Pipe Cold Insulation Specification
description
Transcript of Pipe Cold Insulation Specification
TITRE DU DOCUMENT
PAGE Petrochemical Zone Phase II (Assalouyeh)
Off Site Facilities
CONTRACT NO.: 86-23-122/241
DOCUMENT NO.:SP002 B 18 PI 000 SPH - 023REV.: 0
DOCUMENT TITLE:PIPE COLD INSULATION SPECIFICATIONPAGE: 1 OF 38
PIPE COLD INSULATION SPECIFICATION
A.HA.AM.B.BM.EA.TISSUED FOR COMMENT24/06/080
AUTHORIZEAPPROVEAPPROVECHECKPREPARESTATUS / POIDATEREV.
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Table of Contents
51.SCOPE
52.DEFINITIONS
63.APPLICALBE CODES AND STANDARDS
63.1General
63.2List of Applicable Codes and Standards
84.REFERENCE DOCUMENTS
85.DOCUMENT PRECEDENCE
96.RESPONSIBILITY
97.SPECIFICAITON DEVIATION/CONCESSION CONTROL
98.QUALITY ASSURANCE/QUALITY CONTROL
99.DESIGN OF INSULATION SYSTEMS
99.1General
109.2Insulation Classification
109.3Insulation Codes
109.4Insulation Systems
119.5Extent of Insulation
119.6Insulation Thickness
1210.MATERIALS
1210.1General
1310.2Insulation Materials
1610.3Vapor Barriers
1810.4Joint Sealant/Adhesive Materials
2010.5Metallic Jacketing
2010.6Accessory Materials
2111.HANDLING AND STORAGE
2111.1Packaging and Shipping
2111.2Preservation and Storage
2212.APPLICATION
2212.1General Requirements
2412.2Pipe
2712.3Pipe Supports
2712.4Fittings, Valves, Flanges and Intricate Shapes
2812.5Mechanical Contraction Joints for Bellows Expansion Joints
2913.SAFETY ASPECTS
2914.INSPECTION
2914.1Inspection of Materials
2914.2Pre-Insulation Inspection
3014.3Inspection Procedure for In Situ Molded/Dispensed PUF
3014.4Final Inspection and Release
3115.TESTING
3116.DOCUMENTATION
33ANNEXES
33TABLE 1
34DETAILED SKETCHES
1. SCOPEThis Basic Design specification gives minimum requirements for the design, manufacture, testing, supply, inspection and testing of thermal insulation for cold and dual temperature services for piping of the offsite Phase II and Interconnection project at Bandar ASSALUYEH, Iran.
Cold service is defined as piping at operating temperatures below ambient where reduction of heat gain and the prevention of surface condensation are desired.Dual temperature service is defined as piping at operating temperatures below ambient and where intermittently temperatures may occur up to 250oC, or with normal pipe operating temperatures which are above ambient but intermittently reach ambient temperatures for a longer period of time where good causes for occurrence of condensation within the insulation finish exist.
Cold insulation is required to reduce the transfer of heat to piping, to control process temperatures, avoid condensation and icing on the exterior surfaces, reduce excessive viscosity of fluids and materials and personnel protection.Minimum/maximum operating temperatures shall be taken as those given for the flowing medium as stated in line lists and the equipment data sheets.
This specification covers application of Polyurethane or Polyisocyanurate Foam and Cellular Glass insulation.
This specification does not cover the insulation or coatings for underground piping or buried equipment or insulation for hot services.
Where cross references are made, the number of the section or sub-section referred to is shown in brackets.
2. DEFINITIONSFor the purpose of this specification, the following definitions shall apply:
OWNER: Petrochemical Industries Development Management (P.I.D.M.Co) is the Client.
CONCESSION REQUEST:A deviation requested by the CONTRACTOR or MANUFACTURER, usually after receiving the contract package or purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim, or release materials, components or equipment already in progress or completely manufactured but which does not meet or comply with requirements of this specification. A CONCESSION REQUEST is subject to OWNER approval.
CONTRACTOR:Contractor for Offsite Phase II and Interconnection
FIELD PROVEN:Extended continuous satisfactory operation in sufficient number of similar applications as referenced by major end-users. OWNER reserves its right to accept as valid for the Project purpose, the supporting documentation provided the term sufficient and referenced.
MANUFACTURER:The parties which manufacture and/or supply CONTRACTOR with the insulation materials, technical documents/drawings and services to perform the duties specified by CONTRACTOR.
PROJECT:Offsite Phase II and Interconnection
SHALL:Indicates a mandatory requirement.
SHOULD:Indicates a strong suggestion.
SUBCONTRACTOR:The party which carries out the installation, and testing of the insulation as specified by the CONTRACTOR.
Throughout this specification the following technical abbreviations have been used:
PUF- Polyurethane or Polyisocyanurate foam.
3. APPLICALBE CODES AND STANDARDS
3.1 General
The following codes and standards shall, to the extent specified herein, form a part of this specification. Where a specific edition date is not indicated, it shall be taken that the most current edition (including addenda) in effect at the time of SUBCONTRACTORS proposal or submittal shall apply.
3.2 List of Applicable Codes and StandardsThe publications listed below form a part of this specification to the extent referenced. The publications are referred to, in the text, by the basis designations only.
American StandardsASTM B 209MAluminum-Alloy Sheet and Plate (Metric)
ASTM C 165Test Method for Measuring Compressive Properties of Thermal Insulations
ASTM C 167Tests for Thickness and Density of Blanket or Batt-type thermal insulating Materials.
ASTM C 177Steady State Thermal Transmission Properties by means of the Guarded Hot Plate
ASTM C 240Cellular Glass Insulating block, Standard Method of testing
ASTM C 303Density of Preformed Block-Type Thermal Insulation
ASTM C 518Steady State Heat Flux Measurements and Thermal Transmission Properties by means of Heat Flow Meter Apparatus.
ASTM C 547Specification for Mineral Fiber Performed Pipe Insulation
ASTM C 552Cellular Glass Block and Pipe-Thermal Insulation.
ASTM C 591Unfaced Preformed Rigid Cellular Polyisocyanurate Thermal Insulation.
ASTM C 612Specification for Mineral Fiber Block and Board Thermal Insulation.
ASTM C 623Youngs Modulus, Shear Modules and Poissons Ratio of glass and glass Ceramics by Resonance.
ASTM D 696Coefficient of linear thermal expansions of plastics
ASTM D 1621Compressive Properties of Rigid Cellular Plastics
ASTM D 1623Tensile and tensile adhesion properties of rigid cellular plastics
ASTM D 1622Density Apparent or Rigid Cellular Plastics
ASTM D 1692Rate of Burning and/or Extent and Time of Burning of Cellular Plastics using a Specimen Supported by a Horizontal Screen.
ASTM D 2126Test Method for Response of Rigid Cellular Plastic to Thermal and Humid Ageing.
ASTM D 2842Water absorption of rigid cellular plastics
ASTM D 2856Open Cell Content of Rigid Cellular Plastics by the Air Pycnometer
ASTM D 3014Flame Height, Time of Burning and Loss of Weight of Rigid Cellular Plastics in a Vertical Position.
ASTM D 3039Tensile properties of polymer matrix composite material.
ASTM E 96Water Vapor transmission of Materials in Sheet Form
British StandardsBS 476Fire Tests on Building Materials and Structures Part 7, Surface Spread of Flame Test for Materials.
BS 1470Wrought Aluminum and Aluminum Alloys, Sheet and Strip
BS 2972Methods of Test for Inorganic Thermal Insulating Materials
BS 4370Quality Systems4. REFERENCE DOCUMENTS
In this publication reference is made to the publications listed below. The latest issue of each publication shall be used together with any amendments/supplements/revisions unless otherwise stated.
Project SpecificationSP002-B-18-PI-000-SPH-022Pipe Hot Insulation SpecificationSP002-B-18-PI-000-SPH-024Pipe Painting SpecificationSP002-B-18-PI-000-SPH-015Standard Pipe Support Specification
5. DOCUMENT PRECEDENCE
It shall be the MANUFACTURER and SUBCONTRACTORS responsibility to be or to become, knowledgeable of the requirements of the referenced codes and standards.
The SUBCONTRACTOR shall notify the CONTRACTOR of any apparent conflict between this specification, product data sheets, the codes and standards, and any other specification or document noted herein. Resolution and/or interpretation precedence shall be obtained from the CONTRACTOR in writing before proceeding with application of any insulation material.6. RESPONSIBILITYThe SUBCONTRACTOR shall assume unique responsibility and overall guarantee for the installed insulation system.
7. SPECIFICAITON DEVIATION/CONCESSION CONTROL
Any technical deviation to the purchase order/contract and its attachment including, but not limited to, the data sheets and narrative specification shall be sought by the MANUFACTURER and SUBCONTRACTOR only through the CONCESSION REQUEST format. CONCESSION REQUESTS require the CONTRACTORs and the OWNERs review and approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to OWNER approval are subject to rejection.
8. QUALITY ASSURANCE/QUALITY CONTROL
The SUBCONTRACTOR shall have in effect at all times, a QA/QC program which already establishes the authority and responsibility of those responsible for the quality system. Persons performing quality functions shall have sufficient and well defined authority to enforce quality requirements that initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness of the corrective action.
The SUBCONTRACTOR is solely responsible for all quality control activities and documentation. If the SUBCONTRACTOR is unable to comply with this specification, he shall inform the CONTRACTOR for resolution.
A copy of the SUBCONTRACTORS QA/QC program shall be submitted to the CONTRACTOR with its quotation for the CONTRACTORS review and approval prior to award.
The MANUFACTURER shall submit certified reports of production tests as soon as the tests are satisfactorily completed.
The OWNER/CONTRACTOR reserves the right to inspect materials and workmanship at all stages of manufacture and to witness any or all tests.
9. DESIGN OF INSULATION SYSTEMS
9.1 General
The insulation of cold and dual temperature services is required for:
Cold conservation.
Heat flux control of processes and product lines.
Preventing vapor condensation on the outside surface of the insulating system of piping having a temperature below the dew point of the surrounding atmosphere.
Personnel protection from hot or cold surfaces (cold burns and falling ice).
An important requirement of a cold insulation system is prevent water ingress into the insulation. The presence of water as vapor, liquid or ice in the insulation will decrease its insulating value and may eventually lead to under lagging corrosion of the insulated metal surfaces. In order to prevent water ingress and under lagging corrosion, the vapor barriers should be properly selected and applied and insulated metal surfaces shall be suitably painted in accordance with Project specification for Painting.
9.2 Insulation Classification
9.2.1 Cold Insulation
Where required cold insulation prevents condensation or icing on the outside surface of the insulating system conserves low temperatures or controls heat input into the contained fluid within a temperature range of ambient and below.
9.2.2 Dual Temperature
Where required cold insulation prevents surface condensation, conserves low temperatures or control heat input into the contained fluid within the temperature range of 40oC up to +150oC.9.3 Insulation CodesCFor cold conservation and process temperature control
DDual insulation (Cold and Hot)
KAnti condensation
ACCold and Acoustic insulation
NNot insulated
9.4 Insulation SystemsFor cold and dual-temperature services in the temperature range from below ambient up to 90oC PUF shall be used. Above 90oC, cellular glass shall be used.
The insulation system for cold service shall consist of application of pre-formed sections or radiused and beveled segments of PUF. The insulation system for dual temperature service shall consist of application of pre-formed sections or radiused and beveled segments of cellular glass.
9.5 Extent of Insulation9.5.1 General
When cold insulation is required, the entire system shall be fully insulated to such an extent that all piping are properly included.
All metal parts which protrude through the insulation, except saddle mounted vessels, shall be insulated to a distance of at least 4 times the insulation thickness. Wherever possible, there should be a minimum of 300mm of bare metal after termination of the insulation.
Protruding metal parts include, but are not limited to, skirts, lugs, legs, saddles, clips and pipe trunnion supports.
Each line shall be insulated as a single unit. A minimum clearance of 50 mm shall be provided between the outer surface of the insulation and any obstruction such as structural steel, electrical conduits, piping or other insulated lines, to prevent unnecessary cut outs, thickness reductions etc., which would influence the thermal performance.
9.5.2 Pumps and compressors
When pumps and compressors are to be insulated, thermal dams shall be provided to isolate the pump support from supporting steel or concrete.
9.5.3 Personnel protection
Where personnel protection is specified for uninsulated process piping having an operating temperature of minus 10oC and below and whose location presents a personnel hazard, the surfaces shall be determined and provided with a suitable protection. The extent shall be limited to within the confines of a normal working area bounded by distances of not more than 2.0 m vertically or 0.8 m horizontally beyond access ways, ladders, platforms and work areas at ground level or elevations used by operating and maintenance personnel.
Insulation should only be used for personnel protection if other alternative protective measures such as expanded metal shields, hand railings or other physical barriers are not suitable.
9.6 Insulation ThicknessCold insulation thicknesses shall be as per table 1 in annexes.
Single layer insulation shall be 50 mm maximum.
The thickness of the basic insulation on pipe fittings, valves and flanges shall be the same as the thickness applied on the adjoining pipe.
The thickness of insulation for protruding parts shall be based upon the fluid temperature of the pipe or equipment to which the part is attached and the size determined as follows:
For cylindrical attachments, use the nearest pipe size corresponding to the diameter of the attachment.
For structural shapes, use the longest dimension (of the nominal section size) corresponding to the pipe size. For example:
a 8 wide flange (WF) is equivalent to a 8 pipe
a 6 x 4 angle is equivalent to a 6 pipe.
The insulation thickness for personnel protection shall be a minimum of 25 mm thick.
10. MATERIALS
10.1 General
Materials furnished under this specification shall be standard catalogued products, new and commercially available, suitable for service requiring high performance and reliability with low maintenance and free from all defects.
Materials include insulation materials, accessories (bands, mesh wire, rivets, pins, screws, tape, and similar recommended accessories) and compounds (adhesive, coatings and sealers) and protective finishes and similar items recommended for the applications indicated.
The MANUFACTURER, unless clearly otherwise stated, shall supply materials which meet the requirements in this specification with respect to design criteria, thermal conductivities and all other noted standards.
All accessories and materials (i.e. coatings, adhesives, sealants, sealers etc.) are to be shipped to the job site in the original, marked, unopened containers/boxes as provided by the MANUFACTURERS.
The following methods of manufacture/transportation of the PUF materials should be considered and the MANUFACTURER is required to submit details for consideration:
Manufactured and fabricated at the MANUFACTURERs workshop for straight shell pipe runs only.
Manufactured at the MANUFACTURERS workshop and transported as bun stock for fabrication in field workshop facilities.
Basic premixed chemicals for the in situ molded foam shall be produced freshly and used within the factory advised shelf life of the product, taking into account all time lapses for transportation and storage.
Transport of the basic premixed chemicals for the in situ molded foam shall be done in accordance with the factory instructions for transporting/storing of the chemicals.
10.2 Insulation Materials10.2.1 Pre-formed PUF
Pre-formed PUF shall have the following minimum properties:
Thermal conductivity at 20oC mean temperature per ASTM C-177 measured on 25mm thick foam, cut on both sides and aged at 21oC for 180 days shall be no greater than 0.023 W/m.K. The thermal conductivity for freshly blown foam shall be no greater than 0.020 W/m.K.
Minimum percentage of closed cells 90% (percent) per ASTM D-2856.
Maximum water vapor permeance at 38oC and 100% RH shall be 4.38 x 10-3 g/Ns (ASTM E-96).
Linear coefficient of thermal expansion/contraction 70x10-6 per oC (BS 4370).
Fire resistive properties:
ASTM D-1692 (10/10 SE): self-extinguishing
ASTM D-3014: 90% retention of weight
Maximum leach able halides content 90 ppm.
In addition to the above requirements the foam shall have:
A minimum density of 45 kg/m3, measured per ASTM D-1622.
Compressive strengths of at least 200 kPa and 250 kPa at 10% deformation and at 20oC, perpendicular and parallel to foam rise respectively, as per ASTM D-1621.
The above thermal and structural properties shall be supplemented by the following data:
Test reports on compressive, tensile and shear strength and moduli in X, Y and Z directions at 21oC and also at -165oC. (ASTM C 165).
Thermal conductivity versus temperature curve of the foam from 165oC to 65oC with adequate definition as per ASTM C-177 or C-518 measured on sample cut from freshly blown foam, after initial cure, parallel to foam rise. Minimum of six data points are required.
Thermal conductivity versus time curve of foam aged for 180 days at 21oC and 50% RH measured by ASTM C-158 at 24oC parallel to foam rise. Adequate points are required to define curve.
Thermal conductivity versus temperature curve of foam aged for 180 days from 40oC to 65oC measured by ASTM C-158 parallel to foam rise. Minimum of six data points are required.
Contraction/expansion coefficients versus temperature curves from -165oC to 21oC in X, Y and Z directions.
Where site pre-fabricated in two halves, pipe sections shall be oversized to accommodate contractions.
For all sizes up to and including 10 the PUF shall be applied in two half sections.
For sizes over 10 NPS The foam injection (Dispensed PUF) shall be used.
10.2.2 Pre-formed Spacers
Pre-formed Spacers shall be of PUF with the following minimum properties:
The spacers shall consist of fully monolithic (180o) half pipe sections with a minimum density of 50 kg/m3, designed to form compartments for the in-situ molding operation.
The foam shall have a fire-resistive property as defined in ASTM D-1692 (10/10 SE): self-extinguishing.
Minimum percentage of closed cells 90% per ASTM D-2856.
Thermal conductivity at 20oC mean temperature per ASTM C-177, measured on 25mm thick foam cut on both sides and aged at 21oC for 180 days shall be no greater than 0.025 W/m.K.
The leach able halides content shall not exceed 90 ppm.
10.2.3 In-situ Molded/Dispensed PUF
The foam injection process shall be compatible with the atmospheric site conditions and a minimum temperature of 15oC shall be maintained for foam components.
The products are to be delivered on site in two components ready for use with the following foam properties:
Fire properties Self-extinguishing in accordance with ASTM D-1692 (10/10 SE).
Density after molding shall be 45 kg/m3, 5%, in accordance with ASTM D-1622.
The free rise density shall be 28 ( 2) kg/m3, to ensure good compaction of the foam and good homogeneity due to high compression rate.
Thermal conductivity shall be as in (10.2.1). Minimum percentage of closed cells 90% (percent) per ASTM D-2856.
The leach able halides content shall not exceed 30 ppm.
Structural properties shall be as follows:PropertyUnitRequirementTest
Water absorption% vol.3 or lessASTM D-2842
Coefficient of linear thermal contractionm/moC(50-100) 10-6ASTM D-696
Tensile strength parallel to rise:
- at room temperature
- at-196oCkPa
kPa500-700
600-800ASTM D-1623
ASTM D-1623
Tensile strength perpendicular to rise: - at room temperature
- at-196oCkPa
kPa500-700
600-800ASTM D-1623
ASTM D-1623
Tensile strength parallel to rise:
- at room temperature
- at-196oCMPa
MPaAverage 14
Average 27.5ASTM D-1623
ASTM D-1623
Tensile strength perpendicular to rise:- at room temperature
- at-196oCMPa
MPaAverage 13
Average 28.5ASTM D-1623
ASTM D-1623
10.2.4 Cellular Glass
Cellular glass (bun stock) shall have the following minimum properties:
Rigid cellular glass, site pre-fabricated into half sections, radiused and beveled segments, and slabs of minimum 600 mm length.
Average density 120 kg/m3 (+/-10%) in accordance with ASTM C-303.
Thermal conductivity, as per ASTM C-518:
Mean temperature, oC
W/mK
+20
0.042
0
0.038
-20
0.035
Average compressive strength in accordance with ASTM C-165 shall not be less than 415 kPa.
Water vapor transmission: 0 (ASTM E-96).
Linear coefficient of thermal expansion: 9.0 x 10-6/oC. (10%).
Fire resistive properties as per BS 476: Non-combustible.
Average modulus of elasticity as per ASTM C-623: 800 Mpa.
For pipe sizes involving a diameter of 8 diameter and under, cellular glass insulation shall be supplied in two half sections a minimum of 600 mm long.
For pipe sizes with diameters exceeding 8 cellular glass insulation shall be site pre-fabricated in radiused and beveled segments. For pipe diameters up to 1000 mm, the width of the outside radius of the insulation shall be between 140mm to 160mm. For pipe diameters above 1000mm and up to 7000 mm, the width of the outside radius of the insulation shall be between 210 mm and 435 mm.
All circumferential and longitudinal joints in pipe sections, radiused and beveled segments and slabs shall be of the butt type.
For all temperature from 175oC up to +150oC, the fabrication adhesive for laminating cellular glass billets shall be hot asphalt (ASTM D 312 Type III).
For temperatures exceeding 150oC a double layer construction shall be used. Both layers shall be bonded by means of a high temperature gypsum adhesive.
10.2.5 Medium Density Rock Wool Board
Medium density rock wool board stock having the following properties shall be used for contraction joints:
Density 32 kg/m3 ( 10%).
Thermal conductivity at 25oC mean temperature: 0.035 W/m.K or less.
The material shall be free from delamination or fiber fallout when tested to BS 2972.
10.2.6 Low Density Rock Wool Blankets
Low Density rock wool blankets having the following properties shall be used for packing voids between piping and insulation.
Density: 24 kg/m3 ( 10%).
Thermal conductivity at 25oC mean temperature: 0.034 W/m.K or less.
The material shall be free from delamination and fiber when tested to BS 2972.
10.3 Vapor Barriers10.3.1 Vapor Barrier Mastic for PUF
The vapor barrier mastic shall be a heavy duty highly durable flexible electrometric polymer Hypalon based fire-retardant coating with exceptional dry film strength and good puncture resistance and shall have the following minimum properties:
PropertyUnitValue
Temperature resistanceoC-40 to +120
Water vapor transmission ASTM E-96 at 0.75mm dry film thicknessperms*0.02
Average non-volatileVol.%30
Fire resistance:
ASTM E-84/76A flame spread20
Smoke developed5
Fuel Contribution10
Spread of flame (BS 476)Class 1
Specific gravitykg/11.1-1.3
ConsistencyThixotropic soft paste
Minimum applied thickness (dry film)mm1.2
Minimum HYPALON content%15
Minimum coats3
10.3.2 Vapor Stop Coating/AdhesiveThe vapor stop coating/adhesive shall be a two-part elastomeric material suitable for use in cryogenic conditions with the following minimum properties:
PropertyUnitValue
Specific gravitykg/l1.1-1.2
Non-volatile contentvol.%55-60
Tensile strength (ASTM D-412)kg/cm2>8
Two-component minimum thickness (dry film)mm1.2
Service temperatureoC-196 to +120
Halidesppm