Oisd STD 177

Sr.
Number:OISD/DOC/2016/419
Page No. I
OISD-STD-177
FOR RESTRICTED
CIRCULATION
INSPECTION AND MAINTENANCE

OF
THERMAL INSULATION
OISD STANDARD 177
OIL INDUSTRY SAFETY DIRECTORATE
Government of India
Ministry of Petroleum & Natural Gas
8th Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
Website: www.oisd.gov.in
Tele: 0120-2593800, Fax: 0120-2593802
Sr.Number:OISD/DOC/2016/419
Page No. II
OISD-STD-177
JUNE 1998
FOR RESTRICTED
CIRCULATION ONLY
INSPECTION AND MAINTENANCE
OF
THERMAL INSULATION
Prepared by :
FUNCTIONAL PANEL ON THERMAL INSULATION

8 Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
th
Page No. III
Preamble
Indian petroleum industry is the energy lifeline of the nation and its continuous performance is essential for
sovereignty and prosperity of the country. As the industry essentially deals with inherently inflammable substances
throughout its value chain – upstream, midstream and downstream – Safety is of paramount importance to this
industry as only safe performance at all times can ensure optimum ROI of these national assets and resources
including sustainability.
While statutory organizations were in place all along to oversee safety aspects of Indian petroleum industry, Oil
Industry Safety Directorate (OISD) was set up in 1986 Ministry of Petroleum and Natural Gas, Government of India
as a knowledge centre for formulation of constantly updated world-scale standards for design, layout and operation
of various equipment, facility and activities involved in this industry. Moreover, OISD was also given responsibility of
monitoring implementation status of these standards through safety audits.
In more than 25 years of its existence, OISD has developed a rigorous, multi-layer, iterative and participative
process of development of standards – starting with research by in-house experts and iterating through seeking &
validating inputs from all stake-holders – operators, designers, national level knowledge authorities and public at
large – with a feedback loop of constant updation based on ground level experience obtained through audits,
incident analysis and environment scanning.
The participative process followed in standard formulation has resulted in excellent level of compliance by the
industry culminating in a safer environment in the industry. OISD – except in the Upstream Petroleum Sector – is still
a regulatory (and not a statutory) body but that has not affected implementation of the OISD standards. It also goes
to prove the old adage that self-regulation is the best regulation. The quality and relevance of OISD standards had
been further endorsed by their adoption in various statutory rules of the land.
Petroleum industry in India is significantly globalized at present in terms of technology content requiring its operation
to keep pace with the relevant world scale standards & practices. This matches the OISD philosophy of continuous
improvement keeping pace with the global developments in its target environment. To this end, OISD keeps track of
changes through participation as member in large number of International and national level Knowledge
Organizations – both in the field of standard development and implementation & monitoring in addition to updation of
internal knowledge base through continuous research and application surveillance, thereby ensuring that this OISD
Standard, along with all other extant ones, remains relevant, updated and effective on a real time basis in the
applicable areas.
Together we strive to achieve NIL incidents in the entire Hydrocarbon Value Chain. This, besides other issues, calls
for total engagement from all levels of the stake holder organizations, which we, at OISD, fervently look forward to.
Jai Hind!!!
Executive Director
Oil Industry Safety Directorate
Page No. IV
FOREWORD
The Oil Industry in India is 100 years old. Because of various collaboration
agreements, a variety of international codes, standards and practices have
been in vogue. Standardisation in design philosophies and operating and
maintenance practices at a national level was hardly in existence. This,
coupled with feedback from some serious accidents that occurred in the
recent past in India and abroad, emphasised the need for the industry to
review the existing state of art in designing, operating and maintaining oil
and gas installations.
With this in view, the Ministry of Petroleum and Natural Gas in 1986
constituted a Safety Council assisted by the Oil Industry Safety Directorate
(OISD) staffed from within the industry in formulating and implementing a
series of self-regulatory measures aimed at removing obsolescence,
standardising and upgrading the existing standards to ensure safe
operations. Accordingly, OISD constituted a number of functional
committees of experts nominated from the industry to draw up standards
and guidelines on various subjects.
The present document on "Inspection & Maintenance of Thermal

Insulation", has been prepared by the Functional Committee on "Thermal
Insulation". This document is based on the accumulated knowledge and
experience of industry members and the various national and international
codes and practices. This document is meant to be used as supplement
and not as a replacement for existing codes and practices. It shall be
borne in mind that no standard can be a substitute for the judgment of a
responsible qualified Engineer. Suggestions are invited from the users after
it is put into practice to improve the document further. Suggestions for
amendments to this document should be addressed to
The Coordinator,
Functional Committee on "Thermal Insulation,
th
8 Floor, OIDB Bhavan, Plot No. 2, Sector – 73, Noida – 201301 (U.P.)
This standard in no way supersedes the statutory requirements

of bodies like IBR, CCE, Factory Inspectorate or any other
Government Body which must be followed as applicable.
Page No. V
NOTE
OISD publications are prepared for use in the oil and gas
industry under the Ministry of Petroleum and Natural Gas.
These are the property of Ministry of Petroleum and Natural
Gas and shall not be reproduced or copied and loaned or
exhibited to others without written consent from OISD.
Though every effort has been made to assure the accuracy

and reliability of data contained in these documents, OISD
hereby expressly disclaims any liability or responsibility for
loss or damage resulting from their use.
These documents are intended only to supplement and not

replace the prevailing statutory requirements.
Page No. VI
FUNCTIONAL PANEL ON THERMAL INSULATION
NAME DESIGNATION ORGANISATION
LEADER
SHRI D.C. PATEL, SR. INSP MGR., BPCL REFINERY, MUMBAI
MEMBERS
SHRI S. NEELAKANTAN, SR.MGR (ENGG SERV.) MRL, CHENNAI
SHRI L.J. ROHEKAR, SR. INSP. MGR., IOC, GUWAHATI REFINERY,

GUWAHATI
SHRI M.S. RATHOR, SR. INSPN. MGR., HPCL REFINERY, MUMBAI
SHRI S. GHATAK CHOUDHARY, SIPM, IOC(R&P), SCOPE COMPLEX,

NEW DELHI
SHRI S.B. SARKAR, MGR, GAIL, LPG PROJECT, USAR,

ALIBAGH
SHRI K. NARAYANAN, INSP MGR., CRL, COCHIN
MEMBER COORDINATOR
SHRI A.K. RANJAN, JOINT DIRECTOR(ENGG), OISD, NEW DELHI
------------------------------------------------------------------------------------------------------------------------------------
In addition to the above, various other experts from the industry contributed in the preparation, review and
finalisation of this document.
Page No. VII
CONTENTS
SL. NO. DETAILS PAGE NO.
1.0 Introduction 1
2.0 Scope 1
3.0 Definitions 1
4.0 Hot Insulation 2
4.1 Insulating Material 2
4.2 Procedure for application of hot Insulation 2
4.3 Insulating Procedures for specific Equipment/Component 4
4.4 Inspection 7
4.5 Maintenance Procedure 9
5.0 Cold Insulation 10
5.1 Insulating Material 10
5.2 Procedure for application of cold Insulation 11
5.3 Insulating Procedures for specific Equipment/Components 13
5.4 Inspection 16
5.5 Maintenance Procedure 18
6.0 References 19
OISD – STD – 177 Page No. 1
INSPECTION AND MAINTENANCE OF THERMAL INSULATION
1.0 INTRODUCTION
The need for effective and efficient thermal insulation has become more important with
increasing energy costs & higher operating temperatures. The requirement to keep a product at
the appropriate temperature is necessary either due to process requirements or to maintain the
flow characteristics. These liquids loose their heat energy through metal surfaces in which they
are contained or flowing. As this heat loss amounts to the loss of energy, methods to minimise
these losses need attention. The minimisation of heat loss can be achieved by judicious
application and maintenance of thermal insulation. It also serves the purpose of reduction of
pressure relief loads in event of fire.
2.0 SCOPE
This standard lays down the minimum inspection/ maintenance practices and procedures
adopted for external hot & cold insulation on static/ rotary and mobile equipment/vessels and
pipelines in oil and gas industries. The standard also covers in brief inspection checks at the time
of installation. The design aspects like need for providing insulation at particular location do not
fall under the scope of this standard.
3.0 DEFINITIONS:
3.1 Hot & Cold Insulation:

0
For the purpose of this standard, insulation material used at service temperature of approx. 5 C
and below are termed as "Cold Insulation" whereas, insulation material for service temperature of
0
approx. 60 C and above are termed as "Hot Insulation".
3.2 Preformed Insulation:
Thermal insulating material which is prefabricated in such a manner that at least one surface
conforms to the shape of the surface to be covered and which, when handled, will maintain its
shape without cracking, breaking, crumbling or permanent deformation.
3.3 Blanket Insulation:
A flexible insulating material composed of felt fibrous material without binder, but reinforced with
confining media.
3.4 Block Insulation:
Straight or segmental blocks of board insulation with or without facing and with or without
attachment for application purposes.
3.5 Fibrous Insulation:
Insulation material composed of filaments generally circular in cross section and of length
considerably greater than the diameter.
3.6 Moisture Barrier:
Material used to restrict the transmission of water/vapour.
“OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting
from the use of OISD Standards/Guidelines.”

3.7 Thermal Conductivity:
The quantity of heat flow per unit time (in the steady state) through one square centimeter cross-
section of an infinite piece of material, when the temperature difference between two planes
normal to thermal flux and one centimeter apart is one degree unit.
4.0 HOT INSULATION
4.1 INSULATING MATERIALS
There is a wide range and choice of insulation materials used for thermal insulation. However, it
is necessary that materials used should conform to relevant IS standards like IS3144 etc. for
properties like chloride content, toxicity, incombustibility. Some of the commonly used insulating
materials are described below:-
4.1.1 Glass Wool
Glass wool is made from molten glass in form of staple fiber, continuous filaments mattresses on
semi rigid bonded slabs. It can be used for insulation on surfaces having temperature not
0
exceeding 550 C. However when bonded the same can be used on surfaces with temperature
0
not exceeding 400 C.
4.1.2 Mineral Wool (Rock Wool)
Mineral wool is made from molten mineral rocks by centrifugal spinning process. They can be
0
applied to hot surfaces with temperatures not exceeding 700 C. both as blanket and preformed
sections.
4.1.3 Ceramic Fibers
Ceramic fibers are made by spinning or blown process by making fibers out of molten Aluminium
Oxide and Silica (Ceramic). They are pressed to form a blanket. They are suitable for use upto
0
temperature of 1400 C.
4.1.4 Calcium Silicate
Calcium Silicate block & pipe thermal insulation are composed principally of hydrous calcium
0
silicate reinforced with mineral fibers (except slag wool). It is suitable for temperatures upto 800
C.
4.2 PROCEDURE FOR APPLICATION OF HOT INSULATION
Effectiveness and better operational life of an insulation depends on the way it has been
installed. An improper installation may not only lead to higher heat losses and reduced life, but
also it may lead to corrosion of insulated surfaces. Following minimum standards are
recommended for installation of insulation on equipment, storage tanks and pipelines.
4.2.1 Surface Preparation And Paint Application
The surface to be insulated shall be cleaned thoroughly by solvent cleaning/ thorough wire
brushing or pressure blasting.

Based on service conditions, metallurgy and environment, an appropriate primer/ paint coat shall
0
be applied immediately after surface preparation. All equipment operating below 175 C needs to
be painted before insulation and also equipment likely to remain idle for longer periods need
painting as per the local environmental condition and irrespective of operating temperature.
In case of repairs of thermal insulation, thorough manual cleaning may be resorted to.
4.2.2 Moisture Barrier (Aluminium Foil)
Aluminium foil of 0.1 mm thickness may be used on bare pipe/equipment as a moisture barrier
and also as confining material whenever required. Aluminium foil shall not be used for inner
jacketing of hot SS equipment. Moisture barrier is generally not required for equipment operating
0
above 200 C.
4.2.3 Insulation Fixing Arrangements
Insulation shall be properly held in position by welding lugs or supporting rings at suitable
intervals. Binding / strapping materials like binding wire or band strips and self tapping screws
are to be used for proper fixing of the insulating material. Lugs should be welded on the
equipment before final hydrotest and stress relieving, if any.
The outside diameter of support rings should be equivalent to the outside diameter of the
insulation. In order to minimise direct heat conduction through the stays, a packing of insulation
shall be provided at the joint of stays and equipment.
4.2.4 Insulation fixing procedures
a) Blanket Insulation:
Blanket Insulation mattresses are wrapped on the surface to be insulated and then tied with
wires to hold it in position.
After making the blanket/mattress to required thickness, G.I. chicken wire mesh shall be placed
over it to give it requisite mechanical/structural strength. While wrapping blankets on surfaces,
chicken mesh shall remain outside.
After wrapping blanket on surface and positioning it correctly, the joining end circumferential as
well as longitudinal shall be closed with stitching using galvanised wire.
After blankets are stitched up in position, a GI wire shall be helically wrapped over it and
tightened suitably. This is to give extra strength and uniform shape to the blankets.
b) Preformed/Fabricated Sections:
Preformed shapes shall fit snugly to the surfaces and shall butt closely to each other. Joints
should be staggered and gaps or cavities avoided by trimming the insulation to fit. Where this is
not practical, loose-fill or trowelled-in material having comparable thermal insulation properties to
the main material should be used.
Where shown to be more economical or technically advantageous, the insulation shall consist of
two or more layers of dissimilar materials, provided their respective temperature limits are
appropriate for the duty. All multi-layer insulation shall have individual layers secured by banding,
wires or by self adhesive tapes and all longitudinal and circumferential joints staggered.

4.2.5 Procedures for Fixing Outer Cover
a) Cladding
 Thickness and metallurgy of outer cover sheet should be selected considering service
consideration, metallurgy of equipment and environment.
 All the joints (longitudinal & circumferential) shall have sufficient overlap after wrapping of outer
cover sheet. The overlap shall be arranged to shed water at all times. The minimum overlap is
50 mm for piping insulation and 80 mm for vessel insulation. In case of corrugated cover
sheets, the overlap should at least be one corrugation on vertical joint and 80 mm on horizontal
joints.
 Sheet shall be fixed using self taping screws (also known as Parker Screws) at a maximum
pitch of 150 mm. Screws are not provided in case of joints needing expansion/contraction.
 Aluminium/GI cover sheets wherever required shall be fixed to insulation supports using self
tapping screws.
 In vertical equipment and storage tanks, outer cover sheets shall be provided in such a way so
as to avoid ingress of water at the joints.
 Outer cover sheets provided on equipment shall have their joints in such a manner so as to
avoid ingress of water into the insulation.
 End covers shall be provided at the end of insulation.
 For tall columns, tanks and vertical pipelines, where extra strengthening to outer cover sheets is
required, GI/ Al/SS strips or bands shall be provided.
 All openings and joints shall be properly sealed with bituminous mastic to prevent ingress of
water.
 Aluminium sheets may be protected on the side in contact with the insulation with bituminous
anticorrosive paint
 Parker/tapping screws may be locked against vibration using synthetic resins.
b) Plastering
One coat of hard sealing compound of required thickness troweled to smooth finish is to be
provided. The finishing layer will be of a suitable water proofing compound reinforced with
additional GI hexagonal wire netting. Plastering is generally used for offsite piping.
4.3 INSULATION PROCEDURES FOR SPECIFIC EQUIPMENT/ COMPONENTS
4.3.1 Carbon/Alloy Steel Equipment
The general guideline on procedure for installation of insulation shall be as per para 4.2.
However, additional care as given below shall be taken during insulation of the following:

a) Pipes/ Elbows & Tees
For Preformed Fibrous Insulation (Rigid insulation), the insulation shall be carried out with the
least number of material pieces as possible. The longitudinal joints between the two segments
shall be staggered.
All the circumferential joints shall be closely fitted and the gap, if any, shall be filled with
insulating material.
The insulation shall be fastened using galvanised steel wire and/or strapping bands at suitable
intervals. A band shall be fastened at suitable distance from either end. The ends of the binding
wire shall be tightly twisted together, bent under and pressed into the surface of insulation.
Strapping bands shall be crimped suitably.
In the case of Flexible Fibrous insulation, the blankets, cut to adequate size, shall be applied with
the galvanised chicken wire netting on the outside and be fastened into position with galvanised
wire.
The chicken wire mesh shall be stitched on to one side of insulation blankets with annealed
galvanised wire.
On horizontal lines, loose support rings with stays of Carbon Steel shall be attached to the pipe
at suitable intervals to support the outer cover sheets and to prevent sagging of the insulation.
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On vertical piping or piping inclined at more than 45 from the horizontal and where straight runs
are in excess of 3mtr., an insulation support shall be provided in form of a metal ring or part ring
either clamped or welded to the pipe. Alternatively, angle studs may be used to prevent
downward displacement of the insulation. Support shall be located at the bottom of run and
suitable interval. thereafter.
For Preformed/Flexible Insulation on Elbows and Bends, Insulation material shall be mitered and
shall be same as that applied on pipe. Each mitered section shall be suitably secured with
wires/bands. In the case of Preformed/Flexible Fibrous Insulation on Tees, the Insulation
material shall be same as that applied on pipe. Preformed pipe sections/flexible mattress shall
be carefully cut and shaped around "Tee" junctions and applied to the parent pipe without the
creation of voids and gaps at the junction. Insulation shall be adequately secured by wire/band.
Insulation at solid welded or clamped supports shall be cut and shaped to fit around the support
and bonded securely.
b) Steam Traced Lines
The steam tracing that are used with mainlines shall be held in position. The pipe and steam
tracer shall then be wrapped with a galvanised hex chicken wire mesh/Aluminium foil and bound
with GI wire at suitable intervals.
The insulating material, cut to adequate size, shall be provided with the galvanised chicken wire
netting on the outside. An outer insulating cover shall be then provided and suitably fastened.
The section of the steam tracer that is not required to be in touch with main line shall be wrapped
using 25 mm dia asbestos rope. The winding shall be tight with no gap. The grooves and
notches shall be filled with quick setting plaster. After drying of plaster, bituminous weather
proofing coat shall be applied.

c) Flanged Joints and Valves
Flanged joints and Valves shall be insulated with prefabricated removable aluminium covers,
lined with preformed/flexible fibrous wool insulation. The insulation shall be carried out after
commissioning and hot bolting of the system. Care shall be exercised to seal the gaps from
where rain water may ingress.
In case of valves, the stuffing box shall be kept outside to replace the packing without damaging
insulation.
d) Horizontal Equipment
The vessel shall be provided with insulation support at the horizontal center line and ring support
at radial lines. The insulation supports shall be designed to prevent the channeling and
entrapment of the water. These supports shall have holes/fasteners for insulation securement.
Both the dish end heads may be provided with a suitable ring made of steel rod for insulation
securement.
When preformed insulation is used, the insulation shall be applied with the longer dimension
parallel to the axis of the equipment. Where the total thickness of the slab exceeds 75 mm,
multilayer should be used and no layer shall exceed 75 mm in thickness. When blocks are
applied in multiple layers, all joints in successive layers shall be parallel to the long axis and
staggered between 3 o’clock and 9 o’clock position. The gaps, if any, shall be filled with
insulating material.
e) Vertical Equipment
The vessel shall be provided with suitable insulation supports for insulation securement. The
insulation support on vessels shall be spaced to suit the standard size of insulation but in no
case shall exceed 3mtr vertical pitch.
The insulation shall be applied on the shell, top and bottom in similar manner as described for
horizontal equipment. Care should be taken while designing insulation and its support for bottom
dish end.
f) Pumps, Compressors, Turbines & Irregular Surfaces
These shall be insulated with portable removable type aluminium/steel boxes lined with fibrous
wool insulation.
g) Flanged Nozzle, Exchanger Channels/Covers, Manway etc.
These parts shall be insulated with removable prefabricated covers lined with preformed
fibrous/flexible insulation and secured suitably.
Insulation shall be stopped short of uninsulated flanges and nozzles etc., by leaving a sufficient
distance to permit withdrawal of bolts without affecting the remainder of the insulation. Insulation
shall be weather proofed and sealed. The insulation shall be carried out after commissioning and
hot bolting of the system. It is preferable to lead the nozzle reinforcement pads’ tell-tale holes to
0
outside of insulation through proper connection with a 90 bend.

h) Vertical Storage Tanks
Vertical storage tanks shall be provided with insulation supports. The insulation shall be applied
between rings in horizontal mode. Mattress insulation shall be applied with joints tightly butted
and laced together with galvanised lacing wire. The outside of the insulation shall have a
galvanised chicken wire netting stitched on to one side of insulation blankets. Bottom 150 mm of
the shell should not be insulated to prevent wicking action.
The protective sheeting is to be further fastened by application of strapping bands externally over
it.
i) Tank Trucks
Mobile tank truck vessel shall be provided with insulation supports at the horizontal center line
and ring supports circumferentially. 'L' Shaped lugs shall be welded to the tank shell for
supporting the circumferential rings and providing additional supports in longitudinal direction, in
addition the provision of long lugs of appropriate size welded at suitable intervals on either side to
hold the insulation.
Insulation blanket of suitable thickness shall be then impaled through the lugs. The entire
insulated area is then covered with GI wire netting. In order to prevent conduction between L-
lugs and the circumferential rings, asbestos miller board of required thickness to be provided.
Finally the outer cover sheet of aluminium is to be provided and fixed in position. Care shall be
taken that all grouped lap joint of cladding shall face downwards and sealed to avoid ingress of
water into the joint.
4.3.2 Stainless Steel Equipment
a) Inner jacketing (between metal surface and insulation) shall be carried out using austentic
stainless steel foil of 0.1 mm thickness. Aluminum shall never be used for inner jacketing. If
Aluminum cover sheet is used over insulation, care shall be taken to avoid contact between
Aluminum and Stainless Steel.
b) Only materials that contain less than 25 PPM of Chlorides shall be used over stainless steel
surfaces. However mineral wool shall not be used.
c) After application of insulation the joints & extreme ends of the weather protectors are to be
sealed properly to avoid ingress of water into the insulation.
4.4 INSPECTION
Inspection of insulation plays a vital role to obtain desired results out of it. Inspection will
guarantee that the work is carried out according to laid down norms/procedures and desired
quality obtained.
4.4.1 Inspection of New Insulation during Installation
Inspection at following stages shall be carried out to ensure conformance to design specification.
a) Material Inspection
All materials used for insulation shall be inspected and checked for their conformance to relevant
specifications.

b) Welding Insulation Supports / Rings
Only qualified welders and approved welding procedures shall be used for welding of insulation
supports like lugs, rings etc. Care shall be taken not to induce any injurious defects on the
equipment during welding.
c) Surface Preparation and Painting
The surface of equipment/pipelines to be insulated shall be prepared for application of coating of

surfaces as described in 4.2.1.
The painting applied after thorough cleaning is checked for its quality and required dry film
thickness.
d) Fixing/Wrapping of Insulation
Holding arrangement or any other fixing arrangements as required shall be inspected prior to
fixing of the insulation. After wrapping of insulation it shall be checked for proper fitting, uniformity
and moisture ingress, if any.
e) Application of Moisture Barrier
Wherever required, moisture barrier shall be applied over the fibrous insulation. After its
application the same shall be inspected to ensure no left out or uncovered surfaces. While
tightening tapping screws, care should be taken that moisture barrier does not get damaged.
f) Fixing of Outer Cover
Inspection of outer cover shall be carried out after fixing of the same on the insulated material.
Following shall be checked:
 Bituminous anti-corrosive paint, where ever applicable
 Overlapping between longitudinal and circumferential cover joint.
 The pitch at which the screws are fixed.
g) Sealing of Joint/Nozzles
All the seal joints as well as the sealing around nozzles and locations where insulation ends shall
be inspected and ensured that proper sealing is achieved.
h) Strengthening of insulation
Strengthening of insulation with strapping bands as required shall be inspected.
4.4.2 Periodic Inspection of Existing Insulation
a) Frequency of Inspection
i) Visual Inspection

Frequency of Visual Inspection shall be once a year for plants and mobile equipment, and once
in 3 years for offsites. This visual inspection shall be preferably carried out before monsoon, to
check for any damage/deterioration, and record the same.
ii) Comprehensive Inspection
Frequency of Comprehensive inspection shall be once in 3 Years in case of Plants and once in 5
years for offsites. The inspection should preferably coincide with M&I shutdown of the equipment.
b) Inspection Procedure
The following procedure shall be adopted for inspection of existing insulation.
i) Insulation having inspection windows
The inspection windows shall be opened, insulation material removed and the surface
underneath inspected for paint failure, corrosion, etc.
ii) Inspection at random locations
Outer cover sheets shall be removed at random locations which are prone to deterioration/
corrosion.
The insulation material shall be removed and the surface underneath shall be inspected for paint
failure or corrosion. The insulation shall then be checked for deterioration, if any.
iii) Inspection at Corrosion Prone Location

0
Insulated Equipment/Pipelines operating below 120 C are more prone to external corrosion
underneath the insulation. Additional attention should therefore be given during inspection.
iv) Thermographic Inspection
Thermographic scanning may be carried out on insulated equipment/pipelines for assessing

effectiveness of insulation. The surface temperatures will indicate the condition of the insulation.
v) General Remarks
After inspection and repairs if any, the inspection windows shall be refilled with insulation material
and the covers fixed back securely in position.
Wherever insulation has been removed to facilitate inspection the same shall be refixed after
repairs.
4.5 MAINTENANCE PROCEDURES
Like equipment, insulation also shall be checked and maintained at regular intervals. Preventive
maintenance of insulation is very much necessary for safe and economic operation.
Insulation must be kept dry to remain effective. The prompt replacement of insulation, which for
some reason has been removed or broken off, and the proper maintenance of the moisture
barriers to keep insulation dry will result in significant saving in plant production and operational
costs.

There are many places where damage commonly occur :
a) Foot traffic which breaks the weather barrier and damages the insulation.
b) Cracks caused by expansion
c) Oil spillage ruins the weather barrier and soaks into insulation
d) Gaps on unsealed joints occur in weather barrier jacketing
e) Hot projection through the insulation
f) Shrinkage of weather barrier and subsequent cracks
g) Mechanical damage to insulation due to jobs being carried out in the near vicinity
h) Damage to insulation due to water jet during fire fighting operation
The replacement of damaged/ deteriorated insulation shall be done using same type of insulation
material.
A major thrust shall be give to replacement of detached /deformed Outer cover sheets.
It is better to standardise the inspection pockets on vessels, tanks and pipelines. It is also
advisable to provide these pockets at the time of fresh insulation.
In case of prolonged idle period of equipment, removal of insulation may be done to avoid
external corrosion underneath the insulation.
Whenever, it may become necessary to remove a large area of insulation to facilitate detailed
inspection. In such cases, special care shall be taken to remove it. Aluminium sheets should be
unscrewed and never torn out. Insulation blankets should be removed carefully and kept on
straight flat surface. After completion of work, same material can be used for insulation purpose.
However, at few locations, insulation thickness may have come down due to service over the
years. In such cases, insulation thickness could be built up using fresh required extra thickness
insulation material.
5.0 COLD INSULATION
5.1 INSULATION MATERIALS
5.1.1 Mineral Wool
Mineral wool is made from molten mineral rocks by centrifugal spinning process. They can be
0
applied to cold surfaces with temperatures not below (-)100 C. both as blanket and preformed
sections.
5.1.2 Expanded Polystyrene

The insulation material shall be self extinguishing with closed cell structure in accordance with IS
4671 type SE. These materials are prepared from styrene homopolymer or copolymer containing
0
an expanding agent. They can be applied to cold surfaces with temperatures not below (-)195 C.
5.1.3 Polyurethane Foam
Polyurethane foam is used in the form of slabs or half sections of uniform closed structures, free
from unreacted materials, shrinkage, distortion with a self extinguishing quality. They can be
0
applied to cold surfaces with temperatures not below (-)180 C.
Polyurethane foam in the liquid form is also being used and application is by in-situ pouring
method.
5.1.4 Cellular Glass
Cellular glass is alumino silicate cellular glass with a specially elaborated composition, totally
inorganic, contains no binders. Its unique properties are as follows :-
a) Water vapour proof
b) Water proof
c) Dimensionally stable
d) Non combustible
e) Vermin proof
f) Resistance to all common acids and its fumes
Due to very low coefficient of expansion, provision of expansion/ contraction joints are not
necessary.
Due to this wide range of operation, and various other qualities, cellular glass is widely used for
both hot and cold insulation application. For cold insulation application no vapour barrier is
required. Only weather proofing to be done at the joints. They can be applied to cold surfaces
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with temperatures not below (-)260 C.
5.2 PROCEDURE FOR APPLICATION OF COLD INSULATION:
The following applies to all types of cold insulated equipment and piping.
5.2.1 Surface Preparation & Paint Application:
Surface of the equipment and piping shall be free of dust, foreign matter and loose paint. One
coat of anticorrosive primer shall be applied over carbon/alloy steel surfaces and allowed to dry
for minimum six hours before application of insulation. Austenitic stainless steel surfaces need
no painting.
5.2.2 Insulation Fixing Procedures
Slabs of suitable width cut longitudinally with notch of suitable size, spaced at proper spacing so
as to form a radial segment to match with the profile of the equipment. All insulation joints to be

sealed with bituminised joint sealer. When more than one layer is applied, each layer shall be
bonded separately, with applicable adhesive. The joint sealer shall be applied to ends, edges of
all sections, including those in the inner most layer to seal all joints. All the layers except the final
layer shall be secured in position by metallic bands at suitable intervals. The final layer to be first
secured by GI wire net and then with metallic bands. All the cracks/voids has to be filled up with
applicable filler material.
5.2.3 Vapour Barrier:
A Wet coating of vapour seal mastic is applied on the surface of insulation immediately after
application and then glass cloth of open weave is to be laid over the surface and embedded in
the mastic. Care to be taken to ensure that the glass cloth is laid smooth and free from wrinkles
and no pockets of air are trapped beneath the surface. At junctions in the glass cloth, suitable
overlap to be provided. A second coating of mastic shall be applied after approximately twelve
hours. Care must be taken to ensure that individual coats are not thicker than 3mm (especially in
corners), otherwise some cracking of dried coat may result.
Vapour barrier shall be protected by cladding with aluminium/GI sheets to be secured by

aluminium/GI bands after the vapour barrier is completely dried up. Self tapping screws shall
never be used to secure cladding as they may puncture the vapour barrier.
Hence the following should be ensured:
a) There is no puncture in the vapour barrier
b) Mastic vapour barrier should be applied to uniform design thickness
c) Joints should be overlapped and sealed adequately
d) Where insulation has to be terminated, vapour barrier should be flushed over all the way
upto the surface.
5.2.4 Contraction Joints :
When specified on a pipeline or vessel drawing or where deemed necessary to allow movement
and contraction of the pipe or vessel without producing random cracking of the insulation,
contraction joints shall be provided in the insulation. At contraction joint location, provision is
made in cladding to accommodate contraction of pipe or vessel.
5.2.5 Procedure for Fixing Outer Cover
a) Cladding
 Cladding/Outer cover material is generally Aluminium/GI sheet.
 All the joints (longitudinal & circumferential) shall have sufficient overlap after wrapping of outer
cover sheet.
 Aluminium sheeting shall be secured in position by tensioned metallic bands installed

circumferentially in case vapour barrier has been applied. In case where vapour barrier is not
used, cladding is fixed using self tapping screws..

 Aluminium cover sheets provided on equipment shall have their joints in such a manner so as to
avoid ingress of water into the insulation.
 End covers shall be provided at the end of insulation.
 For tall columns, tanks and vertical pipelines, where extra strengthening to outer cover sheets is
required, GI/ Al strips or bands shall be provided.
 All openings and joints shall be properly sealed with bituminous mastic to prevent ingress of
water.
 Aluminium sheets may be protected on the side in contact with the insulation with bituminous
anticorrosive paint
b) Plastering
One coat of hard sealing compound of required thickness troweled to smooth finish is to be
provided. The finishing layer will be of a suitable water proofing compound reinforced with
additional GI hexagonal wire netting. Plastering is generally used for offsite piping.
5.3 INSULATION PROCEDURES FOR SPECIFIC EQUIPMENT/ COMPONENTS
5.3.1 Using Insulation Slabs:
The general guidelines on procedure for installation shall be as per Para 5.2. However additional
care should be taken during installation of the following:-
a) Vertical Vessels:
i) Top Heads
Slab insulation sections to be installed on top head, bonded and butted tightly to each other.
Insulation shall be held in position by use of suitable supports. The insulation shall be held in
position by use of the radial metallic bands, one end of which shall be fastened to the floating
ring and the other end shall be anchored to the bands placed around the cylindrical section close
to the head. Radial bands shall be properly spaced measured around the circumference of the
vessel.
The final layer of insulation shall be held in position also by metallic wire net laced at the nozzle
location by 2-3 loops of galvanized wire and to the wire net over insulation on the shell of the
cylindrical section close to the head.
When there exists no nozzle of the top of the vortex, the insulation shall be held in position by
wire netting and metallic bands stretched and anchored on the cylindrical section close to the
head by circumferential metallic bands on the shell and near the head.
ii) Bottom Heads
In all the skirt supported vessels, insulation supports are provided inside the skirt.
Suitable supports around the nozzle and bonds shall be used to support downward falling of
insulation.

It the nozzle is not existing, metallic bands to be stretched across the bottom head and anchored
with lagging support angle ring inside the skirt. All the wire ends of wire netting shall be cut short
and turned into the insulation.
Cladding jacket shall be secured in position by radial tensioned metallic bands anchored suitably.
Openings in metal jackets for nozzles, man ways, brackets etc. shall be cut as close as possible
for a snug fit. Sufficient space should be provided for maintenance of flanges.
b) Horizontal Vessels
Care should be taken to keep all the longitudinal joints in the aluminium sheet below the
horizontal plane passing through the axis of the vessel to prevent water or other spillage from
entering into the insulation.
Openings in metal jackets for nozzles, manways, brackets etc. shall be cut as close as possible
for a snug fit.
c) Spherical Vessels
Insulation to be applied shall be shaped according to the contour of the sphere and bonded to
the vessel with applicable adhesive.
All insulation joints should be sealed with joint sealer. The inner layer of insulation shall be held in
position by aluminium bands. These bands are tied up with the floating rings made of SS rod at
the top & bottom of the sphere. The bands shall be staggered at successive layers and the clips
of the bands recessed into the insulation. Over the outermost layer galvanised wire netting shall
be spread over and laced together.
Aluminium cladding of each hemisphere of spherical vessel shall be done with aluminium sheets
placed horizontally and a thick circumferential tensioned band shall be used at the equator to
hold the radial metallic bonds.
d) Heat Exchangers
Heat Exchanger shells shall be insulated exactly in the same manner as indicated for the
vessels. Only exchanger channels, channel covers including flange bolting shall be insulated with
removable aluminum covers lined with insulation slabs of required thickness.
e) Machinery
In general wherever cold insulation is required, aluminum boxes lined with slab insulation of
adequate thickness shall be used for insulation of machinery after giving a coat of anticorrosive
paint.
f) Piping
i) Horizontal Piping:
Application of cold insulation methods are same as indicated for horizontal type vessel
shells. Insulation of piping shall be stopped short of flanges to allow for withdrawal of bolts
for maintenance. For pipe fittings, the insulation shall be completed by applying cut
segments of the same insulation sections used for pipes. For long run pipes, the ends of

insulation section shall be sealed off at proper intervals and vapour barrier to be carried out
upto the metal surface at the point of sealing. Contraction joint shall be provided at proper
intervals.
ii) Vertical Piping
The procedure is same as indicated for horizontal piping. Only insulation supports/spacer
rings be provided at adequate intervals.
iii) Pipe Supports and Hangers
In all the supporting arrangements of both horizontal and vertical piping, dry hard wood pipe
support bearing blocks coated with fire retardant paint/mastic shall be used. Metal cradles, metal
pipe supports, hangers shall be attached to outside of the pipe support bearing blocks and not
directly to bare pipe. Provision to be made to prevent seepage of water into the insulation from
pipe hangers.
iv) Flanges and Valves
Removable type covers shall be provided over all flanges and valves. These covers should be
fitted with quick release clips.
v) Cold Insulation of Piping at or below Ground Level
For cold insulation of piping at or below ground level or where there is likelihood of foot traffic,
instead of providing aluminium cladding over the final layer of vapour barrier, bituminised self
finishing roofing felt confirming to IS-1322 type-3 grade-I shall be wrapped over the final layer of
vapour barrier after it has fully dried with sufficient overlap both on longitudinal and
circumferential joints. The roofing felt shall be secured with the G.I. wire netting laced with GI
wire. A 3mm coat of bitumen emulsion mastic shall be applied for water and weather proofing.
When bitumen emulsion has completely dried, the surfaces to be painted with two coats of
bitumen based aluminium paint.
g) Stainless Steel Piping and Equipment
All pipes, vessels and equipment of stainless steel construction to be wrapped with aluminum foil
(moisture barrier) with adequate overlap having barium chromate sealer interposed in the joint
prior to application of insulation. Foil shall be secured in position by Aluminum bands, taking
every precaution to avoid formation of pin holes or cracking in the aluminium foil. Aluminium/GI
cladding to be done after providing the insulation and vapour barrier as described earlier.
5.3.2 Using In-situ Pouring Method
In-situ pouring of cold insulating material like Polyurethane foam is particularly used for the
following:-
a) Where complicated shapes are involved which would not lend themselves to easy insulation
treatment using preformed rigid materials.
b) Where a joint free insulation is desirable or where the number of joints to be kept to a
minimum. The chances of damage of weather sealing are less.

c) Where very high disbonding stresses are to be encountered by the insulation system.
With the help of special spray gun the insulation material can be sprayed in-situ for storage
tanks, vessels, columns, exchangers, piping, flanges, valves etc. After getting the required
thickness the insulation material should be allowed to be dried up. After complete drying up the
application of vapour barrier and aluminium cladding will be similar as that indicated for general
cold insulation application.
This should be carried out as per IS-13205 (Latest Edition.)
5.4 INSPECTION
Inspection of insulation plays a vital role to obtain desired results out of it. Inspection will
guarantee that the work is carried out according to laid down norms/procedures and desired
quality obtained.
5.4.1 Inspection of New Insulation during Installation
Inspection at following stages during installation shall be carried out to ensure conformance to
design specification. All the materials used for insulating surface shall be inspected and checked
for their conformance to specifications as specified.
a) Welding Insulation Supports / Rings
Only qualified welders and approved welding procedures shall be used for welding of insulation
supports like lugs, rings etc. Care shall be taken not to induce any injurious defects on the
equipment during welding.
b) Surface Preparation and Painting
The surface of equipment/pipelines to be insulated shall be prepared for application of coating of

surfaces as described in 5.2.1.
The painting applied after thorough cleaning is checked for its quality and required dry film
thickness.
c) Fixing/Wrapping of Insulation
Holding arrangement or any other fixing arrangements as required shall be inspected prior to
fixing of the insulation. After wrapping of insulation it shall be checked for proper fitting and
moisture ingress.
d) Application of Moisture Barrier
Moisture barrier shall be inspected for its thickness after its application and also no holiday or
uncovered surfaces should be ensured.
e) Fixing of Outer Cover
Inspection of outer cover shall be carried out after fixing of the same on the insulated material.
Following shall be checked :

 Bituminous anti-corrosive paint, wherever applicable
 Overlapping between longitudinal and circumferential cover joint and sealing of joints
 Securing of cladding in position using proper fixing arrangement
f) Sealing of Joint/Nozzles
All the seal joints as well as the sealing around nozzles and locations where insulation ends shall
be inspected and ensured that proper sealing is achieved.
5.4.2 Periodic Inspection of Existing Insulation
a) Frequency of Inspection
i) Visual Inspection
Frequency of Visual Inspection shall be once a year for plants and mobile equipment, and once
in 3 years for offsites. This visual inspection shall be preferably carried out before monsoon, to
check for any damage/deterioration, sweating of cladding sheet, ice-formation and record the
same.
ii) Comprehensive Inspection
Frequency of Comprehensive inspection shall be once in 5 Years . The inspection should

preferably coincide with M&I shutdown of the equipment.
If during plant operation some of the cold insulation cladding joints are found covered with green
algi formation or some of the places on the cladding are found sweating, then during turnaround/
shutdown, these areas to be exposed completely and a comprehensive inspection of the area is
required to be carried out.
b) Inspection Procedure
The following procedure shall be adopted for comprehensive inspection of existing insulation.
i) Continuous Insulation
Outer cover sheets shall be removed at locations where deterioration is recorded during plant
operation or which are prone to detoriation/corrosion.
The insulation material shall be removed and the surface underneath shall be inspected for
moisture barrier failure or corrosion. The insulation shall then be checked for deterioration, if any.
ii) Refixing of Insulation
After inspection and repairs if any the inspection windows shall be refilled with insulation material
and the covers fixed back securely in position.
Wherever insulation has been removed to facilitate inspection the same shall be refixed after
repairs.
5.5 MAINTENANCE PROCEDURES

Like equipment, insulation also shall be checked and maintained at regular intervals. Preventive
maintenance of insulation is very much necessary for safe and economic operation.
Due to ice formation at the bare surface during plant operation, application/repair of cold
insulation is not possible unless deicing and drying the exposed surface completely are carried
out after taking shut down.
The replacement of damaged/ deteriorated insulation shall be done using similar type of
A major thrust shall be given for replacement of detached /deformed Outer cover sheets.
In case of prolonged idle period of equipment, removal of insulation may be done to avoid
external corrosion underneath the insulation.
Whenever, it may become necessary to remove a large area of insulation to facilitate detailed
inspection. In such cases, special care shall be taken to remove it. Aluminium sheets should be
unscrewed and never torn out. Insulation blankets should be removed carefully and kept on
straight flat surface. After completion of work, same material can be used for insulation purpose.
However, at few locations, insulation thickness may have come down due to service over the
years. In such cases, insulation thickness could be built up using fresh required extra thickness
During turn around/shutdown, wherever the cold insulation are required to be removed (like
various strainers and its spool pieces, covers of heat exchangers, pumps, compressor and other
equipment, flanges, NRVs, valves etc.) the same shall be reinsulated after completion of the job
and before start-up of the plant.
It is not advisable to provide inspection pockets/ windows for cold insulation, as this will tend to
increase the chances of ingress of water vapour, moisture, toxic acid fumes etc. and ultimately
damage the insulation/ parent material.

6.0 References
i) Piping Handbook (Chapter 6) on Thermal Insulation by E.J. Wesemann
ii) UOP 9-11-0 on External Thermal Insulation
iii) BS 3958 on Thermal Insulation Material
iv) IS 13205:1991 Code of Practice for the application of Polyurethane insulation by In-situ
Pouring Method

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INSPECTION AND MAINTENANCE

OISD STANDARD 177

OIL INDUSTRY SAFETY DIRECTORATE

Ministry of Petroleum & Natural Gas

INSPECTION AND MAINTENANCE

FUNCTIONAL PANEL ON THERMAL INSULATION

OIL INDUSTRY SAFETY DIRECTORATE

Page No. III

The present document on "Inspection & Maintenance of Thermal

This standard in no way supersedes the statutory requirements

Though every effort has been made to assure the accuracy

These documents are intended only to supplement and not

FUNCTIONAL PANEL ON THERMAL INSULATION

NAME DESIGNATION ORGANISATION

SHRI L.J. ROHEKAR, SR. INSP. MGR., IOC, GUWAHATI REFINERY,

SHRI M.S. RATHOR, SR. INSPN. MGR., HPCL REFINERY, MUMBAI

SHRI S. GHATAK CHOUDHARY, SIPM, IOC(R&P), SCOPE COMPLEX,

SHRI S.B. SARKAR, MGR, GAIL, LPG PROJECT, USAR,

SHRI K. NARAYANAN, INSP MGR., CRL, COCHIN

Page No. VII

SL. NO. DETAILS PAGE NO.

4.0 Hot Insulation 2

4.1 Insulating Material 2

4.2 Procedure for application of hot Insulation 2

4.3 Insulating Procedures for specific Equipment/Component 4

4.5 Maintenance Procedure 9

5.0 Cold Insulation 10

5.1 Insulating Material 10

5.2 Procedure for application of cold Insulation 11

5.3 Insulating Procedures for specific Equipment/Components 13

5.5 Maintenance Procedure 18

INSPECTION AND MAINTENANCE OF THERMAL INSULATION

3.1 Hot & Cold Insulation:

3.2 Preformed Insulation:

3.3 Blanket Insulation:

3.4 Block Insulation:

3.5 Fibrous Insulation:

3.6 Moisture Barrier:

Material used to restrict the transmission of water/vapour.

OISD – STD – 177 Page No. 2

3.7 Thermal Conductivity:

4.0 HOT INSULATION

4.1 INSULATING MATERIALS

4.1.1 Glass Wool

4.1.2 Mineral Wool (Rock Wool)

4.1.3 Ceramic Fibers

4.1.4 Calcium Silicate

4.2 PROCEDURE FOR APPLICATION OF HOT INSULATION

4.2.1 Surface Preparation And Paint Application

OISD – STD – 177 Page No. 3

4.2.2 Moisture Barrier (Aluminium Foil)

4.2.3 Insulation Fixing Arrangements

4.2.4 Insulation fixing procedures

OISD – STD – 177 Page No. 4

4.2.5 Procedures for Fixing Outer Cover

 End covers shall be provided at the end of insulation.

 Parker/tapping screws may be locked against vibration using synthetic resins.

4.3 INSULATION PROCEDURES FOR SPECIFIC EQUIPMENT/ COMPONENTS