Document Number PEC-QU-GDE-X-11127

Revision 4
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Applicability All
Document Type Guideline

QUALITY CONTROL PROCEDURE

HOT INSULATION
(GUIDELINE)

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REVISION / APPROVAL HISTORY
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Updated Notes, Definitions Venkatraman

4 25-July-2021 Sitaram Gundasi G.K Sridharan
& Reference Document Shanmugam
Document classified as
3 05-Dec-2018 guideline and changes are Ram Prasad V. Diljith Edathil Alan Gray
identified with a vertical line
Updated based on Revised Ram Prasad V.
2 12-Jun-2017 Rajan Sikka Dr. Andrew Thomas
ITP/ITRs
Updated reference
1 09-Mar-2014 Srinivas Pentapalli Rajan Sikka Dr. Andrew Thomas
documents and notes
Approved
0 10-Sep-2012 Srinivas Pentapalli Rajan Sikka Dr. Andrew Thomas
(Issued For Implementation)

Rev. Date Description of Change Developer Reviewer Approver

QCP-PAI-0002 Page 1 of 10

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 Document Number Document Title Revision
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PEC-QU-GDE-X-
Hot Insulation 4
11127

Documented Information of approvals are retained in QMS

CONTENTS
1.0 PURPOSE ............................................................................................................................... 3
2.0 SCOPE .................................................................................................................................... 3
3.0 DEFINITIONS / ABBREVIATIONS ........................................................................................ 3
4.0 REFERENCES ....................................................................................................................... 3
5.0 RESPONSIBILITY & AUTHORITY ........................................................................................ 4
5.1 Insulation Supervisor........................................................................................................... 4
5.2 QC Inspector (QCI) ............................................................................................................. 4
6.0 DESCRIPTION OF ACTIVITIES ............................................................................................ 4
6.1 Insulation types and application .......................................................................................... 4
6.2 Extent of Insulation .............................................................................................................. 4
6.3 Selection of insulating materials ......................................................................................... 4
6.4 Materials and Storage ......................................................................................................... 5
6.5
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Installation ........................................................................................................................... 6
6.5.1 General ........................................................................................................................ 6
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6.5.2 Safety ........................................................................................................................... 7
6.5.3 Piping Insulation........................................................................................................... 7
6.5.4 Equipment Insulation ................................................................................................... 8
6.5.5 Testing and measuring equipment ............................................................................ 10
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7.0 DOCUMENTED INFORMATION TO BE RETAINED (RECORDS).................................... 10

8.0 APPENDICES ....................................................................................................................... 10
Notes:
This document and referenced ITRs shall be applied to Construction/Inspection & Test activities carried out
on Contractor’s Project Sites.

This document is based on widely used international codes, standards and good engineering practice that is
applied in Oil & Gas Projects and is intended to highlight the minimum tests and inspections that ensure
quality requirements are fulfilled within the scope of the document.

This document and referenced ITRs are generated to provide guidelines to Contractor’s Project teams
including their sub-contractors during preparation of project specific QCPs/ITRs and shall be customized to
meet specific requirements based on applicable project specifications and/or other statutory and regulatory
requirements. It may also be utilized at bidding/proposals stage.
In case of any conflict between this document and the Project specification, drawings and applicable codes,
the project specification shall take precedence over this QCP and applicable ITRs.
The referenced Inspection and Test Records (ITRs) are controlled independently. Therefore, the latest
revision of these ITRs, at the time of initiation, shall be utilized.
ITR number suffixed with letter “X” are classified as in-process Site/Field Quality Records and will not be part
of the Turnover System Process where as ITR number suffixed with letter “A” are part of the Turnover Process
and Turnover Records.
When filling ITRs do not leave any blanks. If an item/activity is not applicable, denote as N/A.

QCP-PAI-0002 Page 2 of 10

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 Document Number Document Title Revision
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PEC-QU-GDE-X-
Hot Insulation 4
11127

Use of Blanco, Tipp-ex etc. on ITR is forbidden.

1.0 PURPOSE

The purpose of this procedure is to describe, establish, and control the steps to be taken for achieving
specified quality requirements for hot insulation works.

This procedure identifies general sequence of operations and methodology that shall be used during
the execution and inspection stage.

2.0 SCOPE

This quality control procedure identifies the inspections to be carried out during storage, handling,
installation and testing for hot insulation systems operating in the temperature range ambient to
8700C.

3.0 DEFINITIONS / ABBREVIATIONS

Company : Name of the Client

Contractor

SC or Subcontractor
:

:
e Petrofac, its subsidiaries, or partners

Name of the Subcontractor

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Project : Name of the Project

QCP : Quality control procedure

ITP : Inspection and test plan

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ITR : Inspection and test record

MSDS : Materials Safety Data Sheet

CMP : Construction Management Procedure

4.0 REFERENCES

PEC-QU-ITP-X-11115 : ITP for Hot Insulation

PEC-QU-PRO-X-11151 : QCP-Closed Loop RFI & Inspection Control Procedure

PEC-QU-GDE-X-11152 : QCP-Control of Inspection, Measuring and Test Equipment
PEC-CM-PRO-X-6979 : CMP for Insulation
PEC-QU-PRO-X-14463 : QCP-Closed Loop Site QMS requirements

Code of practice for thermal insulation : BS 5970 (latest revision)

Project Specification : xxx
Applicable / approved product data sheet : xxx
and installation procedures

QCP-PAI-0002 Page 3 of 10

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Hot Insulation 4
11127

Standard and other AFC drawings : xxx

5.0 RESPONSIBILITY & AUTHORITY

5.1 Insulation Supervisor
The insulation supervisor shall be responsible for ensuring correct preparation of surfaces to be
insulated, and application of insulating material in accordance with the project specifications and
performing inspection activities as per responsibilities indicated on the ITP, quality control procedure,
approved method statements, and the insulation materials manufacturer’s recommendations.

5.2 QC Inspector (QCI)

QCI shall ensure thorough monitoring and surveillance that all insulation works are executed in
accordance with the Project specifications and product manufacturer requirements. QCI should also
ensure thorough surveillance that storage conditions for insulation material are being maintained as
per manufacturers’ recommendations by the respective in charge personnel.

6.0 DESCRIPTION OF ACTIVITIES

6.1 Insulation types and application
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The Insulation type and thickness for piping, equipment shall be based on the intended application
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(Heat Conservation, Personnel Protection) as specified on the P & I Diagrams, Line list Index, Piping
Isometric Drawings, Equipment List and equipment data sheets as per project specification.

6.2 Extent of Insulation

The following items shall not be insulated except where otherwise specified:
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▪ Items that are internally insulated to limit shell temperatures.

▪ Expansion and rotation joints.

6.3 Selection of insulating materials

The selection of an insulating material for a specific application shall depend on factors like:

▪ Cold-face temperature (min. and max)

▪ Warm -face temperature (max. and Min)
▪ Ambient temperature and humidity
▪ Thermal conductivity
▪ Thickness of insulation required
▪ Mechanical strength
▪ Health and fire hazard
▪ Differential thermal movement
▪ Vapour sealing
▪ Protective coating and finish
▪ Compatibility with atmosphere and possible spillages
▪ Design plant life.

QCP-PAI-0002 Page 4 of 10

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Hot Insulation 4
11127

6.4 Materials and Storage

• All Insulation materials as mentioned below should be from approved source of manufacturer in
line with project specifications and installation drawings.

Insulation Cladding Accessories

Glass fibre blanket, Mineral SS or aluminium metal flat Fasteners, Bands and seals,
wool, Mineral Wool Preformed cladding, and corrugated Springs, Expansion bands,
Sections, Mineral Wool metal cladding. Wire fastening, Floating Rings,
Mattress, Mineral Wool Slab, Toggle Fasteners, Screws,
Mineral Wool Loose Fill, Pop-Rivets, Expanded Metal,
Glass Fibre Blankets etc., Weld Studs etc.,

• The manufacturer’s instructions and MSDS should always be followed while handling & storage of

•
insulation materials at site.
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Materials should be delivered to the site in the manufacturer’s sealed packing. Upon receipt of
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insulation material at site, the inspector should check the manufacturer, type of product, and
thickness of insulation, and batch number.
• Insulation materials should be stored off the floor under shade in secured and well ventilated areas
away from moisture and water which may lead loosening of insulation strength.
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• Ensure insulation materials are stored separately based on type, width, and thickness. Different
manufacturer products not be allowed to combine and should be stored separately.
• Materials should be used in the same order in which they are delivered, so that the order of
consumption is first-in-first-out.

TYPICAL INSULATING MATERIALS FOR USE AT TEMPERATURES HIGHER THAN AMBIENT

AS PER BS 5970

SL. Material Physical forms Type Approximate Normal bulk

No maximum density kg/m3
operating
temperature 0C

1 Cellular Glass Slabs and pipe Cellular 400 130 to 160

sections

2 Mineral Wool Rigid slabs / lags Fibrous 230 15 to 100

(Glass)

QCP-PAI-0002 Page 5 of 10

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approvals. This document to be treated as uncontrolled copy when downloaded/printed. User is accountable to refer latest version of the
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 Document Number Document Title Revision
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Hot Insulation 4
11127

TYPICAL INSULATING MATERIALS FOR USE AT TEMPERATURES HIGHER THAN AMBIENT

AS PER BS 5970

SL. Material Physical forms Type Approximate Normal bulk

No maximum density kg/m3
operating
temperature 0C

3 Mineral Wool Pre-Formed Pipe Fibrous 400 60 to 100

(Glass) Sections
4 Mineral Wool Loose Wool Fibrous 850 50 to 150
(Rock)
Mineral Wool Fibrous
5 Resin-Bonded 750 20 to 200
(Rock)
Slabs / Lags
Mineral Wool Fibrous
6 Pre-formed pipe 230 Up to 45

7
(Rock)

Mineral Wool
(Rock)
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sections
Flexible Mats
Fibrous
850 90 to 130
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Mineral Wool Fibrous
8 Wired Mattresses 850 30 to 48
(Rock)

Silica Fibrous
9 Loose Fill 1000 50
Microporous
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Silica Fibrous
10 Blanket, Felt 1000 50
Microporous

Silica Fibrous
11 Cloth, Tapes 1000 500 to 800
Microporous

Silica Granular
12 Opacified Aerogel 950 200 to 300
Microporous
Slatted Blanket
6.5 Installation

6.5.1 General
• Insulation shall be applied in accordance with BS 5970, good industrial practice and the additional
requirements as specified in project specification.
• Insulation work shall not commence until testing has been completed, and application of the
specified protective coating system is complete, includes any damaged areas have been properly
repaired, and written approval from piping and equipment to start insulation activities.
• Pipe flanges, flanged pipe fittings, flanged valves, man ways, nozzles, heat exchanger bonnets
and channel sections shall be insulated with removable boxed insulation in line with project
specification.

QCP-PAI-0002 Page 6 of 10

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Hot Insulation 4
11127

• Insulation on piping shall be stopped short of flanges, whether they are separately insulated or
not, and bevelled back to allow for bolt removal. Adequate protection should be provided at these
points and at any termination of the insulation to prevent the ingress of water.
• Inspect support rings and/or studs provided on equipment, to ensure that these have been
installed to specified requirements and have not been damaged or dislodged during
transit/erection.
• Surfaces to be insulated shall be free from grease, dirt and other foreign matter. Presence of any
oil, rust and contamination shall be cleaned with suitable solvents and wire brush prior to start
insulation work.
• Insulation should be covered with cladding as soon as possible after installation. Cladding shall
not be applied over damp insulation.

6.5.2 Safety
• All works shall be carried out in accordance with MSDS, manufacturer(s) recommendations
and project safety requirements.
•

•
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Personal Protective Equipment (PPE) shall be worn at all times. A protective hood or mask
should be used during installation of rock wool / mineral wool insulation materials.
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All operators shall receive adequate training and be fully competent to operate tools and
equipment used for insulation / cladding installation.

6.5.3 Piping Insulation

• Check the provision of support rings, bolting in to position for insulation / cladding for
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horizontal and vertical piping should be as per installation drawing. Carbon steel support
rings for carbon and low alloy steel piping. Austenitic stainless steel support rings for
stainless steel and high alloy piping. Vertical spacing of support rings should be as specified
in insulation specification with additional rings positioned at flanges, elbows, branches and
tees.
• Insulation of pipe work shall be carried out with pre-formed materials where the temperature
limitations permit. Where the pipe diameter is too large slabs or lags used to cover as far as
practically by building up with radiused or bevelled.
• Pipe insulation half sections shall be placed around the pipe with circumferential joints
staggered by half the length of the section. All joints shall be tightly butted. Pipe insulation
supplied as bevelled lags shall have joints tightly butted with circumferential joints staggered
by half the length of the lags.
• Single layer sections and sections for the outer layer of multiple layer installations shall be
secured with stainless steel bands at specified intervals, Bands shall be machine tensioned
and sealed. Longitudinal and circumferential joints in outer layers of multiple layer
installations should be offset from those in adjacent inner layers by 90 degrees and half the
section length, respectively.

QCP-PAI-0002 Page 7 of 10

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Hot Insulation 4
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• Insulation at flanged joints shall be stopped short of the bolts. Sufficient clearance shall be
left on at least one side of flanged connections for bolt removal without damage to adjacent
insulation. The bolts removal clearance left for all flanged connections should be
approximately equal the bolt length plus 25 mm.
• Insulation on heat traced lines shall be oversized preformed pipe sections arranged to
enclose both the line and its accompanying tracer. Oversized pipe sections shall be
installed to provide a snug fit over the pipe and tube bundle without gaps in the longitudinal
joints. External tracer loops around pipe flanges and flanged valves in traced piping shall be
independently insulated for their full length.
• Cladding for pipe insulation shall be finished with flat aluminized steel sheeting rolled to
conform to the insulation diameter and installed with only one longitudinal seam. Overlaps
at circumferential seams between adjacent sheets should be 75 mm or as specified.
• Cladding should be secured with stainless steel bands positioned at each overlap and with
stainless steel self-tapping screws at 150 mm centres, or as specified along all longitudinal
laps. Circumferential lap joints should not be screw fastened. Bands should be positioned

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at each overlap and at approximate 300 mm or as specified intermediate centres between
laps.
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• All overlaps in the cladding shall be sealed by the application of a gun extruded continuous
bead of flashing compound. The applied bead should be a minimum 6 mm diameter, or of
sufficient diameter to provide an effective seal with the overlaps drawn tight.
• “S" clips shall be introduced between individual lengths of metal cladding on vertical pipe
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insulation to prevent telescoping. "S" clips should be fabricated from 12 mm wide x 0.4 mm
(or as specified) thick stainless steel band material. In addition, steel angle support clips
shall be pop-riveted to the internal face of the cladding, at locations coinciding with the
insulation support rings.
• Insulation and cladding at pipe shoes, pipe fittings, threaded and socket weld, pipe fittings,
cladding over bends, Flanged Joints and Valves shall be as per specified installation
drawings.

6.5.4 Equipment Insulation

• Shell sections of vertical and horizontal equipment shall be insulated with preformed pipe
sections up to the maximum available size. Bevelled lags should be used for 1,800 mm (or
as specified) diameter and smaller shell sections where preformed pipe sections are not
commercially available. Rigid slabs should be used for shell sections higher diameter shell
sections as specified.
• Insulation shall be applied in one or more layers to the thicknesses specified. All joints
shall be carefully fitted. Circumferential joints shall be staggered for horizontal equipment
and longitudinal joints shall be staggered for vertical equipment. All joints in the outer layer
of multiple layer installations shall be staggered with respect to inner layer joints.

QCP-PAI-0002 Page 8 of 10

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Hot Insulation 4
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• Insulation shall be secured with stainless steel bands, machine tensioned and sealed.
Bands should be positioned at 250 mm or as specified centres on vertical equipment and
at 300 mm or as specified centres on horizontal equipment. Insulation should be supported
from insulation supports provided by the equipment fabricator in accordance with
installation drawing.
• Insulation for bottom heads and inside skirt surfaces of vessels shall be either curved or
standard flat bonded rigid slabs secured by stainless steel wire or band to insulation rods
provided by the equipment fabricator.
• Insulation for smaller diameter vessel and exchanger heads should be in the form of
circular discs or as required by project specification fabricated from slab insulation.
Insulation shall be fitted as closely as possible around equipment nozzles, Voids formed
local to the knuckle radius of the head should be packed with loose insulation material of
density of 140 - 200 kg/m3 or as specified.
• Insulation at equipment flanges shall be stopped short of the bolts. Sufficient clearance
shall be left on at least one side of flanged connections for bolt removal without damage to

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adjacent insulation. The bolt removal clearance left for all flanged equipment connections
should be equal the bolt length plus 25 mm.
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• Cladding on shell sections of vertical equipment should be lapped a minimum of 1– 1/2
corrugations vertically and 75 mm horizontally or as specified and installed weather side
down.
• Top sections of sheets should be secured to support rings with stainless steel self-tapping
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screws through valleys at specified pitch. Sheets shall be additionally secured through
vertical overlaps with stainless steel self tapping screws and steel bands at specified
intervals. Bands should be machine tensioned and sealed.
• Corrugated sheets on vertical equipment should be supplied to suit support ring spacing.
No circumferential seam is allowed between support rings. Sheeting installation shall
start from the lowest course. Sheets shall be secured from the top by screwing directly
into the insulation support ring.
• Subsequent courses shall also progressively secured from the top by screwing into the
insulation support rings and allowing the bottom of the sheets to overlap without screw
fastening to the underlying sheet.
• Cover fabrication shall be one piece for manways and two or more pieces for heat
exchanger bonnets and channel sections, and shall be secured in place with a sufficient
quantity of stainless steel quick release toggle fasteners to provide stability in service.
• Removable covers shall be lined on all internal surfaces with preformed rigid sections or
slabs and a separate layer of stainless steel wire mesh on the internal surface or hot face.
Insulation thickness should be equivalent to that applied on adjacent piping.

QCP-PAI-0002 Page 9 of 10

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• All overlaps in the cladding shall be sealed by the application of a gun extruded bead of
flashing compound. The bead shall be located within the ball swage provided at
circumferential and horizontal overlaps. The applied bead should be a minimum 6 mm
diameter, or of sufficient diameter to provide an effective seal with the overlaps drawn tight.

6.5.5 Testing and measuring equipment

• The inspection and measuring tools and equipment shall be calibrated and stickers should
clearly indicate therein the date of expiry. Certificates should also be available and
produced upon demand.
• Ensure the following measuring equipment are available at site prior to start of insulation
works:
▪ Thickness gauge – To check Cladding / Insulation Thickness.
▪ Spirit levels / level plumbs to the verticality of the insulation.
• The quality control procedures for all insulation materials shall be in the form of an
inspection and test plan which reference all test procedures, number of sampling, witness

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points, acceptance and rejection criteria, frequency of testing and how the quality is
measured and maintained. Inspection should be carried out after each stage work has
been completed and before the next stage started.
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• Any defective or rejected insulation and cladding as identified, shall be repaired or replaced
by the new insulation.
• Prior to final acceptance of completed work, a joint inspection should be made by the
insulation subcontractor and the inspector and an agreed inspection report signed by both
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parties.
• The proposed method and conditions (Major or minor defects) under which repairs are
carried out shall be as per approved repair procedure, Insulation and/or cladding sustaining
damage shall be marked, removed and repaired. All repairs shall be carried out to the
requirements of project specification.

7.0 DOCUMENTED INFORMATION TO BE RETAINED (RECORDS)

7.1 List of Verifying Documents (ITR):

No. ITR No. Description QMS Reference No.

1 ITR-V-0301X Hot Insulation Application Report

PEC-QU-ITR-X-16411
2 ITR-V-0302A Final Insulation Inspection Report

8.0 APPENDICES
None

QCP-PAI-0002 Page 10 of 10

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