Hot Insulation Procedure.doc

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Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

Doc. No. NBTC M3 QC Insul 26.0 Cont. No.: 03UT02-053

Rev. No. 0 Page 2 of9

TITLE PROCEDURES FOR HOT INSULATION

TABLE OF CONTENTS

1. Purpose

2. Scope

3. References

4. Definitions & Abbreviation

5. Materials

6. Procedure

7. Flanges and Valves

8. QC Inspection

9. Safety

NBTC-M3-Insul-26.0,REV-0,04/11/2007


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1.0 PURPOSE :

This procedure provides the minimum requirements for the applicationof insulation to pipe in conformance with the contract requirements.

2.0 SCOPE :

This procedure shall be applicable for Hot Insulation and PersonalProtection work used in DOW-PIC Olefins 2 Project (OL2K) UtilitiesMechanical Works (M3) contract.

3.0 REFERENCES :

Thermal insulation General Requirements: G15S-0001-00

Hot Insulation-Polyisocyanurate : G15S-1001-00

Hot Insulation-Mineral Wool : G15S-1002-00

Aluminum Jacketing : G15S-4001-00

4.0 DEFINATIONS & ABBREVIATIONS :

Owner : Equate Petrochemical Company, K.S.C.C, Kuwait

Contract : Utilities Mechanical Works OL2K

NBTC : Naser M. Al-Baddah & Partner General Trading & Co. W.L.L

QCI : Quality Control Inspector

5.0 MATERIALS :

5.1 Polyisocynaurate :

5.1.1 Thermal conductivity (Lambda Value) shall be maximum of0.023 W/mK, (0.16 Btu/sq.ft-hr-degr.F) at 0C (32F).

5.1.2 Density shall be minimum of 32 kg/m3 (2pcf)

5.1.3 Foam shall be manufactured without the use of CFCs

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5.2 Mineral Wool :

5.2.1 Mineral Wool Insulation shall be rock or basalt based. Slagor others are not acceptable

5.2.2 Thermal conductivity (Lambda Value)


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6.1.4 Insulation shall be installed after the application of all

required coatings and approved by Owner.

6.2 Insulation application :

6.2.1 Insulation shall be applied only to clean, dry, frost freesurfaces.

6.2.2 Only new and undamaged insulation shall be used. AllInsulation and accessory materials shall be stored in an area

protected from weather before and during application.

6.2.3 Both the insulation materials and surfaces to be insulatedshall be kept dry during application. The jacketing shall beapplied as soon as possible. All work not jacketed at the end ofthe shift shall be covered to protect from the element.

6.2.4 Insulation shall be applied using the staggered jointmethod. In multiple layers the joints of each succeeding layershall be staggered.

6.2.5 Insulation shall be installed in such a way that the gapbetween insulated surface and insulation is less than 1/8.

6.2.6 The insulation for piping shall be single layer for processtemperature up to 3150C and multiple layers shall be appliedabove 3150C.

6.2.7 Polyisocynaurate:

Piping size less than 24 Two Piece Preformed Pipe Insulation.

Piping size less above 24 (up to 144) Performer curvedsegments

Fittings Flanges and Valves Fabricated in minimum number ofpieces so as to minimize void space and number of joints.

6.2.8 Mineral Wool :

Piping size less than 24 Preformed Pipe Insulation.

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Piping size above 24 Medium strength Board

(plates) or multiple curvedsegments.

Vessel Heads and Bottoms High Strength Boards

Fittings Flanges and Valves Preformed or molded sections ifavailable or mitered sectional pipe or board (plates). For Valveboxes insulation blankets shall be used.

6.3 Securements of insulation :

6.3.1 All bands and other attachments shall be type 302 or 304material. The band width shall be of and thickness of 0.020.

6.3.2 In multi layer sections inner layer shall be securedseparately with 9 (250 mm) spacing, For Polyisocynaurate fiberglass reinforced tape up to an insulation dia of 36 for Mineralwool SS wire of size Gauge 18 or 0.051 OD up to an insulationdia of 36.

6.3.3 Outer layer shall be secured with bands and thickness of0.020 with 9(250 mm) spacing.

6.3.4 The insulations shall be securely held in place with bands.Bands shall be placed no closer than 1 or farther than 4.5 fromthe end of section. All pipe section shall have at least 2 bands.Where more than one bridle band is used, head band connections

spacing shall not be exceeding 9.

6.3.5 Bands shall tighten with a mechanical tightening tool andsecured with a wing type or crimp type seal. Seals shall be buriedflush with the Insulation.

6.3.6 After the Insulation is applied, all unfilled joints greater than1/16, and chipped edges shall be filled with piece ofpolyisocynaurate foam cut to fit so as to leave a smooth and evensurface.

6.4 Securement of Jacketing :

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6.4.1 Aluminum jacketing (sheeting) and components shall be of

type 3105-H14 alloys conforming to ASTM B-2009.

6.4.2 Pre manufactured Aluminum components in site shall beinstalled in accordance with the manufacturersrecommendations. Field or site fabricated components shall befabricated and installed in accordance with the job specifications.

6.4.3 Jacketing shall be installed with overlaps oriented toensure the system sheds water.

6.4.4 Longitudinal laps shall face away from the view ofroadways and frequently traveled areas. Overlap of longitudinaland circumferential joints shall be 50mm.

6.4.5 Jackets on piping shall be banded with x 0.020 bandson maximum of 11-1/3 (287.9mm) centers. Eachcircumferential overlap shall be banded.

6.4.6 Jacked on hot pipe shall be secured with screws onmaximum of 150 mm centers.

6.4.7 The heads of the screws used for fastening the jacketsshall be sealed by using a neoprene washer under the screw.

6.4.8 All burrs or sharp areas on exposed edges shall beremoved prior to application.

6.4.9 On vertical pipe, S clips shall be placed on the perimeter ofeach sheet before the next higher sheet is applied. A minimumof two clips shall be used up to 24 diameter. Above 24, clips

shall be equally spaced a maximum of 30 apart. Only one clip isrequired up to 6 insulated diameter.

6.4.10 To prevent the bands from slipping, bands on vertical pipeshall be secured by attaching J clips to the jacket with thescrews.

6.5 Sealant :

6.5.1 The approved sealant shall be selected based on themaximum temperature of the surface to which it is applied.

6.5.2 Silicon sealant shall be applied to all voids, entrance holes,protrusions etc.

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7.0 Fittings, Flanges & Valves :

7.1 Piping adjacent to flanged connections to be insulated shall betotally finished, water proofed and sealed regardless of whetherflanges are insulated or not.

7.2 Flanges, valves shall be insulated with same type of insulation asthe pipe, with easily removable, reusable covers, unless notedotherwise.

7.3 Insulation adjacent to equipment items specified to haveremovable insulation covers shall have a waterproofed, sealed,termination, so that water can not enter the insulation when theremovable cover is removed.

7.4 Covers shall be fabricated in minimum number of pieces toprovide full insulation coverage to all area.

7.5 Covers for flanges and valves shall include space left uninsulated on pipe for bolt removal.

7.6 Jacketing shall be provided with permanently attached strapswith adjustable release fasteners and draw strings on wind flaps.

7.7 Jacketing shall be constructed in a manner to preventpenetration of rain, moisture etc. A three fold binding shall beused on all edges. Pleated corners creating a boxed edge to holdinsulation in place without compressing shall be used. Sewn bartacks shall be used to reinforce the seam ends for draw stringclosures. Sewn retainers shall be provided to prevent movement

of the insulation inside the cover.

8.0 QC INSPECTION :

8.1 Material Inspection for owner approved products.

8.2 Ensure clearance for insulation All mechanical, Tracing Painttouchup works finished.

8.3 Ensure General condition of insulation lagging before cladding.

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8.4 The Insulation metal jacketing shall be visually inspected for

voids, cracked segments, open joints etc. to ensure compliancewith the requirements with this procedure.

8.5 Inspection shall be done as per approved ITP and relevant checklists shall be signed off.

9.0 SAFETY :

9.1 Removal and or disturbance of existing insulation shall notproceed with out Owners approval.

9.2 PPE compliance shall be adhered as per the Owner Standard.Safety harness used for higher elevated wroks more than 1.8

meters shall confirm ANSI Z 359 and 100% tie off shall beensured.

9.3 Induction training and periodical specific training shall beimparted to all the employees working at site.

9.4 The Equipments used for insulations works will be inspected bySafety Supervisor and color coding as per the Ownerrecommendations shall be adhered.

NBTC-M3-Insul-26.0,REV-0,04/11/2007

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Hot Insulation Procedure.doc