DOC NO . : QPS-PI-HI-101 STANDARD SPECIFICATION F0R HOT INSULATION SHEET : I PROCESS SOLUTIONS PVT. LTD. REV : 0 DATE : 21.11.10 STANDARD SPECIFICATION FOR HOT INSULATION (PIPING & EQUIPMENT) 0 21.11.10 Issued As Standard S R Patil PID BKD REV. NO. DATE DESCRIPTION PREPARED BY REVIEWED BY APPROVED BY
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Standard Specification for Hot Insulation (Piping & Equipment)
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DOC NO . : QPS-PI-HI-101
STANDARD SPECIFICATION
F0R HOT INSULATION
SHEET : I
PROCESS SOLUTIONS PVT. LTD. REV : 0
DATE : 21.11.10
STANDARD SPECIFICATION
FOR
HOT INSULATION
(PIPING & EQUIPMENT)
0 21.11.10 Issued As Standard S R Patil PID BKD
REV.
NO. DATE DESCRIPTION PREPARED
BY REVIEWED
BY APPROVED
BY
DOC NO . : QPS-PI-HI-101
STANDARD SPECIFICATION
F0R HOT INSULATION
SHEET : II
PROCESS SOLUTIONS PVT. LTD. REV : 0
DATE : 21.11.10
INDEX
SECTION
NO.
TITLE PAGE
NO.
1.0 GENERAL 1
2.0 DESIGN BASIS 2
3.0 EXTENT OF INSULATION ON PIPING SYSTEM 3
4.0 EXTENT OF INSULATION OF EQUIPMENT 4
5.0 MATERIALS GENERAL 5
6.0 INSULATION MATERIAL FIBROUS MATERIAL (ROCK & GLASS WOOL) 6
7.0 INSULATION MATERIAL (CELLULAR GLASS ) 9
8.0 WEATHER PROTECTION JACKET
8.1 FIBROUS MATERIAL (ROCK & GLASS WOOL)
8.2 REGID MATERIAL (CELLUAR GLASS)
8.3 ANCILLIAR MATERIALS
11
9.0 APPLICATION METHODS (GENERAL) 13
10.0 PIPING 15
11.0 HORIZONTAL EQUIPMENT 20
12.0 VERTICAL EQUIPMENT 22
13.0 FLANGE, NOZZLE, CHANNEL, COVER, MANWAY AND HANDHOLE FLANGED COVER.
23
14.0 IRREGULAR SURFACES SUCH AS PUMP, COMPRESSOR, TURBINE ETC. 24
15.0 VERTICAL STORAGE TANK 25
16.0 INSULATION FINISH (CARBON SETEEL)
16.1 PIPING
16.2 EQUIPMENT
16.3 VERTICAL STORAGE TANK
27
17.0 ANNEXURE – I
17.1 OWNER’S OBLIGATIONS
17.2 CONTRACTORS CONDITIONS
31
18.0 ANNEXURE – II
INSULATION THICKNESS FOR HOT INSULATION (IH)
32
19.0 ANNEXURE – III 33
INSULATION THICKNESS FOR PERSONAL INSULATION (IS)
DOC NO . : QPS-PI-HI-101
STANDARD SPECIFICATION
F0R HOT INSULATION
SHEET : III
PROCESS SOLUTIONS PVT. LTD. REV : 0
DATE : 21.11.10
STANDARD SKETCHES FOR HOT INSULATION STANDARD OF VESSELS, PIPING AND EQUIPMENT
FIG. NO. DESCRIPTION SHEET
01 FIBROUS AND REGID INSULATION DETAILS FOR HORIZONTAL PIPE APPLICATION
34
02 METHOD OF STAGGERING OF SECTION FOR PIPE INSULATION 35
03 FIBROUS MATTRESS INSULATION - DETAILS SPACER RINGS FOR CLADDING SUPPORT (FOR HORIZONTAL PIPE)
36
04 DETAIL OF SPACER RING FOR FIBROUS INSULATION (MATTRESS) 37
05 BOLTED-ON INSULATION SUPPORT FOR VERTICAL PIPE 38
06 INSULATION DETAILS FOR PIPES, BENDS & ELBOWS 39
07 INSULATION DETAILS FOR BENDS & ELBOWS 40
08 INSULATION DETAILS FOR PIPE BRANCHES AND REDUCERS 41
09 INSULATED REMOVABLE COVERS FOR VALVES 42
10 INSULATED REMOVABLE COVERS FOR FLANGED JOINTS 43
11 INSULATED DETAILS FOR LINES ON SHOE 44
12 INSULATION OF STEAM TRACED PIPING 45
13 INSULATION FOR HORIZONTAL EQUIPMENT 46
14 INSULATION FOR EQUIPMENT HORIZONTAL HEADS 47
15 USE OF FLEXIBLE INSULATION IN COMBINATION WITH RIGID INSULATION TO COMPENSATE FOR VESSEL EXPANSION
48
16 INSULATION DETAILS FOR VERTICAL VESSELS 49
17 INSULATION DETAILS FOR VERTICAL VESSEL HEADS 50
19 INSULATION DETAILS FOR VERTICAL STORAGE TANKS 52
20 INSULATION SUPPORTS FOR STORAGE TANKS 53
21 INSULATION SUPPORTS FOR STORAGE TANKS (DETAILS FOR ROOF) 54
22 FIRE PROOFING AND INSULATION SUPPORT FOR VERTICAL VESSEL 55
23 MACHINERY INSULATION 56
24 INSULATION ENCLOUSERS FOR CONTROL VALVES & OTHER IN-LINE INSTRUMENTS
57
25 INSULATIN FOR LEVEL GAUGES 58
26 INSULATION SUPPORTS FOR HORIZONTAL VESSEL 59
STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101
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1.0 GENERAL:
SCOPE
1.1 This specification covers design and material requirements for above ground, external
insulation of piping and equipment operating between ambient temperature and 550 °C for
the purpose of heat conservation, process stabilization, temperature maintenance, personnel
protection and fire protection. Wherever necessary this specification indicates the basis for
selecting a criterion.
1.2 This specification is suitable for use in out door service with normal process plant
atmospheres. Alternative designs and materials would be specified if necessary for corrosive
atmosphere of potential leaks and spills of chemicals.
1.3 This specification does not cover cold service insulation. For cold services QPS Specification
QPS-PI-CI-101 is applicable.
1.4 This specification does not cover insulation for boiler or fired heaters and associated air
heaters, economizers, fuel ducting and air ducting.
1.5 Piping, equipment, storage tanks and vessels requiring insulation shall normally be specified
on the following project documents.
a) Process and Instrument Diagrams (P&IDs) and Line List.
b) Piping General Arrangement Drawings & Isometrics.
c) Instrument Piping Details and Schedules.
d) Vessel, Exchanger, Storage Tank & sphere documents and Insulation Schedules
e) Equipment supplier’s General Arrangement Drawing for equipment items in package
plant.
STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101
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2.0 DESIGN BASIS: CRITERIA
2.1 Heat Conservation Insulation is designed for economic thickness and to limit cold surface
temperatures below 65 °C with 20 °C ambient temperature in still air conditions.
2.2 Internally refractory lined piping and equipment and any other items for which heat loss is
essential shall not be insulated. (See para 4.6-D)
2.3 Insulation is not required for piping and equipment for which heat loss is desired - excepting
for personnel protection or to avoid thermal stress problems.
2.4 Insulation is required for any of the following purposes, as indicated in P&IDs and line lists:
a) Heat conservation.
b) Process stabilization to assist process control.
c) Steam tracing.
d) Electric tracing.
e) Hot water of solvent tracing (liquid).
f) Hot Oil tracing.
g) Steam jacketing.
h) Hot water or liquid jacketing.
i) Hot Oil jacketing.
j) Fire hazard protection to prevent fast boil off of liquid.
k) Personnel protection. Applicable where exposed surface temperature exceeds 65°C in
normal or short-term operating conditions. Over internally insulated piping and equipment,
provide open mesh metal guards and for surfaces which are not internally insulated
provide insulation on that part of surfaces with which operating and maintenance
personnel may come in contact while performing routine duties. The intent of P&IDs, Line
classification lists and engineering drawings etc. which designate insulation for personnel
protection is to call attention only to the eligibility of such service. The actual extent of
insulation shall be determined by Field Construction Personnel and/or operating
personnel using the following criteria: Exposed surfaces operating above 65 °C and
located within 600 mm horizontally or 2100mm vertically of a normal access, walkway of
work area.
2.5 Instruments and associated piping subject to operating flow and/or temperature conditions
prevailing in the connected piping or equipment shall be insulated to the same requirements
as that of piping or equipment.
STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101
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3.0 EXTENT OF INSULATION ON PIPING SYSTEM: 3.1 Insulated piping systems shall have straight pipe, bends, tees and pipe fittings completely
insulated.
3.2 All valves and flanged joints shall be completely insulated only on in steam, condensate
service, hot oil lines and in lines which are steam trace heated or jacketed to maintain
temperature.
3.3 For bucket and float type traps, the inlet piping and trap shall be insulated.
3.4 Insulation on inlet piping to thermostatic and thermodynamic steam traps shall terminate at
approximately 500mm before the trap.
3.5 Steam trap outlet piping other than closed condensate recovery system shall not be insulated
except for personnel protection reasons.
3.6 Instrumentation to be insulated, such as level gages, level controllers, level switches, DP
cells, shall have their fluid containing sections and the associated piping completely
insulated, including pipes, valves and fittings.
3.7 Insulation shall not be applied to the following, unless otherwise specified.
a) Piping which becomes hot intermittently, such as relief valves, vents, steam-out and
snuffing steam systems flare and blow-down systems.
b) Supports for piping, excluding pipe hangers to the extent covered by insulation.
c) Steam Traps (except as noted in paragraph 3.3).
d) Valves, including control valves and flanges in process piping systems (except as noted in
3.2 and 3.8). However, personnel protection insulation for these items shall be applied, as
required.
e) Pipe Union fittings.
f) Thermowell bosses and pressure tappings.
g) Expansion joints, hinged joints and hose.
h) Sight flow indicators.
3.8 Insulation shall be designed to provide an absolute minimum clearance of 25mm between the
outside surface of any insulation finishing material and adjacent surfaces.
3.9 Where insulated horizontal piping is supported on steel shoes, the height of the shoe shall be
such that the underside of the insulation finishing material is clear of the supporting structures
upon which the shoe rests by 25mm minimum.
STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101
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4.0 EXTENT OF INSULATION ON EQUIPMENT: 4.1 Support skirts of insulated vertical vessel greater than 1200mm diameter shall be insulated
both internally and externally for a minimum distance of 600mm below the bottom tangent
line. The insulation shall terminate not less than 300mm above the support concrete or steel
work.
4.2 Support skirts of insulated vertical vessels of 1200mm and less shall be insulated externally
only, as described in Para 4.1 above.
4.3 Bottom heads of insulated vertical vessels enclosed by a support skirt shall be insulated
without finishing material and shall be insulated only when the vessel outside diameter is
greater than 1200mm.
4.4 Turbines and steam ends of reciprocating pump shall be insulated for heat conservation.
4.5 Liquid ends of pumps shall be insulated when heat traced or jacketed.
4.6 Insulation shall not be applied to the following unless otherwise specified.
a) Pumps with operating temperature below 200 °C unless pumped fluid has a pour point
above minimum design ambient temperature.
b) Fans, compressors, blowers or other rotating or reciprocating requirement.
c) Liquid ends of pumps except as noted in the Para 4.5 above.
d) Internally insulated or refractory lined equipment unless specially designed for metal
temperature control.
e) Heads of vessels enclosed by support skirts with vessel diameters 1200mm and less.
f) Internal surfaces of insulated vessel support skirts with vessel diameter 1200mm or less.
g) Turbine casings to be insulated shall exclude shaft seal caps, shaft bearing housings,
throttle valves, governors and supports.
h) Exchanger channel and covers; shell and channel flanges & Exp. Joints.
i) Nozzles, manholes and hand holes and flanges of equipment.
j) Surfaces of coolers and condensers.
k) Nameplates of all equipment items.
l) Thermowell bosses and pressure tappings.
STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101
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5.0 MATERIALS GENERAL: 5.1 All material shall be of high quality and good appearance. This specification covers three
materials - Rock wool, Glass Wool and cellular glass.
5.2 Insulation materials shall be of low chloride content, chemically inert, non-sulphurous, rot
proof, vermin proof, impervious to hot water and steam, non-injurious to health and non-
corrosive to steel and aluminum (even if soaked in water at ambient temperatures for
extended periods).
5.3 The use of insulation or finishing materials containing ASBESTOS in any form is not
permitted.
5.4 Insulation and jacketing material backed with paper or other flammable material is not
acceptable.
5.5 Many common flammable liquids such as oil, butanol, diethanolamine and hexanol will react
and start fires when they leak into inorganic absorbent insulation. Such absorbent insulation
can store large quantities of combustible liquids should a leak occur. This could be a decisive
factor when specifying and evaluating alternative materials and are taken care of by
QUANTA / CLIENT while specifying project insulation specifications.
5.6 Insulation materials have been classified into two categories – i) water absorbing ii) non-
water absorbing. Non-water absorbing insulates like cellular glass is recommended for
services upto 125 °C.
Water absorbing insulation lake fibrous insulation and calcium silicate can be used for all
temperatures except for electrically traced pipe. But for low temperature (i.e. upto 125 °C)
services a suitable moisture barrier shall be used since the substrata is at too low
temperature to evaporate moisture, rain or water.
STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101
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6.0 INSULATION MATERIAL: FIBROUS MATERIAL (ROCK & GLASS WOOL) 6.1 Shall be a performed insulation and shall be of long fiber rock or glass material processed
from a molten state into fibrous form bonded operational temp. range from ambient to 550 °C.
Slag wool is not acceptable.
6.2 Unless otherwise specified herein, insulation material shall strictly conform to all the
requirements of quality standards listed below :
• Performed pipe insulation. - IS : 9842 : Latest issue
• Metal-mesh covered
bonded mineral fibre
blanket & blanket type
pipe insulation.
- IS : 8183 : Latest issue for piping & equipment.
Faced on one side with 20mm galvanised No. 22 SWG. Wire
Mesh, Stitched through with 22 SWG. galvanised lacing wire
: Mattress for Lined covdrs shall be faced on one side with
20mm galvanised 22 SWG wire mesh stitched through with
22 SWG galvanised lacing wire.
• Mineral Fibre blocks &
board thermal insulation.
- IS : 8183 : Latest issue
6.3 Insulation shall conform to following requirement and shall be tested and test certificate on
representative samples furnished to PURCHASER as per IS : 8183 / IS : 9842 (latest issue)
for conformance of each of the following requirements.
• Density - 140 to 150 kg/m3 (Density shall be within this range and density
test shall be as per IS:5688/ IS : 3144 (Latest issue)
• Shot Content
(IS : 3144)
- Shot shall not be more than 5mm in any dimensions, shot
content, when sieved as follows, shall not exceed as per below :
IS Sieve Shot Content, Percent (IS:460 by Mass (Max.) (Latest
issue).
500 micron 5
250 micron 15
• Moisture content and
moisture absorption
(IS : 3144)
- Not more than 2 %
• Incombustibility
(IS : 3144)
- Incombustible; Loss in weight not more then 5 %
• Thermal Conductivity (IS : 3346)
STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101
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* Mean Temperature
°C
Thermal / Conductivity mw/cm °C
50 0.43
100 0.52
150 0.62
200 0.68
250 0.80
300 0.90 * Mean Temperature is Hot Face Temp. + Cold face Temperature.
2 • Sulphur Content
(IS : 3144)
- Not more then 0.6 percent.
• Liner Shrinkage
(IS : 3144)
- Not more then 2 percent when subjected to soaking
conditions of soaking heat at the stated max. temp. of use
(550 °C) for 24 hours.
Heat Resistance
(IS : 3144)
- When heated to max. temp. (550 °C), sample shall maintain
its general form and shall not suffer visible deformation of
the fibrous structure.
• Compressive Strength
(Average) min. at 10 %
deformation
- 120 kg/m2
• Recovery after
compression (IS : 8183-
Appendix ‘A’ IS : 9842-
Appendix ‘A’)
- After compression to 75 % of the original thickness, recovery
shall not be less than 90% of thickness.
• Alkalinity (IS : 8183
Appendix ‘B’ / IS : 9842
Appendix ‘B’)
- pH of the solution of the material shall be between 7.0 and
10.0
• Chloride Content
( IS : 3144 )
- Not to exceed 20 ppm
• Dimension - PIPE SECTION :
Hollow cylinder, split length wise on one or both sides of the
cylindrical axis.
Thickness : 25, 40, 50, 60 & 75mm Tolerance in
Length : ± 3 mm Tolerance in
Thickness : ± 3 mm
When installed on the pipe of the specified size, sections shall
STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101
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fit snugly and shall have tight longitudinal and circumferential
joint.
- BLANKET :
Unless otherwise specifically required, standard width shall be
600mm to 1200mm, standard length 1500mm to 2400mm
Thickness : 25, 30, 40, 50, 60 & 75 mm
Tolerance on thickness :
Positive : 3mm
Negative : -3mm
- BLOCK AND BOARDS ( IS : 8183 ) :
Lengths : 1000mm to 1400mm
widths : 500mm to 1000mm
Tolerance : ± 3mm
Thickness : ± 3mm
STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101
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7.0 INSULATION MATERIAL (CELLULAR GLASS): Cellular Glass foamed and fused into unicellular form can be used upto a temperature of 425
°C. But in view of high thermal conductivity, its use is limited in this specification to 125 °C
only as it has been included essentially for its non-water absorbing nature. Insulation shall
conform to following requirements and test certificates on representative samples shall be
furnished to PURCHASER as per ASTM C552 for conformance to each of the following
requirements:
Density 110 to 150 kg/m3 : Test as per ASTM C303 except that on drying will be
necessary. Determine the No. of specimens as per ASTM
C390.
Thermal conductivity (average max.)
Mean Temp. °C W/m°k
10 0.058
24 0.060
38 0.062
93 0.073
149 0.086
Test thermal conductivity as per ASTM C240, C177 and C518. Test shall be at least for 3
specimens.
Compressive Strength : 517 kPa (average min.)
Test method as per ASTM C240 and Recommended Practice ASTM C165. Test shall be at
least for 4 specimens.
Flexural strength average min. 414 kPa.
Test method as per ASTM C240 and clause ASTM 3.4 C203. Determine the method of test
specimens as per method given in ASTM C390.
Water absorption, volume % (average max.) 0.5.
Test method as per ASTM C240. Test shall be at least for 3 specimens.
Water vapour transmission (average max.) metric perm-cm of grains/24 h.m2 mm Hg. cm of
thickness at 26.7 °C : 0.0084.
Test method as per ASTM E96. Test shall be at least for 2 specimens.
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Dimensions:
Flat Blocks: Shall be rectangular sections and shall be true to form and dimensions, the
corners square and the sides parallel.
Size and thickness shall be as follows:
Width (mm) Length (mm)
300 450
450 600
Pipe Sections : Shall be supplied as hollow cylindrical shapes split in half lengthwise (in a
plane including the cylindrical axis) or as curved segments. Upto 350mm Ø size, only pipe
sections split in half lengthwise shall be used. The insulation shall be supplied in sections of
segments in lengths of 450mm or 600mm to fit standard of pipe. Insulation for pipes upto
150mm Ø size shall be furnished in 600mm length, and for pipe above 150mm Ø nom. size in
450mm length. Thickness for both pipe sections and flat blocks shall be 25, 30, 40, 50, 60 &
75mm. Dimensional Tolerance shall be as follows:
Block Pipe
Length ± 1.6 mm ± 3 mm
Width ± 1.6 mm --
Thickness ± 1.6 mm ± 3 mm
GENERAL:
Periodical checks for density, thickness, shape and size as per above requirements shall be
repeated at site, as per norms and frequency decided at site as per the directions of
PROJECT Site-in-Charge. Special attention is required for fibrous material as its installed
thickness could be reduced due to compression affecting performance.
a) All the codes mentioned shall be the latest issue.
b) PURCHASER shall have right to inspect any or all the test conducted on insulation
material by manufacturer at his shop or at any laboratory.
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8.0 WEATHER PROTECTION JACKET: Aluminium jacketing shall be used as weather protection over insulation unless otherwise
specified and shall be ASTM B209 alloy 3003 H16 or IS : 737 designation 31000 (Old NS3 )
condition H3 for flat sheets and H4 for corrugated sheets. Cladding shall be coated on the
side in contact with the insulation with a bitumen anti-corrosive paint.
8.1 FIBROUS MATERIAL (ROCK & GLASS WOOL): a) For shells of vertical Storage, Tanks & Vessels : 0.71mm (22 SWG) corrugated
b) For tanks Roofs : 1.22mm (18 SWG) Flat
c) For Horizontal vessels shell and heads; vertical
vessel heads.
: 0.71mm (22 SWG) Flat
d) For removable cover : 1.22mm (18 SWG) Flat
e) For all piping, other than grade piping in off-
sites.
: 0.71mm (22 SWG) Flat
f) For grade piping in off-sites : 0.56mm (24 SWG) galvanised steel,
per IS : 277 class I
8.2 RIGID MATERIAL (CELLULAR GLASS): a) Piping, Horizontal Vessel, Vessel head & Tanks
Roof
: 0.56mm (24 SWG) Flat
b) Vertical Vessel Shells & Vertical portion of
Storage Tanks
: 0.56mm (24 SWG) corrugated
c) Removable covers : 1.22mm (18 SWG) Flat
8.3 ANCILLARY MATERIALS: 8.4 Aluminium Foil to protect Stainless Steel surfaces shall be 0.19mm (36 SWG) thick per ASTM
B209 Alloy 3003 H16 or IS : 737 designation 31000 (old NS3) condition H3.
8.5 Securement Bands / Wires
8.6 If material is Aluminium, then specification shall be ASTM B209 Alloy 3003 H16 or IS : 737
designation 31000 (old NS3) condition H3; If Stainless Steel, it shall be 18/8.
8.7 For securing Aluminium foil on Stainless Steel surfaces : Band, 24 SWG thick X 20mm wide,
Aluminium.
8.8 For Securing Fibrous Insulation
a) On Piping.
b) Band, 24 SWG thick X 12mm (min.) wide, Aluminium.
c) On Equipments.
d) Band, 24 SWG thick X 20 wide, Aluminium.
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e) On Vertical Storage Tanks.
f) Band, glavanised steel, 40mm wide X 3mm thk. galvanising per IS : 277 class-2.
8.9 For Securing Rigid Insulation:
a) On Piping upto 16” OD.
Wire, annealed galvanised steel, 16 SWG, galvanised per class 2 (heavy coating of zinc,
nominal 600 g/m2) per IS : 227.
b) On Piping 18” OD and Larger.
Band, galvanised steel, 20 wide X 24 SWG thk., galvanising per above (same as for
piping upto 16” OD).
c) On Vertical & Horizontal Vessels.
Band, galvanised steel, 20 wide X 24 SWG thk, galvanising per above (same as for piping
upto 16” OD).
8.10 For Securing Cladding On Insulation (Both Fibrous And Rigid):
a) For Piping:
Band, Aluminium 12 mm (min.) wide X 24 SWG thk.
b) On Equipment:
Band, Aluminium, 20 mm wide X 24 SWG thk.
c) On Vertical Storage Tanks:
Band, Stainless Steel, 25 mm wide X 24 SWG thk.
8.11 Rivets:
Rivets required for metal jacket securement shall be the expanding Aluminium “POP” blind
eye type, 9.5mm long X 5mm Ø.
8.12 Screws:
Screws required for metal jacket securement shall be cadmium plated steel, self tapping type
A No. 8mm Ø X 12mm long to BS 4176 complete with neoprene washers under the head.
8.13 ‘S’ and ‘J’ clips - Formed from 25mm wide stainless steel banding.
8.14 To ensure prefect water proofing, all the cladding joints shall be packed with sealing materials
which may either be in the from of a elastomeric sealing compound or fiber based bituminous
felt strips.
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9.0 APPLICATION METHODS (GENERAL): 9.1 The application methods, given in this Standard are general in nature. The Contractor is
responsible for applying an insulating system that will give a satisfactory operational
performance and the requirement given herein shall be regarded as the acceptable minimum.
The Contractor shall carryout the work in accordance with the best practices of insulation
application with the minimum of waste and debris and the final job shall have a neat, efficient
and work a like appearance.
9.2 All hydrostatic tests on piping and equipment, including steam tracing systems, shall be
carried out before insulating material is applied.
The insulation Contractor shall only insulate those sections of the plant that has been
specifically released for such work by the engineer-in-charge. If insulation must be installed
before pressure test, then all welds and flanged joints in the pipe shall be left uncovered till
successful completion of pressure test. Then insulation shall be completed.
9.3 Surfaces to be insulated shall be thoroughly cleaned, dried and made free from loose scale,
oil or grease. It shall be the Contractor’s responsibility to remove loosely adhering scale and
dirt before applying insulation.
9.4 Corrosion Prevention:
Carbon steel and low alloy piping and equipment with normal operating temp. of 125 °C and
below shall be protected against corrosion by painting with a 20 microns (min.) dry film
thickness of heat resistant Aluminium paint suitable for the above temperature. While for
equipments (Vessels, Exchangers and Tanks), this coating shall be provided by equipment
fabricator, for piping, it shall be provided by insulation contractor or equipment and piping
painting contractor.
9.5 Insulation cement shall not be used on stainless steel piping or equipment.
9.6 All insulated austentic stainless steel piping and equipment insulated with Rock or Glass
Wool shall be protected against chloride attack as follows:
For operating temperatures upto 450 °C, the surfaces shall be wrapped with 0.19mm thick
Aluminium foil with 50mm overlap at longitudinal and circumferential joints before application
of insulation. All joints of the Aluminium foil shall have barium chromate primer interposed.
Aluminium foil shall be firmly secured on the stainless steel surfaces by Aluminium bands at a
pitch of 500mm. Care shall be taken while applying Aluminium foil to ensure that the foil is not
punctured at any place during wrapping and clamping with Aluminium bands. For operating
temperature above 450 °C, the stainless steel surfaces shall be painted with two coats of
heat resistant silicon Aluminium paint as follows :
STANDARD SPECIFICATION DOC NO . : QPS-PI-HI-101
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Type : Single
Composition : Silicon resin based with Aluminium flakes as pigment
Dry Film Thickness : 20 microns/coat (min.)
Other requirements : It should be suitable to withstand temperature upto 600 °C; when the
paint becomes dry, the painted surfaces shall show no discontinuity.
9.7 The insulation contractor shall not carryout any welding or drilling on plant equipment and
piping.
9.8 Insulation shall be finished, beveled and weatherproofed at all terminal points where it is
required to remove bolts etc. without damage to the insulation.
9.9 Equipment name plates shall remain visible after insulation has been applied by beveling
back the insulating material and carefully sealing the exposed edges to prevent ingress of
moisture.
9.10 All projections, such as lifting lugs, trunnions and stiffeners on piping and equipment (i.e.
vacuum rings) shall be insulated with the same thickness of insulation as specified for the
equipment item or pipeline.
9.11 Thermowell bosses, pressure tappings and weep-hole nipples shall not be insulated in but
left accessible.
9.12 Double layer insulation shall be required when the insulation thickness is greater than 75mm.
Insulation installed in two or more layers shall be staggered joint construction and each layer
shall be secured in place and details of securement shall be the same for each layer.
9.13 Wet or Damage Insulation shall not be used under any Circumstances.
Insulation material to be applied shall not be kept over bare ground to avoid water absorption.
Installed material awaiting its protective cover shall be adequately protected from damage,
rain and contamination, and shall be covered with cladding at a minimum loss of time.
9.14 A minimum clearance of 25mm between outside surface of any insulation finish and adjacent
equipment, pipe or structural members shall be maintained.
9.15 Insulation supports shall not project out of the insulation outer surface and shall be given
sufficient coverage of insulating material to avoid hot spots on the metallic cover at support
positions.
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10.0 PIPING:
10.1 MATERIAL:
10.2 FIBROUS MATERIAL (ROCK OR GLASS WOOL): a) Can be used for all piping other than electrical traced pipes upto 125 °C.
b) Can be used for all temperatures.
c) Shall be in performed pipe section in 2 halves for sizes upto which manufactured and at
least for all pipes with outside diameter over insulation of 500mm. In bigger sizes, multi-
segments are preferable if manufactured, otherwise, blankets are acceptable.
d) Pieces of insulation with crushed and damaged ends shall not be used.
10.3 CELLULAR GLASS: a) Can be used for all piping including electrically traced piping for service temperatures
below 125 °C (with electrical and steam tracing the maximum metal temperature
reached by tracer in order to conduct the requisite heat into the pipe shall be the
deciding factor).
b) In-situ foaming may be allowed by engineering-charge after discussions with client and
head-office.
10.4 CORROSION PROTECTION BEFORE APPLYING INSULATION (All Insulation
Materials) :
a) For operating temperature Upto 125 °C, on carbon and alloy steel piping, provide
painting as per 9.4.
b) For austentic stainless steel piping, provide Aluminium harrier, as per Clause 9.6.
10.5 APPLICATION METHODS (General) :
Insulation material shall be applied to fit snugly against the contours and shaped only where
necessary to achieve this requirement. The insulation shall be carried out with the least
number of material pieces as possible and all unavoidable gaps, cavities, and voids suitably
filled with compatible loose fill material.
10.6 Pipe Section / Molded Blocks / Segments: a) End joints of adjacent blocks shall be staggered one half of the length of the block.
b) Included angle between segments shall not be less than 30° for both single and double
layer insulation,
c) Further, minimum arc length of segments should meet following staggering
requirements.
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d) When double layer is applied, both longitudinal and circumferential joints shall be
staggered. The arc between the longitudinal seam lines of the inside and outside layers
of insulation shall have an angle of over 15° or the longitudinal joints staggered at least
by one layer thickness, whichever is more stringent. Circumferential seams of the inside
and outside layers shall be at least 100mm apart.
10.7 MATTRESS (Fibrous insulation - Rock or Glass Wool):
Shall be applied over the surface with joints tightly butted and laced together with 1 mm dia
a) Bottom and top head insulation shall be supported by 16 SWG annealed galvanised
steel wire drawn through holes in the insulation supports provided by the fabricator.
b) Top head insulation shall be secured by floating ring/ bands provided by vessel
fabricator similar to head or horizontal vessel.
c) Shell insulation shall be supported by bands at every 225mm centres on the cylindrical
portion and the bands shall be kept horizontal.
d) Insulation Securement for Bottom head for vessel supported on legs shall be identical to
that of Top head.
e) For insulation securement of bottom heads inside skirt no floating rings/ bands need be
provided; Firm securement should be ensured just by 16 SWG annealed wire drawn
over insulation tightly and through the holes on support rings provided by the fabricator.
12.7 EXPANSION JOINTS (All insulation materials):
Expansion joints shall be provided every 4000mm (max.) The joint shall be provided at
insulation support rings. It shall be a 25mm space between the top of the insulation and the
bottom of the support ring. The space shall be filled up by compressed Rock-wool fiber.
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13.0 FLANGE, NOZZLE, CHANNEL COVER, MAN-WAY AND HAND-
HOLE FLANGED COVER (All insulation materials):
a) Where insulation is required, these shall be insulated with lined removable prefabricated
covers secured with bands or quick release toggle clips.
b) Otherwise, insulation shall be stopped short of uninsulated flanges and nozzle etc., a
sufficient distance to permit withdrawal of bolts without disturbing the rem inder of the
insulation. Insulation shall be weather proofed and sealed at these locations.
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14.0 IRREGULAR SURFACES SUCH AS PUMPS, COMPRESSORS,
TURBINE ETC: 14.1 Corrosion Protection:
For SS surfaces at all temperatures, provide same protection as indicated for piping,
Clause 10.4
14.2 Application:
14.3 Fibrous Material : Material, application and insulation sacrament: This shall be prefabricated removable aluminum covers, lined with mineral rock / glass wool
pipe sections / lags/ slabs / mattresses.
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15.0 VERTICAL STORAGE TANK (Carbon Steel): 15.1 MATERIAL:
15.2 FIBROUS MATERIAL (ROCK / GLASS WOOL): Shall be in the blanket form.
15.3 APPLICATION:
15.4 SUPPORTING RINGS / SPIKES (RODS) FOR SUPPORTING INSULATION /
CLADDING:
15.5 SHELL: Refer Fig.No. 20 & 21 This Standard indicates the extent of insulation/cladding supporting/
sacrament details provided by tank fabricator. Insulation contractor shall check for its
presence before insulation application work. Following is provided by tank fabricator.
a) Water Shed At the junction of shell and roof, water shed is provided to act as top
covering for the shell insulation as shown in Fig. No.-20 & 21.
b) Insulation Support will consist of 5mm Ø steel rods provided at 400mm Ø diamond
pitch. Length of these lugs is 3mm less than insulation thickness.
c) Cladding Support form tank top, horizontal rings shall be provided at every 1175mm on
tank shell.
15.6 TANK ROOF: Tank roof shall be provided as per Fig. No. 21.
15.7 INSULATION LAYING AND SECUREMENT:
15.8 SHELL: Application of fibrous insulation:
Insulation shall be applied between rings in horizontal mode. Mattress insulation shall be
applied with joints tightly butted and laced together with 1mm Ø galvanised lacing wire.
Matts shall be impaled to the 5mm rod and speed washers fixed and pressed home for
intimate contact of the insulation. In the case of multiple layers, speed washers are
necessary only over the final layers, (upto and including 150mm). Rods and speed washers
of spring steel should be selected to suit each other. While rods are provided by tank
fabricator, speed washers shall be furnished by insulation contractor. Insulation shall be
further secured by bands spaced centrally between insulation supports.
15.9 ROOF (for all materials):
Application of both fibrous and polyisocyanurate shall be similar to that as for shell.
Insulation supports from 5mm Ø MS lugs shall be exactly same as in shell.
15.10 INSULATION FINISH (TANK):
15.11 GENERAL:
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15.12 MOISTURE BARRIER: On all surfaces provided with fibrous materials and calcium solicate for surface upto 125 ºC,
apply a breathing type moisture barrier as below. A 3mm thick coating of mastic shall be
applied to the surface of the insulation as soon as possible, after erection, to reduce the
time the insulation is exposed to the weather, to a minimum. Whilst this coat is still wet,
glass cloth shell be laid over the surface and embedded in thd mastic. Care shall be taken
to ensure that the glass cloth is laid smooth and free from wrinkles and that no pockets of
air are trapped beneath the surface. At junctions in the glass cloth, the overlap shall not be
less than 75mm. A second 3mm thick coat of mastic shall be applied after approximate 12
hrs. When dry this coating shall be a minimum of 1.50mm thick. Care must be taken,
however to ensure that the individual coats are not greater than 3mm (especially corners)
otherwise some cracking of dried coat may be result the mastic shall not be applied over
wet insulation or until the adhesive is dry. During the drying time, the insulation shall be
protected from the weather by “Alkathene” film type tarpailin or similar materials approved
by Engineer-in-Charge.
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16.0 INSULATION FINISH (PIPING): The insulation finish shall provide a weatherproof and mechanical damage resistant
covering over the whole of the insulation areas and be applied and fitted in such a manner
as to provide a close fitting assembly without gaps.
16.1 PIPING (For all materials):
a) Straight pipe shall have metal jacketing cut and machine rolled, (approx. 1 meter long)
wrapped around, with 50mm minimum overlaps on both longitudinal and circumferential
overlaps. All laps shall be arranged to shed water.
b) A single bend shall be made on all overlaps to ensure tight metal-to-metal water tight
arrangement. Self-tapping screws, at every 150mm, shall be provided at all longitudinal
overlaps for both horizontal & vertical piping.
c) At all operating temperature the seams at overlap positions shall be rendered watertight
per clause 8.14 to ensure that insulation remains dry and unwetted, whether the
possible water impingement is from rain, hose or fire sprinklers.
d) The metal coverings shall be secured tightly around the insulation pipe and held in
place with hands on a maximum of 300mm centers. One bend shall be located on each
circumferential lap and the distance. Between laps divided at equal bend spacings. The
bend securing seals shall be kept neatly in line the positioned away from viewing angles
as much as is possible.
e) Vertical overlaps on vertical or near vertical piping shall be staggered to provide
overlaps at ‘North’ and ‘South’ positions in alternate sections of covering.
f) Each section of metal covering on vertical piping with insulation outside dia. larger than
250mm shall be supported from the next lower section each two ‘S’ clips, fabricated
form banding material. The ‘S’ clip shall be of sufficient length to allow the minimum
overlap of 50mm.
g) On vertical piping with O.D. of 600mm and larger, the securing bends shall be
supported by ‘J’ clips, fabricated from banding material. The ‘J’ clip spacing shall be
minimum of two per band All ‘J’ clips shall be screwed into position and secured.
h) Insulation bends and elbows in piping 80mm and larger, shall be metalled with ‘lobster
back’ segments using 10mm minimum ball swage to assist shaping. The metal bands
shall be screwed with self-tapping screws and metal sealants are to provide to get a
completely waterproofed arrangement.
i) Insulation bends and elbows in piping smaller than 80mm may use complete pressed
humped back flat metal elbows or fabricated ‘stove pipe’ elbows.
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j) The practice of locating all joints in the top portion of elevated horizontal pipes for the
sake-of-good-appearance when looking up from grade shall be strongly discouraged.
The joints shall be located to shed water.
16.2 EQUIPMENT (All materials):
a) The metal jacket over vertical vessel shells shall be constructed of sheet metal panels
with the weight of the panel taken on the equipment insulation support rings, via angle
brackets bolted to the panel. Refer Fig. No. 22 for details.
b) The panels shall be applied commencing at the bottom of the vessel. Each
circumferential ring of panels shall be tensioned by means of tensioning bands until the
final joint is screwed tight. ‘S’ clips shall be used as sheeting support at unscrewed
circumferential overlaps.
c) The panels shall be held tight over the vessel insulation by means of circumferential
bands and sealed per. 8.14 the bands shall be positioned on all horizontal overlaps and
at 450 mm centers. Bands shall be held in their relative positions with ‘J’ clips and be
machining stretched and sealed to remove slack only. Those bands, which are not
supported by ‘j’ clips, shall be held in position on cladding by providing pop rivets every
2 meter centers.
d) The panels shall have a minimum overlap of one corrugation on vertical joints and
80mm on horizontal joints. The overlaps shall be arranged to shed water at all times.
e) The vertical and horizontal overlaps shall be secured with self tapping screws at 150mm
pitch except the horizontal overlaps pre-selected to act as expansion joints, these shall
be constructed with a 150 mm overlap and shall remain unscrewed and left free to
permit expansion. All overlaps shall be rendered watertight as per 8.14.
f) All equipment projections such as nozzles shall have the jacketing sealed using a metal
flashing, cut to fit the projection and extending above the jacket at least 80mm. The seal
between the flashing and jacket shall be made watertight by use of self-tapping screws
and sealing mastic.
g) Horizontal cylindrical equipment shall be furnished with flat metal jacket arranged in
circumferential bands with the edge of the sheets, with the longer dimension applied
around the circumference of the equipment insulation.
h) The panels shall have a minimum of 80mm overlap on both longitudinal and
circumferential edges, both overlaps being finished with a simple ball swage and
rendered watertight as detailed in clause 8.14.
i) Horizontal overlaps shall be secured with No. 8 X 12mm long self-tapping set in the
overlap at 150mm intervals, and shall be so arranged that staggered bands of paneling
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encircle the equipment. Vertical overlaps shall not be screwed for horizontal equipment.
j) The metal finish shall be banded and sealed at 450mm centers.
k) The insulated heads of vertical and horizontal equipment shall be fabricated from flat
metal, in an “Orange peel” construction with all radial seams overlapping a minimum of
50 mm and secured with self-tapping screws at 150mm centers. All overlaps shall be
ball swaged and be rendered water tight per 8.14.
l) Projections from the heads shall be sealed using metal flashings, neatly cut to fit around
the projections and extending above the jacket for a minimum of 80mm. The seal
between flashing and jacket shall be weatherproofed with self-tapping screws and
mastics.
m) Insulation at bottom heads of fully skirted equipment does not require weatherproofing.
n) Heads of equipment's 24” OD and smaller shall be finished and waterproofed with
square ended fabricated covers.
16.3 VERTICAL STORAGE TANKS:
16.4 Cladding Applications and Securement:
16.5 Shell (Fig. No. 19, 20 & 21):
Cladding is applied over the system of horizontal rings as follows:
a) Overlaps in the vertical joints will be one corrugation.
b) Overlaps in the horizontal joints shall be 50mm (min.)
c) Cladding to cladding fastening, at both horizontal and vertical overlaps shall be
alternately by “POP” Rivets & self-tapping screws at 150mm (min.).
d) Cladding shall be secured to support ring by bolting. Bolts are provided by tank
fabricator at 300mm centers on angles provided at every 1175 centers vertically.
Cladding is secured as indicated in Fig.No. 20 & 21 Felt washer, aluminium washer and
nut shall be supplied by insulation contractor for all bolted connections at shell, roof and
curb angle.
e) Insulation shall be tucked into the skirt portion of the curb angle. Shell cladding and
extended roof cladding shall be secured to curb angle by bolting as per Fig.No. 20 & 21
every 1500mm.
f) Horizontal stainless steel, steel bands over cladding to be provided every 800mm and
also to coincide at every horizontal cladding overlaps. Bands shall be tightened, locked
and lock fastened featuring stainless steel fastening systems. In order to prevent sliding
of the bands downwards, the bands shall be secured to the cladding using POP rivets
at horizontal pitch not over 2 meters.
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16.6 ROOF: a) All cladding joints shall be sealed by electrometric metal sealants.
b) Min. 75mm overlap shall be ensured at all joints.
c) At all joints, cladding-to-cladding securement shall be provided by self-tapping screws
and proprivets alternately, every 150mm centers.
d) Cladding shall be secured by bolting at every 300mm provided by tank fabricator. For
details of cladding arrangement and bolting, see Fig.No. 20 & 21.
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17.0 ANNEXURE – I:
17.1 OWNER’S OBLIGATIONS: Following free facilities shall be provided near the work site.
a) Open space for storing contractor’s materials shall be provided.
b) Water and Electricity supply.
c) Supply of cement.
17.2 CONTRACTOR’S CONDITIONS:
a) Mode of measurement will be as per IS : 7413-1981 & IS:7240-1981.
b) Contractor should submit the copy of the contract labour license to the personnel Dept.
before starting up the work.
c) Contractor has to maintain certain registers under the contract & the same shall be
shown to the personnel department as and when asked for.
d) Contractor has to maintain certain register under contract labour act.
e) Contractors should comply with ESIS rules and challan of ESI payment should be
submitted regularly during the tenure of the contract.
f) Transportation for contractor’s crew and their accommodation, food etc. will be
arranged by the contractor’s.
g) The rates quoted by the contractor’s must be inclusive of the following :
• Handing and transportation of all items at site.
• Consumable materials.
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18.0 ANNEXURE – II: HOT INSULATION (IH): Recommended thickness in various temperatures for mineral wool. Density of Mineral wool
120 kg/m³. Conductivity 0.039 kcal/hr. m ° C.
Insulation Thickness
Pipe Size Thickness in mm
NB
(mm)
60 °C TO
100 °C
100 °C TO
140 °C
140 °C TO
180 °C
180 °C TO
210 °C
15 25 25 40 50
20 25 40 50 50
25 25 40 50 50
40 40 40 50 65
50 40 50 65 65
65 50 50 65 65
80 50 65 65 75
100 65 65 75 100
125 65 75 75 100
150 75 75 75 100
200 75 75 100 100
Flat Sur. 75 75 100 100
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19.0 ANNXURE – III: TYPE OF INSULATION (IS): 1. Bonded Mineral Wool Pipe Section.