GENERAL GUIDELINES FOR

INSULATION WORKS

This document is a general guideline

about Insulation Work for Equipment and
Pipelines.

Lloyd Insulations India Limited

Mani Casadona, West Tower, 11th Floor
New Town, Kolkata- 700156
 GENERAL NOTES ON
ERECTION OF INSULATION

1. It is important that the sheet metal covering is done, by a experienced and

competent tinsmith.

2. Person, who is doing the actual job, can alter the following said
methods of fixing the sheet metal, as and when necessary, only after
consulting the Erection Engineer.

3. Fixing pin of corresponding thickness of insulation shall be welded by STUD

WELDING process.

4. Circumferential and axial overlapping of outer casing should be 50 mm unless

specified otherwise.

5. FOR HORIZONTAL AND INCLINED DUCT AND PIPE:

1) All overlapping in axial direction should be at the bottom of the duct and
pipe. Provision of beading and Sealing compound is not required.

2) For circumferential overlapping of inclined duct and pipe, provision of

beading and Sealing compound is not required.

3) For circumferential overlapping of horizontal pipe and duct, provide

beading. Apply Sealing compound if necessary.

5A. FOR VERTICAL DUCT AND PIPE:

1) For overlapping in the axial direction provide beading. Apply Sealing

compound if necessary.

2) For circumferential overlapping provision of beading and Sealing

compound is not required.

6. The joints of wool mattresses should be staggered in both circumferential and

axial direction. The Wire netting at the joints of Wool mattresses are to be sewn
together by G.I. sewing wire dia 0.71 mm.

7. In case more than one layer of Wool mattress is to be applied for pipe insulation
the inner layer should be tied by two turns of G.I binding wire dia 1.22 mm at a
pitch of 240 mm, and the outer layer should be tied by two turns of G.I. binding
wire dia 1.22 mm at a pitch of 160 mm. The ends of the wire should be twisted
and pressed in to the insulation.
8. All the overlapping of outer casing should be made such that no rain water
enters into the insulation through the joints.

9. Incase of insulation fixing pin welding to tubes, equal circumferential pitch is to

be maintained. Use a minimum number of 4 pins, at 90 degree radial spacing.

10. The inner side of the Aluminum / G.I sheet of outer casing should be painted
with two coats of anticorrosive Paint (IS:158). Retainer – Type A must be
coated with Aluminum paint to avoid bi-metal corrosion or Neoprene strip must
be provided between Retainer – Type A and Casing support.

11. Self tapping screws should be fixed over the circumferential overlapping. The
axial joints should be on the Casing supports and outer casing should be fixed to
Casing supports with Self tapping screws at a pitch of 150 mm approximately.

12. The outer casing should be wound tightly around the insulation and then fixed
with Self tapping screws when there is not any Fixing pin for insulation.

13. Loose wool can be taken from the Wool mattresses wherever required.

14. Clean the surface to be insulated of rust, dust, grease, loose scale, oil, moisture,
etc.

15. Care shall be taken that flexible insulation is not unduly compressed.

16. After insulating the equipment with Mineral wool mattress, all voids in
the joints shall be filled with loose mineral wool.

17. Each day application of insulation should be weather proofed overnight by either
with the final protective casing or with some temporary weatherproof covering so
that it does not get drenched in rain.

18. The indicated thickness of insulation is the minimum requirement which should
be provided. Any alteration in the thickness of insulation should be done only
after getting the prior approval from the Design Engineer.

19. The layers of Wool mattresses are to be taken as indicated below:

LAYER IN mm
THICKNESS IN mm 1st 2nd 3rd 4th 5th
250 50 50 50 50 50
230 50 60 60 60
210 50 50 50 60
200 50 50 50 50
190 40 50 50 50
180 60 60 60
20. Where junctions between two or three bodies or different dia, occur and different
insulation thickness is specified the greater thickness shall be continued for a
length equal to one dia of the smaller body then smoothly tapered to the
required smaller thickness over a length equal to two dia of the smaller body.
When there is a differential thermal expansion between these bodies, they
should be insulated individually.

21. The required fixing components and outer casing sheets should follow the
Indian standard No : IS14164

22. STORAGE INSTRUCTIONS:

22a) Mineral wool mattress:

These materials should be stored under fully covered sheds. Stocking must be
done over planks and must be out of contact with ground. Height of stacking
should not exceed 3 Meters.

Once drenched in water these materials loose all the desired properties and
become unsuitable for use. Drying the material does not restore the desired
properties.

22b) Outer casing sheets:

Outer surfaces are meant for improving the appearances also scratch marks,
dents, etc, spoil the appearance.

23. Typical insulation arrangement drawings are indicated in IS 14164.

APPLICATION on Equipment:

Install Flat 50 x 6 circumferential bands to fit snugly around the drum.

Flat 50 x 6 lattice bar 8 numbers should be radially placed over the dished end
and contouring the same and it is to be welded over circumferential bands.

Weld the Fixing pins to the lattice bars circumferential bands.

Fix the Wool mattress.

Position the Retainer and tack weld to the Pin.

Tie with Binding wire across the Pins.

Fix the outer casing strips by Self tapping screws.

 INSULATION OF VERTICAL PIPES
(WELDING OF FIXING PINS NOT PERMITTED ON PIPES)

APPLICATION:

At every three meters provide the Clamps over the pipe with bolt but and washer
by using packing cloth in between the pipe and clamp. Fix the sheet
3.15x30x3000 over the pipe and weld to the clamps. Weld the fixing pin over the
sheet. Consult the Welding engineer before welding.

Weld the Flat to the Clamps.

Weld the Supporting sheets to the Flats.

Fix the insulation.

Position the Retainer Type – A and tack weld to the Pins.

Tie the insulation to the pipe with GI biding wire circumferentially.

Fix the casing support to the Retainer by using two numbers of Self tapping
screws, fixed diagonally for each Retainer.

Fix the outer casing sheet with self tapping screws.

 INSULATION OF VALVE

APPLICATION:

The sheeting shall be made in two halves and the Sheet metal clamp mounted.

Wool mattress thickness according to adjacent pipe lines shall be pressed in to

two halves.

The two halves shall be fitted over the valve to be insulated and locked by
Sheet metal clamp.

Self tapping screws shall be used for clamping the two edges of the outer sheet
casing when the length of the valve is more.

After assembling the Clamp put a bit of GI Binding wire as a pin through 1.6 mm
hole provided.
 INSULATION OF DUCT / FLAT SURFACE

APPLICATION:

Weld the Fixing pin over the Duct / Flat surface.

Fix the insulation.

Position the Retainer Type – A and tack weld to the Fixing pins.

The GI Binding wire dia 1.22 shall be wound across the Fixing pins diagonally
underneath the Retainer Type – A.
Fix the Casing support – 650 long to the Retainer Type – A by using two
numbers of Self tapping screws, fixed diagonally for.

Retainer Type – A.

Fix the outer casing by using Self tapping screws.

DUCT STIFFENERS

When the stiffeners protrudes through the insulation and are exposed to
atmosphere, provide an additional 40 mm insulation over the stiffener.

DUCT DAMPER & GATE

Insulation thickness shall be s per the adjacent duct insulation. The stuffing
boxes should not be insulated. A clear gap of 50 mm (minimum) should be
maintained all around the stuffing boxes.

AIR HEATERS

DO NOT insulate over the axial seal, adjuster seal access covers and basket
removal doors insulation should be applied in a manner to permit a free
circulation of ambient air around the bearing.
 INSULATION OF DUCT
(CLEARING STIFFENERS)

APPLICATION:

Weld the Fixing pin over the Duct.

Position the Retainer Type – C so that it will be in the same plane as that of the
top surface of the stiffener.

Tack weld the Retainer – Type – C to the Fixing pin.

For the top plate of the horizontal duct, spread the Weld mesh over the Retainer
Type – C.

This serves as the additional support where people walk over the insulation.

Weld the Corner support to the bottom corners of the duct.

Weld the Angle to the corner support.

This arrangement will help to achieve a sharp corner for the insulation and outr
casing.

Fix the insulation.

Position the Retainer Type – A and tack weld to the Fixing pin.

The Biding wire shall be wound across the pins diagonally underneath the
Retainer Type – A.

Fix the Casing support - 650 mm long to the Retainer by using 2 numbers of
Self tapping screws, fixed diagonally for each Retainer.

Fix the outer casing by using Self tapping screws.

 IMPORTANT POINTS TO BE TAKEN CARE DURING APPLICATION

I) Binding wires for all layers of insulation will be at distance of 300mm.

ii) In addition Aluminum bands/seals also to be provided at distance of 300 mm for

sizes above 500mm.

iii) Aluminum bands/seals to be provided over aluminum sheets at distance of

500mm.

iv) Ceramic mill boards to be used between all ‘L’ type lugs and the support rings.

v) Inside surface of Aluminum sheets to have 2 coats of bituminous paint applied

uniformly.

vi) Gaps to be properly filled with loose wool taken from mattresses.

vii) End of hanger clamp assembly protruding out of insulation at the bottom should
be suitably boxed with Aluminum sheets.

viii) Valves to be insulated properly in box structure as given in enclosed drawings.

ix) Multilayer longitudinal and circumferential joints should be staggered.

General Arrangement Drawings
(As per BHEL specification)