of chemicals. flue ducting and air ducting. Storage Tank and sphere documents and Insulation Schedules. equipment.1 DESIGN BASIS CRITERIA For Insulation thickness tables Process design basis shall be referred. Wherever necessary this specification indicates the basis for selecting a criterion.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. 4935-6-44-0002 Rev. Vessel.6 2. Insulation thickness tables for all types of materials are based on heat loss criteria and the various parameters considered for insulation thickness calculations are as follows: Wind velocity Emissivity Ambient Temperature Maximum surface temperature Heat loss criteria for Ih & It :1m/sec(3.1.1. 0 Page 5 of 51 1. This specification does not cover cold service insulation.4 1. This specification does not cover insulation for boiler or fired heaters and associated air heaters.1. PIPING AND EQUIPMENT JOB SPECIFICATION No.1. personnel protection and fire protection. 1. Exchanger. Piping. This specification is suitable for use in outdoor service with normal process plant atmospheres. Instrument Piping Details and Schedules. 0 Copyright EIL – All rights reserved . All the codes/standards mentioned in this specification shall be of latest issue.0 1.2 1.3 1. temperature maintenance.1.1 GENERAL SCOPE This specification covers design and material requirements for above ground. process stabilisation.2 (For Aluminium cladding) : 30ºC : 65ºC : 150kcal/hr m² for service temperature upto 250ºC : 170kcal/hr m² for service temperature 251-550ºC : 190kcal/hr m² for service temperature 551-760ºC : 15kcal/hrm² for maintenance temp upto 70ºC : 20kcal/hrm² for maintenance temp 71-100ºC :25kcal/hrm² for maintenance temp 101-120ºC : 30kcal/hrm² for maintenance temp 121-140ºC : 35kcal/hrm² for maintenance temp 141-150ºC Heat loss criteria for Ie Format No.1 2.1 1. Piping General Arrangement Drawings & Isometrics. For cold services Specification 4935-6-44-0003 is applicable. external insulation of piping and equipment operating between ambient temperature and 760OC for the purpose of heat conservation. storage tanks & vessels requiring insulation and the temperatures (operating temperatures) shall normally be specified on the following project documents: Piping and Instrument Diagrams (P&IDs) and Line Lists. Equipment suppliers General Arrangement Drawings for equipment items in Package plant. 8-00-0001-F1 Rev. economisers.

4935-6-44-0002 Rev. The actual extent of insulation shall be determined by Field Construction Personnel and/or operating personnel using the following criteria: Exposed surfaces operating above 65OC and located within 600mm horizontally or 2100mm vertically of a normal access. Applicable where exposed surface temperatures exceed 65OC in normal or short-term operating conditions. such as level gages.5 Instruments and associated piping(other than impulse piping/tubing)subject to operating flow and/or temperature conditions prevailing in the connected piping or equipment shall be insulated to the same requirements as that of piping or equipment.3 2.3.1.2. including pipes and fittings. provide open mesh metal guards and for surfaces which are not internally insulated. tees and pipe fittings completely insulated.1.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. condensate service.2. Instrumentation to be insulated. Copyright EIL – All rights reserved 2.4 2. Insulation is not desired for piping and equipment for which heat loss is desired . The intent of P&ID's.6). For bucket and float type traps the inlet piping and trap shall be insulated.1 2.2. 8-00-0001-F1 Rev. hot oil lines.5 2.2 2. provide insulation on that part of surfaces with which operating and maintenance personnel may come in contact while performing routine duties.2 2. line classification lists. level controllers and level switches shall have their fluid containing sections and the associated piping completely insulated.1. All valves and flanged joints shall be completely insulated only in steam.2 2. EXTENT OF INSULATION ON PIPING SYSTEMS Insulated piping systems shall have straight pipe. in lines which are trace heated or jacketed to maintain temperatures and also other process services where the temperature is more than 300degree centigrate. PIPING AND EQUIPMENT JOB SPECIFICATION No.3 2. bends. For impulse piping/tubing refer impulse piping insulation specifications described elsewhere in the document. 2.excepting for personnel protection or to avoid thermal stress problems. (See para 2. as indicated in P&IDs and line lists: Heat conservation Process stabilisation to assist process control.1. 0 Page 6 of 51 2. Steam tracing Electric tracing Hot water or solvent tracing (liquid) Hot oil tracing Steam jacketing Hot water or liquid jacketing Hot Oil Jacketing Fire hazard protection to prevent fast boil off of liquid Personnel protection. Insulation on inlet piping to thermostatic and thermodynamic steam traps shall terminate at approximately 500mm before the trap. Steam trap outlet piping other than closed condensate recovery system shall not be insulated except for personnel protection reasons.2. Insulation is required for any of the following purposes. which designate insulation for personnel protection is to call attention only to the eligibility of such service.2. walkway or work area.2.6 Format No. Over internally insulated piping and equipment. 0 . engineering drawings etc.4 Internally refractory lined piping and equipment and any other items for which heat loss is essential shall not be insulated.

Fans. 0 Page 7 of 51 2. compressors.2. Copyright EIL – All rights reserved 2. Valves. 0 . Support skirts of insulated vertical vessels of 1200mm and less shall be insulated externally only.1 2. However.3 2.2 2. Insulation shall not be applied to the following unless otherwise specified: Pumps with operating temperature below 200OC unless pumped fluid has a pour point above minimum design ambient temperature.6 Format No.3. PIPING AND EQUIPMENT JOB SPECIFICATION No. Supports for piping. flare and blowdown systems. Where insulated horizontal piping is supported on steel shoes. Steam Traps (except as noted in paragraph 2.3. The insulation shall terminate not less than 300mm above the support concrete or steelwork. Piping which becomes hot intermittently. Expansion joints.3. unless otherwise specified. hinged joints and hose assemblies Sight flow indicators.2.2. 8-00-0001-F1 Rev.7 Insulation shall not be applied to the following.2. Thermowell bosses and pressure tappings. including control valves and flanges in process piping systems (except as noted in 2.2.3.3 2. vents. Liquid ends of pumps shall be insulated when heat traced and jacketed.2 and 2.3). 4935-6-44-0002 Rev. steam-out and snuffing steam systems. the height of the shoe shall be such that the underside of the insulation finishing material is clear of the supporting structure upon which the shoe rests by 25mm minimum.3.5 2. such as relief valves.3. Flange joints in Hydrogen service. as described in para 2. EXTENT OF INSULATION ON EQUIPMENTS Support skirts of insulated vertical vessel greater than 1200mm diameter shall be insulated both internally and externally for a minimum distance of 600mm below the bottom tangent line. Liquid ends of pumps except as noted in the paragraph 2. excluding pipe hangers outside pipe insulation boundary.1. blowers or other rotating or reciprocating equipment.5 above. 2. Pipe Union fittings.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS.8). as required. personnel protection insulation for these items shall be applied. Turbines and steam ends of reciprocating pump shall be insulated for heat conservation.3. Bottom heads of insulated vertical vessels enclosed by a support skirt shall be insulated without finishing material and shall be insulated only when the vessel outside diameter is greater than 1200mm.4 2.2.8 2.9 Insulation shall be provided such that an absolute minimum clearance of 25mm is available between the outside surface of any insulation finishing material and any adjacent surfaces.3.

Exchanger channel and covers. Selected material(s) for a particular job shall be as per Process Design Basis. non-sulphurous.5 3. upto 125OC) services a suitable moisture barrier shall be used. For electrically traced pipe Polyurethane foam(PUF) or Polyisocyanate(PIR) shall be used with rockwool as inner layer when the thickness required is more than 25mm. for all applications except for electrically traced pipe. The use of insulation or finishing materials containing ASBESTOS in any form is not permitted.1.4 3. PIPING AND EQUIPMENT JOB SPECIFICATION No. Thermowell bosses and pressure tappings. MATERIALS GENERAL Insulation materials shall be as per specifications described in para 3. shell and channel flanges & Exp.1.1.2 Internally insulated or refractory lined equipment unless specially designed for metal temperature control. calcium silicate.Insulation materials shall be of low chloride content. diethanolamine and hexanol will react and start fires when they leak into inorganic absorbent insulations.6 3. governors and supports. Heads of vessels enclosed by support skirts with vessel diameters 1200mm and less. shaft bearing housings. Turbine casings to be insulated shall exclude shaft seal caps.0 3.3 3.1 3. Nameplates of all equipment items.e. Copyright EIL – All rights reserved 3. Insulation materials to be used over austenitic stainless steel surfaces shall be zinc free and shall be inhibited with sodium silicate as per ASTM C-795. 4935-6-44-0002 Rev. perlite and ceramic fibres can be used for the full temperature range mentioned against the respective material. No flammable material shall be attached to the insulation.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS.1. manholes & handholes and flanges of equipment. In case of calcium silicate it should not exceed 50ppm. Nozzles. Many common flammable liquids such as oil.1 3. butanol.1. Joints. noninjurious to health and non-corrosive to steel and aluminium (even if soaked in water at ambient temperatures for extended periods). Internal surfaces of insulated vessel support skirts with vessel diameter 1200mm or less. 8-00-0001-F1 Rev. Surfaces of coolers and condensers. 0 .1. Water absorbing insulants like fibrous insulants. Such absorbent insulations can store large quantities of combustible liquids should a leak occur. impervious to hot water and steam.7 Format No.1. throttle valves.2.The amount of leachable chloride in the insulation material(except for calcium silicate) before application shall not exceed 10ppm. chemically inert. This could be a decisive factor when specifying and evaluating alternative materials and shall be taken care of while specifying project insulation specifications. rot proof. 0 Page 8 of 51 3. All materials shall be of high quality and good appearance. For the chemical analysis of insulation materials ASTM C-871 shall be referred. For low temperature (i. vermin proof.

stitched through with 22 SWG galvanised lacing wire: Mattress for Lined covers shall be faced on one side with 20mm galvanised 22 SWG wiremesh stiched through with 22 SWG galvanized lacing wire. 3.unless otherwise specified.52 150 0. 80 & 64 kg/m3 for resin bonded pipe sections and resin bonded curved beveled segments or LRB slabs respectively of glasswool.62 200 0.1. The number of pieces to be used shall be as less as possible.90 *The values mentioned are for insulation material as per IS code. shall be provided over flanged joints & valves for Process services above 300 degree centigrade.1 INSULATION MATERIALS Fibrous Materials (Rockwool & Glass Wool) 1 Shall be a preformed insulation and shall be of long fibred rock or glass material processed from a molten state into fibrous form bonded with a binder and suitable for the intended operational temperature range from ambient to 550OC and 350OC for rockwool and glasswool respectively.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. 4935-6-44-0002 Rev. Unless otherwise specified. Max resin content at the above mentioned densities shall be 2% and 5% for rockwool and glasswool respectively.2. PIPING AND EQUIPMENT JOB SPECIFICATION No. Faced on one side with 20mm galvanized No.1. 22 SWG wire mesh.43 100 0. In general the insulation materials shall be as per Indian standard/codes for indigeneous jobs and as per ASTM/BS standards/codes for overseas jobs unless otherwise specified. Slagwool is not acceptable.For Apparent thermal conductivity for material as per ASTM codes refer respective ASTM code.1. unless otherwise specified herein and shall be tested and test certificates on representative samples furnished as per IS:8183/IS:9842/ASTM:C547/ ASTM:C592 /ASTM:C612.2 3.8 Dimensions and dimensional tolerances for pipe sections. 8-00-0001-F1 Rev. mattresses & slabs shall generally be as per respective codes unless otherwise mentioned. 0 Page 9 of 51 3. *Thermal Conductivity **Mean Temperature OC Thermal Conductivity mW/cm OC 50 0.10 Removable box type insulation in calcium silicate material. IS:8183/ASTM C612 TYPE IV/ TYPE V 2 • Mineral fibre block & board thermal insulation 3 Insulation shall conform to the requirements of respective codes. It should also be provided with a drain.9 3.For insulation over ‘Austenitic SS Piping & Equipment’ instead of galvanized wiremesh & lacing wire SS304/316 wiremesh & lacing wire shall be applied.80 300 0. When installed the insulation shall fit snugly and shall have a tight joint. 3. **Mean Temperature = (Hot Face Temperature + Cold Face Temperature) / 2 Density(min) Copyright EIL – All rights reserved • Format No.68 250 0. 0 . insulation material shall strictly conform to all the requirements of quality standards listed below: • • Preformed pipe insulation Metal-mesh covered bonded mineral Fibre blanket & blanket type pipe insulation IS:9842/ASTM C547 TYPE II or TYPE III IS:8183/ASTM C592 TYPE II for piping & equipt. • 140 & 128 kg/m3 for resin bonded pipe sections and resin bonded LRB mattresses respectively of rockwool.

unless otherwise specified herein and shall be tested and test certificates on representative samples furnished as per ASTM C 610 • Bulk Density(min) 192 kg/m3. unless otherwise specified herein and shall be tested and test certificates on representative samples furnished as per IS 9428/ASTM 533 TYPE II. Test as per ASTM C302 (pipe) & ASTM C303(block) Format No. 4935-6-44-0002 Rev.Loss in Mass 15% Compressive Strength Reduction in thickness not exceeding 10% under a load of 345 kN/m2. for 24 hours. Insulation shall conform to the requirements of respective codes. 3. Expanded Perlite. upto a temperature at which the following requirements are met: Max. **Mean Temperature = (Hot Face Temperature + Cold Face Temperature) / 2 Heat Resistance 2 Expanded Perlite Insulation shall be expanded perlite block and pipe in accordance with ASTM C 610. with inhibitors less than10 PPM.max W/mk 200 0. O • *Thermal Conductivity **Mean Temperature C Thermal Conductivity.Linear 2% Shrinkage(length) Max. Sprayed Cast-in-situ PUF and Cellular Glass) 1 Calcium Silicate It shall be suitable for temperatures upto 760OC.2 Rigid Materials (Calcium Silicate. Reduction in thickness shall not exceed 10% a) Dry under a load of 415 kN/m² and b) Wet (after 18 hrs immersion in water) under a load of 170 kN/m². for 24 hrs. temperature of use (550OC). • When tested at increasing temperatures. the material shall be deemed suitable for use under conditions of soaking heat. 250 kg/m2 for resin bonded pipe sections. For stainless steels.110 400 0. 0 Page 10 of 51 Not more than 2 percent when subjected to soaking heat at the stated max. 0 Copyright EIL – All rights reserved .121 450 0. curved bevelled segments and LRB slabs.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS.080 250 0.135 500 0.2.for other materials not to exceed 20 ppm. It shall be compounded from expanded perlite & sodium silicate binder and shall be suitable for temperatures upto 550OC. PIPING AND EQUIPMENT • • • Linear Shrinkage Compressive Strength (minimum) at 10% deformation Chloride Content JOB SPECIFICATION No.097 350 0. 8-00-0001-F1 Rev.088 300 0. • • Bulk Density Compressive Strength 200 to 280 kg/m3. 120 kg/m2 for LRB mattresses.148 • Chloride content Not to exceed 50 PPM for CS as well as SS *The values mentioned are for insulation material as per IS code. For Apparent thermal conductivity for ASTM code material refer respective ASTM code. Insulation shall conform to the requirements of respective codes. Polyurethane Foam (PUF) Blocks. Polyisocynurate.

2 metric perm-cm Test shall be as per ASTM E 96 • • Density Thermal Conductivity • Compressive Strength (Min. Test shall be as per IS:11239 part X.max Linear shrinkage Chloride content • • 260 50 371 60 2%(max) at 649 OC for 24hrs For stainless steels. Unless otherwise stated. After drying at 102OC .086 204 0. 4. at 10% deformation or at yield point.126 149 50 • Water Absorption of thermal Insulation After Heat Aging and 48h Water Immersion. Specimen thickness shall be as per IS:3346 or 25mm per ASTM C177.079 149 0.120OC for constant mass as per ASTM C165.less than10 PPM. 0 Page 11 of 51 412 kPa(Min).% by weight . pipe and fitting insulation shall be manufactured with polyester or polyether resins.106 316 0.238 24 0. shall be 205 KPa.for other materials not to exceed 20 ppm 3 Polyisocyanurate(PIR) Rigid Polyisocyanurate foam block. 8-00-0001-F1 Rev. Shall be as given below: Test method shall be as per ASTM C177/C518(Block) &ASTM C335(Pipe) Mean Temp OC Thermal Conductivity Max. 0 Copyright EIL – All rights reserved . moisture gain. special catalysts and a blowing agent. the test specimens shall be conditioned without external stress at 23±1OC and 50±2 percent relative humidity for a minimum of 24 hours before testing.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS.252 Thermal conductivity test shall be as per IS:3346 or ASTM C177. PIPING AND EQUIPMENT • • Compressive Strength (for blocks only) at 5% deformation ApparentThermal Conductivity JOB SPECIFICATION No. W/mK 93 0. Test as per ASTM C165.. 4935-6-44-0002 Rev.) Water vapour permeability • Format No. Mean Temp.245 38 0. 40 to 64 kg/m3 To be tested as per ASTM C303 for Block-type and ASTM C302 for pipe covering. flammability retarding agents. This can be used upto a temperature of 125 deg. Insulation shall conform to following requirements and shall be tested and test certificates on representative samples furnished for conformance to each of the following requirements: • Selection of samples for testing As per ASTM C390 OR BS:2972 (Frequency of sampling clause IV). OC Thermal Conductivity Max.111 371 0.095 260 0. whichever occurs first. mW/cm deg 10 0.C.

extent of burn) This is applicable to preformed pipe coverings only and shall be 275Kpa(min). PIPING AND EQUIPMENT • Fire properties JOB SPECIFICATION No.6mm • Thickness Pipe Insulation Length 750 to 1000mm Inside diameter To suit standard steel pipe Shall be supplied as cylindrical shape slit in half lengthwise or as curved segments cut from blocks or moulded segments cut from blocks or moulded to shape.6mm 20. Test as per BS:4370 Part – II (Test for closed cell content) Test method as per IS:11239 Part – II The max. 40.9 kg/m3 To be tested as per ASTM C302.019 K Cal/hr. Upto 14” size. Thermal conductivity of polyurethane foam slabs and sections shall not exceed 0. allowable value after aging at 60OC – 90 to 100% relative humidity)-Maximum percent change in linear dimension shall be 4. PUF block.. Insulation shall conform to the requirements of respective codes.) Format No. • • Density Thermal conductivity 35 to 39. 0 Page 12 of 51 • • Flexural Strength Humid aging • • Closed cell content Dimension stability after heating • Standard size and dimensions Insulation shall be self extinguishing type and shall satisfy the requirements for maximum extent of burn (less than 25mm) when tested as per BS:5608(Horizontal burning characteristics-max.C. unless otherwise specified herein and shall be tested and test certificates on representative samples furnished. Test shall be as per ASTM D2126. Minimum percent 85. only pipe sections slit in half lengthwise shall be used. pipe and fitting insulation shall be produced by reacting polyisocyanates with polyhydroxyl compounds and expanded with a blowing agent. 240kPa • Compressive resistance at yield or 10% deformation whichever occurs first (min.Type II. free from unreacted materials. 60 and 75mm 4 Polyurethane Foam(PUF) Rigid Polyurethane foam material shall be self extinguishing type in accordance with ASTM C591. The foam shall be formulated in such a way that it shall under no circumstance cause fire to spread. 100OC ± 2OC (24 hr) 2% 2% 125OC ± 2OC (24 hr) Block Length Width Tolerance upto 2400mm upto 1200mm On length On width On thickness ±6mm ±3mm ±1. dimensional change at different temperatures shall be.Test shall be as per ASTM C446. This limit applies to each of the three foam direction. The thermal conductivity shall be tested by the method prescribed in ASTM C 335. 8-00-0001-F1 Rev. shrinkage and distortion. (Max. 4935-6-44-0002 Rev.mºC (0. 50. 25. The finished foam in the form of half sections shall be with uniform closed cell structure. This can be used upto a temperature of 120 deg. Dimensional Tolerance: Length ±6mm Thickness ±1. 30. 0 Copyright EIL – All rights reserved .JOB SPECIFICATION FOR HOT INSULATION OF VESSELS.16BTU /ft²hrºF/in) at 10ºC mean temperature after ageing.

C. 8-00-0001-F1 Rev. This can be used upto a temperature of 120 deg.094 300 0.The insulation shall conform to the requirements of respective codes.050 50 0. Determine the no. • Compressive (Average min) Strength Format No. unless otherwise specified herein and shall be tested and test certificates on representative samples furnished. .The insulation material shall be in accordance with ASTM C 1029.052 75 0.k 400 0. • • Density Compressive resistance at yield or 10% deformation whichever occurs first (min.) 40 kg/m3 To be determined in accordance with test method ASTM D1622. 0 Copyright EIL – All rights reserved . 0 Page 13 of 51 Minimum percent 95 by volume. 517 kPa Test as per method ASTM C240 and recommended Practice ASTM C165. • • Density Thermal (max) conductivity 110 to 147 kg/m3. Pipes opto 16 : Preformed pipe sections Pipes above 16”: Preformed pipe sections or radial lags Vessel shells : Radial lags Vessel heads : Preformed sections or slabs Equipments : Radial lags or slabs as applicable 5 Sprayed rigid Polyurethane Foam(PUF) Sprayed rigid polyurethane foam material shall produce a complete fire-retardent system.Type3. PIPING AND EQUIPMENT • • Closed cell content Form of insulation JOB SPECIFICATION No.078 200 0. Test at least four specimens. Test at least 3 specimens. Test as per ASTM C303 except that no drying will be necessary. C177 and C518.048 Thermal conductivity shall be tested as per ASTM C240.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. 276 kPa 6 Cellular Glass Cellular Glass formed and fused into unicellular form can be used upto a temperature of 350OC. unless otherwise specified herein and shall be tested and test certificates on representative samples furnished as per ASTM C552. of specimens as per ASTM C390. 4935-6-44-0002 Rev.063 100 0. Mean Temp OF W/m. Insulation shall conform to the requirements of respective codes.

the types of checks. 4935-6-44-0002 Rev. the same shall indicate values for other characteristics of the material. 0 Page 14 of 51 3. The QAP shall also include reference of purchase order number and date.5-3. Vendor shall prepare and submit the Quality assurance plan(QAP). methods of tests followed. Ceramic fibre blankets shall be made out of fibres having fibre length of about 10 cm or more.5 BS-2972 deviation) • Dimensional Tolerance Thickness (-) 0% to (+)40% Width (-)2% (Excess is permitted) Length (-)0% (Excess is permitted) • Shot Content(% Max) 20 ASTM C-892 • Bulk Density(Kg/m³ 128 ASTM C-167 Min) • *Bulk Density (+) 30% & (-)0% Tolerance • Thermal Conductivity 0. 8-00-0001-F1 Rev.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. SL No • Chemical & Physical characteristics of Ceramic Fibre Test Method Blankets Chemical composition(By volume%) Al2O3(Min) 43 IS 1335 ZrO2(Min) IS-10085 Fe2O2(Max) 0. 0 Copyright EIL – All rights reserved .3 High Temperature Insulation Materials (Above 550ºC) Following types of insulations may be used for high temp insulation applications: 1 Ceramic Fibre Insulation Ceramic Fibre shall be composed principally of Alumina silica fibre blanket. lot size & acceptable criteria with permissible deviations. Insulation shall be tested and test certificates on representative samples furnished. the test certificate for similar materials from an international laboratory or any laboratory approved by department of Science & Technology could be considered.11(600ºC) ASTM C-177/IS-3346 (Kcal/M/Hr/ºC)**Max (Mean Temp) • Linear Shrinkage(%) 3(1200ºC) ASTM C-356) (at max temp) for 24hrs • Tensile Strength(Kg/cm²g(min) Longitudnal 0.5 * The density shall be calculated on the basis of actual dimensions and actual weight only. Ceramic fibre blankets shall be sampled for the purpose of test in accordance with ASTM C390. 13mm or 25mm thickness. Grade 8 or to the specifications described in the table below.2. Unless otherwise specified insulation shall conform to the requirements of ASTM C892 Type III. ** In the case of thermal conductivity. frequency of checks. However.6 BS 1902 part 6 Transverse 0. PIPING AND EQUIPMENT JOB SPECIFICATION No.3 IS1527 SiO2(Max) 57 • Mean Fibre Dia(Microns) (Upto 3% Standard 2. It shall normally be of 610 mm width. It should be used in the temperature range of 551ºC to 760ºC. The test certificate shall not be more than 12 months old from the date of offer of material for inspection. Format No. The QAP shall include every stage of manufacturing process starting from raw material stage to final stage of manufacturing.1 IS-1527 TiO2(Max) 0.as offered by the manufacturer.

7lmm (22 SWG) Corrugated.2. 8-00-0001-F1 Rev. PIPING AND EQUIPMENT JOB SPECIFICATION No.coating designation T2-100.3(1). shape and size as per the requirements shall be repeated at site.2(1) & 3. Silicate(Inner layer) & Rockwool(Outer layer) For material specifications refer clause 3. the materials shall be in accordance with ASTM A167 or A240. Cladding shall be coated on the side in contact with the insulation with a polycraft moisture barrier consisting of one layer of one mil high density polyethylene film with a protective layer of 40-pound minimum virgin kraft paper.2.2. Other properties of ceramic fibre shall conform to the specifications as described in clause 3.56mm (24 SWG) Corrugated.2. The profile of corrugated sheet shall be 32mm 5mm Format No. The profile of corrugated sheet shall be 32mm 5mm Thickness for SS/ Aluminized cladding 0.Thickness of the jacketing shall be as follows: 1 Fibrous Material (Rock & Glass Wool) • • Application For shells of vertical storage Tanks & Vessels Thickness for Aluminium cladding(other than grade piping in offsites) 0.5 Additional Tests / Checks for Materials Periodical checks for density. Client/Client’s representative/EIL shall have right to inspect any or all the tests conducted on insulation material by manufacturer at his shop or any laboratory.3. thickness. All the codes mentioned shall be the latest issues.4 Insulation material for Impulse lines For impulse lines insulation material shall be Glass fibre braided Ceramic fibre rope insulation unless otherwise mentioned. as per norms and frequency decided at site as per the directions of Site-inCharge. For stainless steel cladding.1 WEATHER PROTECTION JACKET Unless otherwise mentioned. Galvanized jacketing shall not be used over insulation on or near austenitic stainless steel and/or austenitic nickel steel/alloy Piping & Equipment. the material shall be in accordance with ASTM A463.type 304 or 316.1 4 Combination Insulation of Cal.3 3. Ceramic Fibre rope shall be made up of Ceramic Fibre insulation of min density 200 Kg/m³.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS.type2. 4935-6-44-0002 Rev. Polykraft moisture barrier shall be heat laminated and applied in factory.1 3. Galvanized steel shall be as per IS:277/ASTM A526 with 450 gms/m² of coating. 3.3(1) & 3. 0 Copyright EIL – All rights reserved . aluminium jacketing shall be used as weather protection over insulation except in fire hazardous areas or above 550ºC where it should be stainless steel or aluminized steel.2(1) 3 Combination Insulation of Ceramic Fibre(Inner layer) & Rockwool(Outer layer) For material specifications refer clause 3.2.2. 3. For aluminized steel cladding. Aluminium jacketing shall be as per ASTM B209 Alloy 3003 H16 or IS:737 designation 31000 condition H3 for flat sheets and designation 31500/51300 condition H4 for corrugated sheets. 0 Page 15 of 51 2 Calcium Silicate For material specifications refer clause 3.2.2. For grade piping in offsites jacket material shall be galvanized steel. Special attention is required for fibrous material as its installed thickness could be reduced due to compaction affecting performance.

8-00-0001-F1 Rev. then specification shall be ASTM B209 Alloy 3003 H16 or IS:737 designation 31000 (Old NS3) condition H3. On Vertical Storage Tanks Band.46mm(26 SWG) flat 0.8mm (min. 24 SWG thick x 12mm (min) wide. 4935-6-44-0002 Rev.22mm (18 SWG) Flat 0. 0 . stainless steel. For Securing Rigid Insulation A B On Piping upto 16” OD Wire. Expanded Perlite. Stainless Steel.22mm (18 SWG) Flat of corrugated. Sprayed Cast-in-situ PUF and Cellular Glass) • • • Application Piping. The circular be profile of corrugated sheet shall be 32mm 5mm 1.7lmm (22 SWG) Flat 0.22mm (18 SWG) Flat 0. Polyurethane Foam(PUF) Blocks. 16 SWG. Horizontal Vessel head & Tanks Roof Vertical Vessel Shells & vertical portion of storage Tanks.1 ANCILLIARY MATERIALS Securement Bands / Wires 1 2 If material is Aluminium.46mm (26 SWG) The circular profile corrugated sheet shall 32mm 5mm 1.56mm(24 SWG) flat 0.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. 0 Page 16 of 51 0. On Piping 18” OD & Larger.56mm (24 SWG) corrugated. 25mm wide x 0. vertical vessel heads For removable covers For all piping.4 3. stainless steel.56mm (24 SWG) galvanized steel 1. PIPING AND EQUIPMENT • • For tank Roofs For Horton Spheres & Horizontal vessel shell and heads.7lmm (22 SWG) Flat JOB SPECIFICATION No. If Stainless Steel.22mm (18 SWG) Flat 0.) thk. Vertical and Horizontal equipments Band. Stainless Steel. 4 For Securing Cladding on Insulation (all types) Copyright EIL – All rights reserved Format No. 20 wide x 24 SWG thick. Polyisocynurate. 25mm wide x 24 SWG thick.91mm (20 SWG) Flat 0. Thickness for SS/ Aluminized cladding 0.56mm (24 SWG) Flat • • • 1.56mm (24 SWG) Flat 2 Rigid Material (Calcium Silicate.4. Stainless Steel. On Equipments 24 SWG thick x 20 mm wide. For securing fibrous insulation A B C D 3 On Piping Band. it shall be 18/8. Horton Sphere Band.22mm (18 SWG) Flat • Removable covers 3. Thickness for Aluminium cladding 0. Stainless Steel. other than grade piping in offsites For grade piping in Offsites 1.

SS 12mm (min) wide x 24 SWG thick. The Contractor is responsible for applying an insulating system that will give a satisfactory operational performance and the requirements given herein shall be regarded as the acceptable minimum. It shall be the Contractor’s responsibility to remove loosely adhering scale and dirt before applying insulation. Rivets required for metal jacket securement shall be the expanding Aluminium "POP" blind eye type/ Stainless Steel.5 To ensure perfect water proofing.3 Screws Screws required for metal jacket securement shall be Stainless Steel/cadmium plated steel self tapping type A No. The Contractor shall carryout the work in accordance with the best practices of insulation application with the minimum of waste and debris and the final job shall have a neat. 3. All hydrostatic tests on piping and equipment.5mm long x 5mm diameter.4. 4935-6-44-0002 Rev. 0 Copyright EIL – All rights reserved . dried and made free from loose scale. The insulation shall be so designed/applied such that ingress of water is prevented.1 4. Stainless Steel. 0 Page 17 of 51 A B C 3.1. 3. PIPING AND EQUIPMENT JOB SPECIFICATION No. APPLICATION GENERAL The application methods. 3. all the cladding joints shall be packed with sealing materials which may either be in the form of a elastomeric sealing compound or fibre based bituminous felt strips. SS. 4.4. then all welds and flanged joints in the pipe shall be left uncovered till successful completion of pressure test. including steam tracing systems.3 Format No. 20mm wide x 24 SWG thick.4.2 4.1. shall be carried out before insulating material is applied. If insulation must be installed before pressure test.4.1 4. The insulation Contractor shall only insulate those sections of the plant that have been specifically released for such work by the engineer-in-charge.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. 4. 8-00-0001-F1 Rev. given in this Standard are general in nature.2 Rivets For Piping Band.Formed from 25mm wide stainless steel banding. oil or grease. 25mm wide x 24 SWG thick. efficient and workmanlike appearance. 9.4 Surfaces to be insulated shall be thoroughly cleaned.0 4.' and ‘J’ clips .4 ‘S. On Eguipment Band.1.1.8 dia x 12mm long to BS 4176 complete with neoprene washers under the head. On Vertical Storage Tanks & Spheres Band. leaked product can drain off and vapour can escape. Then insulation shall be completed.

tubing.2 4.1. 4. bevelled and weatherproofed at all terminal points where it is required to remove bolts etc. equipment & tanks with normal operating temperatures of 125OC & below and Stainless Steel at all temperatures shall be protected against corrosion by painting under insulation as per specification 4935-00-06-42-02-2. vacuum rings) shall be insulated with the same thickness of insulation as specified for the equipment item or pipeline.1.1.e.1. without damage to the insulation. 4.13 A minimum clearance of 25mm between outside surface of any insulation finish and adjacent equipment.6 4.15 Pieces of insulation with crushed and damaged ends shall not be used. 4. 8-00-0001-F1 Rev.9 4. rain and contamination and shall be covered with cladding at a minimum loss of time. PIPING AND EQUIPMENT JOB SPECIFICATION No. 4. 4. Insulation shall be finished. otherwise. 4.2.14 Insulation supports shall not project out of the insulation outer surface and shall be given sufficient coverage of insulating material to avoid hot spots on the metallic cover at support positions.11 For Insulation thicknesses upto 75mm only single layer insulation shall be used.7 4. multi-segments are preferable if manufactured. Insulation installed in two or more layers shall be staggered joint construction and each layer shall be secured in place and details of securement shall be the same for each layer. such as lifting lugs.5 Corrosion Prevention Carbon steel and low alloy piping. In bigger sizes.12 Wet or Damaged Insulation shall not be used under any circumstances Material awaiting its protective cover shall be adequately protected from damage.1 PIPING Standard Shapes of insulation 1 Fibrous Material (Rock or Glasswool) Shall be preformed pipe section in 2 halves for sizes upto which manufactured and at least for all pipes with outside diameter over insulation of 500mm. trunnions and stiffeners on piping and equipment (i.1. 0 Page 18 of 51 4. 4.1. 4935-6-44-0002 Rev.only hollow cylindrical shapes slit in Format No. Equipment name plates shall remain visible after insulation has been applied by bevelling back the insulating material and carefully sealing the exposed edges to prevent ingress of moisture.10 Thermowell bosses. blankets are accepatable 2 Calcium Silicate / Expanded Perlite Hollow cylindrical shapes slit in half lengthwise (in a plane including the cylindrical axis) or as curved segments.1.8 The insulation contractor shall not carryout any welding or drilling on plant equipment and piping.1.1. 4.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. pipe or structural members shall be maintained. All projections. Upto 14” pipe size.1.1. Multi-layer insulation shall be required when the insulation thickness is greater than 75mm with the inner layer being larger. pressure tappings and weephole nipples shall not be insulated in but left accessible. 0 Copyright EIL – All rights reserved .

cavities. Insulation Securement (All insulation materials) Each layer of insulation shall be secured firmly in place with at least 3 loops of binding wire / band. Circumferential seams of the inside and outside layers shall be at least 100mm apart. for both single and double layer insulation. When double layer is applied. The arc between the longitudinal seam lines of the inside and outside layers of insulation shall have an angle of over 15 deg. Upto 14” pipe size. 3 Polyisocyanurate / PUF Shall be supplied as cylindrical shape slit in half lengthwise (in a plane including the cylindrical axis) or as curved segments cut from blocks or moulded to shape.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. 0 Page 19 of 51 half lengthwise shall be used. B Pipe Section / Moulded Blocks / Segments End joints of adjacent blocks shall be staggered one half of the length of the block.2. Pipe sections bored / machined out of blocks shall not be used as skin-effect is lost. PIPING AND EQUIPMENT JOB SPECIFICATION No. 0 D Copyright EIL – All rights reserved . or the longitudinal joints staggered at least by one layer thickness. minimum arc length of segments should meet following staggering requirements. Further. The insulation shall be carried out with the least number of material pieces as possible and all unavoidable gaps.2 Application 1 Horizontal Pipe A General Insulation material shall be applied to fit snugly against the contours and shaped only where necessary to achieve this requirement. 4 Cellular Glass Shall be supplied as cylindrical shape slit in half lengthwise (in a plane including the cylindrical axis) or as segments. one loop to be placed not more than 75 from each end Format No.only pipe sections slit in half lengthwise shall be used. 4. whichever is more stringent. 4935-6-44-0002 Rev. and voids suitably filled up compatible loose fill material.2.3. Included angle between segments shall not be less than 30 deg.only pipe sections shall be used. 5 Ceramic Fibre Shall be supplied in blanket strips in sizes as mentioned in the material spec in clause 3. both longitudinal and circumferential joints shall be staggered. 8-00-0001-F1 Rev.Rock or Glasswool) Shall be applied over the surface with joints tightly butted and laced together with 1mm dia galvanised lacing wire. Upto 14” pipe size. C Mattrress (Fibrous insulation .

0 Page 20 of 51 and at least one loop to be equally spaced between end loops. The outside diameter of these rings shall be equivalent to the outside diameter of the insulation. Joints between M. in blanket forms. Rivets with 2 Sheets of 3 thick asbestos mill board interposed. Metal collars shall be of 6 thick M. subject to a minimum of 3 stays. Bands or wires in no case be spaced more than 200mm apart. E For calcium silicate & expanded perlite.( OC) Upto 400 401 to 500 501 to 550 551 to 650 651 to 760 Support Spacing 4500mm 3500mm 2500mm 2000mm 1500mm 3 Expansion Joints (Both vertical and horizontal piping. Spacer rings shall be provided at every approx. of insulation. Spacer rings shall be rivetted to ‘Z’ shaped stays fabricated from the same sized M. or Alloy Steel bar (to suit piping material). 2 Vertical Pipe (All insulation materials) (See Fig. Spacer rings shall be fabricated out of 25x3 M.S. 8-00-0001-F1 Rev. Binding wire shall be drawn about the insulation with ends tightly twisted together. Each layer of insulation shall be secured by the same method as above. Stays shall be provided at intervals of not more than 300 along the circumference of the insulation. bent under & pressed into the surface of insulation. greater than 45 deg. For Cellular glass.D. All insulation Materials) (See Fig. Spacer Ring and stays shall be rivetted by 6 dia M. 4935-6-44-0002 Rev. joints shall be sealed with suitable compatible material. Flats.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. support collar shall be extended to provide for each layer. Piping provided with fibrous resin bonded pipe sections also need not be provided with this framework. 900.S.S.5) Insulation on vertical or near vertical piping (i. for each section. Outside diameter of collar shall be around 12 less than O. all joints shall be sealed with insulating cement of same composition as the moulded block. These rings shall be suitably painted for corrosion protection. This is required only for horizontal pipe runs provided with fibrous insulation.e. Where multi-layer insulation is used.S.S. angle from horizontal) shall be supported by bolted on metal collars. Frame work for supporting cladding fibrous insulation (See Fig: 3 and 4) This is not necessary for rigid materials. PIPING AND EQUIPMENT JOB SPECIFICATION No. Support positions shall be at no greater distance apart than the following: Pipe operating Temp. Flats. a packing of 2 sheets of 3 thick asbestos mill board shall be provided at the joints of the stays and pipes. To minimise direct heat conduction through the stays.5) Copyright EIL – All rights reserved Format No. 0 . PUF and polyisocyanurate. vertical piping provided with fibrous materials need not be provided with this.

At these positions the insulation shall be bevelled and sealed with a metal closure which in turn shall be sealed with waterproof sealing material. 6 Flanged Joints or Valves (all insulation materials (Fig. Insulation securement bands/wire shall be same as that for equivalent dia pipe. 0 Page 21 of 51 Expansion joint shall be provided at regular intervals as below: Temp (OC) Upto 200 201 to 300 301 to 350 351 to 400 401 to 550 551 to 650 651 to 760 Spacing (m) Not required 10 8 6 5 4 3 Expansion joint shall be formed by a 25mm space between the pipe insulation sections and the space shall be filled by compressed mineral rock fibres.9 and 10) Flanged Joints or Valves. 4 Elbows and Bends (All insulation materials) (See Fig. Expansion joints in each layer shall be offset at least 150 from each other in case of multilayer insulation. 7 Insulation Flashing (all insulation materials) Insulation shall be stopped short of flanged joints and unions by a sufficient distance to permit easy removal of the flange nuts and bolts or breaking of the unions to take place without disturbance or damage to the insulating material. 0 Copyright EIL – All rights reserved . 8-00-0001-F1 Rev. Each layer of insulation cement shall be reinforced with 25mm No.7) Insulation material shall be mitred and shall be same as that of pipe. Each mitred section shall be secured with minimum 2 wires/bands.6 and Fig. Fittings below 50mm nom. PIPING AND EQUIPMENT JOB SPECIFICATION No. For bends / elbows of nom. 20 SWG wire netting. but the insulation shall be cut and shaped around the valve stem and kept clear of the stuffing box gland. shall be insulated with oversized pipe sections or lags.8) Preformed pipe sections or segments shall be carefully cut and shaped around "Tee. for all insulation materials. due to lack of space. Insulated valves shall be completely covered. shall be insulated with insulating cement build up in 6mm layers to the thickness of insulation of the adjacent piping. 4935-6-44-0002 Rev. insulation shall be secured by spirally wound 16 SWG galvanized steel wire for hard materials & 10 SWG galvanized steel wire for soft materials. cut and shaped to fit around the body of the valve.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. Insulation shall be adequately secured by wire / bands of same specification as that of same size pipe. lined with pipe sections / lags / slabs. if to be insulated. Format No. shall be insulated with prefabricated removable covers. pipe size 6” & below. Expansion joint for first layer for vertical pipe shall preferably be just below insulation support collars. dia. Welded valves. 5 Tee (All Insulation Materials) (See Fig. Insulation joints of block material shall be suitably sealed with adhesive for isocyanurate /PUF/cellular glass and by insulating cement for calcium silicate/expanded perlite. if insulated. at the junction. if insulated of calcium silicate/expanded perlite.' junctions and the insulation material of the tangential pipe shall be carefully and neatly cut to mate upto the material applied to the parent pipe without the creation of voids or gaps.

2.3. throughout length of tracers. blanket may be accepted. shall be verified for their presence by the insulation contractor.2 Application (All Materials) 1 Following. 2 Calcium Silicate/Perlite/PUF/Polyisocyanurate/Cellular Glass Curved segments / blocks. PIPING AND EQUIPMENT JOB SPECIFICATION No. Alternatively blanket may be accepted.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. 4935-6-44-0002 Rev.3. 10 Electrical Traced Piping (Polyisocyanurate / PUF) Electrical traced piping shall be provided with the same size insulation as would be provided if the piping were not electrically traced. The flats are for insulation support and holes provided in them - Format No. Alternately. 8-00-0001-F1 Rev. Heads: Preformed blocks and slabs cut and shaped to fit.12) Steam traced piping and fittings shall be installed with oversized sections to allow accommodation of both parent pipe and tracer without damage or deformation of the insulation. When the pipe hangers pass through insulation on piping outdoors. Upper bolts of the hanger clamps are not to be covered with insulation.3 4.1 HORIZONTAL EQUIPMENTS Standard Shapes of insulation 1 Fibrous Material (Rock or Glasswool) Shells: Preferably preformed pipe or multi pipe segments or slabs cut and shaped to fit. as indicated in enclosed sketch No. metal hoods packed with a waterproof sealing material shall be furnished and installed. 0 Page 22 of 51 8 Pipe Supports: (All insulation materials) (Fig. 9 Steam Traced Piping (All insulation materials) (Fig.11) Insulation at solid welded or clamped supports shall be cut and shaped to fit around the support and banded securely to enable the insulation to be carried with the pipe movement. 7-12-0033. 4. At vessel heads above 600mm outside diameter are provided flats having 6mm dia holes. These are to be used for insulation securement. 4. 3 Ceramic Fibre Shall be supplied in blanket strips in sizes as mentioned in the material spec in clause 3. Ring support at tangent lines are provided with 6mm diameter holes. Traced instrument line and fittings shall be totally enclosed by the insulation in a similar manner and the designed warm air annulus maintained throughout the tracer pipe length. Insulation supports for vertical pipe shall have suitable clearance for tracer pipe.3. Provided by the vessel fabricator for insulator / cladding support / securement. 0 Copyright EIL – All rights reserved . mitre cut and shaped to fit. Suitable heat transfer cement shall be used to improve the contact between pipe and tracers. before commencing insulation work: For vessels of diameter 2000mm and above are provided insulation support at horizontal centre line as also vertically at tangent lines.

For equipments upto 3000mm in diameter and 200OC. PIPING AND EQUIPMENT JOB SPECIFICATION No. is provided with circular support ring with holes. The calcium silicate block must be cut and fitted to the outside radius of the equipment plus the thickness of the Rockwool spacer insulation. should not compress the fibrous blanket. all joints in successive layers shall be parallel to the long axis. This acts as an expansion area around the equipment to act as mechanical and sometimes thermal cushions. to avoid voids and provide an efficient insulation system.13 and 14) Each layer of insulation on shells of equipment shall be secured by bands at every 225 centres.3. 0 Page 23 of 51 are to be used for insulation securement. so that the use of a leveling coat of insulating cement should not be normally necessary to get an acceptable smooth exterior. This provision is required only for vessels and Exchangers provided with calcium silicate insulation. Also provided on either head is a central ring made of 10 dia galvanised steel rod. Each band shall be machine stretched and tensioned to remove slack only. For vessels which do not have central nozzle. 15) This provision is required to take care of the effects of equipment circumferential thermal expansion on insulation. to take care of equipment circumferential expansion. as indicated in sketch. 4. shall be staggered and sealed with insulating cement for calcium silicate or suitable adhesive for others.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS.3 Insulation Securement (for all insulation materials) (Refer Fig. For such vessels. Each layer of insulation on vessel heads shall be secured as follows: Copyright EIL – All rights reserved Format No. when installed. 2 Boot of vessel. The insulation. the little annular space and the compressiveness of the blocks would suffice to take care of circumferential expansion of equipment. Above provision to take care of circumferential expansion is required both for shell and head. Other block insulation shall be applied with the longer dimension parallel to the axis of the vessel or equipment. Blanket shall be applied over the surface with joints tightly butted and laced together with 1mm dia galvanized lacing wire. If the vessel is above 3000mm in diameter or if temperature is above 200OC or both. insulation contractor shall provide these rings. a 25mm thick Rockwool fibre blanket insulation shall be applied around the equipment prior to the application of calcium silicate. In all cases. Calcium silicate insulation should be installed in bevelled or curved segments only. 3 Special considerations for insulating high temperature Vessels (Required only if provided with calcium silicate insulation) (Fig. the circumferential block is cut and fitted to be 13mm greater in circumference than the equipment and secured so that tension of the bands produces compression on the butt edges rather than on the surface towards the vessel. 4935-6-44-0002 Rev. 8-00-0001-F1 Rev. if any. 0 . When blocks are applied in multiple layers. these rings shall not be provided by vessel fabricator. the insulation is to fit the contour of the vessel or equipment.

Firm securement should be ensured just by 16 SWG annealed SS wire drawn over insulation tightly and through the holes on support rings provided by the fabricator. measured at the girth ring. The space shall be filled up by compressed rockwool fibre.6 IRREGULAR SURFACES SUCH AS PUMPS. Top head insulation shall be secured by floating ring/bands provided by vessel fabricator similar to head of horizontal vessel. COMPRESSORS. a sufficient distance to permit withdrawal of bolts without disturbing the insulation. Copyright EIL – All rights reserved Format No. 4. Insulation shall be weatherproofed and sealed at these locations.). The joint shall be provided at insulation support rings. Insulation shall be laid on insulation support rings provided by the fabricator. 4.. 0 . It shall be a 25mm space between the top of the insulation and the bottom of the support ring. MANWAY & HANDHOLE FLANGED COVER (FOR ALL INSULATION MATERIALS ) Where insulation is required. 17 & 18) Bottom and Top Head insulation shall be supported by 16 SWG annealed galvanized steel wire drawn through holes in the insulation supports provided by the fabricator. TURBINES ETC.4 4.4. NOZZLE. See enclosed sketch 7-12-0025. these shall be insulated with lined removable prefabricated covers secured with bands or quick release toggle clips. CHANNEL COVER. These bands shall be machine stretched and sealed.4 Expansion Joints (All insulation materials) Expansion joints shall be provided every 4000mm (max. PIPING AND EQUIPMENT JOB SPECIFICATION No. 4.5 FLANGE. Outermost layer of insulation shall also be supported by drawing and securing 16 SWG annealed wire through the 6 diameter holes provided in the shell girth ring as also the flats provided on heads. Otherwise. top and bottom heads shall be similar to that of horizontal equipment. 8-00-0001-F1 Rev. 4. 4935-6-44-0002 Rev.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. Insulation Securement for Bottom head for vessel supported on legs shall be identical to that of Top head.2 Application (For all insulation materials) (Fig 16 & 17) Application details on shell.4.1 VERTICAL EQUIPMENTS Standard Shapes Shapes for different materials shall be same as specified for horizontal equipment. Shell insulation shall be supported by bands at every 225 centres on the cylindrical portion and the bands shall be kept horizontal. 4.4. 0 Page 24 of 51 Band shall be in radial direction connecting the head central floating ring and shell girth ring. insulation shall be stopped short of uninsulated flanges and nozzles etc. 4. For insulation securement of bottom heads inside skirt no floating rings/bands need be provided. 16.3 Insulation Securement (For all insulation materials) Fig.4. The wire shall be drawn through every hole and it shall be secured to the ring with a knot. The radial bands shall be placed at not more than 150 centres for rigid and 300 for fibrous insulation.

7. 7-13-0003. 2 Polyisocyanurate / PUF Shall only be be foamed-in-situ. 4. Insulation Support Insulation support will consist of 5mm dia steel rods provided at 400mm dia diamond pitch. Insulation contractor shall check for its presence before insulation application work.2 Application 1 Supporting rings / spikes (rods) for supporting insulation / cladding A Shell Refer Standard 7-13-0003 Sh.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. Each layer shall be covered with a layer of 25mm hex. PIPING AND EQUIPMENT JOB SPECIFICATION No. 4.1 Application 1 Fibrous Material: Material. shaft seal caps and bearing boxes. Insulation shall be bevelled back at 45 deg. Insulation shall be applied in maximum 25mm thick layers until the scheduled thickness is obtained.7 4. The final layers shall be trovelled to a smooth finish with a 6mm thick finishing cement. from all casing flanges. lined with pipe sections / lags / slabs / mattresses. 2 Calcium silicate/Expanded perlite Insulation material shall be insulating cement/block insulation cut and fitted. 0 Copyright EIL – All rights reserved .7. Following is provided by tank fabricator : Water Shed At the junction of shell and roof.1 VERTICAL STORAGE TANKS (CARBON STEEL) Standard Shapes of insulation 1 Fibrous Material (Rock or Glasswool) Shall be in blanket form. Length of these lugs is 3mm less than insulation thickness. 8-00-0001-F1 Rev. 0 Page 25 of 51 4.6. 4935-6-44-0002 Rev. Cladding Support Format No.. application and insulation securement This shall be Prefabricated removable covers.1&2 of 2. a water shed is provided to act as top covering for the shell insulation as shown in Std. 20 SWG galvanised iron wire mesh for other than SS surfaces and with SS wire mesh for SS surfaces. This Standard indicates the extent of insulation / cladding supporting / securement details provided by tank fabricator.

lugs shall be exactly same as in shell. The wire shall be rightly drawn over the insulation and the insulation firmly secured. galvanised lacing wire. Application of Polyisocyanurate / PUF Shall be foamed in situ as per vendor's procedure (approved by EIL/Client/Client’s representative) and to the satisfaction of Site-in-Charge.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS.8. 4935-6-44-0002 Rev. polyisocyanurate and PUF shall be similar to that as for shell.S. in the horizontal leg of the insulation support angle ring. Format No. The wire shall be drawn through every single individual hole and it shall be secured with angle with a knot at every fourth hole. B Tank Roof Shall be provided as per Standard 7-13-0003. Mattresses insulation shall be applied with joints tightly butted and laced together with 1mm dia. While rods are provided by tank fabricator. 2 Insulation laying and securement Insulation shall be applied between rings. 0 Copyright EIL – All rights reserved . speed washers shall be furnished by insulation contractor. horizontal rings shall be provided at every 1175mm on tank shell. Insulation shall be secured by drawing and securing tightly 16 SWG stainless steel wire through the 6 dia holes. provided every 200 centres. Rods and speed washers of spring steel should be selected to suit each other. 4.8 4.2 Application 1 Structural members provided by spheres fabricator for insulation/cladding securement. speed washers are necessary only over the final layers.8. 4. (upto and including 150mms). Matts shall be impaled to the 5mm rod and speed washers fixed and pressed home for intimate contact of the insulation. 8-00-0001-F1 Rev. Mattress insulation shall be applied with joints tightly butted and laced together with 1mm dia galvanised lacing wire. Insulation support from 5mm dia M. 2 Insulation laying and securement A Shell Application of fibrous insulation Insulation shall be applied between rings in horizontal mode.1 HORTON SPHERES Standard shapes & Material Shall be only Rockwool / Glass wool blanket. Insulation & Cladding supports shall be as per Standard 7-13-0015. 0 Page 26 of 51 From tank top. B Roof (For all materials) Application of both fibrous. Insulation shall be further secured by bands spaced centrally between insulation supports. PIPING AND EQUIPMENT JOB SPECIFICATION No. In the case of multiple layers.

glass cloth shall be laid over the surface and embedded in the mastic. The size of the inspection windows shall be as follows: Pipe dia 2” 35mm dia Pipe dia 3” 45mm dia Pipe dia 4” 75mm dia Pipe dia 6” 100mm dia Pipe dia 8” 100mm dia Pipe dia > 8” 120mm dia 4.1.3 Columns & Vessels Heads shall be provided with one inspection window each. Atleast 50% of the bends shall be provided with inspection windows.10 IMPULSE LINES Wrap the impulse lines with insulation(Ceramic rope) of required thickness. Minimum two inspection windows shall be prowided on shell portion. It should be provided at the bottom i. Whilst this coat is still wet. 4. At junctions in the glass cloth. Minimum two inspection windows shall be provided on the shell side. 0 Page 27 of 51 4.2 Exchangers All the heads shall be provided with one inspection window each.1 INSPECTION WINDOWS Piping Plug type inspection windows shall be provided on all the insulated pipe lines having diameter 2” and above. the overlap shall not be less than 75mm. 5. A second 3mm thick coat of mastic shall be applied after approximately 12 hrs.50mm thick.9. Copyright EIL – All rights reserved Format No.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. A 3mm thick coating of mastic shall be applied to the surface of the insulation. When dry this coating shall be a minimum of 1.9 4. Ensure that the rope has been tightly wrapped. 4. The sheet metal of the inspection windows shall of the gauge as of the sheet metal cladding on insulation.9. provided with fibrous materials. Care shall be taken to ensure that the glass cloth is laid smooth and free from wrinkles and that no pockets of air are trapped beneath the surface. 4.9.9. A suitable sealant shall be provided to stop the water ingress at the termination points of insulation.One inspection window shall be provided at a distance of every 20meters of straight length of pipe.1 5. At 4-6-8 clock position whichever is convenient.1 INSULATION FINISH GENERAL Moisture Barrier 1 On all surfaces except horton sphere. 8-00-0001-F1 Rev. 4935-6-44-0002 Rev.4 Tanks One inspection window shall be provided at each course of the tank and also at the top. There must be atleast one inspection window between two bends which are minimum 10 meters apart.e. One inspection window shall be provided at every platform.Expanded perlite and calcium silicate. 0 . Apply a coat of aluminium paint of DFT 25 microns over the mastic after it has dried completely.0 5. PIPING AND EQUIPMENT JOB SPECIFICATION No.

1 PIPING (FOR ALL MATERIALS) Straight pipe shall have metal jacketing cut and machine rolled. at every 150. On vertical piping with OD's of 600mm and larger.7 5. Each sections of metal covering on vertical piping with insulation OD's larger than 250mm shall be supported from the next lower section with two ‘S' clips. The band securing seals shall be kept neatly in line and positioned away from viewing angles as much as is possible. 5.2. 0 Page 28 of 51 For surfaces upto 125OC.2 5. hose or fire sprinklers. A second 3mm thick coat of mastic shall be applied after approximately 12 hrs. 5. When dry this coating shall be a minimum of 1. glass cloth shall be laid over the surface and embedded in the mastic.2 5.3 5. The metal coverings shall be secured tightly around the insulated pipe and held in place with hands on a maximum of 300m centres. (approx. All laps shall be arranged to shed water.2. to a minimum. the insulation shall be protected from the weather by "Alkathene” film type tarpaulin or similar materials approved by Engineer-in-Charge. fabricated from banding material. Care shall be taken to ensure that the glass cloth is laid smooth and free from wrinkles and that no pockets of air are trapped beneath the surface. PIPING AND EQUIPMENT JOB SPECIFICATION No. All ‘J’ clips shall be screwed into position and secured.2 Insulation Finish The insulation finish shall provide a weatherproofed and mechanical damage resistant covering over the whole of the insulated areas and be applied and fitted in such a manner as to provide a close fitting assembly without gaps. to reduce the time the insulation is exposed to the weather. 4935-6-44-0002 Rev.1. shall be metalled with 'lobster back' segments using 10mm minimum ball swage to assist shaping. At junctions in the glass cloth. after erection.2.2.2. to ensure that the individual coats are not greater than 3mm (especially corners) otherwise some cracking of dried coat may result. whether the possible water impingement is from rain.4 5. Vertical overlaps on vertical or near vertical piping shall be staggered to provide overlaps at 'North.50mm thick. 1metre long) wrapped around. however. the overlap shall not be less than 75mm. Whilst this coat is still wet. apply a breathing type moisture barrier as below. The mastic shall not be applied over wet insulation or until the adhesive is dry. A 3mm thick coating of mastic shall be applied to the surface of the insulation as soon as possible. shall be provided at all longitudinal overlaps for both horizontal & vertical piping. 8-00-0001-F1 Rev. The metal bands shall be screwed with self tapping screws and metal sealants are to be provided to get a completely waterproofed arrangements. with 50mm minimum overlaps on both longitudinal and circumferential overlaps.6 5.2.' and 'South' positions in alternate sections of covering.8 Format No. Insulated bends and elbows in piping 80mm and larger. The ‘J’ clip spacing shall be a minimum of two per band.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS.5 5. A single bead shall be made on all overlaps to ensure tight metal to metal water tight arrangement. 0 . fabricated from banding material.2. One band shall be located on each circumferential lap and the distance between laps divided at equal band spacings. During the drying time. Self tapping screws. At all operating temperatures the seams at overlap positions shall be rendered watertight per clause 3. the securing bands shall be supported by ‘J’ clips.2. Copyright EIL – All rights reserved 5.4.6 to ensure that insulation remains dry and unwetted. The ‘S' clip shall be of sufficient length to allow the minimum overlap of 50mm. Care must be taken.

shall have the jacketing sealed using a metal flashing.3 5. Horizontal cylindrical equipment shall be furnished with flat metal jacket arranged in circumferential bands with the edge of the sheets.2 5. Format No. 0 Copyright EIL – All rights reserved . Bands shall be held in their relative positions with ‘J’ clips and be machine stretched and sealed to remove slack only.3 5.4.3. 5.6.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS.3.3. Horizontal overlaps shall be secured with No.3. 5.3.7 5. The panels shall be applied commencing at the bottom of the vessel.5 5. The bands shall be positioned on all horizontal overlaps and at 450mm centres. The panels shall be held tight over the vessel insulation by means of circumferential bands and sealed per 3.3.1 EQUIPMENTS (FOR ALL MATERIALS) The metal jacket over vertical vessel shells shall be constructed of sheet metal panels with the weight of the panel taken on the equipment insulation support rings.6. shall be held in position on cladding by providing pop rivets every 2 metre centres.2. these shall be constructed with a 150mm overlap and shall remain unscrewed and left free to permit expansion.3. Refer standard 7-12-0025 for details.10 The practice of locating all joints in the top portion of elevated horizontal pipes for the sake of good appearance when looking up from grade shall be strongly discouraged. with the longer dimension applied around the circumference of the equipment insulation.8 5. The seal between the flashing and jacket shall be made watertight by use of self-tapping screws and sealing mastic. an "Orange peel" construction with all radial seams overlapping aminimum of 50mm and secured with self-tapping screws at 150mm centres. Each circumferential ring of panels shall be tensioned by means of tensioning bands until the final joint is screwed tight. All overlaps shall be ball swaged and be rendered water tight per 3. The joints shall be located to shed water. The vertical and horizontal overlaps shall be secured with self tapping screws at 150mm pitch except the horizontal overlaps pre-selected to act as expansion joints. and shall be so arranged that staggered bands of panelling encircle the equipment.4. PIPING AND EQUIPMENT JOB SPECIFICATION No. via angle brackets bolted to the panel.2. 8x12mm long self-tapping screws set in the overlap at 150mm intervals.9 Insulated bends and elbows in piping smaller than 80 mm may use complete pressed and humped back flat metal elbows or fabricated 'stove pipe' elbows.6.9 5. cut to fit the projection and extending above the jacket at least 80mm. 5.4 5. 8-00-0001-F1 Rev. both overlaps being finished with a simple ball swage and rendered watertight as detailed in clause 3. The panels shall have a minimum of 80mm overlap of both longitudinal and circumferential edges. The overlaps shall be arranged to shed water at all times.6. 4935-6-44-0002 Rev.4.3. Vertical overlaps shall not be screwed for horizontal equipment.3. 0 Page 29 of 51 5.3. 5. The panels shall have a minimum overlap of one corrugation on vertical joints and 80mm on horizontal joints. 'S' clips shall be used as sheeting support at unscrewed circumferential overlaps. All equipment projections such as nozzles. Those bands which are not supported by 'J’ clips.11 The insulated heads of vertical and horizontal equipment shall be fabricated from flat metal.10 The metal finish shall be banded and sealed at 450mm centres.6 5.4. All overlaps shall be rendered watertight as per 3.3.

12 Projections from the heads shall be sealed using metal flashings. At all joints. Bands shall be tightened. see sketch 7-13-0003. 4935-6-44-0002 Rev.13 Insulation at bottom heads of fully skirted equipments does not require weatherproofing. Sh. Cladding is secured as indicated in sketch 7-13-0003. every 150 centres. Overlaps in the horizontal joints shall be 50mm (min. every 1500. For details of cladding arrangement and bolting. 19 and Standard 7-13-0003. In order to prevent sliding of the bands downwards. neatly cut to fit around the projections and extending above the jacket for a minimum of 80mm. 8-00-0001-F1 Rev.4.). - - 2 Roof All cladding joints shall be sealed by elastoimeric metal sealents. Horizontal stainless steel steel bands over-cladding to be provided every 800mm and also to coincide at every horizontal cladding overlaps.4 5. the bands shall be secured to the cladding using POP rivets at horizontal pitch not over 2 metres. Insulation shall be tucked into the skirt portion of the curb angle. 5. roof and curb angle.3. Felt washer. cladding to cladding securement shall be provided by self tapping screws and proprivets alternately. Min. Bolts are provided by tank fabricator at 300mm centres on angles provided at every 1175 centres vertically. PIPING AND EQUIPMENT JOB SPECIFICATION No. 0 Copyright EIL – All rights reserved . Cladding to cladding fastening. at both horizontal and vertical overlaps shall be alternately by "POP" Rivets & self tapping screws at 150mm pitch. Cladding shall be secured by bolting at every 300 provided by tank fabricator. 5. 0 Page 30 of 51 5. aluminium washer and nut shall be supplied by insulation contractor for all bolted connections at shell.3. 75mm overlap shall be ensured at all joints. Format No.1 VERTICAL STORAGE TANKS Cladding Applications and Securement 1 Shell (Fig.1 and 2 of 2) Cladding is applied over the system of horizontal rings as follows : Overlaps in the vertical joints will be one corrugation. The seal between flashing and jacket shall be weatherproofed with self-tapping screws and mastics.JOB SPECIFICATION FOR HOT INSULATION OF VESSELS. Shell cladding and extended roof cladding shall be secured to curb angle by bolting as per sketch 7-13-0003. locked and lock fastened featuring stainless steel fastening systems. 5. Cladding shall be secured to support ring by bolting.14 Heads of equipments 24” OD and smaller shall be finished and waterproofed with square ended fabricated covers.3.

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