Standard Specification for Hot Insulation (Piping & Equipment)

DOC NO . : QPS-PI-HI-101

STANDARD SPECIFICATION

F0R HOT INSULATION

SHEET : I

PROCESS SOLUTIONS PVT. LTD. REV : 0

DATE : 21.11.10


FOR

HOT INSULATION

(PIPING & EQUIPMENT)

0 21.11.10 Issued As Standard S R Patil PID BKD

REV.

NO. DATE DESCRIPTION PREPARED

BY REVIEWED

BY APPROVED

BY



F0R HOT INSULATION

SHEET : II


DATE : 21.11.10

INDEX

SECTION

NO.

TITLE PAGE

NO.

1.0 GENERAL 1

2.0 DESIGN BASIS 2

3.0 EXTENT OF INSULATION ON PIPING SYSTEM 3

4.0 EXTENT OF INSULATION OF EQUIPMENT 4

5.0 MATERIALS GENERAL 5

6.0 INSULATION MATERIAL FIBROUS MATERIAL (ROCK & GLASS WOOL) 6

7.0 INSULATION MATERIAL (CELLULAR GLASS ) 9

8.0 WEATHER PROTECTION JACKET

8.1 FIBROUS MATERIAL (ROCK & GLASS WOOL)

8.2 REGID MATERIAL (CELLUAR GLASS)

8.3 ANCILLIAR MATERIALS

11

9.0 APPLICATION METHODS (GENERAL) 13

10.0 PIPING 15

11.0 HORIZONTAL EQUIPMENT 20

12.0 VERTICAL EQUIPMENT 22

13.0 FLANGE, NOZZLE, CHANNEL, COVER, MANWAY AND HANDHOLE FLANGED COVER.

23

14.0 IRREGULAR SURFACES SUCH AS PUMP, COMPRESSOR, TURBINE ETC. 24

15.0 VERTICAL STORAGE TANK 25

16.0 INSULATION FINISH (CARBON SETEEL)

16.1 PIPING

16.2 EQUIPMENT

16.3 VERTICAL STORAGE TANK

27

17.0 ANNEXURE – I

17.1 OWNER’S OBLIGATIONS

17.2 CONTRACTORS CONDITIONS

31

18.0 ANNEXURE – II

INSULATION THICKNESS FOR HOT INSULATION (IH)

32

19.0 ANNEXURE – III 33

INSULATION THICKNESS FOR PERSONAL INSULATION (IS)



F0R HOT INSULATION

SHEET : III


DATE : 21.11.10

STANDARD SKETCHES FOR HOT INSULATION STANDARD OF VESSELS, PIPING AND EQUIPMENT

FIG. NO. DESCRIPTION SHEET

01 FIBROUS AND REGID INSULATION DETAILS FOR HORIZONTAL PIPE APPLICATION

34

02 METHOD OF STAGGERING OF SECTION FOR PIPE INSULATION 35

03 FIBROUS MATTRESS INSULATION - DETAILS SPACER RINGS FOR CLADDING SUPPORT (FOR HORIZONTAL PIPE)

36

04 DETAIL OF SPACER RING FOR FIBROUS INSULATION (MATTRESS) 37

05 BOLTED-ON INSULATION SUPPORT FOR VERTICAL PIPE 38

06 INSULATION DETAILS FOR PIPES, BENDS & ELBOWS 39

07 INSULATION DETAILS FOR BENDS & ELBOWS 40

08 INSULATION DETAILS FOR PIPE BRANCHES AND REDUCERS 41

09 INSULATED REMOVABLE COVERS FOR VALVES 42

10 INSULATED REMOVABLE COVERS FOR FLANGED JOINTS 43

11 INSULATED DETAILS FOR LINES ON SHOE 44

12 INSULATION OF STEAM TRACED PIPING 45

13 INSULATION FOR HORIZONTAL EQUIPMENT 46

14 INSULATION FOR EQUIPMENT HORIZONTAL HEADS 47

15 USE OF FLEXIBLE INSULATION IN COMBINATION WITH RIGID INSULATION TO COMPENSATE FOR VESSEL EXPANSION

48

16 INSULATION DETAILS FOR VERTICAL VESSELS 49

17 INSULATION DETAILS FOR VERTICAL VESSEL HEADS 50

18 INSULATION DETAILS FOR VERTICAL VESSEL (`J’ & `S’ CLIPS) 51

19 INSULATION DETAILS FOR VERTICAL STORAGE TANKS 52

20 INSULATION SUPPORTS FOR STORAGE TANKS 53

21 INSULATION SUPPORTS FOR STORAGE TANKS (DETAILS FOR ROOF) 54

22 FIRE PROOFING AND INSULATION SUPPORT FOR VERTICAL VESSEL 55

23 MACHINERY INSULATION 56

24 INSULATION ENCLOUSERS FOR CONTROL VALVES & OTHER IN-LINE INSTRUMENTS

57

25 INSULATIN FOR LEVEL GAUGES 58

26 INSULATION SUPPORTS FOR HORIZONTAL VESSEL 59

STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101

FOR HOT INSULATION SHEET : 1 OF 59

PROCESS SOLUTIONS PVT. LTD. PIPING AND EQUIPMENT REV : 0

DATE : 21.11.10

1.0 GENERAL:

SCOPE

1.1 This specification covers design and material requirements for above ground, external

insulation of piping and equipment operating between ambient temperature and 550 °C for

the purpose of heat conservation, process stabilization, temperature maintenance, personnel

protection and fire protection. Wherever necessary this specification indicates the basis for

selecting a criterion.

1.2 This specification is suitable for use in out door service with normal process plant

atmospheres. Alternative designs and materials would be specified if necessary for corrosive

atmosphere of potential leaks and spills of chemicals.

1.3 This specification does not cover cold service insulation. For cold services QPS Specification

QPS-PI-CI-101 is applicable.

1.4 This specification does not cover insulation for boiler or fired heaters and associated air

heaters, economizers, fuel ducting and air ducting.

1.5 Piping, equipment, storage tanks and vessels requiring insulation shall normally be specified

on the following project documents.

a) Process and Instrument Diagrams (P&IDs) and Line List.

b) Piping General Arrangement Drawings & Isometrics.

c) Instrument Piping Details and Schedules.

d) Vessel, Exchanger, Storage Tank & sphere documents and Insulation Schedules

e) Equipment supplier’s General Arrangement Drawing for equipment items in package

plant.




DATE : 21.11.10

2.0 DESIGN BASIS: CRITERIA

2.1 Heat Conservation Insulation is designed for economic thickness and to limit cold surface

temperatures below 65 °C with 20 °C ambient temperature in still air conditions.

2.2 Internally refractory lined piping and equipment and any other items for which heat loss is

essential shall not be insulated. (See para 4.6-D)

2.3 Insulation is not required for piping and equipment for which heat loss is desired - excepting

for personnel protection or to avoid thermal stress problems.

2.4 Insulation is required for any of the following purposes, as indicated in P&IDs and line lists:

a) Heat conservation.

b) Process stabilization to assist process control.

c) Steam tracing.

d) Electric tracing.

e) Hot water of solvent tracing (liquid).

f) Hot Oil tracing.

g) Steam jacketing.

h) Hot water or liquid jacketing.

i) Hot Oil jacketing.

j) Fire hazard protection to prevent fast boil off of liquid.

k) Personnel protection. Applicable where exposed surface temperature exceeds 65°C in

normal or short-term operating conditions. Over internally insulated piping and equipment,

provide open mesh metal guards and for surfaces which are not internally insulated

provide insulation on that part of surfaces with which operating and maintenance

personnel may come in contact while performing routine duties. The intent of P&IDs, Line

classification lists and engineering drawings etc. which designate insulation for personnel

protection is to call attention only to the eligibility of such service. The actual extent of

insulation shall be determined by Field Construction Personnel and/or operating

personnel using the following criteria: Exposed surfaces operating above 65 °C and

located within 600 mm horizontally or 2100mm vertically of a normal access, walkway of

work area.

2.5 Instruments and associated piping 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.




DATE : 21.11.10

3.0 EXTENT OF INSULATION ON PIPING SYSTEM: 3.1 Insulated piping systems shall have straight pipe, bends, tees and pipe fittings completely

insulated.

3.2 All valves and flanged joints shall be completely insulated only on in steam, condensate

service, hot oil lines and in lines which are steam trace heated or jacketed to maintain

temperature.

3.3 For bucket and float type traps, the inlet piping and trap shall be insulated.

3.4 Insulation on inlet piping to thermostatic and thermodynamic steam traps shall terminate at

approximately 500mm before the trap.

3.5 Steam trap outlet piping other than closed condensate recovery system shall not be insulated

except for personnel protection reasons.

3.6 Instrumentation to be insulated, such as level gages, level controllers, level switches, DP

cells, shall have their fluid containing sections and the associated piping completely

insulated, including pipes, valves and fittings.

3.7 Insulation shall not be applied to the following, unless otherwise specified.

a) Piping which becomes hot intermittently, such as relief valves, vents, steam-out and

snuffing steam systems flare and blow-down systems.

b) Supports for piping, excluding pipe hangers to the extent covered by insulation.

c) Steam Traps (except as noted in paragraph 3.3).

d) Valves, including control valves and flanges in process piping systems (except as noted in

3.2 and 3.8). However, personnel protection insulation for these items shall be applied, as

required.

e) Pipe Union fittings.

f) Thermowell bosses and pressure tappings.

g) Expansion joints, hinged joints and hose.

h) Sight flow indicators.

3.8 Insulation shall be designed to provide an absolute minimum clearance of 25mm between the

outside surface of any insulation finishing material and adjacent surfaces.

3.9 Where insulated horizontal piping is supported on steel shoes, the height of the shoe shall be

such that the underside of the insulation finishing material is clear of the supporting structures

upon which the shoe rests by 25mm minimum.




DATE : 21.11.10

4.0 EXTENT OF INSULATION ON EQUIPMENT: 4.1 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. The insulation shall terminate not less than 300mm above the support concrete or steel

work.

4.2 Support skirts of insulated vertical vessels of 1200mm and less shall be insulated externally

only, as described in Para 4.1 above.

4.3 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.

4.4 Turbines and steam ends of reciprocating pump shall be insulated for heat conservation.

4.5 Liquid ends of pumps shall be insulated when heat traced or jacketed.

4.6 Insulation shall not be applied to the following unless otherwise specified.

a) Pumps with operating temperature below 200 °C unless pumped fluid has a pour point

above minimum design ambient temperature.

b) Fans, compressors, blowers or other rotating or reciprocating requirement.

c) Liquid ends of pumps except as noted in the Para 4.5 above.

d) Internally insulated or refractory lined equipment unless specially designed for metal

temperature control.

e) Heads of vessels enclosed by support skirts with vessel diameters 1200mm and less.

f) Internal surfaces of insulated vessel support skirts with vessel diameter 1200mm or less.

g) Turbine casings to be insulated shall exclude shaft seal caps, shaft bearing housings,

throttle valves, governors and supports.

h) Exchanger channel and covers; shell and channel flanges & Exp. Joints.

i) Nozzles, manholes and hand holes and flanges of equipment.

j) Surfaces of coolers and condensers.

k) Nameplates of all equipment items.

l) Thermowell bosses and pressure tappings.




DATE : 21.11.10

5.0 MATERIALS GENERAL: 5.1 All material shall be of high quality and good appearance. This specification covers three

materials - Rock wool, Glass Wool and cellular glass.

5.2 Insulation materials shall be of low chloride content, chemically inert, non-sulphurous, rot

proof, vermin proof, impervious to hot water and steam, non-injurious to health and non-

corrosive to steel and aluminum (even if soaked in water at ambient temperatures for

extended periods).

5.3 The use of insulation or finishing materials containing ASBESTOS in any form is not

permitted.

5.4 Insulation and jacketing material backed with paper or other flammable material is not

acceptable.

5.5 Many common flammable liquids such as oil, butanol, diethanolamine and hexanol will react

and start fires when they leak into inorganic absorbent insulation. Such absorbent insulation

can store large quantities of combustible liquids should a leak occur. This could be a decisive

factor when specifying and evaluating alternative materials and are taken care of by

QUANTA / CLIENT while specifying project insulation specifications.

5.6 Insulation materials have been classified into two categories – i) water absorbing ii) non-

water absorbing. Non-water absorbing insulates like cellular glass is recommended for

services upto 125 °C.

Water absorbing insulation lake fibrous insulation and calcium silicate can be used for all

temperatures except for electrically traced pipe. But for low temperature (i.e. upto 125 °C)

services a suitable moisture barrier shall be used since the substrata is at too low

temperature to evaporate moisture, rain or water.




DATE : 21.11.10

6.0 INSULATION MATERIAL: FIBROUS MATERIAL (ROCK & GLASS WOOL) 6.1 Shall be a performed insulation and shall be of long fiber rock or glass material processed

from a molten state into fibrous form bonded operational temp. range from ambient to 550 °C.

Slag wool is not acceptable.

6.2 Unless otherwise specified herein, insulation material shall strictly conform to all the

requirements of quality standards listed below :

• Performed pipe insulation. - IS : 9842 : Latest issue

• Metal-mesh covered

bonded mineral fibre

blanket & blanket type

pipe insulation.

- IS : 8183 : Latest issue for piping & equipment.

Faced on one side with 20mm galvanised No. 22 SWG. Wire

Mesh, Stitched through with 22 SWG. galvanised lacing wire

: Mattress for Lined covdrs shall be faced on one side with

20mm galvanised 22 SWG wire mesh stitched through with

22 SWG galvanised lacing wire.

• Mineral Fibre blocks &

board thermal insulation.

- IS : 8183 : Latest issue

6.3 Insulation shall conform to following requirement and shall be tested and test certificate on

representative samples furnished to PURCHASER as per IS : 8183 / IS : 9842 (latest issue)

for conformance of each of the following requirements.

• Density - 140 to 150 kg/m3 (Density shall be within this range and density

test shall be as per IS:5688/ IS : 3144 (Latest issue)

• Shot Content

(IS : 3144)

- Shot shall not be more than 5mm in any dimensions, shot

content, when sieved as follows, shall not exceed as per below :

IS Sieve Shot Content, Percent (IS:460 by Mass (Max.) (Latest

issue).

500 micron 5

250 micron 15

• Moisture content and

moisture absorption

(IS : 3144)

- Not more than 2 %

• Incombustibility

(IS : 3144)

- Incombustible; Loss in weight not more then 5 %

• Thermal Conductivity (IS : 3346)




DATE : 21.11.10

* Mean Temperature

°C

Thermal / Conductivity mw/cm °C

50 0.43

100 0.52

150 0.62

200 0.68

250 0.80

300 0.90 * Mean Temperature is Hot Face Temp. + Cold face Temperature.

2 • Sulphur Content

(IS : 3144)

- Not more then 0.6 percent.

• Liner Shrinkage

(IS : 3144)

- Not more then 2 percent when subjected to soaking

conditions of soaking heat at the stated max. temp. of use

(550 °C) for 24 hours.

Heat Resistance

(IS : 3144)

- When heated to max. temp. (550 °C), sample shall maintain

its general form and shall not suffer visible deformation of

the fibrous structure.

• Compressive Strength

(Average) min. at 10 %

deformation

- 120 kg/m2

• Recovery after

compression (IS : 8183-

Appendix ‘A’ IS : 9842-

Appendix ‘A’)

- After compression to 75 % of the original thickness, recovery

shall not be less than 90% of thickness.

• Alkalinity (IS : 8183

Appendix ‘B’ / IS : 9842

Appendix ‘B’)

- pH of the solution of the material shall be between 7.0 and

10.0

• Chloride Content

( IS : 3144 )

- Not to exceed 20 ppm

• Dimension - PIPE SECTION :

Hollow cylinder, split length wise on one or both sides of the

cylindrical axis.

Thickness : 25, 40, 50, 60 & 75mm Tolerance in

Length : ± 3 mm Tolerance in

Thickness : ± 3 mm

When installed on the pipe of the specified size, sections shall




DATE : 21.11.10

fit snugly and shall have tight longitudinal and circumferential

joint.

- BLANKET :

Unless otherwise specifically required, standard width shall be

600mm to 1200mm, standard length 1500mm to 2400mm

Thickness : 25, 30, 40, 50, 60 & 75 mm

Tolerance on thickness :

Positive : 3mm

Negative : -3mm

- BLOCK AND BOARDS ( IS : 8183 ) :

Lengths : 1000mm to 1400mm

widths : 500mm to 1000mm

Tolerance : ± 3mm

Thickness : ± 3mm




DATE : 21.11.10

7.0 INSULATION MATERIAL (CELLULAR GLASS): Cellular Glass foamed and fused into unicellular form can be used upto a temperature of 425

°C. But in view of high thermal conductivity, its use is limited in this specification to 125 °C

only as it has been included essentially for its non-water absorbing nature. Insulation shall

conform to following requirements and test certificates on representative samples shall be

furnished to PURCHASER as per ASTM C552 for conformance to each of the following

requirements:

Density 110 to 150 kg/m3 : Test as per ASTM C303 except that on drying will be

necessary. Determine the No. of specimens as per ASTM

C390.

Thermal conductivity (average max.)

Mean Temp. °C W/m°k

10 0.058

24 0.060

38 0.062

93 0.073

149 0.086

Test thermal conductivity as per ASTM C240, C177 and C518. Test shall be at least for 3

specimens.

Compressive Strength : 517 kPa (average min.)

Test method as per ASTM C240 and Recommended Practice ASTM C165. Test shall be at

least for 4 specimens.

Flexural strength average min. 414 kPa.

Test method as per ASTM C240 and clause ASTM 3.4 C203. Determine the method of test

specimens as per method given in ASTM C390.

Water absorption, volume % (average max.) 0.5.

Test method as per ASTM C240. Test shall be at least for 3 specimens.

Water vapour transmission (average max.) metric perm-cm of grains/24 h.m2 mm Hg. cm of

thickness at 26.7 °C : 0.0084.

Test method as per ASTM E96. Test shall be at least for 2 specimens.




DATE : 21.11.10

Dimensions:

Flat Blocks: Shall be rectangular sections and shall be true to form and dimensions, the

corners square and the sides parallel.

Size and thickness shall be as follows:

Width (mm) Length (mm)

300 450

450 600

Pipe Sections : Shall be supplied as hollow cylindrical shapes split in half lengthwise (in a

plane including the cylindrical axis) or as curved segments. Upto 350mm Ø size, only pipe

sections split in half lengthwise shall be used. The insulation shall be supplied in sections of

segments in lengths of 450mm or 600mm to fit standard of pipe. Insulation for pipes upto

150mm Ø size shall be furnished in 600mm length, and for pipe above 150mm Ø nom. size in

450mm length. Thickness for both pipe sections and flat blocks shall be 25, 30, 40, 50, 60 &

75mm. Dimensional Tolerance shall be as follows:

Block Pipe

Length ± 1.6 mm ± 3 mm

Width ± 1.6 mm --

Thickness ± 1.6 mm ± 3 mm

GENERAL:

Periodical checks for density, thickness, shape and size as per above requirements shall be

repeated at site, as per norms and frequency decided at site as per the directions of

PROJECT Site-in-Charge. Special attention is required for fibrous material as its installed

thickness could be reduced due to compression affecting performance.

a) All the codes mentioned shall be the latest issue.

b) PURCHASER shall have right to inspect any or all the test conducted on insulation

material by manufacturer at his shop or at any laboratory.




DATE : 21.11.10

8.0 WEATHER PROTECTION JACKET: Aluminium jacketing shall be used as weather protection over insulation unless otherwise

specified and shall be ASTM B209 alloy 3003 H16 or IS : 737 designation 31000 (Old NS3 )

condition H3 for flat sheets and H4 for corrugated sheets. Cladding shall be coated on the

side in contact with the insulation with a bitumen anti-corrosive paint.

8.1 FIBROUS MATERIAL (ROCK & GLASS WOOL): a) For shells of vertical Storage, Tanks & Vessels : 0.71mm (22 SWG) corrugated

b) For tanks Roofs : 1.22mm (18 SWG) Flat

c) For Horizontal vessels shell and heads; vertical

vessel heads.

: 0.71mm (22 SWG) Flat

d) For removable cover : 1.22mm (18 SWG) Flat

e) For all piping, other than grade piping in off-

sites.


f) For grade piping in off-sites : 0.56mm (24 SWG) galvanised steel,

per IS : 277 class I

8.2 RIGID MATERIAL (CELLULAR GLASS): a) Piping, Horizontal Vessel, Vessel head & Tanks

Roof


b) Vertical Vessel Shells & Vertical portion of

Storage Tanks

: 0.56mm (24 SWG) corrugated

c) Removable covers : 1.22mm (18 SWG) Flat

8.3 ANCILLARY MATERIALS: 8.4 Aluminium Foil to protect Stainless Steel surfaces shall be 0.19mm (36 SWG) thick per ASTM

B209 Alloy 3003 H16 or IS : 737 designation 31000 (old NS3) condition H3.

8.5 Securement Bands / Wires

8.6 If material is Aluminium, then specification shall be ASTM B209 Alloy 3003 H16 or IS : 737

designation 31000 (old NS3) condition H3; If Stainless Steel, it shall be 18/8.

8.7 For securing Aluminium foil on Stainless Steel surfaces : Band, 24 SWG thick X 20mm wide,

Aluminium.

8.8 For Securing Fibrous Insulation

a) On Piping.

b) Band, 24 SWG thick X 12mm (min.) wide, Aluminium.

c) On Equipments.

d) Band, 24 SWG thick X 20 wide, Aluminium.




DATE : 21.11.10

e) On Vertical Storage Tanks.

f) Band, glavanised steel, 40mm wide X 3mm thk. galvanising per IS : 277 class-2.

8.9 For Securing Rigid Insulation:

a) On Piping upto 16” OD.

Wire, annealed galvanised steel, 16 SWG, galvanised per class 2 (heavy coating of zinc,

nominal 600 g/m2) per IS : 227.

b) On Piping 18” OD and Larger.

Band, galvanised steel, 20 wide X 24 SWG thk., galvanising per above (same as for

piping upto 16” OD).

c) On Vertical & Horizontal Vessels.

Band, galvanised steel, 20 wide X 24 SWG thk, galvanising per above (same as for piping

upto 16” OD).

8.10 For Securing Cladding On Insulation (Both Fibrous And Rigid):

a) For Piping:

Band, Aluminium 12 mm (min.) wide X 24 SWG thk.

b) On Equipment:

Band, Aluminium, 20 mm wide X 24 SWG thk.

c) On Vertical Storage Tanks:

Band, Stainless Steel, 25 mm wide X 24 SWG thk.

8.11 Rivets:

Rivets required for metal jacket securement shall be the expanding Aluminium “POP” blind

eye type, 9.5mm long X 5mm Ø.

8.12 Screws:

Screws required for metal jacket securement shall be cadmium plated steel, self tapping type

A No. 8mm Ø X 12mm long to BS 4176 complete with neoprene washers under the head.

8.13 ‘S’ and ‘J’ clips - Formed from 25mm wide stainless steel banding.

8.14 To ensure prefect water proofing, all the cladding joints shall be packed with sealing materials

which may either be in the from of a elastomeric sealing compound or fiber based bituminous

felt strips.




DATE : 21.11.10

9.0 APPLICATION METHODS (GENERAL): 9.1 The application methods, given in this Standard are general in nature. The Contractor is

responsible for applying an insulating system that will give a satisfactory operational

performance and the requirement given herein shall be regarded as the acceptable minimum.

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, efficient

and work a like appearance.

9.2 All hydrostatic tests on piping and equipment, including steam tracing systems, shall be

carried out before insulating material is applied.

The insulation Contractor shall only insulate those sections of the plant that has been

specifically released for such work by the engineer-in-charge. If insulation must be installed

before pressure test, then all welds and flanged joints in the pipe shall be left uncovered till

successful completion of pressure test. Then insulation shall be completed.

9.3 Surfaces to be insulated shall be thoroughly cleaned, dried and made free from loose scale,

oil or grease. It shall be the Contractor’s responsibility to remove loosely adhering scale and

dirt before applying insulation.

9.4 Corrosion Prevention:

Carbon steel and low alloy piping and equipment with normal operating temp. of 125 °C and

below shall be protected against corrosion by painting with a 20 microns (min.) dry film

thickness of heat resistant Aluminium paint suitable for the above temperature. While for

equipments (Vessels, Exchangers and Tanks), this coating shall be provided by equipment

fabricator, for piping, it shall be provided by insulation contractor or equipment and piping

painting contractor.

9.5 Insulation cement shall not be used on stainless steel piping or equipment.

9.6 All insulated austentic stainless steel piping and equipment insulated with Rock or Glass

Wool shall be protected against chloride attack as follows:

For operating temperatures upto 450 °C, the surfaces shall be wrapped with 0.19mm thick

Aluminium foil with 50mm overlap at longitudinal and circumferential joints before application

of insulation. All joints of the Aluminium foil shall have barium chromate primer interposed.

Aluminium foil shall be firmly secured on the stainless steel surfaces by Aluminium bands at a

pitch of 500mm. Care shall be taken while applying Aluminium foil to ensure that the foil is not

punctured at any place during wrapping and clamping with Aluminium bands. For operating

temperature above 450 °C, the stainless steel surfaces shall be painted with two coats of

heat resistant silicon Aluminium paint as follows :




DATE : 21.11.10

Type : Single

Composition : Silicon resin based with Aluminium flakes as pigment

Dry Film Thickness : 20 microns/coat (min.)

Other requirements : It should be suitable to withstand temperature upto 600 °C; when the

paint becomes dry, the painted surfaces shall show no discontinuity.

9.7 The insulation contractor shall not carryout any welding or drilling on plant equipment and

piping.

9.8 Insulation shall be finished, beveled and weatherproofed at all terminal points where it is

required to remove bolts etc. without damage to the insulation.

9.9 Equipment name plates shall remain visible after insulation has been applied by beveling

back the insulating material and carefully sealing the exposed edges to prevent ingress of

moisture.

9.10 All projections, such as lifting lugs, trunnions and stiffeners on piping and equipment (i.e.

vacuum rings) shall be insulated with the same thickness of insulation as specified for the

equipment item or pipeline.

9.11 Thermowell bosses, pressure tappings and weep-hole nipples shall not be insulated in but

left accessible.

9.12 Double layer insulation shall be required when the insulation thickness is greater than 75mm.

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.

9.13 Wet or Damage Insulation shall not be used under any Circumstances.

Insulation material to be applied shall not be kept over bare ground to avoid water absorption.

Installed material awaiting its protective cover shall be adequately protected from damage,

rain and contamination, and shall be covered with cladding at a minimum loss of time.

9.14 A minimum clearance of 25mm between outside surface of any insulation finish and adjacent

equipment, pipe or structural members shall be maintained.

9.15 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.




DATE : 21.11.10

10.0 PIPING:

10.1 MATERIAL:

10.2 FIBROUS MATERIAL (ROCK OR GLASS WOOL): a) Can be used for all piping other than electrical traced pipes upto 125 °C.

b) Can be used for all temperatures.

c) Shall be in performed pipe section in 2 halves for sizes upto which manufactured and at

least for all pipes with outside diameter over insulation of 500mm. In bigger sizes, multi-

segments are preferable if manufactured, otherwise, blankets are acceptable.

d) Pieces of insulation with crushed and damaged ends shall not be used.

10.3 CELLULAR GLASS: a) Can be used for all piping including electrically traced piping for service temperatures

below 125 °C (with electrical and steam tracing the maximum metal temperature

reached by tracer in order to conduct the requisite heat into the pipe shall be the

deciding factor).

b) In-situ foaming may be allowed by engineering-charge after discussions with client and

head-office.

10.4 CORROSION PROTECTION BEFORE APPLYING INSULATION (All Insulation

Materials) :

a) For operating temperature Upto 125 °C, on carbon and alloy steel piping, provide

painting as per 9.4.

b) For austentic stainless steel piping, provide Aluminium harrier, as per Clause 9.6.

10.5 APPLICATION METHODS (General) :

Insulation material shall be applied to fit snugly against the contours and shaped only where

necessary to achieve this requirement. The insulation shall be carried out with the least

number of material pieces as possible and all unavoidable gaps, cavities, and voids suitably

filled with compatible loose fill material.

10.6 Pipe Section / Molded Blocks / Segments: a) End joints of adjacent blocks shall be staggered one half of the length of the block.

b) Included angle between segments shall not be less than 30° for both single and double

layer insulation,

c) Further, minimum arc length of segments should meet following staggering

requirements.




DATE : 21.11.10

d) When double layer is applied, both longitudinal and circumferential joints shall be

staggered. The arc between the longitudinal seam lines of the inside and outside layers

of insulation shall have an angle of over 15° or the longitudinal joints staggered at least

by one layer thickness, whichever is more stringent. Circumferential seams of the inside

and outside layers shall be at least 100mm apart.

10.7 MATTRESS (Fibrous insulation - Rock or Glass Wool):

Shall be applied over the surface with joints tightly butted and laced together with 1 mm dia

galvanised lacing wire.

10.8 INSULATION SECUREMENT (All Insulation Materials):

a) Each layer of insulation shall be secured firmly in place with at least 3 loops of binding

wire/ band, one loop to be placed not more than 75 from each end and at least one loop

to be equally spaced between end loops, for each section. Binding wire shall be drawn

about the insulation with ends tightly twisted together, bent under & pressed into the

surface of insulation. Bands or wires in no case are spaced more than 200mm apart.

b) For all joints shall be sealed with insulating of same composition as the molded block.

c) For Cellular glass and polyisocyanurate, joints shall be sealed with suitable compatible

material.

d) Each layer of insulation shall be secured by the same method as above.

10.9 FRAME WORK FOR SUPPORTING CLADDING:

FIBROUS INSULATION (See Fig. 3 And 4):

This is not necessary for rigid material. This is required only for horizontal pipe runs

provided with fibrous insulation, in blanket forms; vertical piping provided with fibrous

materials need not be provided with this. Piping provided with fibrous resin bonded pipe

sections also need not be provided with this framework.

Spacer rings shall be fabricated out of 25 X 3mm M.S. Flats. The outside diameter of these

rings shall be equivalent to the outside diameter of the insulation. Spacer rings shall be

riveted to ‘Z’ shaped stays, fabricated from the same sized MS Flats. These rings shall be

suitably painted for corrosion protection. Stays shall be provided at intervals of not more

than 300mm long the circumference of the insulation, subject to a minimum of 3 stays.

Spacer rings shall be provided at every approx. 900mm distance. To minimize direct heat

conduction through the stays, a packings of 2 sheets of 3mm thick asbestos mill board shall

be provided at the joints of the stays and pipes. Joints between MS Spacer ring and stays

shall be riveted by 6mm Ø M.S. rivets with 2 sheets of 3mm thick asbostos mill board

interposed.




DATE : 21.11.10

10.10 VERTICAL PIPE (All Insulation Materials) (See Fig. 5):

a) Insulation on vertical or near vertical piping (i.e. greater than 45 °C angle from

horizontal) shall be supported by bolted on metal collars. Metal collars shall be of 6mm

thk. M.S. or alloy steel bar (to suit piping materials).

b) Outside diameter of collar shall be around 12mm less than OD of insulation. Where

multi-layer insulation is used, support collar shall be extended to provide for each layer.

c) Support positions shall be at no greater distance apart than the following :

Piping Operating Temp. Support Spacing

Upto 400 °C 4500mm

400 to 500 °C 3500mm

500 to 550 °C 2500mm

d) Expansion Joints (Both vertical and horizontal piping. All insulation materials)

(See Fig. 3)

e) Expansion joint shall be provided at regular intervals as below :

Temp. °C Spacing (Meter)

Upto 200 Not required

200 to 300 10

300 to 350 8

350 to 400 6

400 to 450 5

f) Expansion joint shall be formed by a 25mm space between the pipe insulation sections

and the space shall be filled by compressed mineral rock fibers. Expansion joints in

each layer shall be offset at least 150 from each other in case of multilayer insulation.

Expansion joint for first layer for vertical pipe shall preferably be just below insulation

support collars.

10.11 ELBOWS AND BENDS (All insulation materials) (See Fig. 6 and Fig. 7):

Insulation material shall be mitered and shall be same as that of pipe. Insulation

securement band / wire shall be same as that for equivalent dia pipe. Each mitered section




DATE : 21.11.10

shall be secured with minimum 2 wires / bands. For bends/ elbows of nom. pipe size 6” &

below, due to lack of space, for all insulation materials, insulation shall be secured by spiral

wound 16 SWG galvanised steel wire for hard materials & 10 SWG galvanised steel wire for

soft materials. Insulation joints of block material shall be suitably sealed with adhesive for

isocyanurate/ callular glass.

10.12 TEE (All insulation materials) (See Fig. 8):

Preformed pipe sections or segments shall be carefully cut and shaped around ‘Tee’

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, at

the junction insulation shall be adequately secured by wire/ band of same specification as

that of same size pipe.

10.13 FLANGED JOINTS OR VALVES (All insulation materials) (See Fig. 9 and Fig. 10):

a) Flanged Joints or valves, if to be insulated, shall be insulated with prefabricated

removable Aluminium covers, lined with pipe sections/ lags/ slabs.

b) Welded valves, if insulated, shall be insulated with oversized pipe sections or lags, cut

and shaped to fit around the body of the valve. Insulated valves shall be cut and shaped

around the valve stem and kept clear of the stuffing box gland.

10.14 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. At these positions the insulation

shall be bevelled and sealed with a metal closure which inturn shall be sealed with

waterproof sealing material.

10.15 PIPE SUPPORTS (All insulation materials) (See 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.

When the pipe hangers pass through insulation on piping outdoor, metal hoods packed with

a waterproof sealing material shall be furnished and installed. Upper bolts of the hanger

clamps are not to be covered with insulation.

10.16 STEAM TRACED PIPING (All insulation materials) (See Fig. 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. Traced instrument line and fittings shall be totally enclosed by the insulation in a




DATE : 21.11.10

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.

Suitable pulley or cement shall be used to improve the contact between pipe and tracers,

throughout length of tracers.

10.17 ELECTRICAL TRACED PIPING (Polyisocyanurate / Cellular Glass):

Electrical traced piping shall be provided with the same size insulation as would be provided

if the piping were not electrically traced.




DATE : 21.11.10

11.0 HORIZONTAL EQUIPMENT: 11.1 MATERIAL

11.2 FIBROUS MATERIALS (Rock or Glass Wool):

a) Can be used for all temperatures.

b) Shells - Preferably performed pipe or multi pipe segments or slabs cut and shaped

to fit. Alternately, blanket may be accepted.

c) Heads - Preformed blocks and slabs cut and shaped to fit. Alternatively blanket may

be accepted.

11.3 CELLULAR GLASS: a) Can be used on all surfaces.

b) Temperature limitation for each shall be as per 7.0

c) Curved segments/ blacks, miter cut and shaped to fit.

11.4 CORROSION PROTECTION BEFORE APPLYING INSULATION (All insulation

materials):

For stainless steel surfaces, provide same protection as for piping per Clause 10.4

11.5 APPLICATION (All materials):

11.6 Following, Provided by the vessel fabricator for insulator/ cladding support/ securement, as

indicated in enclosed Fig. No. 13, 16 & 19 shall be verified for their presence by the

insulation contractor, before commencing insulation work :

For vessels of diameter 2000mm and above are provided with insulation support at

horizontal center line as also vertically at tangent lines. Ring support at tangent lines are

provided with 6mm Ø holes. These are to be used for insulation securement.

At vessel heads above 600mm outside diameter are provided with flats having 6mm Ø

holes. The flats are for insulation support and holes provided in them are to be used for

insulation securement. Also provided on either head is a central ring made of 10mm Ø

glavanised steel rod. For vessels which do not have central nozzle, these rings shall not be

provided by vessel fabricator. For such vessels, insulation contractor shall provide these

rings.

Boot of vessel, if any is provided with circular support ring with holes, as indicated in Fig.

No. 26.

11.7 Blanket shall be applied over the surface with joints tightly butted and laced together with

1mm Ø galvanised lacing wire.

Other block insulation shall be applied with the longer dimension parallel to the axis of the

vessel or equipment. When blocks are applied in multiple layers, all joints in successive

layers shall be parallel to the long axis, shall be staggered and sealed with insulating




DATE : 21.11.10

cement for calcium silicate or suitable adhesive for others. In all cases, the insulation is to fit

the contour of the vessel or equipment, so that the use of a leveling coat of insulating

cement should not be normally necessary to get an acceptable smooth exterior.

11.8 INSULATION SECUREMENT (All insulation materials) (See Fig. 13 and 14):

a) Each layer of insulation on shell of equipment shall be secured by bands at every 225

mm centers. Each band shall be machine stretched and tensioned to remove slack

only.

b) Each layer of insulation on vessel heads shall be secured as follows :

Band shall be in radial direction connecting the head central floating ring and shell girth

ring. The radial bends shall be placed at not more than 150mm centers for regid and

300mm for fibrous insulation, measured at the girth ring. These bands shall be machine

stretched and sealed. Outermost layer of insulation shall also be supported by drawing

and securing 16 SWG annealed steel wire through the 6mm diameter holes provided in

the shell grith ring as also the flats provided on heads. The wire shall be drawn through

every hole and it shall be secured to the ring with a knot.




DATE : 21.11.10

12.0 VERTICAL EQUIPMENT: 12.1 MATERIAL: 12.2 Fibrous material shall be same as specified for horizontal equipment.

12.3 Calcium silicate, Polyisocyanurate and cellular glass shall be same as for horizontal

equipment.

12.4 Corrosion protection shall be applied before applying insulation (All insulation materials)

Corrosion prevention before applying insulation for stainless steel surfaces shall be same

as specified for horizontal equipment.

12.5 Application (All insulation materials) (Fig. 13 & 14):

Application details on shell, top and bottom heads shall be similar to that of horizontal

equipment. Insulation shall be laid on insulation support rings provided by the fabricator.

See enclosed sketch (Fig. No. 22).

12.6 INSULATION SECUREMENT (All insulation materials) (Fig. 13, 14 & 15):

a) Bottom and top head insulation shall be supported by 16 SWG annealed galvanised

steel wire drawn through holes in the insulation supports provided by the fabricator.

b) Top head insulation shall be secured by floating ring/ bands provided by vessel

fabricator similar to head or horizontal vessel.

c) Shell insulation shall be supported by bands at every 225mm centres on the cylindrical

portion and the bands shall be kept horizontal.

d) Insulation Securement for Bottom head for vessel supported on legs shall be identical to

that of Top head.

e) For insulation securement of bottom heads inside skirt no floating rings/ bands need be

provided; Firm securement should be ensured just by 16 SWG annealed wire drawn

over insulation tightly and through the holes on support rings provided by the fabricator.

12.7 EXPANSION JOINTS (All insulation materials):

Expansion joints shall be provided every 4000mm (max.) The joint shall be provided at

insulation support rings. It shall be a 25mm space between the top of the insulation and the

bottom of the support ring. The space shall be filled up by compressed Rock-wool fiber.




DATE : 21.11.10

13.0 FLANGE, NOZZLE, CHANNEL COVER, MAN-WAY AND HAND-

HOLE FLANGED COVER (All insulation materials):

a) Where insulation is required, these shall be insulated with lined removable prefabricated

covers secured with bands or quick release toggle clips.

b) Otherwise, insulation shall be stopped short of uninsulated flanges and nozzle etc., a

sufficient distance to permit withdrawal of bolts without disturbing the rem inder of the

insulation. Insulation shall be weather proofed and sealed at these locations.




DATE : 21.11.10

14.0 IRREGULAR SURFACES SUCH AS PUMPS, COMPRESSORS,

TURBINE ETC: 14.1 Corrosion Protection:

For SS surfaces at all temperatures, provide same protection as indicated for piping,

Clause 10.4

14.2 Application:

14.3 Fibrous Material : Material, application and insulation sacrament: This shall be prefabricated removable aluminum covers, lined with mineral rock / glass wool

pipe sections / lags/ slabs / mattresses.




DATE : 21.11.10

15.0 VERTICAL STORAGE TANK (Carbon Steel): 15.1 MATERIAL:

15.2 FIBROUS MATERIAL (ROCK / GLASS WOOL): Shall be in the blanket form.

15.3 APPLICATION:

15.4 SUPPORTING RINGS / SPIKES (RODS) FOR SUPPORTING INSULATION /

CLADDING:

15.5 SHELL: Refer Fig.No. 20 & 21 This Standard indicates the extent of insulation/cladding supporting/

sacrament details provided by tank fabricator. Insulation contractor shall check for its

presence before insulation application work. Following is provided by tank fabricator.

a) Water Shed At the junction of shell and roof, water shed is provided to act as top

covering for the shell insulation as shown in Fig. No.-20 & 21.

b) Insulation Support will consist of 5mm Ø steel rods provided at 400mm Ø diamond

pitch. Length of these lugs is 3mm less than insulation thickness.

c) Cladding Support form tank top, horizontal rings shall be provided at every 1175mm on

tank shell.

15.6 TANK ROOF: Tank roof shall be provided as per Fig. No. 21.

15.7 INSULATION LAYING AND SECUREMENT:

15.8 SHELL: Application of fibrous insulation:

Insulation shall be applied between rings in horizontal mode. Mattress insulation shall be

applied with joints tightly butted and laced together with 1mm Ø galvanised lacing wire.

Matts shall be impaled to the 5mm rod and speed washers fixed and pressed home for

intimate contact of the insulation. In the case of multiple layers, speed washers are

necessary only over the final layers, (upto and including 150mm). Rods and speed washers

of spring steel should be selected to suit each other. While rods are provided by tank

fabricator, speed washers shall be furnished by insulation contractor. Insulation shall be

further secured by bands spaced centrally between insulation supports.

15.9 ROOF (for all materials):

Application of both fibrous and polyisocyanurate shall be similar to that as for shell.

Insulation supports from 5mm Ø MS lugs shall be exactly same as in shell.

15.10 INSULATION FINISH (TANK):

15.11 GENERAL:




DATE : 21.11.10

15.12 MOISTURE BARRIER: On all surfaces provided with fibrous materials and calcium solicate for surface upto 125 ºC,

apply a breathing type moisture barrier as below. A 3mm thick coating of mastic shall be

applied to the surface of the insulation as soon as possible, after erection, to reduce the

time the insulation is exposed to the weather, to a minimum. Whilst this coat is still wet,

glass cloth shell be laid over the surface and embedded in thd mastic. 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. At junctions in the glass cloth, the overlap shall not be

less than 75mm. A second 3mm thick coat of mastic shall be applied after approximate 12

hrs. When dry this coating shall be a minimum of 1.50mm thick. Care must be taken,

however to ensure that the individual coats are not greater than 3mm (especially corners)

otherwise some cracking of dried coat may be result the mastic shall not be applied over

wet insulation or until the adhesive is dry. During the drying time, the insulation shall be

protected from the weather by “Alkathene” film type tarpailin or similar materials approved

by Engineer-in-Charge.




DATE : 21.11.10

16.0 INSULATION FINISH (PIPING): The insulation finish shall provide a weatherproof and mechanical damage resistant

covering over the whole of the insulation areas and be applied and fitted in such a manner

as to provide a close fitting assembly without gaps.

16.1 PIPING (For all materials):

a) Straight pipe shall have metal jacketing cut and machine rolled, (approx. 1 meter long)

wrapped around, with 50mm minimum overlaps on both longitudinal and circumferential

overlaps. All laps shall be arranged to shed water.

b) A single bend shall be made on all overlaps to ensure tight metal-to-metal water tight

arrangement. Self-tapping screws, at every 150mm, shall be provided at all longitudinal

overlaps for both horizontal & vertical piping.

c) At all operating temperature the seams at overlap positions shall be rendered watertight

per clause 8.14 to ensure that insulation remains dry and unwetted, whether the

possible water impingement is from rain, hose or fire sprinklers.

d) The metal coverings shall be secured tightly around the insulation pipe and held in

place with hands on a maximum of 300mm centers. One bend shall be located on each

circumferential lap and the distance. Between laps divided at equal bend spacings. The

bend securing seals shall be kept neatly in line the positioned away from viewing angles

as much as is possible.

e) Vertical overlaps on vertical or near vertical piping shall be staggered to provide

overlaps at ‘North’ and ‘South’ positions in alternate sections of covering.

f) Each section of metal covering on vertical piping with insulation outside dia. larger than

250mm shall be supported from the next lower section each two ‘S’ clips, fabricated

form banding material. The ‘S’ clip shall be of sufficient length to allow the minimum

overlap of 50mm.

g) On vertical piping with O.D. of 600mm and larger, the securing bends shall be

supported by ‘J’ clips, fabricated from banding material. The ‘J’ clip spacing shall be

minimum of two per band All ‘J’ clips shall be screwed into position and secured.

h) Insulation bends and elbows in piping 80mm and larger, shall be metalled with ‘lobster

back’ segments using 10mm minimum ball swage to assist shaping. The metal bands

shall be screwed with self-tapping screws and metal sealants are to provide to get a

completely waterproofed arrangement.

i) Insulation bends and elbows in piping smaller than 80mm may use complete pressed

humped back flat metal elbows or fabricated ‘stove pipe’ elbows.




DATE : 21.11.10

j) 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.

The joints shall be located to shed water.

16.2 EQUIPMENT (All materials):

a) 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, via angle

brackets bolted to the panel. Refer Fig. No. 22 for details.

b) The panels shall be applied commencing at the bottom of the vessel. Each

circumferential ring of panels shall be tensioned by means of tensioning bands until the

final joint is screwed tight. ‘S’ clips shall be used as sheeting support at unscrewed

circumferential overlaps.

c) The panels shall be held tight over the vessel insulation by means of circumferential

bands and sealed per. 8.14 the bands shall be positioned on all horizontal overlaps and

at 450 mm centers. Bands shall be held in their relative positions with ‘J’ clips and be

machining stretched and sealed to remove slack only. Those bands, which are not

supported by ‘j’ clips, shall be held in position on cladding by providing pop rivets every

2 meter centers.

d) The panels shall have a minimum overlap of one corrugation on vertical joints and

80mm on horizontal joints. The overlaps shall be arranged to shed water at all times.

e) 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, these shall

be constructed with a 150 mm overlap and shall remain unscrewed and left free to

permit expansion. All overlaps shall be rendered watertight as per 8.14.

f) All equipment projections such as nozzles shall have the jacketing sealed using a metal

flashing, cut to fit the projection and extending above the jacket at least 80mm. The seal

between the flashing and jacket shall be made watertight by use of self-tapping screws

and sealing mastic.

g) Horizontal cylindrical equipment shall be furnished with flat metal jacket arranged in

circumferential bands with the edge of the sheets, with the longer dimension applied

around the circumference of the equipment insulation.

h) The panels shall have a minimum of 80mm overlap on both longitudinal and

circumferential edges, both overlaps being finished with a simple ball swage and

rendered watertight as detailed in clause 8.14.

i) Horizontal overlaps shall be secured with No. 8 X 12mm long self-tapping set in the

overlap at 150mm intervals, and shall be so arranged that staggered bands of paneling




DATE : 21.11.10

encircle the equipment. Vertical overlaps shall not be screwed for horizontal equipment.

j) The metal finish shall be banded and sealed at 450mm centers.

k) The insulated heads of vertical and horizontal equipment shall be fabricated from flat

metal, in an “Orange peel” construction with all radial seams overlapping a minimum of

50 mm and secured with self-tapping screws at 150mm centers. All overlaps shall be

ball swaged and be rendered water tight per 8.14.

l) Projections from the heads shall be sealed using metal flashings, neatly cut to fit around

the projections and extending above the jacket for a minimum of 80mm. The seal

between flashing and jacket shall be weatherproofed with self-tapping screws and

mastics.

m) Insulation at bottom heads of fully skirted equipment does not require weatherproofing.

n) Heads of equipment's 24” OD and smaller shall be finished and waterproofed with

square ended fabricated covers.

16.3 VERTICAL STORAGE TANKS:

16.4 Cladding Applications and Securement:

16.5 Shell (Fig. No. 19, 20 & 21):

Cladding is applied over the system of horizontal rings as follows:

a) Overlaps in the vertical joints will be one corrugation.

b) Overlaps in the horizontal joints shall be 50mm (min.)

c) Cladding to cladding fastening, at both horizontal and vertical overlaps shall be

alternately by “POP” Rivets & self-tapping screws at 150mm (min.).

d) Cladding shall be secured to support ring by bolting. Bolts are provided by tank

fabricator at 300mm centers on angles provided at every 1175 centers vertically.

Cladding is secured as indicated in Fig.No. 20 & 21 Felt washer, aluminium washer and

nut shall be supplied by insulation contractor for all bolted connections at shell, roof and

curb angle.

e) Insulation shall be tucked into the skirt portion of the curb angle. Shell cladding and

extended roof cladding shall be secured to curb angle by bolting as per Fig.No. 20 & 21

every 1500mm.

f) Horizontal stainless steel, steel bands over cladding to be provided every 800mm and

also to coincide at every horizontal cladding overlaps. Bands shall be tightened, locked

and lock fastened featuring stainless steel fastening systems. In order to prevent sliding

of the bands downwards, the bands shall be secured to the cladding using POP rivets

at horizontal pitch not over 2 meters.




DATE : 21.11.10

16.6 ROOF: a) All cladding joints shall be sealed by electrometric metal sealants.

b) Min. 75mm overlap shall be ensured at all joints.

c) At all joints, cladding-to-cladding securement shall be provided by self-tapping screws

and proprivets alternately, every 150mm centers.

d) Cladding shall be secured by bolting at every 300mm provided by tank fabricator. For

details of cladding arrangement and bolting, see Fig.No. 20 & 21.




DATE : 21.11.10

17.0 ANNEXURE – I:

17.1 OWNER’S OBLIGATIONS: Following free facilities shall be provided near the work site.

a) Open space for storing contractor’s materials shall be provided.

b) Water and Electricity supply.

c) Supply of cement.

17.2 CONTRACTOR’S CONDITIONS:

a) Mode of measurement will be as per IS : 7413-1981 & IS:7240-1981.

b) Contractor should submit the copy of the contract labour license to the personnel Dept.

before starting up the work.

c) Contractor has to maintain certain registers under the contract & the same shall be

shown to the personnel department as and when asked for.

d) Contractor has to maintain certain register under contract labour act.

e) Contractors should comply with ESIS rules and challan of ESI payment should be

submitted regularly during the tenure of the contract.

f) Transportation for contractor’s crew and their accommodation, food etc. will be

arranged by the contractor’s.

g) The rates quoted by the contractor’s must be inclusive of the following :

• Handing and transportation of all items at site.

• Consumable materials.




DATE : 21.11.10

18.0 ANNEXURE – II: HOT INSULATION (IH): Recommended thickness in various temperatures for mineral wool. Density of Mineral wool

120 kg/m³. Conductivity 0.039 kcal/hr. m ° C.

Insulation Thickness

Pipe Size Thickness in mm

NB

(mm)

60 °C TO

100 °C

100 °C TO

140 °C

140 °C TO

180 °C

180 °C TO

210 °C

15 25 25 40 50

20 25 40 50 50

25 25 40 50 50

40 40 40 50 65

50 40 50 65 65

65 50 50 65 65

80 50 65 65 75

100 65 65 75 100

125 65 75 75 100

150 75 75 75 100

200 75 75 100 100

Flat Sur. 75 75 100 100




DATE : 21.11.10

19.0 ANNXURE – III: TYPE OF INSULATION (IS): 1. Bonded Mineral Wool Pipe Section.

2. Bonded Mineral Wool Mattress.

Insulation Thickness in mm

OPERATING TEMPERATURE ° C

Nom. Dia.

(mm)

Pipe O.D. (mm)

≥ 125

126 TO 150

151 TO 200

201 TO

-32.0

15 21 25 25 25 25

20 27 25 25 25 25

25 34 25 25 25 25

40 48 25 25 25 25

50 60 25 25 25 25

80 89 25 25 25 25

100 114 25 25 25 25

150 168 25 25 25 25

200 219 25 25 25 40

250 273 25 25 25 40

300 324 25 25 25 40

350 356 25 25 25 40

400 406 25 25 25 40

450 457 25 25 25 40

500 &

Above

25 25 25 40

Flat Sur. 25 25 25 40

Standard Specification for Hot Insulation (Piping & Equipment)

Documents

Transcript of Standard Specification for Hot Insulation (Piping & Equipment)