000-A-Ee-0020009 r.3 - Hot Insulation Specification

06 May 2016
STAR RAFNER, A.. CONTRACT N

AEGEAN REFINERY PROJECT (ARP) STAR-C-01
CONTRACTOR DOC No: SH/OF
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DOCUMENT No.
HOT INSULATION SPECIFICATION
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TABLE OF CONTENTS
1. PURPOSE 4
2. SCOPE 4
3. DEFINITIONS 5
3.1 ABREVIATIONS 5
4. REFERENCES 5
4.1 OWNER SPECIFICATIONS AND PROCEDURES 5
4.2 CONTRACTOR SPECIFICATIONS AND DOCUMENTS 5
4.3 Codes and standard 6
5. RESPONSIBILITIES 7
5.1 Contractor 7
5.2 Subcontractor 7
6. REQUIREMENTS 8
6.1 Insulation to be omitted. 8
6.2 Flanged joints to be insulated. 8
6.3 Valves to be insulated 8
6.4 Various 9
6.5 Insulation Thickness to be adopted 9
7. MATERIALS 9
7.1 General 9
7.2 Synthetic resin bonded mineral wool. 10
7.3 Synthetic resin bonded mineral wool Blankets 11
7.4 Calcium Silicate ASTM C-533 type II 12
7.5 Metal weatherproofing 13
7.6 Accessory Material 14
8. GENERAL APPLICATION 15
8.1 Insulation of Straight Pipes. 16
8.2 Metal cladding over pipe 18
8.3 Insulation and metal cladding at pipe supports 20
This document is the property of TSGI Mhendislik naat Limited Company. Its reproduction without a written permission is strictly forbidden.
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8.4 Insulation and Metal Cladding on Pipe Fittings 20

8.5 Insulation and Metal Cladding on flanged joints 22
8.6 Insulation and Metal Cladding on valves 24
9. DETAILS OF APPLICATION ON EQUIPMENT 24
9.1 Application of Insulation. 24
9.2 Metal Cladding Finish over Equipment 26
9.3 Tanks 29
9.4 Pumps and Turbines 29
9.5 Acoustic Insulation and Combined Acoustic / Hot Insulation. 30
9.6 Expanded metal shields 31
9.7 Inspection Windows on thermal Insulation for Piping & Equipment 31
10. TABLE I (I) INSULATION THICKNESS 35
11. TABLE II (P) INSULATION THICKNESS PERSONEL PROTECTION 36
12. TYPICAL HOT INSULATION INSTLLATION / FINISHING SKETCHES 37
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1. PURPOSE
This specification defines minimum requirements for the materials and their method of application
for external insulation of piping and equipment in hot service.
No variations from this specification shall be permitted unless approved by Contractor / Owner.
2. SCOPE
This specification covers the requirements for the application of insulation systems to external
surfaces of piping and equipment in hot service, where the operating temperatures are within
+20C and +450C.
Hot service insulation shall be installed where heat conservation is required for process control,
and where heat tracing is specified.
Hot service insulation shall be installed for personnel protection on surfaces operating at
temperatures above +150C which are accessible to personnel in order to lowering the skin
temperature at a value not greater than +65C.
Insulation for personnel protection shall be confined to the areas of piping and equipment within
2.15 m height and 1 m reach of walkways, working platforms and access ladder etc.
Piping and Equipment in high temperature service shall be insulated when designated on line list
and equipment list as well as on relevant P&ID.
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3. DEFINITIONS
OWNER: STAR RAFNER, A.. (STAR)
CONTRACTOR: Joint Venture between Tcnicas Reunidas (TR), Saipem, GS E&C and
Itochu.
PROJECT: Means the Aegean Refinery (AR) Project, being executed by OWNER or its
affiliates.
Company which, under Contractors coordination, will perform all or part of
SUBCONTRACTOR:
the activities described in this specification.
PMC:
Project Management Consultant
3.1 ABREVIATIONS
(I): Insulation for heat conservation purpose
(P): Insulation for personel protection purpose
4. REFERENCES
4.1 OWNER SPECIFICATIONS AND PROCEDURES
STGPS N3 Hot Insulation General

4.2 CONTRACTOR SPECIFICATIONS AND DOCUMENTS
000-N-PE-0020001 Specification for acoustic insulation
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4.3 Codes and standard
The ASTM latest editions of the following publications and standards shall be used when
referenced in the project specification:
ASTM A-167 Specification for Stainless and Heat-Resisting Chromium-Nickel Steel
Plate, Sheet, and Strip
ASTM A-463 / A 463M Standard Specification for Steel Sheet, Aluminum coated, by the
Hot dip Process
ASTM A-526 Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) by the
Hot-Dip Process
ASTM C-165 Standard Test Method for Measuring Compressive Properties of
Thermal Insulations
ASTM C-547 Standard Specification for Mineral Fiber Pipe Insulation
ASTM C-533 Type II Standard Specification for Calcium Silicate Thermal Insulation
ASTM C-592 Standard Specification for Mineral Fiber Blanket and Blanket-type Pipe
Insulation (Metal Mesh covered).
ASTM C-612 Standard Specification for Mineral Fiber Block and Board Thermal
Insulation
ASTM C-795 Standard Specification for Thermal Insulation for Use in Contact with
Austenitic Stainless Steel.
ASTM C-447 Standard Practice for Estimating the Maximum Use Temperature of
Thermal Insulations.
ASTM C-177 Standard Test Method for Steady-State Heat Flux Measurements and
Thermal Transmission Properties by Means of the Guarded-Hot-Plate
Apparatus.
ASTM C-871 Standard Test Methods for Chemical Analysis of Thermal Insulation
Materials for Leachable Chloride, Fluoride, Silicate, and Sodium Ions
ASTM E-84 Standard Test Method for Surface Burning Characteristics of Building
Materials
ASTM B-209 Standard Specification for Aluminum and Aluminum-Alloy Sheet and
Plate.
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ASTM C-302 Standard Test Method for Density and Dimensions of Preformed Pipe-
Covering-Type Thermal Insulation.
ASTM E-674 Standard Specification for Industrial Perforated Plate and Screens
(Round Opening Series).
ISO 15665 Acoustic insulation for pipes, valves , flanges
5. RESPONSIBILITIES
5.1 Contractor
Contractor shall be responsible of assuring that the Subcontractor shall execute the installation
works in compliance with this specification.
5.2 Subcontractor
It is responsibility of the Subcontractor to:

Supply all necessary materials and facilities to carry out the insulation works. All categories of
labor, supervisory and administrative staff, equipment, tools, transportation and other services shall
be provided by Subcontractor.
To make provisions for acceptance, dry storage, control and issue of his materials delivered to
jobsite.
To maintain the site clean with regard to his own construction and storage debris.
To be responsible for surface preparation with regard to cleaning oil and dirt deposits.
To prepare and issue material take-off for insulation materials, progress reports for completed
works every month and inspection forms for the signature of Contractor's inspector for piping and
equipment insulated.
To prepare and submit to Contractor for approval the details of the intended methods of
application, fabrication and erection, including, expansion and contraction joints. The details shall
be in accordance with the requirements of this specification, type of materials used and the
standard practices applied in refineries.
To, at all times during the work, organize his equipment, tools, scaffolding and materials in a neat
and workmanlike manner so as to avoid interference with other work in progress. To protect all
equipment, buildings and roadways etc. from any littering of his materials and clean such items if
this should occur.
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6. REQUIREMENTS
6.1 Insulation to be omitted.
Insulation shall be omitted on the items listed below unless personnel protection is required.
a. All equipment and piping where heat loss is desired.
b. Internally insulated piping or equipment.
c. Flanged joints, except those listed in par. 6.2.
d. Valve bodies, including control valves, whose operating temperature is between ambient
and 150C, except those listed in par. 6.3.
e. Piping and equipment which becomes hot intermittently, such as relief valves, relief
systems, vents, drains, pump-out and blowdown systems, steam out and purge steam
systems.
f. Pipe union fittings.
g. Strainers, filters, steam traps.
h. Bellows portion of expansion joints, hinged joints, and hose assemblies.
i. Sight flow indicators.
j. Nameplates on vessels, heat exchangers, and machinery.
k. Supports for piping and equipment.
l. Vessel manway covers and heat exchanger channel covers.
6.2 Flanged joints to be insulated.
a. Those in steam and condensate service.

b. Those heated by a tracer or jacket.
6.3 Valves to be insulated
a. Those in steam and condensate service.

b. Those heated by a tracer or jacket.
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6.4 Various
Compressors, pumps, and other mechanical equipment shall be insulated on an individual

basis with consideration given to the requirements for process access and equipment
maintenance. Equipment manufacturer shall be informed about insulation of his equipment.
Tanks shall be insulated with the same type of insulation as per the vessels. In particular,
for large diameter tanks, the insulation system shall be determined on a case by case
basis, and submitted to Contractor / Owner for review and approval.
Expansion loops and crossovers in the heat tracer tubing that are external to the insulation
shall be protected with a removable metal weatherproofing box attached to the insulation
weatherproofing metal
Flanges, valves and instrument manifolds, when insulated, shall be provided with
removable boxes, easy to place (and to remove).
6.5 Insulation Thickness to be adopted
Recommended equipment and piping insulation thicknesses shall be as shown in Table I

(I), Table II (P).
The thickness of insulation given is the nominal thickness of the basic insulating medium
and does not include the finishing or weatherproofing materials.
7. MATERIALS
7.1 General
Asbestos and its compounds, or other carcinogenic mineral fiber shall not be used in any
form.
It is absolutely forbidden to use materials classified (according to EU Directive 67/548 and
following amendments) under any of the hazard warning labels listed below:
R39 - Danger of very serious irreversible effects
R40 - Possible risk of irreversible effects
R45 - May cause cancer
R49 - May cause cancer by inhalation
The materials shall be:
Transported protected from weather and moist during transport and shall be
delivered at the construction site in their original unopened packaging.
Stored in closed and covered premises, protected from mechanical damages and
ambient conditions (such as rains etc.).
Shall not be stored in contact with the ground.
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Shall not be used above the limiting temperature given by the ASTM code or by the
manufacturer.
Certificate of Origin , Product Information Sheet and material safety data sheet for all
insulation materials shall be submitted to owner before use .
Insulation material to be used over austenitic stainless steel surfaces shall be in
accordance with ASTM Specification C 795. All mastics, cements, binders and other
materials used in conjunction with insulation on austenitic stainless steel shall contain less
than 100 ppm leachable chlorides.
Chloride content of water used for mixing any materials shall not exceed 5 ppm.
All insulating materials shall be non-corrosive to the metal being covered.
All insulation and ancillary materials shall be new and of prime quality. They shall be
applied and maintained in a dry state until completion of the work by means of temporary
covers when necessary.
7.2 Synthetic resin bonded mineral wool.
Minimum Nominal Density (ASTM C-302): 100 kg/m3

Temperature Range (ASTM C-447): Min Service Temperature 23C to Max. Service
Temperature+450C
Melting Temperature: +800C
Thermal Conductivity (ASTM C-177):
Max. 0.035 W/m K @ Tavg = 0C (average material temperature)
Max. 0.052 W/m K @ Tavg = +100C (average material temperature)
Where: Tavg = 0.5 x ( Thot face + Tcold face )
Fiber Dimensions:
Avg. diameter 5 m
Length 50 mm
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Shot Content: in accordance with ASTM C-612

Water Absorption (AGI Q136): 10% by volume
Compressive Strength (ASTM C-165): > 8.0 kPa at -10% thickness changes under
compression
Dimensional Stability: in accordance with ASTM C-547
Leachable Chlorides (ASTM C-871): 10 ppm
pH value (ASTM C-871): min. 6.0, max 10.5
Flame Spread Index (ASTM E-84): 0
Linear Coefficient of Thermal Expansion: 2 x 10-6 C -1
Tolerances for Dimensions: in accordance with ASTM C-547
Standard Dimensions: Length min. 800mm, Nominal Thicknesses: 25, 30, 40, 50, 60, 70,
80 and 90 mm.
Synthetic resin bonded mineral wool pipe sections and mitered elbows shall be composed
of diabase or basalt rock as principal raw material, in accordance with ASTM C-547.
7.3 Synthetic resin bonded mineral wool Blankets
Synthetic resin-lightly bonded rock wool metal wire mesh covered blankets with diabase or
basalt rock as principal raw material.
Mesh covered blankets, stitched with 0.8 mm diameter high alloy wire on stainless steel
(minimum 304 types) wire mesh with a maximum mesh width of 1 (25 mm), in accordance
with ASTM C-592.
On stainless steel and nonferrous piping or equipment the use of blankets with galvanized
netting is not allowed. For this application, use preformed sections, blocks, slabs etc.
without mesh, or use blankets with annealed 18-8 stainless steel hexagonal netting
Minimum Nominal Density (ASTM C-302): 100 kg/m3
Temperature +650C
Melting Temperature: +800C
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Where: Tavg = 0.5 x (Thot face + Tcold face)
Fiber Dimensions:
Avg. diameter 5 m
Length 50 mm
Shot Content: in accordance with ASTM C-612
Water Absorption (AGI Q136): 10% by volume
Compressive Strength (ASTM C-165): > 8.0 kPa at -10% thickness changes under
compression
Leachable Chlorides (ASTM C-871): 10 ppm
pH value (ASTM C-871): min. 6.0, max 10.5
Flame Spread Index (ASTM E-84): 0
Tolerances for Dimensions: in accordance with ASTM C-592
Dimensions: Width x Length min. 600 x 3000mm, Nominal Thicknesses: 30, 40, 50, 60,
70, 80 and 90 mm.
7.4 Calcium Silicate ASTM C-533 type II
Temperature +927C
Maximum Nominal Density (ASTM C-302): 352 kg/m3
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7.5 Metal weatherproofing
Note - The metal weatherproofing shall be aluminium except for fire protection.
For aluminum weatherproofing, the materials shall be in accordance with ASTM B 209
type 3003 or 3105 with H 14 or H 16 temper.
Flat or smooth finish may be used on piping up to 36" in diameter. Thickness shall
be 0.60 mm. up to 6 and 0.8 mm. over 6 in diameter.
Flat or smooth finish shall be used on piping over 36 in diameter, horizontal
vessels, vertical vessels, storage tanks, exchangers and other equipment.
Thickness shall be 1 mm.
Metal jacketing for vessels heads, machinery, pipe fittings, removable boxes (for
valves, flanges and instruments) and other irregular surfaces shall be flat and
thickness shall be 1 mm.
For fire protection, metal jackets shall be flat galvanized steel, ASTM A526 coating
designation G90, Regular Spangle; aluminum coated steel ASTM A463 coating designation
T2 or flat Stainless Steel ASTM A167 Type 301, 302, 304 or 316.
The thickness shall be:
0.6 mm minimum for piping and equipment with O.D. less than 1500 mm (including
insulation)
0.8 mm minimum for piping and equipment with O.D. larger than 1500 mm (including
insulation)
0.8 mm for removable boxes for valves, flanges and instruments.
Important The use of zinc coated steel jackets on stainless steel piping and
equipment is not allowed.
In case aluminum sheets are used to jacket calcium silicate insulation on piping and
equipment, a coat of non-flammable mastic shall be applied by the Insulation Subcontractor
between the outside surface of the calcium silicate and the inner face of the aluminum
jacket in order to prevent their direct contact that may be origin of galvanic corrosion,
particularly in presence of high air humidity and or heavy rains.
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7.6 Accessory Material
Glass wool fiber Blanket for use at expansion joints in insulation made with preformed
sections of mineral wool at all service temperature in all applications at service temperature
T > +100C:
Nominal thicknesses shall be 30 mm;
Nominal density min. 30 kg/m3;
Maximum Service Temperature: rated for the intended maximum service
temperature of installation.
Quick Release Toggles shall be ASTM A-167 Type 304; dimensions shall be suitable for
tensioning bands.
Wire used to secure mineral wool insulation in place shall be 1.7 mm diameter stainless
steel (Type 304 or 316.) wire in the annealed condition.
Tensioning Bands to be used to secure mineral wool and for metal cladding shall be
stainless steel ASTM A-167 type 304 and dimensions:
13 x 0.5mm (wide x thickness) for piping and equipment with O.D. over insulation up
to 60 (1500 mm)
19 x 0.5mm (wide x thickness) for piping and equipment with O.D. over insulation
above 60(1500mm)
Seals for tensioning bands (wing type) shall be stainless steel ASTM A-167 type 304 and
dimensions to suit bands.
Self-tapping screws for fastening the metal weatherproofing to steel supports shall be
stainless steel ASTM A-167 type 304 with dimensions 6 x 12 mm (diameter x length), Style
B, to be supplied with neoprene washers
Sheet metal screws for metal weatherproofing lap joints shall be 7 x 9,5 mm long, Type-A,
ASTM A-167 type 304stainless steel pan head, self-tapping and with neoprene washer
under head.
Blind pop rivets shall be stainless steel type 304, dimensions 3.2 x 9 mm and 4.8 x 9 mm.
Rubber mastic tape for isolation layer at overlaps between aluminized steel and stainless
steel cladding.
Composition: A carrier of weather resistant PVC tape provided with a layer of flexible
rubber mastic. The adhesive side is provided with a protective foil of silicone treated paper
as releasing layer as per.
Material Performances:
Temperature Range of Use (ASTM D-1000): -20 to +65C
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Application Temperature Range (ASTM D-1000): 0 to +40C

Tensile Strength (ASTM D-1000): > 20 N/cm (at 10% of elongation)
Elongation at Break (ASTM D-1000): > 200%
Tear Resistance (ASTM D-1000): > 80 N/cm
Total Thickness (ASTM D-1000): > 1.0 mm
Tape Dimensions: 50 mm x approx. 10 m (width x length of rolls)
Weather proof Sealant for steel cladding at overlaps shall be a soft paste aluminum color
sealant, applicable by gun, such as FOSTER FIRE RESISTIVE ALUMINUM METAL
SEALANT 95-44 or an approved equal, temperature range from -73C to +121 C.
Springs for tensioning bands shall be of 304 type stainless steel and suitable for 19 x
0.5mm (wide x thickness) bands such as Childers, Techalloy or an approved equal.
" S " and " J " clips shall be 19 mm wide x 0.5 mm thick, Type 304 stainless steel.
8. GENERAL APPLICATION
Piping and equipment shall have all welding completed; including painting and touch up
painting where specified and shall be pressure tested prior to application of insulation.
Surfaces to be insulated shall be free from oil, grease, loose scale, and foreign material and
dry.
The Subcontractor shall be responsible for inspecting supports rings provided on equipment
by the vessel fabricator, to ensure that these have been installed to specified requirements
and have not been damaged or dislodged during transit / erection. The Subcontractor shall
always advise the Contractor of any remedial work that may be required in advance prior to
commencement of insulation works.
Insulation materials shall be stored in dry conditions in properly constructed containers.
During transport and temporary storage to the work site prior to immediate use, insulation
materials shall be kept dry by wrapping in heavy duty polythene film. Only insulation and
accessory materials that have been properly stored and are dry and free of contamination
shall be used.
Insulation that have been installed but is awaiting metal cladding shall be provided with
effective temporary weather protection using polythene sheeting. Mineral wool insulation
material that has become wet shall be removed and replaced with dry material.
The use of broken pieces of insulation for the filling of gaps or voids caused by incorrect
fitting is not permitted. Where such gaps or voids arise the insulation shall be removed
and properly refitted.
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Where thermowell bosses, pressure tapping, nameplates and the like are to be left clear of
insulation, the metallic cladding around these points shall be cut back and effectively
sealed.
Metal cladding shall be secured by means of screw fasteners, pop rivets at specific
applications and with metal bands with the addition of breather springs in specific
applications.
On vertical piping and equipment, S clips fabricated from stainless steel bands shall be
incorporated in the circumferential joints of the cladding to prevent telescoping.
Insulation thicknesses in excess of 90 mm shall be applied as multi-layer with all
circumferential and longitudinal joints staggered.
" J " clips shall be used to support the bands on vessels over 3 m in diameter. The "J" clips
shall be attached to the jacket with self tapping screws and shall be spaced about 1.8 m
apart.
8.1 Insulation of Straight Pipes.
The Insulation Subcontractor shall supply and install all necessary insulation supports to the
requirements of applicable standard and check the correctness of insulation supports rings
width and spacing before the commencement of any insulation installation activity.
Insulation shall comprise mineral wool pipe sections, mineral wool metal mesh covered
blankets, calcium silicate pipe shells and pipe segments.
Where pipe shells supplied in two halves are to be used, all circumferential joints shall be
tightly fitted and longitudinal joints shall be staggered. On horizontal pipes the longitudinal
joints of pipe shells supplied in two halves shall be placed horizontally, slightly staggered
each to other in order to shed water. Alternatively, where the preformed pipe shells are
supplied in hinged lengths, longitudinal joints shall be placed downward, staggered with an
angle of 45 to 90 each to other. On vertical pipes, longitudinal joints shall be placed away
from prevailing wind direction.
Mineral wool blankets shall be positioned with only one longitudinal joint to be arranged with
staggering.
Mineral wool preformed sections shall be tightly butted together and secured by stainless
steel wire for O.D. outside insulation up to 300 mm or with stainless steel bands otherwise.
Mineral wool blankets shall be circumferentially and longitudinally tacked with stainless
steel wire Mineral wool preformed insulation securement shall be arranged so that each
mineral fiber length is secured at three or four positions, i.e. centrally and at positions no
nearer than 50 mm to each end.
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Mineral wool blankets shall be secured with stainless steel bands, at intervals of no more
than 300 mm between bands so that each mineral fiber standard length of 600 mm is
secured at least at two positions. Bands shall be circumferentially tied with stainless steel
wire to blanket metal mesh to prevent dislodging.
On carbon steel piping, expansion joints shall be positioned at the following maximum
centers on both horizontal and vertical lines:
Rigid Mineral Wool Insulation:
5.0 m on lines with operative temperature T +200C
4.5 m on lines with operative temperature +200 < T +300C
4.0 m on lines with operative temperature +300C < T
On stainless steel piping, expansion joints shall be positioned at the following maximum
centers on both horizontal and vertical lines:
Rigid Mineral Wool Insulation:
4.0 m on lines with operative temperature T +200C
3.5 m on lines with operative temperature +200 < T +300C
3.0 m on lines with operative temperature +300C < T
For both horizontal and vertical pipes, at least one compensation joint shall be
provided between points at which freedom of movement may be restricted, regardless of
effective distance between fixed points, and the metal cladding arranged at this position to
accommodate expansion and contraction by means of metal cladding sheets relative
movement at overlaps.
With vertical pipes the expansion joint shall be positioned directly below each insulation
support ring.
Each expansion joint for rigid mineral wool insulation and for calcium silicate insulation at
service temperature above +100C shall be filled with resilient glass fiber, cut into segments
normal to the orientation and lay up of the fibers to allow for expansion and contraction of
the material without crushing the fibers. The resilient glass fibers material shall be
compressed at installation. Nominal expansion joint width shall be 25 mm, resilient glass
fibers shall be double folded in a U shaped profile, compressed to 50% of its original
thickness before being inserted into the joint and secured in position with stainless steel
lacing wire.
Each expansion joint for calcium silicate insulation at service temperature up to +100C
shall be filled with flexible expanded closed cells elastomer foam, cut into strips. The
elastomer foam shall be compressed at installation. Nominal expansion joint width shall be
25 mm, elastomer foam shall be cut to size, with strip width equal to 50 mm (2 times the
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width of expansion joint to be filled), and compressed to 50% of its original thickness before
being inserted into the joint and secured in position with glass filament reinforced tape.
Insulation shall be stopped short to the studs and nuts at flanged joints, allowing sufficient
distance to facilitate the withdrawal of studs without damaging adjacent insulation. For this
purpose the clearance at each side of the flange shall be extended to equal the stud/bolt
length plus 30 mm. Insulation termination shall be made watertight and with a mechanical
protection by means of metal collars cut to pipe size.
For typical finishing/installation of insulation on straight pipes see Fig.1-4 Chapter 12.
8.2 Metal cladding over pipe
Insulation shall be protected with sheet metal cladding, rolled where necessary to conform
to the external diameter of insulation.
Metal cladding shall be installed so that all seams shed water and suitably flashed.
Individual lengths of rolled metal sheeting shall be in one piece with one longitudinal joint
only. The individual sheets length shall be provided with a circumferential 8 mm diameter
ball swage located close to one end of the sheet.
All circumferential joints of metal sheeting shall have a minimum overlap of 50 mm, on
vertical pipes the layout shall be arranged to shed water.
In correspondence of compensation joints, i.e. at pipe supports, bends, tees, etc., one
circumferential overlap shall be designed as sliding point to absorb expansion/contraction
by increasing the metal sheeting overlap from 50 to 100 mm. The sliding overlap metal
sheeting should be positioned at half way between any two fixed points and shall be left
free from screws or rivets circumferentially or longitudinally. In order to control movement of
the sheets at the sliding point, all other circumferential joints shall be secured with self-
tapping screws. Double swage with the interposition of a tensioning band shall be carried
out at expansion joint.
Longitudinal joints shall be arranged at alternate positions of 135 and 225 between
adjacent sheets. The leading edge of horizontal overlaps shall be provided with an 8 mm
ball swage positioned close to the edge of the sheet in order to prevent the overlaps from
opening up when bands are tensioned. All longitudinal joints shall be arranged to shed
water, with a minimum overlap of 50 mm. No longitudinal joints are permitted along the
bottom between the 135 and 225 positions, or along the top between the 315 and 45
positions.
On vertical pipes, longitudinal overlaps in metal sheeting shall be arranged away from the
prevailing weather conditions and staggered between adjacent sheets.
On pipes in hot service, breather springs are to be used for tensioning bands, in all that
cases where the following relationship is satisfied:
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O.D. (pipe diameter over insulation, m) x T (max. service temperature, C) 1000

All circumferential and longitudinal overlaps (except overlaps at compensation joints) shall
incorporate a preformed sealant strip to provide an effective seal when overlaps are drawn
tight. Butyl rubber based 8 mm diameter strip may be used to seal ball swages, located
within the swage itself.
The sheeting shall be secured with stainless steel bands and positioned at each overlaps
as close to the ball swage joint as practicable. All stainless steel bands shall be
machine tensioned and secured with stainless steel seals. For all applications other than
where breather springs are employed and in correspondence of all compensation joints,
longitudinal laps shall be secured with stainless steel self-tapping screws at max. 100mm
centers. Self-tapping screws shall be interrupted at each expansion joint.
Where breathing springs are to be used for tensioning stainless steel bands, banding shall
be positioned at centers no greater than 400 mm, otherwise each sheet length shall have at
least 2 fixing bands.
Due attention shall be paid to the fittings of sheeting to ensure proper overlaps of seams
and effective sealing where breaks in the metal sheeting occur (e.g. supports, shoes,
tracing entry/exit points, etc.) to ensure a layout that allow a rapid water run-off and that
prevent water ingress.
For sealing cutouts around projections, close fittings sheet metal collars shall be fabricated
and fitted. These shall be effectively sealed, screwed to the main sheet pipe metal cladding
and flashed to shed water.
Band shall be provided at each circumferential joint, plus at least one intermediate band.
Maximum band spacing shall be 230 mm.
Preformed butyl based sealant strips shall be used wherever possible to seal breaks in the
sheeting, but where this is impracticable at small crevices, etc., a gun extruded sealant
shall be used (such as Foster Metal Sealant 95-55 or an approved equal) while a
weatherproof heat resisting silicone sealant shall be used for sealing between metal
flashing and hot pipes.
On vertical piping, S clips fabricated from 13 x 0.5 mm or 19 x 0.5 mm (wide x length)
steel strips obtained from bands shall be installed between individual lengths of metal
sheeting to prevent telescoping. Depending from O.D. over insulation, S clips equally
spaced over the entire circumference of the sheeting overlap shall be installed. Alternatively
J clips adequately pop riveted to lower sheet may be used.
Provisions shall be made for supporting the weight of the metal sheeting on vertical piping
by means of S or J shaped clips and provision of additional angle supports clips pop
riveted to the internal face of the sheeting sections, at locations corresponding with the
insulation support rings. The angle support clips shall be stopped short of the pipe wall by a
distance no lower than the half width of the insulation support.
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" S " clips shall be spaced at 300 mm intervals , but not less than two clips per sheet.
"J" clips shall be attached to the jacket with self tapping screws and shall be spaced about
1.8 m apart.
8.3 Insulation and metal cladding at pipe supports
For lines supported on shoes, it is essential that unimpeded movement is maintained and
the guide angles at sides of the shoes are not restricted by insulation. To accommodate the
shoes, the insulation at the bottom of the pipe shall be cut away so that to clear the top of
the guide angles. The metal cladding shall be neatly cut back and folded under so as to
provide a weather shield.
Where shoes are fitted with guides or lateral line stops, sufficient clearance shall be allowed
to permit unimpeded movement at each side of the line stops.
For line supported by pipe trunnion, the insulation shall be extended over the trunnion for a
distance not lower than the pipe insulation.
For pipes supported by hangers, the hanger shall be flashed to the pipe metal cladding with
a metal collar shaped as a Chinese hat to shed water.
For typical finishing/installation of insulation at pipe supports see Fig.5-6 Chapter 12.
8.4 Insulation and Metal Cladding on Pipe Fittings
Insulation and protection of pipe fittings such as bends, elbows, tees, caps, reductions, etc.
shall be done as described in this section.
To cover tees, caps, reductions and any other irregular surface, mineral fiber preformed
pipe sections or blankets and calcium silicate preformed pipe shells or sections shall be cut
and fitted in the field.
The insulation on pipe bends and elbows to be carried out with mineral wool pipe sections,
shall be arranged in mitered segments individually cut from preformed pipe sections to suit
the radius of the bend. Depending from segments size, securing shall be carried out
with stainless steel wire / bands. All joints shall be closely fitted without cracks or voids.
All the fabrication joints between calcium silicate insulation pieces, used to fabricate the
cover for tees, elbows, bends, reducers, etc. using cut to size pieces obtained from pipe
shells or pipe segments, shall have the fabrication adhesive which is rated for the expected
service temperature. In particular, for all applications at service temperature above +100C,
only fabrication adhesive for high temperatures must be used.
Calcium silicate insulation covers on 45 and 90 standard length pipe elbows (R = 1.5 x D)
with O.D. over insulation up to approx. 300 mm shall be preferably made using monolithic
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milled pieces to the sizes and thicknesses which are commercially available for pipe shells
and pipe segments. All no-standard length and all large diameter elbows (O.D. over
insulation greater than 300 mm) shall be fabricated in a mitered layout; segments of
preassembled elbows shall be adhered with the fabrication adhesive.
T-pieces covers of calcium silicate or preformed mineral wool insulation shall be cut as
follows:
When run pipe and branch are of the same diameter, T- pieces shall be obtained from a
pipe shell by 45 angle cut by means of a mitre-box.
In case of T-connection of 2 different pipe sizes, the circumference of the smaller insulation
section must be marked off on the surface of the bigger section by means of the saw blade.
The bigger section must be cut out following the mark-line until the smaller section contour
fits into the bigger one. Calcium silicate joints shall be sealed with an HT adhesive and the
anti-abrasive coating applied to the inner side of cut to size pieces of pipe shells or
segments.
The metal cladding over bends and elbows shall be arranged in lobster back segments with
fitting waterproof ball swaged joints between adjacent segments. For this purpose each
segment shall be fabricated with both sides swaged parallel to the curved edge, one edge
swaged to fit under and the other edge swaged to fit over.
The overlap execution between adjacent lobster back segments shall be swage in swage
for diameters over insulation 600 mm, and swage in swage and overlap of 15 mm of the
inner swage for diameters over insulation > 600mm. For R = 1.5 D elbows, 90, number of
cladding segments per elbow shall be no lower than 5 pieces (included the 2 half-segments
with 50 mm overlap at both elbow ends). Only for small size elbows where the number of
swaged elbow segments is limited by constriction at the bend throat, the metal cladding
may be executed as T piece with end-cap layout.
The minimum permissible swage size for elbow segments shall be as follows:
8 mm diameter ball swage for O.D. outside insulation up to 300 mm
12 mm diameter ball swage for 300 < O.D. outside insulation 600mm
16 mm diameter ball swage for O.D. outside insulation > 600mm
Stainless steel self-tapping screws with neoprene washers and stainless steel bands and
seals shall be used to secure in place elbow steel segments depending by elbow diameter.
A minimum 8 mm diameter countersunk drain hole shall be drilled in the cladding,
positioned at the lowest point in the jacket at the bottom of vertically installed bends, to
prevent water from becoming trapped in the piping insulation.
For typical finishing/installation of insulation on pipe fittings see Fig.7-11 Chapter 12.
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8.5 Insulation and Metal Cladding on flanged joints
Where specified as requiring insulation, flanged joints shall be encased in removable

insulated metal boxes in accordance with the following guidelines:
a) Calcium silicate insulation and Flange O.D. < Pipe O.D. + Insulation Thickness: In this
case the flange is insulated with pipe shells or segments having the I.D. equal to the O.D.
of adjacent pipe insulation.
b) Calcium silicate insulation and Flange O.D. Pipe O.D. + Insulation Thickness: In this
case the flange is insulated with pipe shells or segments having the I.D. equal to the O.D.
of adjacent pipe insulation, with the adjacent pipe insulation increased in thickness to
satisfy the relationship at above clause a).
In both clauses a) and b) the flange insulation shall overlap the adjacent pipe insulation
(and its metal cladding) for a minimum distance equal to 50 mm or the insulation
thickness itself whichever is greater.
Calcium silicate Insulation shells or segments are to be adhesive bonded to the steel box.
Adhesive shall be rated for the expected service temperature. Additional support clips or
studs pop riveted to the beneath metal box shall be used to secure insulation lining of metal
box, if deemed necessary.
c) Mineral wool preformed sections insulation and Flange O.D. < Pipe O.D. + Insulation
Thickness: In this case the flange is insulated with pipe sections having the I.D. equal to the
O.D. of adjacent pipe insulation.
d) Mineral wool preformed sections insulation and Flange O.D. Pipe O.D. + Insulation
Thickness: In this case the flange is insulated with pipe shells or segments having the I.D.
equal to the O.D. of adjacent pipe insulation, with the adjacent pipe insulation increased in
thickness to satisfy the relationship at above clause c).
In both clauses c) and d) the flange insulation shall overlap the adjacent pipe insulation
(and its metal cladding) for a minimum distance equal to 50mm or the insulation thickness
itself whichever is greater.
e) Mineral wool blanket insulation: the flange is insulated with cut to size mineral wool
blankets. The flange insulation shall overlap the adjacent pipe insulation (and its metal
cladding) for a minimum distance equal to 50 mm or the insulation thickness itself
whichever is greater.
At both insulation terminations over adjacent pipe, metal end-caps are required as
mechanical support for the removable flange box to be installed.
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On horizontal flanged joints, metal end-caps of flat layout are recommended while on
vertical flanged joints the lower end-cap must be arranged with a cone layout with the upper
end-cap flat.
Mineral wool preformed insulation shall be adhered and secured to the metal box by means
of fixing studs or steel clips pop riveted to the beneath metal box. A sufficient number of
studs or clips shall be provided to ensure that the entire insulation is firmly held in place and
of sufficient length for bending over the insulation. The insulation shall be faced on the
internal face (hot face) with a separate stainless steel wire netting cut and fitted into place,
the whole being fixed to supporting studs or clips.
Mineral wool flexible blanket insulation adhered and secured to the metal box by means of
fixing studs or steel clips pop riveted to the beneath metal box. A sufficient number of studs
or clips shall be provided to ensure that the entire insulation is firmly held in place and of
sufficient length for bending over the insulation and for fixing to the metal mesh cover of the
blankets. At any joint between pieces of blankets, the metal mesh cover shall be stitched
with steel wire.
Removable steel boxes shall be constructed from flat aluminized or stainless steel with
circumferential locking seams (toggle clips). Fabrication shall be in 2 or more pieces, with
no piece weighting more than 20 kg and arranged with 50 mm overlaps secured by means
of stainless steel quick release toggle fasteners. The boxes shall be provided with a 10 mm
min. diameter drain tube at the lowest point.
The number of toggle fasteners used on each side of the steel box may vary according to
the box size but with a minimum of 2 toggle fasteners per side and when additional
fasteners are to be used, they shall be equally spaced and with centers at no more than
300mm each to other.
In the fabrication and installation of flange boxes, all joints in the cladding and between
boxes and piping shall be fully sealed. All boxes shall have a sufficient structural rigidity to
ensure that in the course of insulation removal to an adjacent free standing area and
subsequent replacement, no damage to the insulation lining and no distortion of the metal
box will occur.
Flange boxes to be installed over horizontal lines shall have a cylindrical layout with both
flat heads on vertical lines the upper head of the metal boxes shall have a cone layout to
shed water.
Fabrication joints of metal box on such a parts not to be dismantled shall be secured with
self-tapping screws with neoprene washers or (preferably) with pop rivets.
For typical finishing/installation of insulation on flanges see Fig.12-14 Chapter 12.
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8.6 Insulation and Metal Cladding on valves
Where specified as requiring insulation, valves shall be encased in removable insulated

metal boxes and in accordance with the following guidelines:
All valve boxes shall be constructed so that the stem and stuffing box gland is left clear
from insulation. In the case of ball or plug valves, the construction shall allow sufficient
clearance for operating the valve handle. Any gap between the valve neck and the fitted
cover shall be sealed, to ensure that any leakage from the gland cannot enter the
insulation.
a) Calcium silicate insulation: Depending by the valve shape and by the welded or flanged
ends, the insulation shall be carried out using pipe shells, pipe segments or slabs to
enclose it using the most suitable boxing shape. The solution with the minimum number of
joints shall always be chosen.
Calcium silicate pieces shall be adhesive bonded to the underneath metal box. Adhesive
shall be rated for the expected service temperature. Insulation Additional metal clips or
supporting studs pop riveted to the beneath metal box shall be used to firmly secure the
calcium silicate lining.
b) Mineral wool insulation: Depending by the valve type and size, either mineral wool
preformed pipe sections or flexible mineral wool blankets may be used. Mineral wool
preformed sections or flexible mineral wool blankets shall be adhered and secured as
above described for flanged joints.
In both clauses a) and b) the valve insulation shall overlap the adjacent pipe insulation (and
its metal cladding) for a minimum distance equal to 50 mm or the insulation thickness itself
whichever is greater.
Clauses relevant to flanged joints are applicable to valves as well.
In particular for valves with spectacle blind, metal cladding end plates shall be fitted on both
sides of spectacle blind itself down against the flange bolts to prevent water ingress and the
open space left void until spectacle blind will be operated, shall be sealed with self-
adhesive rubber tape.
For typical finishing/installation of insulation on valves see Fig.15-21 Chapter 12.
9. DETAILS OF APPLICATION ON EQUIPMENT
9.1 Application of Insulation.
Insulation and cladding for equipment up to 750 mm O.D. shall be applied as described for
piping.
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The shell sections of vertical and horizontal equipment above 750 mm O.D. shall comprise
calcium silicate curved segments or mineral wool flexible blankets. Calcium silicate vessels
segments and mineral wool blankets shall be applied in the maximum available sizes
commensurate with the vessel diameter.
The insulation on shell section of equipment shall be secured with stainless steel bands,
machine tensioned and sealed. The bands shall be positioned in such a manner that each
piece of calcium silicate is held in place by means of at least 2 bands. Flexible mineral wool
insulation shall have all longitudinal and circumferential joints tackled with stainless steel
wire plus stainless steel banding at approx. 300 mm centers so that each mineral fiber
standard 600 mm width shall be secured with at least 2 bands.
Bands shall incorporate stainless steel expansion elements in cases where the following
relationship is satisfied: D (O.D. over insulation, m) x T (max. service temperature, C)
1000.
The insulation shall be supported from insulation supports already provided by the
equipment fabricator.
Expansion joints shall be installed below the insulation support rings on vertical vessels.
Expansion joints details shall follow the same requirements as described for piping.
Insulation for equipment heads above 750 mm O.D. outside insulation shall be radiused
and beveled segments of calcium silicate insulation and flexible blankets for mineral wool
insulation. Insulation shall be secured with stainless steel bands radially spaced from a
steel floating ring to be positioned over and centered with, the head. Maximum spacing
between adjacent bands at tangent line shall be 300 mm.
For equipment heads of 750 mm O.D. and below, insulation shall be as described at above
para for mineral wool insulation and in the form of a disc cut from a block for calcium silicate
insulation, to be inserted in the shell calcium silicate insulation which has been extended
sufficiently in length to square off the corners. The calcium silicate disc shall be retained in
place with stainless steel bands circumferentially positioned.
Insulation for bottom heads inside of skirts on vertical vessels over 1000 mm O.D., shall be
flexible mineral wool blankets insulation or radiused and beveled vessels head segments of
calcium silicate insulation. Securing shall be by means of stainless steel bands or wire fixed
to insulation clips provided by vessel fabricator. On large diameter vessels, where bands
are to be used, they will be radially spaced from a steel floating ring. In the case of calcium
silicate insulation, metal cladding shall be substituted by a weather barrier mastic finish
layer, 2 coats are to be applied with the interposition of a reinforcing mesh. Mineral wool
flexible blanket insulation on bottom heads within skirt shall be installed without the metal
cladding.
Insulation shall be laid with staggered, closely fitted joints. Metal mesh faced mineral wool
blankets shall be tackled with steel wire at all joints. At equipment flanges, insulation shall
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be stopped short of the studs and nuts allowing sufficient distance to facilitate the
withdrawal of studs without damaging adjacent insulation. For this purpose, the clearance
shall be extended to equal the stud/bolt length plus 30 mm.
Insulation shall be fitted as closely as possible around equipment nozzles and effectively
sealed.
For typical finishing/installation of insulation on equipments see Fig.22-42 Chapter 12.
9.2 Metal Cladding Finish over Equipment
Insulation on the shell sections of vertical equipment above 750 mm diameter shall be
protected with profiled (corrugated) steel cladding or with flat sheets otherwise. In case
corrugated steel cladding is used OWNER confirmation is required. Profiled sheets shall be
lapped a minimum of 1 corrugations vertically and 75 mm horizontally, all laps arranged
to shed water. Flat sheets overlap shall be 50 mm on all vertical longitudinal laps and 75
mm on all horizontal circumferential laps, all laps being arranged to shed water.
Tops of sheets shall be secured to support rings by means of angle clips pop riveted to the
sheets and additionally secured through vertical overlaps with stainless steel self-tapping
screws (except where breathing springs are to be used to allow for circumferential
expansion) positioned at maximum 100mm pitch and with stainless steel bands at
maximum 450 mm centers, including one (1) band over each circumferential overlap. All
bands shall be machine tensioned and sealed.
Sheets on vertical equipment shall be arranged in such a manner to suit the support rings
spacing, assembly shall commence from the lowest course to enable the sheets to be
secured from the top by angle clips and pop-rivets at support ring. Subsequent courses
shall also be progressively secured from the top in a similar manner and allowing the
bottom of the sheets to overlap the preceding course by the specified 75 mm horizontal
overlap, this being left free to compensate vertical expansions. Should the distance
between adjacent support rings be covered with the arrangement of more than one sheet,
at all circumferential sheets overlaps, S clips shall be provided to secure sheets and to
prevent telescoping. S clips shall be banded in correspondence of overlaps of the upper
onto the lower sheet in order to avoid clips displacement. Alternatively J shaped clips may
be used, adequately pop riveted to the lower sheet at overlaps.
" S " clips shall be spaced at 300 mm intervals , but not less than two clips per sheet.
"J" clips shall be attached to the jacket with self tapping screws and shall be spaced about
1.8 m apart.
Insulation on the shell sections of horizontal equipment above 750 mm diameter shall be
protected with flat steel cladding with the sheets overlap of a minimum of 75 mm on all
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vertical circumferential laps and 50 mm on all horizontal longitudinal laps, all laps being
arranged to shed water.
Sheets on shell sections of horizontal equipment shall be secured with self-tapping screws
(except where breathing springs are to be used to allow for circumferential expansion) with
neoprene washers at maximum 100mm pitch through all longitudinal overlaps and with
stainless steel bands at maximum 450 mm centers, including one (1) band over each
circumferential overlap. The bands shall be machine tensioned and sealed.
Finishing detail at expansion joint in equipment cladding shall have a double swage shape
with the interposition of a band. Sheet overlaps at expansion joints shall be increased from
75 to 100 mm.
Heads of vertical or horizontal equipment above 1000 mm O.D. outside insulation, other
than those within a skirt, shall be finished with the steel cladding arranged in radial
segments from a central disc (or ring for flanged heads). Each segment shall be swaged
(male swage at one edge and female swage at min. 30 mm from the other edge), adjacent
segments shall be overlapped and secured by means of pop-rivets (for prefabricated
segments pieces) and with self-tapping screws and neoprene washers on the remainder
overlaps (for easy removal of the head cover in 2 or 4 prefabricated sector pieces).
Between steel head cover and steel sheets on shell section (e.g. at tangent line), an
overlaps of minimum 50 mm shall be made, with edge of steel head cover to be swaged.
At this position, each segment of the head cover shall be secured to underneath shell
cladding sheet by means of self-tapping screws and neoprene washers, at approx. 100 mm
pitch, adjustment in the pitch may be done and it shall be commensurate to each segment
radial dimension as measured at tangent line.
For horizontal vessels and exchangers 1000 mm O.D. outside insulation and below, the
insulation shall be finished with a flat metal end-cap fabricated from flat steel sheets
incorporating a lock formed corner or finished with a conical head segmented cap, each
segment being arranged in radial segments from a central disc (or ring for flanged heads).
Each segment shall have both edges bent at a vertical position, minimum 25 mm wide.
Bent edges of adjacent segments shall be butt jointed, covered by a U metal strip
obtained from sheets, flashing shall be with metal sealant and finally the U strip shall be
secured to segments edges by means of self-tapping screws (or pop-rivets for
prefabricated segments pieces). At tangent line, a milled corner L metal sheet shall be
installed, screwed or pop-riveted as appropriate to the side at laps with head conical
segments and secured with self-tapping screws and neoprene washers at overlap with shell
metal cladding. Laps of the L corner cover with adjacent cladding shall be min. 50 mm.
For top head of vertical vessels 1000 mm O.D. and below, the insulation shall be finished
with conical head cover only, while bottom head may be flat or conical.
Heat exchanger bonnets, bonnet flanges, channel flanges and vessels man-ways requiring
thermal insulation shall be provided with removable covers constructed from flat metal
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sheets with circumferential lock formed joints. Fabrication shall be in one or two pieces
arranged with a min. of 25 mm overlaps and secured by means of stainless steel quick
release toggle fasteners in sufficient quantity and layout to ensure stability in service. The
boxes shall be designed so that they are completely waterproof and with each cover section
provided with stainless steel lifting handles to facilitate removal when its weight will be
greater than 20 kg and shall be of such a size and shape that can be easily handled by two
men.
Removable boxes shall be lined on all internal surfaces with preformed scheduled
insulation material, of equivalent thickness to that applied on adjacent equipment. The
insulation shall be faced on the internal (hot) face with a separate layer (except where
scheduled insulation material is mineral wool metal faced flexible blankets) of stainless
steel wire netting cut and fitted into place, the whole being impaled over metal studs or
metal strip clips, fabricated from the same metal cladding used for the box or from stainless
steel bands, as more appropriate, pop riveted to the inside of the boxes. Sufficient numbers
of studs or clips shall be provided to ensure that the insulation is firmly held in place, for
which purpose they shall be of sufficient length for bending over the wire netting (or metal
meshes of blankets) faced insulation. Main securing of insulation by an adhesive or by
friction grip washers attached to steel pins is not acceptable. Only calcium silicate insulation
need to be adhesive bonded to beneath steel box as additional securing method.
All overlaps in the cladding shall be sealed by means of butyl-rubber strips to be inserted in
the swages of cladding laps, where strips are impracticable the sealing shall be by means
of gun extruded metal sealant (such as Foster 95-55 or a approved equal). The strips shall
for convenience be located within the ball swages provided at circumferential and
longitudinal overlaps and shall be minimum 8 mm diameter and sufficient to provide an
effective seal with the overlap drawn tight.
Due attention shall be paid to the fitting of cladding to ensure proper overlap of seams and
effective sealing where breaks in the cladding occur, to ensure rapid water run-off and to
prevent liquids ingress.
Cut outs around projections shall be effectively sealed with a 3 mm diameter dry film
thickness of heat resistant sealant. At locations where a heat resistant sealer is not
sufficient, a close fitting with metal collars shall be used. These shall be carefully sized,
fabricated, flashed, sealed and secured to adjacent cladding surfaces.
The exposed insulation faces at insulation terminations occurring each side of exchangers
and other equipment flanges, nozzles, etc. shall be provided with metal end-caps.
In the case of bands for retention of metal cladding on shell section of equipment satisfying
the size/temperature relationship D (Diameter over insulation, m) x T (max. service
temperature, C) 1000, stainless steel expansion elements such as breathing springs,
such as Mity-Spring or an approved equal, shall be incorporated. To accommodate
expected expansion of the object, the number of compression springs to be installed is
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based on a maximum of 1-1/2 (approx. 40 mm) of compression each spring, with springs
evenly distributed around the circumference at no more than 8.0 m centers.
Insulation and finishing detail at vacuum rings / stiffeners exceeding shell insulation
thickness shall be carried out.
9.3 Tanks
Tanks shall be insulated in a manner similar to the vessels, except that the first course of
insulation at the base of the tank shall start at an elevation of 300 mm above grade or
above to the bottom (annular) plate. The bare surface shall be protected with a complete
painting system.
9.4 Pumps and Turbines
Pumps and turbines and other small shaped irregular shaped equipment shall have blanket
or block mineral fibre insulation applied and secured as prescribed.
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9.5 Acoustic Insulation and Combined Acoustic / Hot Insulation.
Insulation for combined sound control / heat conservation shall refer to sound control only.
Insulation shall be performed by mineral fiber applied in two layers, with inner and outer layers of
aluminized or stainless steel cladding, based on pipe size as shown in the table below.
Nominal Pipe Diameter Acoustic Insulation Construction

(Minimum Thickness and Cladding Weight)
Below NPS 12 Acoustic Insulation Layers Total Thk of Table 1
Acoustic Cladding (steel) 1.0 mm
1st Acoustic Insulation Layer Total Thk of Table 1 50 mm
NPS 12
1st Acoustic Cladding (steel) 0.8 mm
< NPS 26
2nd Acoustic Insulation Layer 50 mm
2nd Acoustic Cladding (steel) 1.0 mm
1st Acoustic Insulation Layer Total Thk of Table 1 50 mm
NPS 26
1st Acoustic Cladding (steel) 0.8 mm
2nd Acoustic Insulation Layer 50 mm
2nd Acoustic Cladding (steel) 1.25 mm
An inner layer of mineral fiber applied and secured in accordance with the relevant
requirements detailed above for the item being insulated. The thickness of the inner layer
shall be equal to the total thickness shown at Table 1, less 50 mm.
An outer layer of mineral fiber applied and secured in accordance with the relevant
requirements detailed above for the item being insulated. The outer mineral fiber layer shall
in all cases be 50 mm thick.
Inner (1st layer) and outer (2nd layer) layer of steel cladding applied and secured in
accordance with the relevant requirements detailed above for the item being insulated.
However drain holes shall not be drilled in the steel cladding. Each layer of cladding shall
have end caps.
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Steel cladding shall be acoustically isolated from metal protrusions, such as hanger rods,
using either vibro-acoustic seals or sealant, as allowed by exposure temperature.
Piping and Equipment items requiring insulation for sound control shall be insulated to the
extend defined at above.
Pipe support trunnions shall be fully insulated. Pipe support clamps that extend outside the
pipe insulation shall be fully insulated. Insulation thickness over acoustic insulation blocks
may be reduced to 30 mm total thickness to allow proper sealing at base plate.
The same accessories and attachment materials will be used as normal hot insulation .See
chapter 7.6 , for further details see also specification 000-N-PE-0020001.
9.6 Expanded metal shields
Shields for personnel protection shall be perforated sheeting according to ASTM E 674 (or
DIN 10215)
Shields for personnel protection shall be designed for convenient easy removal for
maintenance access.
Individual sections shall not weight more than 20 kg
The shields shall be located at a minimum distance of 75 mm from the hot surface
Galvanized shields will not be used on stainless steel piping and equipments.
9.7 Inspection Windows on thermal Insulation for Piping & Equipment
Piping Thermal Insulation

The piping 2 NPS and above that is thermally insulated in hot service shall be provided
with inspection windows (plugs and associated seal flanges assembly) for carrying out NDT
thickness survey.
Minimum requirements for number and position of inspection windows shall be as follows:
Inspection Windows shall be preferably provided at bottom i.e.4-6-8 clock position
whichever is convenient.
One location in every 20m length of the straight pipe subject to minimum of 1 (one)
point every straight length of piping.
There must be at least 1 (one) Inspection Window between 2 (two) bends which are
minimum 10 (ten) meters apart.
Location shall be at least 6 distance from fitting where changes in direction occur
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Whenever line changes its direction, it is considered a new part and shall have
inspection window.
Pipes NPS 8 and below: 2 (two) points (at 4-10 or 6-12 or 2-8 clock position)
Pipes NPS above 8: 4 (four) points (at 1-4-7-10 or 3-6-9-12 or 2-5-8-11 clock posit.)
Bends and Elbows NPS 6 and below: 1 (one) inspection window outside axis in
proximity of changing direction
Bends and Elbows NPS 8 to 18 : 1 (one) inspection window at 45
Bends and Elbows NPS above 18: 2 (two) inspection windows , 1 (one) at 30 and
1 (one) at 60
Equipment Thermal Insulation

Minimum requirements for number and position of inspection windows shall be as follows:
The dished ends with 1 (one) to 2 (two) meter diameter shall have a minimum of 3
(three) inspection windows on knuckle areas.
The dished ends with 2 (two) to 4 (four) meter diameter and greater shall have a
minimum of 4 (four) inspection windows on knuckle areas.
The shell portion shall have 2 (two) inspection windows 180 apart each 2 (two)
meters of length, with a minimum of 2 (two) inspection windows.
In case of vertical vessels (e.g. columns) a minimum of 2 (two) inspection windows
180 apart shall be provided on each platform level excluding manway nozzles.
Thermally insulated storage tanks shall have inspection windows along the ladder
after every 2 (two) meters length on shell.
Thermally insulated roof of tanks shall have a minimum of 8 (eight) inspection
windows equally spaced near the top walking/working platform or railings.
Design of Inspection Windows

The inspection window shall be an assembly of a removable plug and a sealing flange, set
tight on outside thermal insulation metal cladding.
The removable plug shall be made of silicone rubber and secured with a small chain or
lanyard made of stainless steel. Sealing flange shall be made of aluminum or stainless steel
to match insulation metal cladding metallurgy avoiding galvanic corrosion. Only on small
piping (up to 5 OD outside insulation) it is allowed to install Sealing Flanges made of
Silicone Rubber same as Plug material.
An O ring made of rubber shall be placed for any metal Seal Flange for proper retrofit.
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Plug Flange shall be silicone sealed to outside insulation metal cladding for a perfect
watertight assembly sealing.
Plug Flange shall be fixed by screws and washers to outside insulation metal cladding,
metallic type shall be secured with a SS band and seal.
The following inspection windows nominal dimensions shall be used with respect to OD
insulation metal cladding:
Recommended NDT Window Size OD Insulation Cladding
1.5 in. (38mm) Min. 4.0 in.
2.5 in. (64mm) Min. 6.0 in.
3.0 in. (76mm) Min. 10 in.
5.0 in. (127mm) Min. 1000 mm (Vessels & Tanks)
Where installed on corrugated metal cladding of insulation, a neoprene transition gasket

shall be installed between cladding and flange.
Inspection windows positions shall be identified by Subcontractor and verified / approved by
Contractor / Owner before to commencing the installation.
The typical Inspection Windows assembly is shown here below in an explosion-view:
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10. TABLE I (I) INSULATION THICKNESS
TABLE I (I)
INSULATION THICKNESS (mm)
OPERATING TEMPERATURES (C) Nominal pipe sizes
Nominal Pipe sizes 93 149 204 260 316 371 427 482 538
1-1/2" & Smaller 40 40 50 50 65 65 75 75 75
2" 40 40 65 65 65 75 75 75 90
3" 40 50 65 75 75 75 100 100 100
4" 40 50 65 75 75 100 100 100 100
6" 40 50 75 75 100 100 100 125 125
8" 40 65 75 100 100 100 100 150 150
10" 40 75 75 100 100 100 100 150 150
12" 50 75 75 100 100 100 150 150 150
14" 50 75 75 100 100 125 150 150 150
16" 50 75 75 100 100 125 150 150 150
18" 50 75 75 100 100 125 150 150 150
20" 50 75 75 100 100 125 150 150 150
24" 65 75 75 100 100 125 150 150 180
30" 65 75 75 125 125 150 150 180 180
Over 30" 65 75 75 125 125 150 150 180 180
Note - Insulation thickness greater than 100 mm shall be applied in two or more layers.
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11. TABLE II (P) INSULATION THICKNESS PERSONEL PROTECTION
TABLE II (P)
INSULATION THICKNESS PERSONEL PROTECTION (mm)
OPERATING TEMPERATURES (C) sizes
Nominal pipe sizes 93 149 204 260 316 371 427 482 538
1-1/2" & Smaller 20 20 20 40 40 50 60 60 70
2" 20 30 30 40 40 50 60 70 80
3" 30 30 30 40 40 50 60 70 90
4" 30 30 30 50 50 50 60 80 90
6" 40 40 40 60 60 60 70 80 100
8" 40 40 40 60 60 60 70 90 100
10" 40 40 40 60 60 60 70 90 100
12" 40 40 40 60 60 60 70 90 110
14" 40 40 40 60 60 60 80 90 110
16" 40 40 40 60 60 60 80 90 110
18" 40 40 40 60 60 60 80 90 110
20" 40 40 40 60 60 60 80 100 110
24" 40 40 40 60 60 60 80 100 120
30" 40 40 40 60 60 60 80 100 120
Over 30" 40 40 40 60 60 70 90 110 130
Notes:
Insulation for thickness greater than 100 mm shall be applied in two or more layer.
These thicknesses have been selected to have external jacket temperature less than 65C in still
air condition at 30C.
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12. TYPICAL HOT INSULATION INSTLLATION / FINISHING SKETCHES
Figure 1 Typical installation/finishing of insulation by means of pipe sections and blankets
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Figure 2 Typical installation/finishing detail of metal jacketing
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Figure 3 Typical installation/finishing at expansion joints
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Figure 4 Typical installation/finishing for traced piping in pipe sections and wire mesh blankets
Note : 1- Metal mesh and aluminium foil will be used to wrap pipe and tracer before insulation , in
order to prevent the tracer from burying in the insulation .
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Figure 5 Typical installation/finishing on trunnion supports
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Figure 6 Typical installation/finishing on hanger supports
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Figure 7 Typical installation/finishing on elbows

Notes: 1- swage in swage for diameter <600mm, for diameter >600mm with overlap
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Figure 8 Typical installation/finishing on tees
Figure 9 Typical installation/finishing on endcap/teepiece
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Figure 10 Typical installation/finishing on concentric reducers
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Figure 11 Typical installation/finishing on eccentric reducers
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Figure 12 Typical installation/finishing at non-insulated flanges

Notes: 1- Distance between insulation and flange to be bolt length + 30mm
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Figure 13 Typical installation/finishing removable flange box horizontal

2- Insulation thickness
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Figure 14 Typical installation/finishing removable flange box vertical

3- Apply detail A for fixing blind flange box
4- Per box minimal 2 box support strips 30mm wide and 0.8mm thick.
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Figure 15 Typical installation/finishing removable valve box DN150

Figure 16 Typical installation/finishing removable valve box with extended spindle DN80
Notes: 1- Insulation thickness
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Figure 17 Typical installation/finishing removable valve box vertical DN150

3- Apply detail A for fixing blind flange box
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Figure 18 Typical installation/finishing removable valve box T connection vertical DN150

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Figure 19 Typical installation/finishing removable valve box T connection horizontal DN150

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Figure 20 Typical installation/finishing removable valve box for valve with spectacle blind vertical
3- Top and bottom plates shall be fitted up against the valve bolts
4- To prevent water ingress, open space shall be sealed with aluminium tape
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Figure 21 Typical installation/finishing removable valve box for valve with spectacle blind horizont
3- Top and bottom plates shall be fitted up against the valve bolts
4- To prevent water ingress, open space shall be sealed with aluminium tape
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Figure 22 Typical installation/finishing for vertical pipe connection to equipment
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Figure 23 Typical installation/finishing of bands on equipment

Notes: 1- Crossing bands to be interlinked with clips of the same material
2- Fasten equipment head bands to anchoring bands alternating
3- Fixing layout shall be with a central floating ring and radially spaced bands on
equipments with OD outside insulation 750mm
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Figure 24 Typical installation/finishing on conical head
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Figure 25 Typical installation/finishing on spherical head
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Figure 26 Typical installation/finishing on top/vertical manhole connection
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Figure 27 Typical installation/finishing on skirt
Figure 28 Typical installation/finishing on support to equipment
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Figure 29 Typical installation/finishing on ladder supports
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Figure 30 Typical installation/finishing on horizontal nozzle
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Figure 31 Typical installation/finishing on manhole horizontal connection
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Figure 32Typical installation/finishing at overlap at vertical and horizontal longitudinal and circular
joints
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Figure 33 Typical installation/finishing at overlap at name plate support
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Figure 34 Typical installation/finishing at horizontal and vertical bottom side equipment nozzle
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Figure 35 Typical installation/finishing at vessel supports

Notes: 1- In case of heat loss near support is unacceptable, void to be filled with insulating
material
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Figure 36 Typical installation/finishing at lifting lugs
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Figure 37 Typical installation/finishing on spherical head (semi-eliptical)

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Figure 38 Typical installation/finishing on spherical head (semi-elliptical) with manhole
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Figure 39 Typical installation/finishing bottom nozzle box
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Figure 40 Typical installation/finishing on dome head (horizontal)

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Figure 41 Typical installation/finishing on removable manhole box (horizontal) two sections

Notes: 1- Bands to be fixed onto box by means of blind rivets
2- Distance between insulation and flange to be bolt length + 30mm
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Figure 42 Typical installation/finishing on vertical top side equipment nozzle

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06 May 2016

STAR RAFNER, A.. CONTRACT N

8.4 Insulation and Metal Cladding on Pipe Fittings 20

OWNER: STAR RAFNER, A.. (STAR)

(I): Insulation for heat conservation purpose

(P): Insulation for personel protection purpose

4.1 OWNER SPECIFICATIONS AND PROCEDURES

STGPS N3 Hot Insulation General

000-N-PE-0020001 Specification for acoustic insulation

4.3 Codes and standard

It is responsibility of the Subcontractor to:

6.1 Insulation to be omitted.

6.2 Flanged joints to be insulated.

a. Those in steam and condensate service.

6.3 Valves to be insulated

a. Those in steam and condensate service.

Compressors, pumps, and other mechanical equipment shall be insulated on an individual

6.5 Insulation Thickness to be adopted

Recommended equipment and piping insulation thicknesses shall be as shown in Table I

7.2 Synthetic resin bonded mineral wool.

Minimum Nominal Density (ASTM C-302): 100 kg/m3

Shot Content: in accordance with ASTM C-612

7.3 Synthetic resin bonded mineral wool Blankets

Max. 0.062 W/m K @ Tavg = +150C (average material temperature)

7.4 Calcium Silicate ASTM C-533 type II

Max. 0.073 W/m K @ Tavg = +427C (average material temperature)

7.5 Metal weatherproofing

7.6 Accessory Material

Application Temperature Range (ASTM D-1000): 0 to +40C

8.1 Insulation of Straight Pipes.

8.2 Metal cladding over pipe

O.D. (pipe diameter over insulation, m) x T (max. service temperature, C) 1000

8.3 Insulation and metal cladding at pipe supports

8.4 Insulation and Metal Cladding on Pipe Fittings

8.5 Insulation and Metal Cladding on flanged joints

Where specified as requiring insulation, flanged joints shall be encased in removable

8.6 Insulation and Metal Cladding on valves

Where specified as requiring insulation, valves shall be encased in removable insulated

9. DETAILS OF APPLICATION ON EQUIPMENT

9.1 Application of Insulation.

9.2 Metal Cladding Finish over Equipment

9.4 Pumps and Turbines

9.5 Acoustic Insulation and Combined Acoustic / Hot Insulation.

Nominal Pipe Diameter Acoustic Insulation Construction

Below NPS 12 Acoustic Insulation Layers Total Thk of Table 1

Acoustic Cladding (steel) 1.0 mm

1st Acoustic Insulation Layer Total Thk of Table 1 50 mm

2nd Acoustic Cladding (steel) 1.0 mm

1st Acoustic Insulation Layer Total Thk of Table 1 50 mm

2nd Acoustic Insulation Layer 50 mm

2nd Acoustic Cladding (steel) 1.25 mm

9.6 Expanded metal shields

9.7 Inspection Windows on thermal Insulation for Piping & Equipment

Piping Thermal Insulation

Equipment Thermal Insulation

Design of Inspection Windows

Recommended NDT Window Size OD Insulation Cladding

1.5 in. (38mm) Min. 4.0 in.

2.5 in. (64mm) Min. 6.0 in.