IOCL Insulation

8/13/2019 IOCL Insulation

1/43

ABB Lummus Global B.V.

SPECIFICATION

100585910-8.DOC Page 1 of 43

T H I S D O C U M E N T / D R A W I N G I S T H E P R O P E R T Y O F A B B L U M M U S G L O B A L B

. V . I

N C L U D I N G A L L P A T E N T E D A N D P A T E N T A B L E F E A T U R E S A N D / O R C O N F I D E N T I A L I N F O R M A T I O N A N D I T S U S E I S C O N D I T I O N E D U P O N T H E U S E R S A G R E E M E N T N O T T O R E P R O D U C E

T H E D O C U M E N T / D R A W I N G

, I N W H O L E O R I N P A R T , N O R T H E M A T E R I A L D E S C R I B E D T H E R E O N

, N O R T O U S E T H E D O C U M E N T / D R A W I N G F O R A N Y P U R P O S E O T H E R T H A N A S S P E C I F I C A L L Y P E R M I T T E D

I N W R I T I N G B Y A B B L U M M U S G L O B A L B

. V .

Client Indian Oil Corporation LTD. (IOCL) Always refer to this number

Plant Naphtha Cracker Unit 120231 04184 L-611

Location Panipat, Haryana, India Dept./Sect. Project Specification

Doc. No. 04184-120231-L-611 Rev. 0

Specification For:

INSULATION OF PIPING AND EQUIPMENT

L-611

0 2005-03-11 For Feed Package JIS FPM HHI

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED


2/43


SPECIFICATION

Client Indian Oil Corporation LTD (IOCL) Always refer to this number



Doc. No. 04184-120231-L-611 Rev. 0

INDEX

SECTION PAGE

100585910-8.DOC Page 2 of 43

1. GENERAL 5

1.1 SCOPE 5

1.2 DEFINITIONS 5

1.3 EXCLUSIONS 5

1.4 REFERENCE CODES, STANDARDS AND SPECIFICATIONS 5

1.5 OPERATING TEMPERATURE DEFINITION 6

1.6 SURFACE PREPARATION AND PAINTING 6

1.7 FIELD WELDING 6

1.8 LEGEND OF APPLIED INSULATION CODES 6

2. EXTENT OF INSULATION 6

2.1 INSULATION APPLICATION 6

2.2 DOCUMENTS FOR INSULATION SCOPE DEFINITION 8

3. MATERIALS 8

3.1 GENERAL 8

3.2 MATERIALS FOR ACOUSTIC INSULATION 9

3.3 SHEETING MATERIALS 9

3.4 AUXILIARY MATERIALS 10

4. INSULATION THICKNESSES 11

5. APPLICATION 11

5.1

GENERAL REMARKS 11

5.2 HOT INSULATION APPLICATION 12 5.2.1 Piping 12 5.2.2 Vessel Insulation 14


3/43


SPECIFICATION

Client Indian Oli Corporation LTD (IOCL) Always refer to this number



Doc. No. 04184-120231-L-611 Rev. 0

INDEX (Contd)

SECTION PAGE

100585910-8.DOC Page 3 of 43

5.2.3 Tank Insulation 14 5.2.4 Expansion Joints 15

5.3 COLD INSULATION 15

5.4 INSULATION/SHEETING SUPPORTS 16 5.4.1 Piping 16 5.4.2 Vessels 16 5.4.3 Tanks 16

5.5 PERSONNEL PROTECTION 17

5.6 FINISHING LAYER 17 5.6.1 Metal Finishing Layer 17 5.6.2 Vapor Retardant Layer 18 5.6.3 Applying of the Metal Finishing Layer 18 5.6.4 Fastening of the Metal Finishing Layer 21

6. tables 22

6.1 INSULATION THICKNESS FOR HOT SERVICE HEAT CONSERVATION 22

6.2 INSULATION THICKNESS FOR COLD SERVICE (INCLUDING REFRIGERATION AND ANTI-SWEAT) 23

6.3 INSULATION THICKNESS FOR PERSONNEL PROTECTION 24

6.4 QUALITY REQUIREMENTS OF INSULATION MATERIALS 25

6.5 MINIMUM THICKNESS OF THE FINISH SHEETING 26

6.6 SPACING BETWEEN EXPANSION JOINTS 27

7. FIGURES 28

7.1 HEAT INSULATION AT VESSEL SKIRT 28

7.2 WIRE NETTING CAGE FOR PERSONNEL PROTECTION 29

7.3 INSULATION/SHEETING SUPPORT RING 30

7.4 COLD INSULATION OF PIPING WITH PIPE SECTIONS AND BLANKETS 31

7.5 HOT AND COLD INSULATED HORIZONTAL VALVE 32

7.6 INSULATION OF TRACED PIPING WITH PIPE SECTIONS AND BLANKETS 33


4/43


SPECIFICATION

Client Indian Oli Corporation LTD (IOCL) Always refer to this number



Doc. No. 04184-120231-L-611 Rev. 0

INDEX (Contd)

SECTION PAGE

100585910-8.DOC Page 4 of 43

7.7 INSULATED MANHOLE 34

7.8 NONINSULATED FLANGES AND END CONNECTIONS 35

7.9 PERFORATED PLATE SHIELDING FOR PERSONNEL PROTECTION 36

7.10 SHEETING OVERLAPS OF EXPANSION JOINTS 37

7.11 INSULATION OF HORIZONTAL AND VERTICAL BENDS 38

7.12 HORIZONTAL AND VERTICAL CONTRACTION JOINTS (COLD INSULATION) 39

7.13 RAIN COVER FOR PIPE SUPPORT 40

7.14 REMOVABLE EXPANSION BELLOW CAP 41

7.15 SEALING PLATE FOR PROTRUDING PARTS 42

7.16 SHEETING OF VERTICAL EQUIPMENT 43


5/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 5 of 43

1. GENERAL

1.1 SCOPE

This specification gives minimum requirements for the design, materials and execution of exter-nal thermal insulation of aboveground surfaces of piping, equipment, instruments, etc. Externalacoustic insulation of pipes, valves and flanges shall be executed in accordance with EEMUA-142

1.2 DEFINITIONS

For this specification, the following definitions are applicable:

Client : Indian Oil Corporation LTD (IOCL)

Buyer : Client or Clients representatives.

Contractor : Insulation Contractor, supplying and installing insulation materials at the jobsite

Shall : Is to be understood mandatory.

Should : Is to be understood as strongly recommended.

May be : Is to be understood as giving a freedom of choice.

1.3 EXCLUSIONS

Excluded from this specification are:

n Insulation of heating ventilation and air-conditioning installations.

n Building insulation.

n Internal lining of furnaces and other equipment.

n Fireproofing of structural steel and piping/equipment supports.

1.4 REFERENCE CODES, STANDARDS AND SPECIFICATIONS

The following codes, standards and specifications shall form part of this specification to the ex-tent specified herein:

n EEMUA 142 "The Engineering Equipment and MaterialsUsers Association", Acoustic Insulation of Pipes, Valvesand Flanges.

n SDWG. 04-3230-01.027 Insulation Support for Vertical Vessels Cold Service.

n SDWG. 04-3230-01.028 Insulation Support for Vertical Vessels Hot Service.

n SDWG. 04-3230-01.060 Insulation Supports for Storage Tanks.


6/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 6 of 43

n 04184-120231-O-611 Specification for Surface Preparation and Painting.

The latest issue of each of the above-listed documents shall be used.

1.5 OPERATING TEMPERATURE DEFINITION

The operating temperature is the temperature which exists inside equipment and piping duringthe intended normal process operation. The insulation requirements during abnormal conditions(e.g. during regenerating cycles) shall be considered on a case-by-case basis, taking into ac-count the temperature resistance of the insulation materials and the personnel protection re-quirements as a minimum.

1.6 SURFACE PREPARATION AND PAINTING

All steel surfaces to be insulated shall be dry, clean and free from rust, loose mill scale, grease,oil, dirt and other foreign matters. In general, external surfaces to be insulated will have corro-sion protection in accordance with the paint specification 04184-120231-O-611.

Painting damaged by contractor shall be repaired by the contractor in accordance with the paintspecification 04184-120231-O-611.

1.7 FIELD WELDING

Field welding, such as welding of studs, nuts or clips for insulation, on any piece of equipment orpiping is prohibited without prior written approval of Buyer.

1.8 LEGEND OF APPLIED INSULATION CODES

H Normal Heat conservationF Full Heat conservationP Personnel protectionR Refrigeration/Cold conservation.D Anti-sweatM Dual temperatureV Noise controlE Electrical tracingT Steam tracing .

2. EXTENT OF INSULATION

2.1 INSULATION APPLICATION

2.1.1 Insulation shall be applied for one or more of the following reasons:

n For heat or cold conservation of piping and equipment, when economically justified.

Insulation for heat conservation will normally be applied for piping, equipment and in-struments with operating temperatures above 50C.

Under 50C and above 20C operating temperature, insulation will only be applied ifrequired for process reasons and on traced systems.

Insulation for cold conservation will normally be applied for piping, equipment and in-struments with operating temperatures of 20C and below.


7/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 7 of 43

n Process control, e.g. to avoid condensation, solidification, or too high viscosity, rapidtemperature variations.

n In combination with process heat tracing and tracing for prevention of damage toequipment and piping from exposure to freezing conditions.

n Personnel protection, for piping and equipment having an operating temperature of> 70C or < -10C if the location presents a danger to personnel.

n Noise reduction of piping and equipment.

n Prevention of condensation on outside surfaces with a temperature below the normaldew point of the surrounding atmosphere.

2.1.2 The following items shall not be insulated for thermal insulation, unless otherwise specified:

n Valves and flanges in (hot) insulated process lines with operating temperatures below300C.Note: For exceptions refer to paragraph 2.1.3.

n Flanges for hydrogen or sour service.

n Manholes and handholes, with operating temperature less than 300C.

n Channel covers operating below 100C.

n Steam traps.

n Stuffing boxes.

n Steam condensate lines downstream of steam traps discharging to drainage system.

n Untraced branches from traced lines downstream of the first block valve.

n Drain and vent piping on insulated equipment downstream of the first block valve.

n Pumps and compressors.

n Nameplates which indicate design and/or operating data and warnings, sight glassesand thermowells.

2.1.3 The following items shall be insulated for heat conservation insulation unless otherwise speci-fied:

n Traced level displacer chambers and traced level gauges.

n Steam and gas turbines, boiler feedwater pumps.

n Lead and return lines to and from transmitters shall be insulated, as small bore piping,specified in subsection 5.2.1.4.


8/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 8 of 43

n Skirts, legs or supports of insulated vessels shall be insulated externally according toSDWG. 04-3230-01.028 or to within 50 mm of the top of the fireproofing, as applicable(see figure 7.1).

n Valves and flanges in insulated steam supply lines, steam exhaust lines or condensatelines.

n Steam-traced, hot-water traced, hot-oil traced and electrically traced piping, valves,flanges and equipment, except for hydrogen service.

n Manifolds for hot water/steam tracing (contractor to propose his standard).

2.2 DOCUMENTS FOR INSULATION SCOPE DEFINITION

The extent of insulation is specified in the following documents:

For piping (including in-line instruments):

n Line schedule.

n Isometrics.

n Piping and instrument diagrams

For equipment:

n Equipment data sheets.

n Equipment insulation schedule.

n Piping and instrument diagram

For off-line instruments:

n Instrument-tracing details.

n Piping and instrument diagrams

3. MATERIALS

3.1 GENERAL

Insulation materials shall be selected from 6.4, however the following guidelines apply:

n For operating temperatures between 20C and 600C, mineral wool products (readglass or rockwool) as listed in 6.4 should be used.

n For operating temperatures between 600C and 750C, calcium silicate products maybe considered, if economically justified.

n For operating temperatures above 750C, calcium silicate products should be used.


9/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 9 of 43

n For operating temperatures between 20C and -200C, PUR or PIR shall be used, ifeconomically justified.

n For operating temperatures between -200C and -260C, cellular glass shall be used.

n For dual temperature service, with operating temperatures varying between -260C and+400C, cellular glass should be considered or a combination of hot and cold insulationmaterial.

All acceptable acoustic insulation materials are listed in EEMUA 142, subsection 5.1. For excep-tions on acoustic insulation materials refer to subsection 3.2.

In addition, foamed polyurethane is allowed to be used on cold tanks and spheres, provided thatno local major voids will occur and that all manufacturer's recommendations for installation willbe complied with.

Ceramic and asbestos products shall not be used in view of health and safety requirements.

All insulation and finishing materials shall be new, free of damage and in conformity with thisspecification and the minimum requirements stated in table 6.4 (the requirements apply to "ex-factory" quality).

All fastening materials such as binding wire, strapping bands, self-tapping screws, rivets, clipsand quick-release toggles applied on metal finishing shall be of stainless steel; exception hardaluminum self-tapping screws or rivets applied on aluminum finishing may be considered.

Insulation, fastening and sheeting material to be applied on stainless-steel surfaces shall notcontain zinc or be galvanized. To prevent interchanging of insulation materials intended forstainless application and intended for carbon/low/medium alloy steel application, the materialsintended for stainless-steel application and their packing shall be clearly identified.

Materials deviating from this specification shall not be used, unless contractor has written priorapproval from Buyer.

3.2 MATERIALS FOR ACOUSTIC INSULATION

All acoustic insulation materials as specified in EEMUA 142 can be used, with exception of:

n Open-cell plastic foam.

3.3 SHEETING MATERIALS

For thickness of the sheeting, refer to 6.5.

n Aluminum:

AlMg 99.5 (lS) alloy 1060, temper H14, in accordance with ASTM B-209M.

n Aluminized steel:

Steel with a T2-100c aluminum coating, in accordance with ASTM A463. Aluminumlayer in accordance with ASTM A428 (300 gr/m in total for both sides).

n Aluminum zinc steel:


10/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 10 of 43

Steel provided with an aluminum and zinc layer, in accordance with ASTM A792M,tested in accordance with ASTM A370. Aluminum zinc layer tested in accordance with

ASTM A90 and A525 (185 gr/m in total for both sides).

n Hot-dip galvanized steel:

Steel provided with a zinc layer, in accordance with ASTM A527M, tested in accordancewith ASTM A370. Zinc layer tested in accordance with ASTM A90 (275 gr/m in total forboth sides). Properties in accordance with ASTM A525M, or equivalent Indian standard..

n Stainless steel:

Stainless steel in accordance with ASTM A167, type 304.

n Perforated plate:

For personnel protection reference is made to subsection 5.5.

Perforated plate for shielding:

Material : The same as sheeting material.

Perforated area : At least 35%.

Hole diameter : Maximum 5 mm in a triangular grid pattern.

Plate thickness : 1.0 mm.

If protective shielding is with wire netting cage, refer to figure 2.

3.4 AUXILIARY MATERIALS

n Support ring material for piping:

Outer ring: St. 37.Inner ring: Stainless steel 304 (see figure 3).

n Weather-resistant vapor barrier finishing layer:

Tough, elastic finishing layer onto latex base (Foster Monolar Mastic 60-91 or equiva-lent).

n Flexible elastomer or silicone paste:

Metal sealant (Foster Elastolar 95-44 or equivalent).

n Seam filler:

Joint sealant/adhesive (Foster Adhesive 81-82 or equivalent).

n Glass fabric:

(Glass cloth V 10, 600 gr/m or equivalent.)


11/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 11 of 43

n Nonabrasive:

(Foster 30-16 or equivalent.)

4. INSULATION THICKNESSES

Thicknesses of insulation are listed in:

6.1 Insulation Thickness for Hot Service.

6.2 Insulation Thickness for Cold Service.

6.3 Insulation Thickness for Personnel Protection.

The normal operating temperature and nominal diameter in 6.1, 6.2 and 6.3 are the basis forinsulation thickness selection.

Thicknesses should be rounded off to the nearest higher manufacturer's thickness.

To determine the insulation thickness of oil-traced, steam-traced and hot water-traced piping,the nominal diameter shall be the sum of the pipe diameter and the tracer pipe diameter. Thenormal operating temperature shall be the highest of the process temperature and the tracertemperature (condensation temperature of steam, if steam tracing is applied).

Flanges, valves and expansion bellows shall have the same insulation material and thickness asthe piping and equipment concerned.

For compressors and exchangers use the higher of the inlet or outlet temperatures for insulationthickness selection.

5. APPLICATION

5.1 GENERAL REMARKS

5.1.1 Application of all thermal insulation shall be in accordance with this specification.

5.1.2 Application of all acoustic insulation shall be in accordance with EEMUA 142, taking into accountthe general remarks of this section.

5.1.3 Deviation from this specification is only allowed when Contractor has written prior approval fromBuyer.

5.1.4 Application of insulation materials, if not outlined in this specification, shall be in line with manu-facturer's specifications/recommendations.

5.1.5 Insulation through walls, partitions and floors shall be uninterrupted and of uniform thickness.

5.1.6 Removable parts shall have lifting lugs, if their mass exceeds 25 kg.

5.1.7 Prior to the application of sprayed insulation or sealing materials, all adjacent surfaces, instru-ments, etc., shall be protected from splatter, rebound and overspray.


12/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 12 of 43

5.1.8 For insulation thicknesses of 100 mm and more, insulation shall be applied in two (2) or morelayers. Also in case the operating temperature is 300C and above, at least two (2) insulationlayers shall be applied.

5.1.9 Insulation for piping/vessels can be applied either with preformed sections or blanket-type insu-lation, depending on availability as well as economical justification.

Performed pipe sections and segments shall be supplied as factory premoulded cylindrical parts. Any damages as well as poorly closing joints are not acceptable.

5.1.10 Instruments requiring insulation shall be insulated with standard prefabricated insulation boxes.

5.2 HOT INSULATION APPLICATION

5.2.1 Piping

5.2.1.1 General

If insulation starts or terminates on vertical lines, end caps shall be executed in accordance with7.8. All seams shall be sealed.

5.2.1.2 Insulation with Preformed Pipe Sections

The pipe sections and segments shall be shaped to fit properly around the pipeline. The circum-ferential joints shall be staggered and properly closed. An overlap of at least 150 mm shall beobserved between the sections.

Bends, reducers and T-pieces shall be insulated with premoulded insulation sections or cutsegments of the same insulation material as the connecting pipe.

For fastening of sections and segments, at least three (3) stainless-steel wires (diameter 1 mm)per section shall be used for each layer of insulation. The twisted ends of the wire shall bepressed into the insulation material to prevent damage to the finishing layer.

For calcium silicate sections, wires shall only be used on the inner layer of insulation. The outerlayer shall be fastened with strapping bands (minimum 13 x 0.5 mm), placed at intervals ofmaximum 300 mm, with a minimum of two (2) bands per section.

5.2.1.3 Insulation with Blankets

Blankets shall be cut to a length equal to the circumference of the pipe plus two (2) times theinsulation thickness.

Blankets shall be wrapped around the pipe with wire mesh on the outside. Blankets shall beclose fitted to the pipe and to each other, all fitted in between support rings (if applied).

For fastening of mineral wool metal mesh blankets, the longitudinal and circumferential jointsshall be tacked with a stainless-steel wire (diameter 1 mm) or stainless-steel blanket hooks at apitch of 50 mm. The contractor has to make sure that blankets are not compressed more than3 mm by the wires.

For vertical piping with more than one (1) insulation layer, the wire mesh of each blanket shall befastened to the upper support ring.


13/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 13 of 43

5.2.1.4 Complex and Small Bore Piping (3/4 inch and smaller)

For complex piping isometrics, where large numbers of insulation segments for elbows, tees,etc. have to be cut, contractor shall recommend his most cost effective insulation applicationmethod, for approval by Buyer.

A number of small bore lines running parallel to each other may be insulated with mineral woolslabs. Slabs shall be cut to the required dimensions and fastened with binding wire.

5.2.1.5 Traced Piping

For insulation of oil-traced, steam-traced or water-traced piping with pipe sections, oversizedsections shall be used with diameter equal to the diameter of the pipe and tracer (see figure 7.6,detail A). For blanket insulation, contractor shall create a heated space by using a 1 mm thickaluminum channel (see figure 7.6, detail B).

For insulation of electrically traced piping with pipe sections, oversized sections are not required.The pipe nominal diameter shall be the basis. However, if electrical tracers thicker than 2 mmare used, oversized sections should be considered.

5.2.1.6 Flanges and Valves

When flanged connections and valves are to be insulated, this shall be done with enclosuresmanufactured from metal plate (same material as sheeting associated pipe). See figure 5.

The enclosure shall be lined internally with same insulation material in the same thickness as forthe associated pipe. The insulation material shall be attached to the inside of the enclosure withclips as shown in 7.7. Wire mesh of blankets shall face the object to be insulated. Clips shall bescrewed to the enclosure wall.

The insulation shall be fitted over the connected pipe insulation as shown in 7.5.

The stuffing box gland of all insulated valves shall be kept outside the insulation enclosure.

Heat exchanger flanges shall be insulated with removable enclosures, except for those in hy-drogen service.

Insulation enclosures for valves and flanges for viscous fluids shall be provided with drainageoutlets, which give visible indication of a possible leak.

Enclosures with quick release toggles.

When the following valves and flanges have to be insulated, the enclosures shall be providedwith quick release toggles to allow frequent and/or easy removal:

n Control valves.

n Safety/relief valves.

n Remote-operated valves.

n Flanges of strainers.


14/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 14 of 43

n Flanges and valves connected to spool pieces around pumps and compressors.

n Spectacle blinds, spades and spacers.

5.2.2 Vessel Insulation

5.2.2.1 General

Heads of columns, vessels, heat exchangers, manholes, etc. with a diameter up to 1000 mm,may be insulated with insulated caps of metal plate. Refer to 7.7.

Caps shall be internally lined with mineral wool blankets, as described for valve enclosures (seesubsection 5.2.1.6).

Heads of columns, vessels, heat exchangers, manholes, etc. with a diameter over 1000 mmshall be insulated with blankets, with wire mesh at the outside.

For support of insulation and sheeting a floating ring with support bands may be used.

Stiffeners, rings, girders, etc. attached to insulated towers, tanks, vessels, heat exchangers, etc.shall, unless otherwise indicated, be insulated with the same insulation material in the samethickness as for the equipment concerned.

For vessels with a normal operating temperature above 400C an air space shall be providedbetween vessel and skirt (see 7.1).

A sealing plate with all seams sealed, shall be fitted around protruding parts of vessels, e.g.nozzles, saddles (see 7.15).

5.2.2.2 Insulation with Preformed Boards/Slabs

Slabs shall be mounted with all longitudinal seams staggered and shall be close fitted to thewall with all joints closely butted.

Slabs shall be secured with strapping bands at intervals of 500 mm and 50 mm from the edge ofeach slab.

Strapping bands shall be provided with expansion elements where necessary due to equipmentexpansion.

At locations where mechanical damage during operation and maintenance of the plant is possi-ble, contractor shall use compression resistant slabs.

5.2.2.3 Insulation with Blankets

The blankets shall be applied with the wire mesh on the outside, with all circumferential jointsstaggered and placed into position with strapping bands at intervals of 500 mm. The blanketsshall not be compressed more than 3 mm by the bands.

When the vessel is provided with insulation support pins (i.e. horizontal vessels), the blanketsshall be pressed over the pins and the protruding ends shall be bent.

5.2.3 Tank Insulation


15/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 15 of 43

5.2.3.1 Insulation with Preformed Boards

Tank wall insulation shall be as described in subsection 5.2.2.2.

5.2.3.2 Sprayed Polyurethane Foam (PUR)

PUR may be considered for tanks and spheres with operating temperatures up to 90C.

The PUF shall be sprayed in accordance with manufacturer's specifications.

The insulation shall be made smooth and properly sealed, including the seams, where supports,nozzles, etc. protrude through the insulation.

5.2.4 Expansion Joints

For horizontal pipelines and equipment, expansion joints (minimum 20 mm resilient loose min-eral wool) shall be made in every outside, intermediate and inside layer of the insulation. Inter-mediate spacing of expansion joints shall be as indicated in 6.6.

For vertical pipelines and equipment, an insulation expansion joint shall be positioned directlybelow each support or reinforcing ring, except at the bottom.

5.3 COLD INSULATION

5.3.1 For cold insulation, the following materials may be applied:

n Preformed pipe section (all material types).

n Boards or slabs (all material types).

n In-situ injection of PUR.

5.3.2 In-situ injection of PUR may be considered by Contractor. Contractor shall make a detailed pro-posal for the execution in order to ensure a consistent quality of insulation throughout area toconform with the following basic requirements:

n Delivered on site in two components, to provide the following foam properties:

Thermal conductivity, after aging 0.023 W/m.K. Density 45 kg/m, 10%. Self extinguishing (ASTM D.1692, 10/10 SE).

5.3.3 It is essential that a vapour barrier is always applied to prevent moisture from entering the insu-lation. Refer to 3.4 for materials and 5.6.2 for application details.

5.3.4 Insulation joints between sections and segments of cold insulated piping and equipment shall besealed with a seam filler. In the event of several layers, the seam filler of the first inner layer maybe omitted.

5.3.5 As a barrier against moisture movement, a 150 mm wide band of seam filler shall be appliedbetween the pipe or equipment surface and the insulation and between the layers at 3000 mmintervals.


16/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 16 of 43

5.3.6 For the fastening of PUR/PIR and cellular glass pipe sections, stainless-steel strapping bands(minimum 13 x 0.5 mm) or glass fiber tapes shall be used at intervals of maximum 300 mm, witha minimum of two (2) bands/tapes per section.

5.3.7 A contraction joint shall be installed on each side of an elbow, when the operating temperature isbelow -25C, midway between two (2) pipe supports (see figure 7.12).

5.3.8 The space between cold insulation material and flanges, manholes and handholes, etc. shall befilled with loose mineral wool.

5.4 INSULATION/SHEETING SUPPORTS

5.4.1 Piping

For blanket insulation on horizontal piping, clamped distance rings shall be attached to the pip-ing at intervals of 1 m to support the sheeting and to prevent compression of the blanket insula-tion. For preformed sections on horizontal piping, no support rings are required.

The weight of the insulation on inclined and vertical pipelines with angle between 45C and 90Cand with a total insulated diameter larger than 350 mm, shall be carried by support rings,clamped around the pipeline with an intermediate distance of 3800 mm for blankets and5700 mm for sections (see 7.3). A support ring shall also be mounted above every flange con-nection.

5.4.2 Vessels

For vertical vessels (larger than diameter 1000 mm), welded-on support rings will be provided bythe vessel manufacturer. These rings support the insulation and form a break in the insulation toallow for expansion.

The spacing of welded support rings, depends on the type of insulation material (see fig-ure 7.16):

For mineral wool blankets : approx. 2000 mmFor preformed mineral wool sections : 3000 - 4000 mmFor preformed PUR/PIR or cellularglass section : 3000 - 4000 mm

Reference is made to standard drawings 04-3230-01.027 and 028.

Vessel heads (larger than diameter 1000 mm) may be provided with a floating ring with supportbands.

5.4.2.1 Horizontal Vessels

Insulation on horizontal vessels shall be supported by steel strips with pins, bolted around thevessel circumference, at intervals of 500 mm.

For vessel heads, refer to subsection 5.2.2.1.

5.4.3 Tanks

For tanks, insulation supports will be provided by the tank manufacturer as per standard drawing04-3230-01.060.


17/43


18/43


19/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 19 of 43

Contractor shall pay special attention to crossings of longitudinal and circumjacent sheetingseams.

Spots that do not preclude watering despite an accurate finish shall be made weather resistantby means of a cord of flexible elastomer or silicone paste.For vertical sheeting, the sections shall be set by means of "s" clips.

5.6.3.2 Piping

For a number of small bore lines running parallel to each other and insulated with mineral woolslabs, metal sheets shall be applied.

Pipe hangers shall be provided with rain caps, as shown in figure 7.13.

Ends of insulated parts at flanges, flanged valves, instruments, etc. shall be provided with endcaps. See figure 7.8.

For noninsulated flanges, flanged valves and instruments, seams between end caps, pipe andsheeting shall be sealed. See figure 7.8.

For tees, bends, elbows, etc. contractor shall cut, furrow and form sections of sheeting. See fig-ure 7.11.

If close fitting of sheeting around noninsulated protruding parts is not possible, sheeting shall beprovided with sealing plates. See figure 7.15.

Sheeting shall be provided with expansion facilities at the following locations:

n Bends or elbows.

n Between hangers or supports in long straight lines.

n All locations, where sheeting is fixed to a certain position (e.g. branch connections).

Expansion seams shall be provided with an overlap of at least 100 mm, double furrows and fas-tening with stainless-steel band, between the furrows. See figure 7.10.

Sheeting for traced pipe shall be executed as for untraced pipe, however, contractor shall pro-vide holes for entering and leaving of the tracer. These holes shall be provided with a sealingcompound to prevent damage to the tracer pipe/cable and to achieve a watertight sealing.

For flanges and valves, refer to subsection 5.2.1.6.

For horizontal pipes the longitudinal seams shall as much as possible be provided on the leeside of the pipe, sloping downwards (see figure 7.10).

For the sheeting of insulated bends the segments shall be provided with round ridges, i.e. aridge and a counter ridge, and slope downwards (see figure 7.11). Bends with a small bendingradius shall have sheeting with a peaked cap tee (see figure 7.11).

For the sheeting of expansion bellows, a stainless-steel sheet cover shall be mounted over theupper side of the bellows' expansion section to avoid the insulation material obstructing the ac-tion of the expansion bellows. The sheeting shall have sufficient overlap (insulation thickness


20/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 20 of 43

plus expansion of the bellow) to absorb the expansion with a minimum of 100 mm. (See fig-ure 7.14.)

5.6.3.3 Vessels

Heads of vessels shall be finished with segmental sheeting, which shall be overlapped andsealed to prevent moisture entering under the vertical sheeting.

Caps around reinforcing rings shall be used to compensate expansion of the column, vessel ortank.

If there are no reinforcing rings applied to the equipment, contractor shall provide at least one (1)expansion seam per 10 meters (see figure 7.16).

Caps for heads and heat exchangers, manholes, etc. with a diameter up to 1000 mm, shall bemounted over the insulation of the equipment body and shall be attached to the body sheetingby means of a 20 mm wide flanged rim (see figure 7.7).

For exchangers with a diameter over 1000 mm sheeting shall be cut in segments and formed tofit closely to the head of the exchanger.

Around openings for protruding parts in the outer layer a 50 mm wide space shall be left in thesheeting to permit inspection of the underlaying joint. This space shall be made weather resis-tant by means of a sealing plate with furrowed edges.

Aluminum sheeting on calcium silicate in a moist environment shall be lined inside with suitablepaper provided with a polyethylene film to prevent the aluminum sheeting from being attackedby calcium silicate components (appropriate coating on the inside of aluminum sheeting may beconsidered).

5.6.3.4 Nameplates, Thermowells, Sightglasses, etc.

Metal boxes with perspex glasses shall be inserted in the openings provided for nameplates,thermowells, sightglasses, etc.

Boxes shall be screwed on top of the vessel sheeting with self-tapping screws and all seamsshall be sealed.

5.6.3.5 Tanks

Flat or corrugated sheeting may be applied on tank walls.

The sheeting shall be fastened to the welded-on insulation supports, as shown on standarddrawing, 04-3230-01.060.

Method of fastening shall according to contractor's standard. Any additional fastening stubs orstrips may be bolted or welded to the standard supports.

For fixed tank roofs, which require metal sheeting, a framework shall be erected on the roof toprovide means of sheeting support.

Sheeting of the tank roof shall overlap the flashing ring at the roof edge and the wall sheetingunderneath it.


21/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 21 of 43

5.6.4 Fastening of the Metal Finishing Layer

The sheeting shall be fastened by means of bands with closures, self-tapping screws or blindrivets in such a way that it fits properly around the insulation of piping and equipment. In case ofcold insulation fastening materials shall not effect the vapor retardant layer (stop strips for self-tapping screws may be considered).

The self-tapping screws or blind rivets shall be placed at maximum intervals of 100 mm (seefigure 10). For sealing plates and sheeting sections for tees shall be fastened with a minimum offour (4) screws.

Expansion springs shall be provided for banding on vessels over 4.5 m in diameter and operat-ing above 300C. A minimum of two (2) springs shall be used 180 degrees apart. For each addi-tional 7.5 m of circumference, one (1) additional spring shall be installed. Springs shall beequally spaced around banding.

Expansion springs shall be provided for banding on storage tanks for a maximum of every 15 mof circumference.


22/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 22 of 43

6. TABLES

6.1 INSULATION THICKNESS FOR HOT SERVICE HEAT CONSERVATION

MATERIAL ROCKWOOL OR GLASSWOOL, IN MMNOMINAL PIPESIZE OR VES-SEL DIAME-TER (INCHES) OPERATING TEMPERATURE IN C

< 100 < 200 < 300 < 400 < 500 < 6001123468101214161820243034364042Flat surfaces

Storage tankShellRoof

25252530303030404040404040404040404040404040

404040

30404040404050505050505050505060606060606060

606060

40405050505060606060607070707070707070707070

707070

50505060607070708080808080808090909090909090

N.A.

60606070708080909090

100100100100100100110110110110110110

N.A.

707080809090

100110110110120120120120130130130130130130140140

N.A.


23/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 23 of 43

6.2 INSULATION THICKNESS FOR COLD SERVICE (INCLUDING REFRIGERATION AND ANTI-SWEAT)

MATERIAL PUR OR PIR, IN MMNOMINALPIPE SIZEOR VESSELDIAMETER(INCHES)

OPERATING TEMPERATURE IN C

+20 to0

-1 to-10

-11 to-20

-21 to-40

-41 to-60

-61 to-80

-81 to-100

-101 to-120

-121 to-140

to 11 to 2346810121416202224>24

2525253030303035353535353535

2525303030353540404040404040

2530303540404040505050505050

3030354040505050505060606060

4050506060607070707070707070

6060707080809090909090909090

6070808090

100100100100120120120120120

708090

100100110120120130130130130130130

90100110120120130130140140140150150150160


24/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 24 of 43

6.3 INSULATION THICKNESS FOR PERSONNEL PROTECTION

SHIELD-ING(NOTE 1)

INSULATION (mm) MINERAL WOOL

NORMAL OPERATING TEMPERATURE C

NORMAL PIPE SIZE OR VESSELDIAMETER (INCHES)

70 to 250 251 to 350 351 to 450 451 to 600< 1234681012 and larger

5050505050

100100100

3030304040404040

4050505050606060

5050606060607070

Note: 1. The dimensions represent distance between pipe and perforated plate (no insu-lation material applied).


25/43


26/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 26 of 43

6.5 MINIMUM THICKNESS OF THE FINISH SHEETING

OUTSIDEDIAMETERINSULATION

FLAT SHEETING MATERIAL CORRUGATEDSHEETING(ref. 5.6.3.5)

(2) ALUMINUMTHICKNESS(mm)

(1) STEELTHICKNESS(mm)

ALUMINUMTHICKNESS (mm)

< 200 0.8 0.6 -200 - 600 0.8 0.8 -> 600 1.0 0.8 -Tanks 1.0 0.8 0.7

Notes: 1. Steel may be:

Stainless steel, type 304.

CS Galvanized, ASTM A527M.

CS Aluminized, ASTM A463.

CS with Aluminum zinc layer, ASTM A792M.

2. All removable covers shall be 1.0 mm thick, irrespective of the material used.

3. For acoustic insulation, refer to EEMUA 142.


27/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 27 of 43

6.6 SPACING BETWEEN EXPANSION JOINTS

INSULATIONMATERIAL

OPERATINGTEMPERATURE C

SPACING BETWEENEXPANSION JOINTS (m)

CELLULAR GLASS

PIPING & EQUIPMENT

20 - 4041 - 160

161 - 200201 - 430

Not necessary65

3.5

CALCIUM SILICATE

EQUIPMENT

50 - 350351 - 650

651 - 1000

52.5

2

CALCIUM SILICATE

PIPING

50 - 350251 - 650

651 - 1000

63.5

2

PUR/PIR

PIPING & EQUIPMENT

20 - 100 6


28/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 28 of 43

7. FIGURES

7.1 HEAT INSULATION AT VESSEL SKIRT

VESSEL DIAMETER(mm)

HEIGHT OF AIR SPACEHmin (mm)

< 2000 1502000 3000 2003000 4500 250

> 4500 300


29/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 29 of 43

7.2 WIRE NETTING CAGE FOR PERSONNEL PROTECTION


30/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 30 of 43

7.3 INSULATION/SHEETING SUPPORT RING


31/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 31 of 43

7.4 COLD INSULATION OF PIPING WITH PIPE SECTIONS AND BLANKETS


32/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 32 of 43

7.5 HOT AND COLD INSULATED HORIZONTAL VALVE


33/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 33 of 43

7.6 INSULATION OF TRACED PIPING WITH PIPE SECTIONS AND BLANKETS


34/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 34 of 43

7.7 INSULATED MANHOLE


35/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 35 of 43

7.8 NONINSULATED FLANGES AND END CONNECTIONS


36/43


37/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 37 of 43

7.10 SHEETING OVERLAPS OF EXPANSION JOINTS


38/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 38 of 43

7.11 INSULATION OF HORIZONTAL AND VERTICAL BENDS


39/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 39 of 43

7.12 HORIZONTAL AND VERTICAL CONTRACTION JOINTS (COLD INSULATION)


40/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 40 of 43

7.13 RAIN COVER FOR PIPE SUPPORT


41/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 41 of 43

7.14 REMOVABLE EXPANSION BELLOW CAP


42/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

100585910-8.DOC Page 42 of 43

7.15 SEALING PLATE FOR PROTRUDING PARTS


43/43


SPECIFICATION




Doc. No. 04184-120231-L-611 Rev. 0

7.16 SHEETING OF VERTICAL EQUIPMENT

Documents

IOCL Insulation