180530-00-ME-SPC-0004-A[1]

PETROM SA EXPLORATION &

PRODUCTION DIVISION

PROJECT NO: 180530

DOC NO: 180530–00–ME–SPC-0004-A PAGE 1 OF 17

ENGINEERING SPECIFICATION

DOCUMENT TITLE: INSULATION SPECIFICATION

PROJECT DESCRIPTION: FEED AND PRE-FEASIBILITY STUDY FOR SURFACE PRODUCTION SYSTEMS IN OIL AND GAS

ORIGINATOR: G. DONZELLI

DATE: 7 JAN. 08

REV. DATE DESCRIPTION BY CHK APP’D CLIENT

0 15/01/08 ISSUED FOR INTERNAL REVIEW GD PC PC 1 17/01/08 ISSUED FOR CLIENT REVIEW GD PC PC A 24/01/08 APPROVED FOR DESIGN GD PC PC


PRODUCTION DIVISION

PROJECT NO: 180530


REVISION DESCRIPTION SHEET

Rev. Para. Revision Description

0 Issued for Internal review 1 Issued for Client Review A Approved for Design

Hold No. Para. Description of Hold

1 3.2 P&ID Legend document numbers


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PROJECT NO: 180530


1 EXECUTIVE SUMMARY .........................................................................4

1.1 Project Outline ........................................................................................4

2 SCOPE ....................................................................................................5

3 CODES, STANDARDS AND PROJECT DOCUMENTS .........................5

3.1 Codes and Standards .............................................................................5

3.2 Project Documents..................................................................................5

4 DEFINITIONS ..........................................................................................6

5 THERMAL INSULATION CLASSIFICATIONS .......................................6

6 MATERIALS ............................................................................................7

7 INSULATION FOR HOT SERVICE .........................................................7

7.1 Materials for Hot Service.........................................................................7

7.2 Weather Covering and Accessories........................................................8

7.3 Application of Hot Service Insulation.......................................................8

8 INSULATION FOR COLD SERVICE.....................................................10

8.1 Materials for Cold Service .....................................................................10

8.2 Weather Covering and Accessories......................................................10

8.3 Application of Cold Service Insulation...................................................11

9 ACOUSTIC INSULATION .....................................................................13

10 INSULATION FOR PERSONNEL PROTECTION.................................14

11 WEATHER COVERING APPLICATION ...............................................14

12 VALVES AND FLANGES......................................................................15

13 QUALITY CONTROL ............................................................................15

14 INSULATION THICKNESS TABLES ....................................................16


PRODUCTION DIVISION

PROJECT NO: 180530


1 EXECUTIVE SUMMARY

PETROM have issued a reimbursable engineering contract to WorleyParsons to provide a Front End Engineering Design (FEED) and EPC ITT documentation for the Central and East Region OSPS Facilities consisting of 284 Parks contained within 23 Projects (22 in Central Region and 1 in the East). In addition, Pre-feasibility Studies leading to future FEED design work are to be carried out on 92 Parks (contained within 15 Projects) for the Western Region as well as for 45 Tank Farms in the three regions (2 in the Eastern Region; 38 in the Central Region; and 5 in the Western Region).

1.1 Project Outline

The Project Scope is comprised of the modernisation or abandonment of existing Park facilities. Modernisation consists of complete replacement of the existing Park facilities, sized to present production capacities. The Park facilities will be designed to be of modular construction, the modules to consist of PETROM design for manifold only (PMAN) or one of five metering point (MP) designs as put forward by PETROM. In addition, there are five Metering Point Production (MPP) designs covering 20 Park facilities in the Central and East Regions that are to be evaluated for abandonment, modernising, upsizing or downsizing in addition to others in the Eastern Region that are to be identified. Given the size and complexity of these facilities, only partial modularisation is expected. Work on the West Region Parks will culminate in a Pre-feasibility Study following a detailed data gathering exercise and verification of the same. There are 92 Parks contained in 15 Projects that will be assessed for upgrade or abandonment. The 45 Tank Farms are to be examined for upsizing, downsizing, modernisation or abandonment and will also culminate as a Pre-feasibility Study. The scope of work begins at the manifold inlet to the Park facilities and continues through to the delivery points of the Tank Farms or MPP’s; i.e. pipelines and wellheads upstream of the manifolds upstream are not considered. However, interconnecting and delivery pipelines will have to be considered in the overall assessment of the project.


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2 SCOPE

This specification gives the material and application requirements for thermal insulation in hot service applications, the requirements for acoustic insulation and the requirements for personnel protection. The insulation will be applied to process piping, utility piping, vessels, columns, heat exchangers, storage tanks, instrument and instrument impulse lines located within the above mentioned PETROM - OSPS Facilities.

3 CODES, STANDARDS AND PROJECT DOCUMENTS 3.1 Codes and Standards

The latest editions of the following codes and standards form part of this specification.

SR EN ISO 12241

Thermal Insulation for Building Equipment and Industrial Installations - Calculation Rules

SR EN 10326 Continously hot coated steel strip and sheet for construction. Technical delivery conditions.

SR EN 10327 Continously hot coated steel strip and sheet made of low carbon content for cold forming. Technical delivery conditions.

ASTM E96 Test Methods for Water Vapour Transmission of Materials.

ASTM E84 Standard Test Method s for Surface Burning Characteristics

ASTM A 167 Corrosion Resisting Chromium Nickel Steel Plate, Sheet and Strips

ASTM C547 Mineral Fibre Pre-formed Pipe Insulation

ASTM C552 Cellular Glass Block and Pipe Thermal Insulation

ASTM C592 Ceramic Fibre Blanket Insulation for Pipe and Vessels

ASTM C612 Mineral Fibre Block and Board Thermal Insulation

BS 5970 Code of Practice for Thermal Insulation of Pipework and Equipment in the Temperature Range -100 Degrees C to +870 Degrees C

3.2 Project Documents

180530–00–PR–PHL-0004 Winterization Philosophy

180530–00–ME–SPC-0003 Painting and Coating Specification

180530–00–PR–PID-XXXX-Z P & ID Legend (HOLD)


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PROJECT NO: 180530


4 DEFINITIONS

Within this specification the following definitions shall apply:

HOT INSULATION Insulation applied to surfaces with fluid operating temperatures greater than 20°C

COLD INSULATION Insulation applied to surfaces with fluid operating

temperatures less than 20°C ACOUSTIC INSULATION Insulation applied to surfaces in order to prevent or

reduce the transmission of noise to the environment. PERSONNEL PROTECTION Insulation or guards applied to surfaces not normally

insulated to prevent personnel suffering hot burn by accidental contact with hot surfaces.

5 THERMAL INSULATION CLASSIFICATIONS

Thermal insulation requirements will be shown on the following project documentation:

• Process and Instrument Diagrams (P&ID`S) • Piping Line Lists • Piping Isometrics • Equipment Data Sheets

The symbols listed below will be used to denote the insulation classification

AI Acoustic Insulation CC Cold Conservation ET Electrically Traced FP Frost Protection HC Heat Conservation PP Personnel Protection using thermal insulation PG Personnel Protection using guards or barriers


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PROJECT NO: 180530


6 MATERIALS

All surfaces that are to be insulated shall be subject to surface preparation and painting in accordance with Project Specification 180530–00–ME–SPC-0003 Painting and Coating Specification All materials shall be asbestos free. Approval shall be obtained before any material, including all ancillary materials, are installed. In order for a material to be approved a current data sheet for the material shall be submitted. The data sheet must detail all the relevant chemical and physical properties of the material.

If alternative materials are proposed the thermal and acoustic performance must be equal to or better than the specified material.

7 INSULATION FOR HOT SERVICE

Hot service insulation shall be applied when the fluid operating temperature of the piping or equipment is greater than 20°C and when the item is heat traced for winterisation purposes or to maintain specific process conditions.

7.1 Materials for Hot Service

Piping and equipment with fluid operating temperatures greater than 20°C shall be insulated with water repellent grade mineral wool. Process and utility piping shall be insulated with preformed pipe sections or for large diameter pipes pipe section mats. All other equipment such as vessel, heat exchangers, drums filters etc. shall be insulated with mineral slabs radiused and bevelled to fit the surface curvature; where the equipment diameter permits pipe section mats may be used. The mineral wool shall have a density of 120 kg/m³, a maximum operating temperature of + 700°C, and thermal conductivity values expressed as W/Mk as given in Table 1.

Table 1: Thermal conductivity values for mineral wool [W/Mk]

Mineral Wool Form Thermal conductivity values at various temperatures

Mean Temperature, °C 50 100 150 200 250 300 350 400

Preformed Pipe Sections 0.037 0.044 0.051 0.060 0.070 0.081 0.93 0.106

Mineral Wool Slabs 0.037 0.044 0.051 0.060 0.070 0.081 0.93 0.106

Mineral Wool Pipe Section Mats 0.037 0.044 0.051 0.060 0.070 0.081 0.93 0.106

Mineral Wool Wire Backed Mats 0.037 0.044 0.052 0.061 0.071 0.082 0.096 0.109


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PROJECT NO: 180530


7.2 Weather Covering and Accessories

The weather covering shall be Hot Dipped Aluminised Steel throughout on piping systems

and equipment.

The Aluminised Steel shall be BQ quality with a coating weight of 240 gr/m2 including both sides.

Self tapping screws shall be 316 Stainless Steel complete with sealing washers.

Banding shall be 316 Stainless Steel; 316 Stainless Steel banding clips shall be used to secure the banding.

Mastics shall be silicone based they shall be crack resistant and have a minimum elongation of 95%.

Butyl Rubber strip may be used in lieu of mastic.

Pressure sensitive tape shall be 25 mm wide self-adhesive polyester with glass reinforcement.

Insulation supports, for piping, or equipment when they are not supplied with the article, shall be 3mm thick carbon steel designed to be bolted on.

7.3 Application of Hot Service Insulation

Fully trained skilled operatives shall be employed to apply insulation. Prior to the application of insulation all surfaces shall be clean, dry, free from contamination and be confirmed that all surface preparation and painting has been carried out .

The insulation materials must be kept dry at all times. The installation of the insulation and weather protection shall proceed so that the insulation is not left without weather protection over night. Where this is not practical the insulation shall be kept dry by means of temporary weather protection until the specified weather protection is installed, wrapping with polythene is an acceptable method for this. Materials that become wet due to atmospheric precipitation or by any other means shall be removed and scrapped.

7.3.1 Piping

Mineral wool pipe section shall be applied so that a snug fit on to the pipe surface is achieved with all longitudinal joints staggered.


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When the specified insulation thickness is greater than 50mm the insulation shall be applied in two layers. If the layers of insulation are un-equal in thickness, the thinnest layer shall be installed as the first layer. The circumferential between layers shall be staggered Bends and elbows for pipes sizes 2 inches (50 mm) or less, a single cut mitres may be used all bends and elbows greater than 2 inches (50 mm) shall be a segmented construction. Pre-formed bends and elbows will be acceptable. On long pipe runs in high temperature service it will be necessary to allow for expansion by installing expansion joints. Expansion joints shall be filled with loose mineral wool. The location and frequency of expansion joints will be determined using the final piping configuration and the highest operating temperature. The number and location of all expansion joints will be subject to approval. Note that the highest temperature may be that of steam out encountered during pre-commissioning activities. On vertical pipes, bolt on carbon steel insulation supports shall be installed. These shall be positioned at the lowest point of each vertical pipe run and above each flange or elbow and additionally, for pipes 4 inches (100 mm) to 16 inches (400 mm) in diameter as required to maintain a maximum distance between supports of 6m and for pipes above 16 inches (400 mm) in diameter as required to maintain a maximum distance between supports of 4 m. For the insulation of piping that is electrically heat traced, the pre-formed pipe sections internal bore shall have a slot made in it to accommodate the tracing cable. For piping that is steam traced the next largest commercially available preformed pipe section may be used. The preformed pipe section shall be secured with two stainless steel bands or tie wire on every section. When two layers of insulation are applied the inner layer may be secured with pressure sensitive tape.

7.3.2 Equipment Equipment includes vessels, storage tanks, towers, heat exchangers, filters and drums. All equipment shall be insulated with mineral wool. Where two layers of insulation are required the joints between layers shall be staggered both axially and radially an overlap of at least 150 mm shall be maintained. Insulation supports on equipment will usually be incorporated during the fabrication of the equipment. However, if additional supports are required these shall be bolt on. Welding on any piece of equipment will not be permitted. Lifting lugs and trunnions will generally not be removed from the vessel after the equipment has been erected; these areas are to be insulated with the same thickness of insulation as that of equipment. Where lifting lugs are attached to the heads of equipment they shall be insulated in a way that prevents the collection of water and dirt in the space between the lifting lug and the curvature of the equipment head.


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8 INSULATION FOR COLD SERVICE 8.1 Materials for Cold Service

Piping and equipment with fluid operating temperatures less than 20°C shall be insulated with cellular glass.

The cellular glass shall have a density of 120 kg/m³, a maximum operating temperature of + 427°C, a minimum operating temperature of – 200°C and thermal conductivity values expressed as W/Mk as given in Table 2.

Table 2: Thermal conductivity values for cellular glass

Mean Temperature, °C

Thermal Conductivity W/mK

+ 400 max 0.13 + 350 max 0.12 + 300 max 0.10 + 250 max 0.087 + 200 max 0.074 + 150 max 0.063 + 100 max 0.053 + 50 max 0.044 0 max 0.036 - 50 max 0.029 - 100 max 0.023 -150 max 0.018 - 180 max 0.016

An anti abrasive coating shall be applied to the inner surface of cellular glass. For fluid operating temperatures between –180°C and +120°C the anti abrasive coating shall be based on an oil modified urethane cut with mineral spirits. For fluid operating temperatures between +120°C and +350°C this shall be based on modified calcium sulphate with inert mineral fillers.

8.2 Weather Covering and Accessories

Weather covering, banding, banding seals, expansion springs for cold service insulation shall be as described for hot service in section 7.2. Pop rivets and screws shall not be used for fixing sheet metal in cold service applications. Joint sealer / adhesive for cellular glass to be a two component isocyanate cured mastic. This material is acceptable when applied in two layers reinforced with glass fabric, as a vapour barrier.


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PROJECT NO: 180530


Glass fabric for vapour barrier reinforcement shall be alkali resistant glass fabric with a minimum mesh opening of 3 mm. Pressure sensitive tape shall be 25mm wide glass reinforced polyester self adhesive tape.

8.3 Application of Cold Service Insulation

8.3.1 General Operations to apply insulation shall not be started until hydro-testing has been satisfactorily carried out. Prior to the application of insulation all surfaces shall be clean, dry, and free from any other type of contamination. Under no circumstances will it be acceptable to apply any type of insulation onto surfaces that are contaminated by moisture. The surface shall be dried and shall remain dry during the application of the insulation. If dry surface condition is not possible to achieve then application shall be postponed until such conditions can be achieved. This requirement will not be the subject of any extra costs to the project. The insulation materials shall be kept dry at all times. The installation of the insulation and weather protection shall proceed so that the insulation is not left without weather protection over night. Where this is not practical the insulation shall be kept dry by means of temporary weather protection until the specified weather protection is installed, wrapping with polythene is an acceptable method for this. All mastics used for joint sealing and vapour barriers, shall be applied in strict accordance with the manufactures instructions. Special attention shall be paid to manufactures recommendations regarding application conditions and curing times.

Mastics that are applied in contravention of the manufactures recommendations will be rejected. Materials that become wet due to atmospheric precipitation or by any other means shall be removed and scrapped.

8.3.2 Piping and Equipment

Where cold insulation is specified the entire system shall be insulated including drains, instrument lines, strengthening rings, lifting lugs, man ways, instrument lines, etc. Cellular glass for piping shall be pre-formed pipe sections; bends and other fitting shall be factory formed by the manufacturer. Equipment shall be insulated with insulation sets specifically manufactured for each equipment item. The cellular glass shall be fitted so that it is a snug fit onto the surface and all edges are square. Edges that are damaged shall be removed and trimmed and re-fitted. All joints shall


PRODUCTION DIVISION

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be filled full thickness with joint sealer and neatly pointed. Joint sealer shall not be used to fill voids. All joints shall be staggered for equipment, which can be achieved by adopting a castellated pattern. For piping the circumferential joints shall be staggered by a distance equivalent to 50% of one pipe section length. For multi layer applications the joints between layers shall be staggered both axially and radially and overlap of at least 150 mm shall be maintained. The cellular glass shall be secured with stainless steel bands spaced at 0.25 m intervals with a minimum of two bands per section. As an alternative pressure sensitive tape spaced at 0.25 m intervals with a minimum of three tapes per section may be used. On multi layer applications pressure sensitive tape shall be used to secure the inner layer. On dome heads on vertical and horizontal vessels the insulation shall be secured with stainless steel finger bands radiating from a central floating ring. In all instances where stainless steel banding is used to secure cellular glass a metal plate 6 mm thick 50 mm square plate shall be installed between the banding clip and the cellular glass. For equipment in cold service where it is not possible to provide a satisfactory thermal break that would allow the identification plate to remain visible a spare identification plate will be supplied that will be fixed to the outer surface of the insulation A vapour barrier consisting of two layers of mastic reinforced with glass fabric shall be applied over the cellular glass. The first layer of mastic shall be applied so that the surface of the cellular glass is fully covered with an even smooth coating of mastic, the glass fabric should then be embedded into the mastic ensuring that it is covered with mastic but that the weave is still visible. An overlap of 50mm shall be maintained at all joints. After the first layer has fully cured the second layer of mastic shall be applied. The mastic shall be applied in accordance with manufacturers’ instructions and thickness recommendations. Where cold insulation terminates for example at ladder supports, brackets for cable trays etc. the insulation shall be extended at the same thickness for a distance equal to four times the insulation thickness, the vapour barrier shall continue for a distance no less than 50 mm on to the steel surface. Where a fully welded sealing plate is installed as part of the support the vapour barrier shall be applied over the plate, the plate shall be insulated and the insulation extended along the support as described above. Trunnions and all fully welded pipe supports shall be insulated to the same thickness as the pipe.


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Pipe hanger type supports, pipe cradle supports and pipe guiding attachments shall be insulated using specially designed load bearing insulation incorporated into the support. These items will be installed during pipe erection as part of the pipe erection activities. Details of the insulation interface with these items will be developed during detail design. Contraction joints shall be located at each insulation support on vertical piping and equipment on horizontal piping and equipment the location of the contraction joints shall be determined taking into account the differential contraction between the piping and or equipment using the lowest temperature condition.

9 ACOUSTIC INSULATION

Acoustic insulation is required for the control of noise emissions to the work area neighbourhood. Unless otherwise specified all valves and flanges will require insulation in acoustic service. Acoustic insulation should be provided as indicated in P&ID per process requirements. For acoustic insulation mineral wool with a minimum density of 180 Kg/m3 shall be used and the sheet metal weather covering shall be a minimum of 0.9 mm thick. The use of lead impregnated vinyl sheet will not be permitted. Where acoustic insulation and thermal insulation is required for hot service the insulation shall be applied to the thickness that fulfils the most stringent of the two requirements. However the materials specified for acoustic insulation shall be used.

When a dual requirement exists in cold service the full system for cold service shall be applied including the vapour barrier, the acoustic insulation shall then be applied over the cold system no credit for acoustic control shall be taken for the cold insulation component.

9.1 Classes of Acoustic Insulation

In view of requirements for noise reduction but to avoid over-design, acoustic insulation is divided in 3 classes:

• Class A The lightest and most economic class • Class B Medium noise reduction • Class C Heavy noise reduction

The dimensions of the acoustic insulation for the three defined classes shall be as indicated in Table 3, unless otherwise specified.


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Table 3. Classes of acoustic insulation.

Class Thickness of the layer (mm)

A 50 B 75 C 100

10 INSULATION FOR PERSONNEL PROTECTION

Surfaces operating at temperatures above 70°C that are accessible from normal working areas and access ways shall be provided with personnel protection to a height of 200 mm above the walkway level and no more than 800mm horizontally from the access walkway. The personnel protection shall consist of open mesh guards or barriers. For surfaces where the operating temperature is greater than 250°C normal hot service insulation shall be used.

11 WEATHER COVERING APPLICATION All joints, circumferential and longitudinal, shall comprise of an interlocking male and female ball swage with a 50 mm overlap being maintained throughout. On horizontal pipe runs the longitudinal joints should be staggered and located below the centre line of the pipe. Provision for drainage shall be provided by installing 10 mm drain holes in the sheet metal located at all low points and every 3m on underside of all horizontal pipe runs. The sheet metal for Hot Service Insulation and Acoustic insulation shall be secured as follows:

• Horizontal piping pop rivets or self-tapping screws at 100 mm centres for all longitudinal joints circumferential joints shall not be screwed or riveted.

• Vertical piping pop rivets or self-tapping screws at 100mm centres for all

longitudinal joints circumferential joints pop rivets or self-tapping screws at 150mm centres, for expansion joints S clips shall be used.

• Equipment in hot service longitudinal joints and circumferential screws or pop

rivets at 150mm centres, expansion springs and storm bands as appropriate.


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For cold service insulation the sheet metal shall be secured as follows:

• Stainless steel bands a minimum of three per sheet, screws and pop rivets shall not be used with exception for fabricated fittings such as dome head sections, elbows T pieces etc. however the length of the rivets or screws shall be such that puncturing of the vapour barrier is avoided.

The thickness of the sheet metal and banding sizes is given in table 4. Table 4 Sheet metal weather covering thickness and stainless steel banding

Pipe or Equipment Diameter inches

(Measured over the insulation)

Sheet Metal Thickness (mm) Stainless Steel Banding

Up to 8 inches 0.6 mm 13 mm wide x 0.4 mm thick

Greater than 8 inches 0.9 mm 20 mm wide x 0.4 mm thick

Acoustic Insulation any diameter 0.9 mm 20 mm wide x 0.4 mm thick

Removable Boxes any diameter 0.9 mm 20 mm wide x 0.4 mm thick

Storage Tanks any diameter 0.9 mm 20 mm wide x 0.4 mm thick

Areas Subjected to foot traffic 1.6 mm 20 mm wide x 0.4 mm thick

Where the specified thickness of sheet metal is not available the next higher thickness is to be used Alternative weather protection materials such as external mastics or polymeric sheets may be acceptable but prior approval will be required before they are used.

12 VALVES AND FLANGES Valves and flanges in hot service shall in general not be insulated.

13 QUALITY CONTROL

The insulation SELLER shall produce a set of drawings showing each geometry that is to be insulated with each insulation classification. The drawings shall contain a materials legend and show the application details. After these drawings are approved they shall become the basis for inspection. Any deviation from these drawings that has not been approved will be the basis for rejection of the insulation.


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14 INSULATION THICKNESS TABLES

Classifications:

Heat Conservation (HC), Electrically Traced (ET), Frost Protection (FP)

Fluid Operating Temperature °C Pipe

Diameter Inches 50 100 150 200 250 300 350

1 40 50 50 50 50 50 50

2 40 50 50 60 60 70 70

3 50 50 50 60 70 70 90

4 50 50 60 70 70 90 90

6 50 60 70 70 80 90 100

8 50 60 70 80 90 100 110

10 50 60 80 90 100 110 110

12/14 70 70 80 90 100 110 120

16/18 70 70 90 90 110 120 130

20 70 70 90 100 110 130 160

24 to Flat 70 100 120 130 150 160 160

Notes:

1) Insulation material to be mineral wool pipe sections and slab, weather covering is sheet metal

2) Thickness greater than 50mm to be applied in multiple layers. 3) For temperatures outside the range given use the next highest temperature to

determine the required insulation thickness. 4) Based on a minimum ambient temperature of -35° C. 5) Wind speed at 40 m/sec.


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Classifications: - Cold Conservation (CC)

Fluid Operating Temperature °C Pipe Diamet

er Inches

20 to 0 -20 -40

1 40 40 50

2 40 40 50

3 40 50 65

4 40 50 65

6 40 50 65

8 40 50 65

10 40 50 80

12/14 40 65 80

16/18 40 65 80

20 40 65 90

24 to Flat

40 65 115

Notes: 1) Insulation material mineral wool pipe sections and slab, weather covering is

mastic or sheet metal 2) Thickness greater than 50mm to be applied in multiple layers. 3) For temperatures outside the range given use the next highest temperature to

determine the required insulation thickness. 4) Based on a maximum ambient temperature of +43° C. 5) Wind speed at 40 m/sec.