Ibce 6373 C00 PJM Ten Epcc 11 - 6of22 250 300
Ibce 6373 C00 PJM Ten Epcc 11 - 6of22 250 300
IBCE
THIS VOLUME EMBODIES PROPRIETARY INFORMATION OF TOYO ENGINEERING INDIA PVT. LTD. THIS VOLUME OF THE MATERIAL DESCRIBED
THEREON MAY NOT BE COPIED OR DISCLOSED IN ANY FORM OR MEDIUM TO THIRD PARTIES, OR USED FOR OTHER THAN THE PURPOSE FOR WHICH
IT HAS BEEN PROVIDED, IN WHOLE OR IN PART IN ANY MANNER EXCEPT AS EXPRESSLY PERMITTED BY TOYO ENGINEERING INDIA PVT. LTD.
CONTENTS
Page No.
1.0 GENERAL 3
2.0 EXTENT OF INSULATION 5
3.0 MATERIAL 9
4.0 APPLICATION 19
5.0 INSULATION FINISH 32
6.0 SAFETY 36
7.0 GUARANTEE 36
8.0 GENERAL REQUIRMENTS 37
9.0 THIKNESS OF INSULATION 38
10.0 LIST OF ATTACHMENTS/ DRAWINGS 39
ATTACHMENTS 40-65
1.0 GENERAL
1.1 Intent
This specification covers the specific requirements for design and materials of the
thermal insulation engineered by Contractor.
1.2 Scope
a) This specification shall be applied to the thermal insulation for equipment and
piping shown on the P & I flow diagram and utility flow diagram, but not to the
thermal insulation to be supplied by the manufacturer complete with equipment.
b) This specification is suitable for use in normal process plant atmospheres.
Alternative designs and materials would be specified if necessary for corrosive
atmosphere or potential leaks and spills of chemicals.
c) All the codes and standards mentioned in this specification shall be of latest
issue.
d) This specification does not cover cold service insulation. For cold service,
specification IBCE-6373-C00-PIP-SPC-000-0005 is applicable.
1.3 Units
Unless otherwise specified, SI units shall be applied as the measurement system for
the drawings and documents to be submitted. Nominal sizes of piping components
shall be in accordance with inch system (NPS).
ASTM C610 : Standard specification for Molded expanded perlite block and pipe thermal
insulation
ASTM C612 : Standard specification for Mineral fiber block and board thermal insulation
ASTM C795 : Standard specification for thermal insulation for use in contact with austenitic
stainless steel
ASTM C892 : Standard specification for High temperature fiber blanket thermal insulation
ASTM C165 : Measuring Compressive properties of thermal insulations
ASTM C240 : Standard test methods of testing Cellular glass insulation block
ASTM C302 : Standard test method for Density and dimensions of preformed pipe-covering-
type thermal insulation
ASTM C303 : Standard test method for Density and dimensions of preformed block and board
type thermal insulation
ASTM C335 : Standard test method for Steady-state heat transfer properties of horizontal pipe
insulation
ASTM C356 : Standard test method for Linear shrinkage of preformed high-temperature
thermal insulation subjected to soaking heat
ASTM C390 : Standard criteria for Sampling and acceptance of preformed thermal insulation
lots
ASTM C871 : Standard test methods for Chemical analysis of thermal insulation materials for
leachable chloride, fluoride, silicate and sodium ions
ASTM D1622 : Test method for apparent density of rigid cellular plastics
ASTM D2126 : Test method for response of rigid cellular plastics to thermal and humid aging
ASTM E96 : Standard test methods for Water vapor transmission of materials
ASTM A240 : Standard Specification for Chromium and Chromium-Nickel Stainless Steel
Plate, Sheet, and Strip for Pressure Vessels and for General Applications
ASTM A463 : Specification for steel sheet, aluminum coated, by hot-dip process
ASTM A526 : Specification of steel sheet, zinc coated (galvanized) by the hot-dip process,
commercial quality
ASTM A653 : ASTM A653/A653M - Standard Specification for Steel Sheet, Zinc-Coated
(Galvanized) or Zinc-Iron Alloy- Coated (Galvannealed) by the Hot-Dip Process
ASTM B209 : Aluminum - Alloy sheet and plate
(2) IS Standards And Specifications
IS 12436 : Preformed rigid Polyurethane (PUR) and Polyisocyanurate (PIR) foams of
thermal insulation
IS 3346 : Method for determination of Thermal conductivity of thermal insulation materials
(two slab guarded hot plate method)
IS 737 : Specification for wrought aluminum and aluminum alloy sheet and strip for
general engineering purposes
IS 8183 : Bonded mineral wool-Specification
IS 9428 : Calcium silicate insulation blocks and pipe-coverings
IS 9842 : Preformed Fibrous pipe insulation-Specification
IS 10085 : Chemical analysis of zircon flour or sand
IS 11239 : Method of test for Rigid cellular thermal insulation materials
IS 1335 : Method for direct determination of alumina in refractory materials
IS 1527 : Method for Chemical analysis of high silica refractory materials
IS 277 : Specification for Galvanized steel sheets (plain & corrugated)
1.5 Restrictions
a) Where materials are referred to by trade names within this specification, the use
of such names is intended to describe the kind or quality of the material required
and any deviation must be submitted in writing for PMC/Owner’s approval.
b) Galvanized or zinc coated materials shall not be in contact with metal surfaces
that have temperature above 370 °C. It shall not be used when, in case of fire, it
could drip on stainless steel.
c) The minimum allowable value of sodium plus silicate shall be in accordance with
Fig.1 of ASTM C795 for acceptability of insulation material.
d) Insulation materials to be used over austenitic stainless steel surfaces shall be
3 zinc free and shall be inhibited with sodium silicate as per ASTM C-795.The
amount of leachable chloride in the insulation material (except for calcium
silicate) before application shall not exceed 10ppm. In case of calcium silicate it
should not exceed 50ppm. For the chemical analysis of insulation materials
ASTM C-871 shall be referred.
e) Insulation containing sodium plus silicate shall not be used for insulating
austenitic stainless steels containing molybdenum (such as type 316) operating
at 815 °C or greater.
f) Insulation materials containing asbestos shall not be used.
g) Internally refractory lined piping and equipment and any other items for which
heat loss is essential shall not be insulated.
h) Contact between dissimilar materials which might cause galvanic corrosion shall
be avoided.
i) No flammable materials shall be attached to the insulation.
2.0 EXTENT OF INSULATION
2.1 General
Thermal conductivity of thermal insulation materials shall be in accordance with
applicable standard as specified in the table of respective insulation material
applications.
Hot Insulation
Hot insulation shall generally be applied to equipment and piping operating at 80 °C
and above, except for the case where heat loss is desired. Where heat loss is to be
restricted, however, full heat conservation insulation shall be applied, even when the
operating temperature is below 80 °C.
2.4 Limitations
The following piping components & equipment shall not be insulated unless
otherwise specified
A) Hot Insulation
a) Visible parts such as Name plate, code inspection plates, stampings, sight glass
and level gauge.
b) Shield or guard
c) The following parts of the rotating machinery, which need a heat dissipation and
cooling, unless otherwise specified.
- Stuffing box
- Packing ground
- Piping and jacket for cooling water
- Packing sealed piping
- Bearing
- Oil cooler
- Gear shift case, etc.
d) Fans, compressors, blowers or other rotating or reciprocating equipment or
machinery, unless otherwise specified.
e) Downstream piping of block valves without tracing insulation.
f) Safety valves along with its outlet piping and downstream piping of such valves
as steam blow off valve vent and drain valve.
g) Steam traps and the lines downstream of them which require no recovery of
heat of the drain and no prevention of freezing-up, unless specified in the
drawing.
h) Flanges in Hydrogen services
i) Parts having moving element, such as expansion and swivel joint and sliding
valves.
j) Support legs and inside of skirts
k) For equipment and piping with inside lining of refractory or insulating material,
except for the case where the metal temperature must be controlled.
50 0.43
100 0.52
150 0.62
200 0.68
250 0.80
300 0.90
*The values mentioned are for insulation material as per IS code; For Apparent thermal conductivity
for material as per ASTM codes refer respective ASTM code.
**Mean Temperature = (Hot Face Temperature + Cold Face Temperature) / 2
Linear Shrinkage Not more than 2 percent when subjected to soaking heat at the stated
max. temperature of use (550°C ), for 24 hours
Compressive Strength 250 kg/m2 for resin bonded pipe sections, curved beveled segments
(minimum) at 10% and LRB slabs; 120 kg/m2 for LRB blankets(mattresses) unless
deformation otherwise specified
Chloride Content For stainless steels, with inhibitors less than 10 PPM, for other
materials not to exceed 20 ppm.
3.2.2 Rigid Materials (Calcium Silicate, Molded Expanded Perlite, Cellular Glass)
1. Calcium Silicate
It shall be suitable for temperatures up to 760°C. Insulation shall conform to the
requirements of respective codes, unless otherwise specified herein and shall be
tested and test certificates on representative samples furnished as per IS
9428/ASTM C533 TYPE II.
Bulk Density 200 to 280 kg/m3.
Compressive Strength Reduction in thickness shall not exceed 5% when tested
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.
Heat Resistance When tested at increasing temperatures, the material shall be
deemed suitable for use under conditions of soaking heat, for
24 hrs, upto a temperature at which the following requirements
are met:
Max.Linear 2%
Shrinkage(length)
Max. Loss in Mass 15%
Compressive Strength Reduction in thickness
Not exceeding 10%
under a load of
345 kN/m2
*Thermal Conductivity (max) **Mean Thermal Conductivity (W/mk)
Temperature °C
200 0.080
250 0.088
300 0.097
350 0.110
400 0.121
450 0.135
500 0.148
Chloride content Not to exceed 50 ppm for CS & 25 ppm for SS
*The values mentioned are for insulation material as per IS code; For Apparent thermal conductivity
for ASTM code material refer respective ASTM code.
93 0.079
149 0.086
204 0.095
260 0.106
316 0.111
371 0.126
Water Absorption thermal insulation After heat 149 50
aging & 48 hr water immersion, moisture
gain, % by weight (max)
260 50
371 60
Linear shrinkage For length & width 2%(max) and for thickness
3
8%(max) at 649 OC for 24hrs
Chloride content For stainless steels, less than10 PPM, for other
materials not to exceed 20 ppm
Fire properties Insulation shall be self- extinguishing type and shall satisfy the
requirements for maximum extent of burn (less than 25mm for
PIR and 125mm for PUR) when tested as per BS:5608
(Horizontal burning characteristics- max. extent of burn) or
IS:12436
Flexural Strength This is applicable to preformed pipe coverings only and shall be
275Kpa(min).Test shall be as per ASTM C446.
Humid aging (Max. allowable value after aging at 60°C – 90 °C to 100%
relative humidity)-Maximum percent change in linear dimension
shall be 4. This limit applies to each of the three foam direction.
Test shall be as per ASTM D2126.
Closed cell content Minimum percent 85. Test as per BS:4370 Part – II (Test for
closed cell content)
Dimension stability after Test method as per IS:11239 Part – II
heating
The max. dimensional change at different temperatures shall be
100°C ± 2°C(24 hr) = 2%
125°C ± 2°C (24 hr) = 2%
Standard size and Block
dimensions Length up to 2400mm & Width up to 1200mm
Tolerance
On length ±6mm / On width ±3mm /On thickness ±1.6m
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 molded segments cut from
blocks or molded to shape. up to 14” size, only pipe sections slit in
half lengthwise shall be used
Dimensional Tolerance:
On Length ±6mm /Thickness ±1.6m
Thickness 20, 25, 30, 40, 50, 60 and 75mm
4. Cellular Glass
Cellular Glass formed and fused into unicellular form can be used up to a
temperature of 350°C. Insulation shall conform to the requirements of
respective codes, unless otherwise specified herein and shall be tested and
test certificates on representative samples furnished as per ASTM C 552.
Density 110 to 147 kg/m3. Test as per
ASTM C303 except that no
drying will be necessary.
Determine the no. of specimens
as per ASTM C390
Thermal conductivity (max) Mean Temp °C Thermal
Conductivity
Thermal conductivity shall be tested as per ASTM C240, C177
Max. W/mK
and C518.Test at least 3 specimens.
149 0.078
3
93 0.063
38 0.052
24 0.050
10 0.048
Thermal conductivity shall be tested as per ASTM C240, C177 & C518. Test at least 3 specimens.
Linear Shrinkage (%) (at max temp) for 3(1200ºC) ASTM C-356
24hrs
Transverse 0.5
*The density shall be calculated on the basis of actual dimensions and actual weight
only, as offered by the manufacturer.
** In case of thermal conductivity, the test certificate from an international laboratory
or any laboratory approved by department of Science & Technology could be
considered. However, the same shall indicate values for other characteristics of the
material. The test certificate shall not be more than 12 months old from the date of
offer of material for inspection.
2. Combination of Insulation of ceramic fibre (Inner layer) & Rock wool (Outer
layer) OR
Combination of Insulation of calcium silicate (Inner layer) & Rock wool (Outer
layer) can be used however material requirements stated above shall be
followed.
For Horton Spheres & 0.71mm (22 SWG) Flat 0.56mm (24 SWG) Flat
Horizontal vessel shell and
heads; vertical vessel heads
For removable covers 1.22mm (18 SWG) Flat 1.22mm (18 SWG) Flat
For all piping, other than grade 0.71mm (22 SWG) Flat 0.56mm (24 SWG) Flat
piping in offsites
For grade piping in Offsites 0.56mm (24 SWG) Galvanized
steel (Refer note below)
4.0 APPLICATION
4.1 GENERAL
a) 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 requirements 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 workmanlike appearance.
b) The insulation shall be so designed /applied such that ingress of water is
prevented, leaked product can drain off and vapor can escape.
c) 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
have 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.
d) 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.
Corrosion Prevention
Piping, Equipment, Tanks etc. shall be protected against corrosion by painting
under insulation as per Painting specification. Document attached elsewhere in
tender document, Doc. No.: IBCE-6373-C00-FQC-PRC-000-0002.
a) The insulation Contractor shall not carry out any welding or drilling on plant
equipment and piping.
b) Insulation shall be finished, beveled and weatherproofed at all terminal points
where it is required to remove bolts etc. without damage to the insulation.
c) Equipment nameplates 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.
d) 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.
e) Thermowell bosses, pressure tapping’s and weep hole nipples shall not be
insulated in but left accessible.
f) For Insulation thicknesses up to 75mm only single layer insulation shall be used.
Multi- layer insulation shall be required when the insulation thickness is greater
than 75mm with the inner layer being larger. 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.
g) Wet or Damaged Insulation shall not be used under any circumstances 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.
h) A minimum clearance of 25mm between outside surface of any insulation finish
and adjacent equipment, pipe or structural members shall be maintained.
i) 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.
j) 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 structure upon which the shoe rests by 25mm minimum.
k) Pieces of insulation with crushed and damaged ends shall not be used.
l) When operating temperature is below 200°C, pipe shall be wrapped with
aluminium foil / SS foil (in case of SS lines) prior to insulating the line. Only SS foil
shall be used for SS piping.
m) All pipes shall be coated with zinc silicate coatings below 120°C and silicon
aluminium above 120°C. No painting shall be done on SS lines
4.2 PIPING
4.2.1 Standard Shapes of insulation
1) Fibrous Material (Rock or Glass wool)
Shall be pre-formed pipe section in 2 halves for sizes up to 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.
2) Calcium Silicate I Molded Expanded Perlite
Hollow cylindrical shapes slit in half lengthwise (in a plane including the
cylindrical axis) or as curved segments. Up to 14" pipe size, only hollow
cylindrical shapes slit in half lengthwise shall be used. Pipe sections bored I
machined out of blocks shall not be used.
3) Polyisocyanurate / Polyurethane
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 molded
to shape. Up to 14" pipe size, only pipe sections slit in half lengthwise shall be
used.
4) Cellular Glass
Shall be supplied as cylindrical shape slit in half lengthwise (in a plane
including the cylindrical axis) or as segments. Up to 14" pipe size, only pipe
sections shall be used.
5) Ceramic Fiber
Shall be supplied in blanket strips in sizes as mentioned in the material
spec in clause 3.2.3
4.2.2 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. The
insulation shall be carried out with the least number of material pieces as
possible and all unavoidable gaps, cavities, and voids suitably filled up
compatible loose fill material.
block.
- Included angle between segments shall not be less than 30 deg. for both single
and double layer insulation.
- Further, minimum arc length of segments should meet following staggering
requirements.
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 deg. 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.
C) Blankets (Fibrous insulation- Rock or Glass wool) shall be applied over the surface
with joints tightly butted and laced together with 1 mm diameter galvanized lacing
wire.
E) Frame work for supporting cladding fibrous insulation (See Drawing 3 and 4)
i. This is not necessary for rigid materials. 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.
ii. Spacer rings shall be fabricated out of 25x3 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 M.S. Flats. These rings shall be suitably painted for corrosion
protection. Stays shall be provided at intervals of not more than 300 along the
circumference of the insulation, subject to a minimum of 3 stays. Spacer rings
shall be provided at every approx. 900. To minimize direct heat conduction
through the stays, a packing of 2 sheets of 3 thick mill board shall be provided
at the joints of the stays and pipes. Joints between M.S. Spacer Ring and
stays shall be riveted by 6 dia. M.S. Rivets with 2 Sheets of 3 thick mill board
interposed.
c) Ceramic Fiber
Shall be supplied in blanket strips in sizes as mentioned in the material spec in
clause 3.2.3
2. Blanket shall be applied over the surface with joints tightly butted and
laced together with 1 mm dia. galvanized 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
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.
both, a 25mm thick Rockwool fiber blanket insulation shall be applied around
the equipment prior to the application of calcium silicate. This acts as an
expansion area around the equipment to act as mechanical and sometimes
thermal cushions. The calcium silicate block must be cut and fitted to the
outside radius of the equipment plus the thickness of the Rockwool spacer
insulation. The insulation, when installed, should not compress the fibrous
blanket.
f) Above provision to take care of circumferential expansion is required both for
shell and head.
4.3.3 Insulation Securement (for all insulation materials)
(Refer Drawing 13 and 14)
a) Each layer of insulation on shells of equipment shall be secured by bands at
every 225 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 bands shall be placed at not more than 150 centers
for rigid and 300 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 wire through the 6 diameter holes provided in the shell girth
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.
4.4.3 Insulation Securement (For all insulation materials) ( Drawing 16, 17 & 18)
a) Bottom and Top Head insulation shall be supported by 16 SWG SS 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 of horizontal vessel.
c) Shell insulation shall be supported by bands at every 225 centers 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 SS wire drawn over insulation tightly and through the holes on
support rings provided by the fabricator.
4.7.2 Application
1. Supporting rings/spikes (rods) for supporting insulation/cladding
A) Shell
Refer drawing 23 This Standard indicates the extent of insulation/ cladding
supporting/ securement details provided by tank fabricator. Insulation
Contractor shall check for its presence before insulation application work.
Following is provided by tank fabricator:
- Water Shed
At the junction of shell and roof, a watershed is provided to act
as top covering for the shell insulation as shown in drawing 23
- Insulation Support
Insulation support will consist of 5mm dia. steel rods provided at 400mm dia.
diamond pitch. Length of these lugs is 3mm less than insulation thickness.
- Cladding Support
From tank top, horizontal rings shall be provided at every 1175mm on tank
shell.
B) Tank Roof
Shall be provided as per drawing 23
2. Insulation laying and securement
A) Shell (Application of fibrous insulation)
a) Insulation shall be applied between rings in horizontal mode. Mattresses
insulation shall be applied with joints tightly butted and laced together with 1
mm dia. galvanized 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, (up to and including 150mms). 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.
4.8.2 Application
a) Structural members provided by spheres fabricator for insulation/cladding
securement.
b) Insulation laying and securement
i. Insulation shall be applied between rings. Insulation shall be applied with joints
tightly butted and laced together with 1 mm dia. galvanized lacing wire.
ii. Insulation shall be secured by drawing and securing tightly 16 SWG stainless
steel wire through the 6 dia. holes, provided every 200 centers, in the horizontal
leg of the insulation support angle ring. The wire shall be rightly drawn over the
insulation and the insulation firmly secured. The wire shall be drawn through
every single individual hole and it shall be secured with angle with a knot at
every fourth hole. For application of bands for securement of insulation and
cladding refer Drawing 20.
whether the possible water impingement is from rain, hose or fire sprinklers.
d) The metal coverings shall be secured tightly around the insulated pipe and held
in place with hands on a maximum of 300mm centers. One band shall be located
on each circumferential lap and the distance between laps divided at equal band
spacing’s. The band securing seals shall be kept neatly in line and 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 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,
fabricated from banding material. The 'S' clip shall be of sufficient length to allow
the minimum overlap of 50mm.
g) On vertical piping with OD's of 600mm and larger, the securing bands shall be
supported by 'J' clips, fabricated from banding material. The 'J' clip spacing shall
be a minimum of two per band. All 'J' clips shall be screwed into position and
secured.
h) Insulated bends and elbows in piping 80mm and larger, shall be metaled 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
be provided to get a completely waterproofed arrangement.
i) Insulated bends and elbows in piping smaller than 80mm may use complete
pressed and humped back flat metal elbows or fabricated 'stove pipe' elbows.
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.
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 I 50mm overlap
and shall remain unscrewed and left free to permit expansion. All
overlaps shall be rendered watertight as per 3.4.1.
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 of both longitudinal and
circumferential edges, both overlaps being finished with a simple
ball swage and rendered watertight as detailed in clause 3.4.1.
i) Horizontal overlaps shall be secured with No. 8mm x l2mm long self-tapping
screws set in the overlap at 150mm intervals, and shall be so
arranged that staggered bands of paneling 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, an "Orange peel" construction with all radial seams
overlapping a minimum of 50mm and secured with self-tapping screws at
150mm centers. All overlaps shall be ball swaged and be rendered water tight
per 3.4.1.
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 24" OD and smaller shall be finished and waterproofed with
square ended fabricated covers.
• Roof
- All cladding joints shall be sealed by elastomeric metal sealants.
Min. 75mm overlap shall be ensured at all joints.
- At all joints, cladding-to-cladding securement shall be provided by
self-tapping screws and pop rivets alternately, every 150 centers.
- Cladding shall be secured by bolting at every 300 provided by tank fabricator.
fastened to MS I AS angles using two S.S. Rivets or four Nos. of Aluminum POP
rivets, per angle cleat.
6.0 SAFETY
The insulation Contractor shall provide adequate protective appliances like hand
gloves, masks, glasses etc. to the workmen carrying out the insulation work, to
protect them from inhaling and touching insulation dust and fibers.
7.0 GUARANTEE
a) Insulation Contractor shall guarantee all insulation works against the defects due
to material and workmanship effecting performance for a period of eighteen
months from the date of completion of total insulation works and shall repair
/replace promptly, without cost, any part or parts of the material that fails within
said period.
b) The insulation Contractor shall submit along with the tender, authentic test
certificates confirming that the insulation materials offered conform to the
8.1 All applications of insulation shall be made in accordance with this specification.
Contractor shall submit with his proposal, information on intended practices of
insulation application, which are not covered in this specification, for approval. This
information shall include all the details and sketches including those for the following:
- Removable insulation housings;
- Flashing details;
- Additional Insulation supports;
- Vessel head insulation supports;
- Expansion joints;
- Vessel insulation details;
- Exchanger removable housings;
- Machinery removable housings etc.
8.2 Protection of Materials During Storage:
a) Insulation materials must be protected against any damage, from delivery to
finish cladding.
b) Decking and covering with tarpaulins alone are not considered sufficient
protection from weather for any length of time and shall not be permitted.
c) Insulation material slabs and sections shall be stored on a flat surface in a
horizontal position. Insulation material shall never be stacked directly on the
ground.
d) The Contractor shall provide covered storage for insulation materials as
directed by the Engineer-in-Charge.
8.3 Protection of Partially Completed Jobs
a) All precautions shall be taken to ensure that each day's work is vapor sealed
and cladded during erection and before being left over-night to prevent seepage
of water into the materials and getting trapped.
b) The system shall be protected by tarpaulins, water shed and other protective
means.
SR.
DESCRIPTION DRAWING NUMBER
NO.
Pipe Insulation Details (Fibrous & Rigid
1 DRAWING. No. 01
Insulations)
Pipe Insulation method of staggering of
2 sections Rigid & Fibrous Insulation DRAWING. No. 02
(Preformed pipe sections only)
3 Details of Spacer rings for cladding support DRAWING. No. 03
Details of Spacer rings Fibrous Insulation
4 DRAWING. No. 04
(Mattress)
5 Bolted on insulation support for vertical Pipe DRAWING. No. 05
6 Insulation Details for Bends/Elbows DRAWING. No. 06
7 Insulation Details for Pipe Bends/Elbows DRAWING. No. 07
8 Insulation Details Pipe branched & reducer DRAWING. No. 08
9 Insulated removable cover: Valves DRAWING. No. 09
10 Insulation removable cover-Flanged Joints DRAWING. No. 10
11 Insulation Details Pipe supports DRAWING. No. 11
12 Insulation of Steam Traced Piping DRAWING. No. 12
13 Horizontal equipment Insulation DRAWING. No. 13
14 Horizontal equipments heads DRAWING. No. 14
Use of flexible insulation in combination with
15 rigid insulation to compensate for vessel DRAWING. No. 15
expansion
16 Insulation Details Vertical vessel DRAWING. No. 16
17 Insulation Details Vertical vessel heads DRAWING. No. 17
18 Insulation Details Vertical vessel DRAWING. No. 18
19 Insulation Details for Vertical storage tank DRAWING. No. 19
20 Insulation Details for Sphere DRAWING. No. 20
21 Insulation for Instruments- Level gauge DRAWING .No. 21A
22 Typical insulation for Pressure piping DRAWING .No. 21B
23 Hot Insulation Supports for Horizontal vessel DRAWING. No. 22
DRAWING. No.
24 Hot Insulation Supports for Storage Tanks
23A/B/C
DRAWING. No. 01
Pipe Insulation Details (Fibrous & Rigid Insulations)
DRAWING. No. 02
Pipe Insulation method of staggering of sections
Rigid & Fibrous Insulation (Preformed pipe sections only)
Drg. 4
DRAWING. No. 03
Details of Spacer rings for cladding support
DRAWING. No. 04
Details of Spacer rings Fibrous Insulation (Mattress)
DRAWING. No. 05
Bolted on insulation support for vertical Pipe
...............
DRAWING. No. 06
Insulation Details for Bends/Elbows
DRAWING. No. 07
Insulation Details for Pipe Bends/Elbows
DRAWING. No. 08
Insulation Details Pipe branched & reducer
DRAWING. No. 09
Insulated removable cover: Valves
DRAWING. No. 10
Insulation removable cover-Flanged Joints
DRAWING. No. 11
Insulation Details Pipe supports
DRAWING. No. 12
Insulation of Steam Traced Piping