Hot Insulation Procedure.doc

Naser M.Al-Baddah & Partner General Trading & Contracting Contracting Co. W.l.l.

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NBTC – M3 – QC – Insul Insul – 26.0

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TITLE

PROCEDURES FOR HOT INSULATION

TABLE OF CONTENTS 1.

Purpose

2.

Scope

3.

References

4.

Defi Defini niti tion ons s & Abbre bbrevi viat atio ion n

5.

Materials

6.

Procedure

7.

Flanges and Valves

8.

QC Inspection

9.

Safety

NBTC-M3-Insul-26.0,REV NBTC-M3-Insul-26.0,REV-0,04/11/2 -0,04/11/2007 007

Cont. No.: 03UT02-053

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Naser M.Al-Baddah & Partner General Trading & Contracting Co. W.l.l.

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PURPOSE : This procedure provides the minimum requirements for the application of insulation to pipe in conformance with the contract requirements.

2.0

SCOPE : This procedure shall be applicable for Hot Insulation and Personal Protection work used in DOW-PIC Olefins 2 Project (OL2K) Utilities Mechanical Works (M3) contract.

3.0

4.0

5.0 5.1

REFERENCES : Thermal insulation General Requirements :

G15S-0001-00

Hot Insulation-Polyisocyanurate

:

G15S-1001-00

Hot Insulation-Mineral Wool

:

G15S-1002-00

Aluminum Jacketing

:

G15S-4001-00

DEFINATIONS & ABBREVIATIONS : Owner

:

Equate Petrochemical Company, K.S.C.C, Kuwait

Contract

:

Utilities Mechanical Works – OL2K

NBTC

:

Naser M. Al-Baddah & Partner General Trading & Co. W.L.L

QCI

:

Quality Control Inspector

MATERIALS : Polyisocynaurate : 5.1.1 Thermal conductivity (Lambda Value) shall be maximum of 0.023 W/mK, (0.16 Btu/sq.ft-hr-degr.F) at 0C (32F). 5.1.2 Density shall be minimum of 32 kg/m3 (2pcf) 5.1.3 Foam shall be manufactured without the use of CFC’s

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Mineral Wool :

5.2

5.2.1

Mineral Wool Insulation shall be rock or basalt based. Slag or others are not acceptable

5.2.2

Thermal conductivity (Lambda Value)<0.065 W/mK, (0.45 Btu/sq.ft-hr-deg-F) at 200C (392F)

5.2.3

Density shall be minimum of 96 kg/m3 (6.0 pcf)24"-42", 128 kg/m3 (8.0 pcf) Upto 24" Dia incl., 192 kg/m3 (12.0 pcf)

5.2.4 5.2.5

5.3

Cont. No.: 03UT02-053

The free chloride content shall not exceed 10 ppm. Insulation shall be treated so that water absorption shall be lell than 10% after immersion in water for 24 hours.

Metal Jacket: 0.024” thick and 3/16” Corrugated Aluminum sheet with Poly-surlyn moisture barrier shall be used for straight pipe and smooth finish 0.024” Thick for fitting, Valve box, etc. 0.020” thick & ½” wide SS 304 band and 1 mm SS wire seals.

5.4 5.5

Owner Approved Metal Sealant Foster 95-44 based on surface temperature.

6.0

PROCEDURE : General Requirements :

6.1

6.1.1

Insulation shall be applied over the pipe lines as per the applicable Engineering specifications / approved drawings / Standard insulation details.

6.1.2

It shall be ensured before start of job, that surfaces are ready for insulation and cleared by Owner.

6.1.3

Insulation shall not be applied until hydrostatic and or / other testing has been completed and the item approved by the Owner. If it is authorized to apply insulation prior to completion of testing, all joints, including welds, shall be left un insulated and exposed during the test.

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Insulation shall be installed after the application of all required coatings and approved by Owner.

Insulation application :

6.2

6.2.1

Insulation shall be applied only to clean, dry, frost free surfaces.

6.2.2

Only new and undamaged insulation shall be used. All Insulation and accessory materials shall be stored in an area protected from weather before and during application.

6.2.3

Both the insulation materials and surfaces to be insulated shall be kept dry during application. The jacketing shall be applied as soon as possible. All work not jacketed at the end of the shift shall be covered to protect from the element.

6.2.4

Insulation shall be applied using the staggered joint method. In multiple layers the joints of each succeeding layer shall be staggered.

6.2.5

Insulation shall be installed in such a way that the gap between insulated surface and insulation is less than 1/8”.

6.2.6

The insulation for piping shall be single layer for process temperature up to 315 0C and multiple layers shall be applied above 3150C.

6.2.7

Polyisocynaurate : Piping size less than 24” – Two Piece Preformed Pipe Insulation. Piping size less above 24” (up to 144”) – Performer curved segments Fittings Flanges and Valves – Fabricated in minimum number of pieces so as to minimize void space and number of joints.

6.2.8

Mineral Wool : Piping size less than 24”

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Preformed Pipe Insulation.


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Piping size above 24”

–

Medium strength Board (plates) or multiple curved segments.

Vessel Heads and Bottoms

–

High Strength Boards

Fittings Flanges and Valves – Preformed or molded sections if available or mitered sectional pipe or board (plates). For Valve boxes insulation blankets shall be used.

Securements of insulation :

6.3

6.4

6.3.1

All bands and other attachments shall be type 302 or 304 material. The band width shall be of ½” and thickness of 0.020”.

6.3.2

In multi layer sections inner layer shall be secured separately with 9” (250 mm) spacing, For Polyisocynaurate – fiber glass reinforced tape up to an insulation dia of 36” for Mineral wool – SS wire of size Gauge 18 or 0.051” OD up to an insulation dia of 36”.

6.3.3

Outer layer shall be secured with bands ½” and thickness of 0.020” with 9” (250 mm) spacing.

6.3.4

The insulations shall be securely held in place with bands. Bands shall be placed no closer than 1” or farther than 4.5” from the end of section. All pipe section shall have at least 2 bands. Where more than one bridle band is used, head band connections spacing shall not be exceeding 9”.

6.3.5

Bands shall tighten with a mechanical tightening tool and secured with a wing type or crimp type seal. Seals shall be buried flush with the Insulation.

6.3.6

After the Insulation is applied, all unfilled joints greater than 1/16”, and chipped edges shall be filled with piece of polyisocynaurate foam cut to fit so as to leave a smooth and even surface.

Securement of Jacketing :

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6.4.1

Aluminum jacketing (sheeting) and components shall be of type 3105-H14 alloys conforming to ASTM B-2009.

6.4.2

Pre manufactured Aluminum components in site shall be installed in accordance with the manufacturer’s recommendations. Field or site fabricated components shall be fabricated and installed in accordance with the job specifications.

6.4.3

Jacketing shall be installed with overlaps oriented to ensure the system sheds water.

6.4.4

Longitudinal laps shall face away from the view of roadways and frequently traveled areas. Overlap of longitudinal and circumferential joints shall be 50mm.

6.4.5

Jackets on piping shall be banded with ½” x 0.020” bands on maximum of 11-1/3” (287.9mm) centers. Each circumferential overlap shall be banded.

6.4.6

Jacked on hot pipe shall be secured with screws on maximum of 150 mm centers.

6.4.7

The heads of the screws used for fastening the jackets shall be sealed by using a neoprene washer under the screw.

6.4.8

All burrs or sharp areas on exposed edges shall be removed prior to application.

6.4.9

On vertical pipe, S clips shall be placed on the perimeter of each sheet before the next higher sheet is applied. A minimum of two clips shall be used up to 24” diameter. Above 24”, clips shall be equally spaced a maximum of 30” apart. Only one clip is required up to 6” insulated diameter.

6.4.10

To prevent the bands from slipping, bands on vertical pipe shall be secured by attaching “J clips” to the jacket with the screws. Sealant :

6.5

6.5.1

The approved sealant shall be selected based on the maximum temperature of the surface to which it is applied.

6.5.2

Silicon sealant shall be applied to all voids, entrance holes, protrusions etc.

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Fittings, Flanges & Valves : 7.1

Piping adjacent to flanged connections to be insulated shall be totally finished, water proofed and sealed regardless of whether flanges are insulated or not.

7.2

Flanges, valves shall be insulated with same type of insulation as the pipe, with easily removable, reusable covers, unless noted otherwise.

7.3

Insulation adjacent to equipment items specified to have removable insulation covers shall have a waterproofed, sealed, termination, so that water can not enter the insulation when the removable cover is removed.

7.4

Covers shall be fabricated in minimum number of pieces to provide full insulation coverage to all area.

7.5

Covers for flanges and valves shall include space left un insulated on pipe for bolt removal.

7.6

Jacketing shall be provided with permanently attached straps with adjustable release fasteners and draw strings on wind flaps.

7.7

Jacketing shall be constructed in a manner to prevent penetration of rain, moisture etc. A three fold binding shall be used on all edges. Pleated corners creating a boxed edge to hold insulation in place without compressing shall be used. Sewn bar tacks shall be used to reinforce the seam ends for draw string closures. Sewn retainers shall be provided to prevent movement of the insulation inside the cover.

QC INSPECTION : 8.1

Material Inspection for owner approved products.

8.2

Ensure clearance for insulation – All mechanical, Tracing Paint touchup works finished.

8.3

Ensure General condition of insulation lagging before cladding.

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8.4

The Insulation metal jacketing shall be visually inspected for voids, cracked segments, open joints etc. to ensure compliance with the requirements with this procedure.

8.5

Inspection shall be done as per approved ITP and relevant check lists shall be signed off.

SAFETY : 9.1

Removal and or disturbance of existing insulation shall not proceed with out Owner’s approval.

9.2

PPE compliance shall be adhered as per the Owner Standard. Safety harness used for higher elevated wroks more than 1.8 meters shall confirm ANSI Z 359 and 100% tie off shall be ensured.

9.3

Induction training and periodical specific training shall be imparted to all the employees working at site.

9.4

The Equipments used for insulations works will be inspected by Safety Supervisor and color coding as per the Owner recommendations shall be adhered.

NBTC-M3-Insul-26.0,REV-0,04/11/2007

Hot Insulation Procedure.doc

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