Job Specification 126158-82A3 Insulation of Coke Drum

SOCAR & TURCAS AEGEAN Refinery (STAR) Delayed Coker Unit 190 Aliaga, Izmir, Turkey

REF: 13-126158-02 DATE: Dec. 15, 2010 PAGE: App.D-1 REV: 1

BASIC DESIGN PACKAGE

APPENDIX D – JOB SPECIFICATIONS

D-1

Insulation of Coke Drums, 126158-82A3

Rev.1

______________________CONFIDENTIAL_____________________ THIS DOCUMENT CONTAINS CONFIDENTIAL TECHNICAL INFORMATION OF FOSTER WHEELER USA CORPORATION AND IS TO BE AND REPRODUCED, ONLY IN ACCORDANCE WITH THE WRITTEN PERMISSION OF FOSTER WHEELER USA CORPORATION, USED, FOR SOCAR & TURCAS RAFINERI A.S. (STRAS) AT SOCAR & TURCAS AEGEAN REFINERY (STAR), ALIAGA, IZMIR, TURKEY.

FWUSAC

SOCAR & TURCAS RAFINERI A.S. (STRAS) STAR (SOCAR & TURCAS AEGEAN REFINERY) PROJECT DELAYED COKING UNIT, UNIT 190 ALIAGA, IZMIR, TURKEY

CONTRACT No. 126158-02 Page: 1 OF 19

JOB SPECIFICATION 126158-82A3

INSULATION OF COKE DRUM The subject job specification is issued herewith. Please discard any previous issue of this specification. For convenience, the nature of the revision is briefly noted under remarks.

Revision Number Log Rev

Date

By

Pages

Approved by

Reason for Issue

1

23RD AUG 2010

RP/TC

19

SD

Issued for Client Review


FWUSAC SPECIFICATION No:126158-82A3 Page: 2 OF 19 REV No: 1

INSULATION OF COKE DRUM

TABLE OF CONTENTS

I.

SCOPE

4

II.

INSULATION MATERIALS

4

III.

INSTALLATION OF INSULATION

6

IV.

INSULATION DETAILS

9



INSULATION OF COKE DRUM REVISION INDEX PAGE

REV

DATE

*1 *2 *3 *4 *5 *6 *7 *8 *9 *10 *11 *12 *13 *14 *15 *16 *17 *18 *19

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010 08/23/2010

REASON FOR REVISION

* Asterisk represents pages revised for this issue.




I.

SCOPE This standard defines the requirements for 6” thick external insulation of coke drums. Special requirements of coke drum insulation include the following items: - Special attachment clips and insulation support rings for insulation on shell, skirt and cone. - Use of inspection lanes for shell, skirt and cone for circumferential weld seams. - For routine inspection of critical circumferential welds, use of removable insulation blocks at critical inspection lanes. Critical inspection lanes for routine inspection of circumferential weld seams shall be specified by owner. Critical circumferential weld seams are, as a minimum, skirt junction, etc. - Requirement for T.I.’s be located outside the inspection lanes (Typ. – shell, skirt and cone).

II.

INSULATION MATERIALS A. Insulation 1.

Insulating material for coke drums (shell, skirt, cone, and top head) shall be 6” total thick asbestos free mineral wool blanket conforming to ASTM C 592, Class II, consisting of 2 layers. The inner layer shall be 3" thick, 12 lb/ft3 density, faced with 22 gauge (.028" diameter) stainless steel 1" hexagonal mesh poultry netting on both sides. The outer layer shall be 10 lb/ft3 density, 3” thick, and faced with 22 gauge stainless steel 1" hexagonal mesh poultry netting on both sides.

2.

Insulating material for the shell at nuclear level devices shall be 1” thick 8 lb/ft3 density, ceramic fiber blanket conforming to ASTM C892 Grade 8 Type I. See Figure 2 for details.



INSULATION OF COKE DRUM B. Weatherproofing Metal jacketing for weatherproofing shall have a factory-applied moisture barrier bonded to the inside surface. The moisture barrier may be polyethylene - kraft paper, polysurlyn or other approved proprietary alternate. 1.

Insulation on the cylindrical section of the drums shall be weatherproofed using 0.032" thick aluminum jacketing conforming to ASTM B209 Alloy 3003 Temper H14, Alloy 3105 Temper H14 or equal. The jacketing shall have corrugations measuring 1¼” in length (peak to peak) and ¼” in total depth.

2.

Insulation on the top head shall be weatherproofed using 0.032" thick flat stainless steel jacketing conforming to ASTM B209 Alloy 3003 Temper H14, Alloy 3105 Temper H14 or equal.

3.

Insulation on the bottom cone, inside of the skirt shall be weatherproofed using 0.032" thick flat stainless steel jacketing conforming to ASTM A240 Type 304 or equal.

4.

Insulation on the outside of the skirt shall be weatherproofed using 0.032" thick stainless steel jacketing conforming to ASTM A240 Type 304 or equal. The jacketing shall have corrugations measuring 1¼” in length (peak to peak) and ¼” in total depth.

C. Bands shall be type 304 stainless steel, ¾” wide x 0.020" thick, with 0.025" thick closed crimp seals. D. "J" and "S" Clips shall be type 304 stainless steel, ¾” wide x 0.030" thick. E. Tie wire shall be 16 gauge (approx. 1/16" diameter) fully annealed Type 304 stainless steel. F. Sheet Metal Screws 1.

Type 304 stainless steel #10 gauge x ½” long self-tapping screws with Neoprene gaskets shall be used for securing sheet metal to sheet metal. "Poprivets" are an



INSULATION OF COKE DRUM acceptable substitute. The insulation subcontractor must submit type and size for approval. 2.

Type 304 stainless steel ¼” diameter x 5/8” long self-tapping screws with Neoprene gaskets shall be used for securing sheet metal to insulation support angles.

G. Expansion springs for bands on insulation shall be type 302 stainless steel INSULMATE ES-7 expansion springs, manufactured by RPR Products, Inc. or CHILSPRING expansion springs, manufactured by Childers Products Company, Inc. H. Compression springs for bands on jacketing shall be type 302 stainless steel Childers MITY-SPRING or approved equal shall be used. J. Insulation support pins on cone shall be 5 mm dia. stud pins and ½” longer than the insulation thickness and supplied with speed clips. Pins shall be constructed of TP 405 stainless steel with a maximum carbon content of 0.08%. Alternatively, pins may be constructed of 410 or 409 stainless steel. Nelson Type TPC or approved equal shall be used. If TP 405, 409, and 410 SS pins are unavailable, Cr-MO pins with a larger diameter are permissible. Hammer testing of welded pins shall be performed 100% immediately after welding to insure integrity of the weld. Weld tips of pins shall be free of any plating. K. Mastic sealer shall be asbestos free Childers Chil-Joint CP-70 or equal. L. Bulk ceramic fiber and mineral wool material shall be suitable for 1200°F or higher service temperatures. M. Material for flashing shall be 0.010" thick type 304 stainless steel.

III.

INSTALLATION OF INSULATION A. Blanket Insulation 1.

Blanket insulation shall be installed in 2 layers. Seams in the layers shall be staggered by a minimum of 12".



INSULATION OF COKE DRUM 2.

The insulation shall be installed as tightly as possible against the supports and against the other layer to prevent opening of the seams during vessel expansion due to operating temperature fluctuations.

3.

The blanket seams shall be further secured by means of wire lacing. Hog ringed seams are not permitted.

4.

Pins shall be used to hold the insulation blanket to the bottom cone and the inside of the skirt. Pins shall be installed on 12” (max.) centers. Pins are to start 9” (max.) above inspection lanes on cone and 6” (max.) below inspection lanes on the cone. Pins shall be installed by the vessel fabricator prior to post weld heat treatment (PWHT).

5.

The insulation on the cylindrical section of the drum shall be held in place by metal bands spaced around the circumference on 12" (max.) vertical centers, with expansion springs spaced not more than 15 ft. apart.

6.

The insulation on the top head shall be held in place by metal bands attached to the floating ring and the top insulation support ring. Bands shall be spaced 12” apart at the support ring.

7.

Expansion joints shall be provided under insulation supports using bulk ceramic fiber or mineral wool insulation.

8.

Bands on field fabricated drums shall run from a vertical bar at one inspection lane to another vertical bar at the next inspection lane.




B. Jacketing 1.

Jacketing on the cylindrical on the cylindrical section of the vessel shall be corrugated and installed in overlapping sections to shed water. The overlaps shall be a minimum of 3 corrugations in vertical seams, and 4” in horizontal seams. “S” clips shall be used between courses of jacketing. Jacketing shall be held in place by bands spaced on 12” (max.) vertical centers with compression springs spaced no more than 15 ft. apart. “J” clips, spaced 5 ft. apart shall be used to prevent the bands from slipping. “J” clips shall be attached to the jacket with self tapping screws. A minimum of 2 screws shall be used for each clip.

2.

Top head and bottom cone jacketing as well as jacketing on the inside of the skirt shall be flat. "Standing seam" construction shall be used on the top head and bottom cone although alternative methods of jacketing installation may be used subject to prior written approval by Foster Wheeler. Where standing seam construction is used the height of the seams shall not exceed 2". Jacketing on the bottom cone and the inside of the skirt shall be impaled on pins. Mastic sealer shall be applied between the jacket overlaps. Self-tapping screws spaced 6" apart shall be used to fasten the jacket segments together.

C. Inspection Lanes 1.

All circumferential weld seams on the shell, skirt and bottom cone head will have inspection lanes. The insulation in the inspection lanes will (2)-3” layers and banded to the shell, skirt, and cone. See Figure 1 for insulation supports and inspection lanes on the shell. See Figures 3, 4A/B for insulation supports and inspection lanes on the cone.

2.

Insulation support will be provided directly above and below the skirt junction as shown in Figures 4A/B.

D. Miscellaneous 1.

When complete, jacketing shall present a neat appearance with no buckling.




IV.

2.

Top and bottom manway flanges shall not be insulated. Temporary insulation shall be provided during PWHT of field fabricated drums.

3.

Contact between aluminum jacketing and vessel steel shall be avoided.

4.

Flashing rings shall be installed on all nozzles to prevent infiltration of water. Flashing joints shall be fully weatherproofed using a high temperature mastic coating.

5.

All temperature indicators will be mounted outside inspection lanes but as close to circumferential weld seams as possible.

6.

The temperature indicators for the bottom shell to cone head weld will be mounted just above the inspection lane.

INSULATION DETAILS Figures 1-5 and Details A1-A3, B1-B3, and C1-C2 on the following pages show insulation arrangements and details for the shell, skirt, bottom cone, and top head. These sketches depict details of critical areas of insulation. Deviations from these sketches require the prior written approval of Foster Wheeler.




FIGURE 1 ARRANGEMENT OF INSULATION SUPPORT & T.I.’S




FIGURE 2 INSULATION DETAIL AT NUCLEAR LEVEL DETECTORS




DETAIL A1 INSULATION SUPPORT RING AND ATTACHMENT CLIP ON SHELL AND SKIRT

DETAIL A2 ATTACHMENT CLIP SLOT DETAILS ON SHELL AND SKIRT




DETAIL A3 ATTACHMENT CLIP DETAILS ON SHELL AND SKIRT




FIGURE 3 ARRANGEMENT OF INSULATION SUPPORT RINGS AND ATTACHMENT CLIPS ON CONE




FIGURE 4A (Weld Build-Up Skirt Junction) INSULATION DETAILS – FOR BOTTOM CONE AND SKIRT




FIGURE 4B (Forged Ring Skirt Junction) INSULATION DETAILS – FOR BOTTOM CONE AND SKIRT




DETAIL B1 INSULATION SUPPORT RING AND ATTACHMENT CLIP FOR CONE

DETAIL B2 ATTACHMENT CLIP SLOT DETAILS FOR CONE




DETAIL C1 MANHOLE IN TOP HEAD

DETAIL C2 NOZZLE IN TOP HEAD

DETAIL C3 TOP L-RING




FIGURE 5 ARRANGEMENT FOR FIELD FABRICATED DRUMS




APPENDIX D – JOB SPECIFICATIONS (Continued)

D-2

Painting, 126158-83A1

Rev.1



FWUSAC CONTRACT No. 126158-02 Page: 1 OF 23


PAINTING

The subject job specification is issued herewith. Please discard any previous issue of this specification. For convenience, the nature of the revision is briefly noted under remarks.


Date

By

Pages

Approved by

Reason for Issue

1

23RD AUG 2010

UVP/TC

23

SD



FWUSAC SPECIFICATION No: 126158-83A1 Page: 2 OF 23 REV No: 1

PAINTING TABLE OF CONTENTS

I.

SCOPE

3

II.

REFERENCES

5

III.

GENERAL

6

IV.

SURFACE PREPARATION

8

V.

PAINT APPLICATION

11

VI.

PAINTING OF PREVIOUSLY PAINTED SURFACES (MAINTENANCE PAINTING)

12

VII.

FIELD PROTECTION, CLEANUP & INDUSTRIAL HYGIENE

13

VIII.

INSPECTION

14

IX.

SELECTION OF PAINT

15

TABLE A - PAINT SYSTEMS

17

TABLE B - PRIMER MATERIALS

19

TABLE C INTERMEDIATE & FINISH MATERIALS

20

TABLE D ADDITIONAL EXAMPLES OF PAINT SELECTION

22

REASON FOR CHANGES:

23



PAINTING

REVISION INDEX PAGE

REV

DATE

REASON FOR REVISION Entire JOB SPEC is projectised.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10

* Asterisk represents or will represent

I.

pages revised for this issue.

SCOPE A.

This specification outlines the general requirements for the external painting of piping, pipe supports, steel structure, machinery and equipment for shop and field painting. Painting includes surface preparation, selection, application, inspection and clean-up of paints. Internal coatings and linings are not covered in this specification.



PAINTING B.

This specification does not apply to off the shelf, factory finished or other items for which a vendor has a defined painting system(s) in place equivalent to the paint systems listed herein. Vendors of such items shall be informed of the environment to which the items will be exposed and the coatings systems must be selected accordingly, the finish color of the equipment item shall be Aluminum. Any deviation to these requirements or doubt regarding a vendor supplied paint system shall be brought to the attention of the purchaser for approval/resolution. If required, vendor supplied standard coating systems can generally be upgraded in the field using paint system UMS1A as given in Table A.

C.

This specification does not specify paint systems above 1000oF. such are required, appropriate paint systems must be devised.

If

D. This specification specifies shop application of primers and finish coats for various items. Depending on economics or specific contracts, this activity may be transferred to the field. E. Vessels fabricated overseas shall also be painted unless waived by the FWUSAC. Applicable painting system shall be per this specification. E. Paint systems, including surface preparation, paint materials, application, etc., must comply with applicable local, state and federal laws. See also Tables A, Table B, Table C and Table D. F. The vendor or Contractor shall advise FWUSAC, in writing, of any conflicts between the requirements of this specification and other requirements. G. latest editions of any federal, state or local codes, regulations, standards and guidelines that existed prior to January, 2009 shall govern and supercede any prior federal, state or local codes, regulations, standards and guidelines referenced in this specification.



PAINTING II.

REFERENCES The latest editions and revisions of the following documents are referred to in this specification. A.

U. S. Federal Documents 1.

B.

Steel Structures Painting Council (SSPC) Manual 1.

2.

C.

Occupational Safety and Health (OSHA) Standards

Volume 2, Systems and Specifications a. b.

SSPC-PA1, SSPC-PA2,

c. d. e. f. g. h. j. k. l. m.

SSPC-SP1, SSPC-SP2, SSPC-SP3, SSPC-SP5, SSPC-SP6, SSPC-SP7, SSPC-SP8, SSPC-SP10, SSPC-SP11, SSPC-SP12,

Shop, Field and Maintenance Painting Measurement of Dry Paint Thickness with Magnetic Gauges Solvent Cleaning Hand Tool Cleaning Power Tool Cleaning White Metal Blast Cleaning Commercial Blast Cleaning Brush-off Blast Cleaning Pickling Near-White Blast Cleaning Power Tool Cleaning to Bare Metal Ultra High Pressure Water Jetting

Vis 1, Pictorial Surface Preparation a. Standard D SA 2 1/2 b. Standard D SA 2

National Association of Corrosion Engineers (NACE) Publications 1.

NACE TM-01, Visual Standard for Surfaces of New Steel Air blast Cleaned with Sand Abrasive a. b. c. d.

No. No. No. No.

1, 2, 3, 4,

White Metal Blast Cleaning Near-White Blast Cleaning Commercial Blast Cleaning Brush-off Blast Cleaning



PAINTING III.

GENERAL A.

Painting of steel surfaces shall be performed in accordance with SSPC-PA1, manufacturer's recommendations, and OSHA (Part 1910, Paragraph 1910.144) requirements for safety colors, unless modified by this specification.

B. Surface preparation of steel surfaces shall be in accordance with SSPC or NACE Specifications. In many locations, other surface preparation standards are more widely known and more often used than the SSPC standards (e.g. Swedish Standard SIS 05 59 00 in European locations). The local standard may be used subject to approval by FWUSAC. A cross reference chart is given in Paragraph IV.J. C. Where manufacturer's instructions or those in SSPC-PA1 are given in permissive terms, e.g., "should," "may," and "recommend" these shall be considered mandatory. D.

The following surfaces shall not be painted: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Concrete Building Brick, Masonry Units and Wall Tile Asbestos Cement Galvanized Surfaces Insulation Weatherproofing Aluminum, Copper, Brass, and other Nonferrous Metals Uninsulated stainless steel (except in preparation for ocean shipment or storage/installation in a coastal area). Equipment supplied with manufacturer's standard finish coat Tripping Mechanisms of Steam Turbines Plastic and Plastic Coated Materials Machined and Gasket Surfaces Nameplates

E.

Shop fabricated equipment, towers, vessels, structural steel, exchangers, pumps, motors, piping, etc. requiring painting shall be cleaned and completely painted (shop applied primer, intermediate and finish coats) by the fabricator or manufacturer. Surface preparation and application of primer and finish shall be performed in the field on field fabricated piping, pipe supports, steel structures, and equipment.

F.

The general contractor shall be responsible for properly handling and storing the painted materials prior to erection to minimize damage to the coating system.

G.

Damaged areas of the coating system shall be repaired after erection by the painting contractor to the satisfaction of FWUSAC.



PAINTING H.

If practical, for field applied coatings the intermediate coat shall be applied not later than 60 days after application of the prime coat.

J.

If over 60 days old, the prime coat shall be inspected by FWUSAC to determine if acceptable as the prime coat. If the prime coat has weathered to an extent that it is not acceptable, FWUSAC will determine how much repriming is required and will request a price from the painting contractor for this additional work.

K.

The paint system is to be based on the corrosive environment and the operating temperature of equipment and piping except: 1.

The outside temperature of internally lined items shall be used where specified in the requisition.

2.

Supports (skirts, legs, saddles, etc.) shall be considered as operating below 300oF, unless otherwise noted.

3.

Higher temperatures required for steamout, start-up, or other non-operating conditions shall be used where specified in the requisition.

L.

Only paint and painting materials approved by FWUSAC shall be used. These materials shall be delivered to the job site in sealed and labeled containers. They shall be stored in a location that is protected from the elements, well ventilated, and free from excessive heat, open flame, or other sources of ignition. Paint materials susceptible to freezing shall be stored in a heated area.

M.

Primer and finish coats for a particular system shall be from the same manufacturer, whenever possible, to assure compatibility.

N.

Paint shall be thoroughly mixed and thinned in accordance with the manufacturer's instructions immediately prior to application. Only thinners of a type recommended by the paint manufacturer shall be used.

P.

The recommendations and specifications of the paint manufacturer shall be strictly followed in applying the paint systems covered by this specification.



PAINTING Q.

The items listed below shall be shielded to prevent damage during surface preparation and painting operations. All openings, including those that are flanged or threaded, shall be sealed to prevent entry of sand, dust, or coating material. After completion of painting operations all material used for shielding and sealing shall be removed. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

IV.

Nameplates Packing Glands Packing Seals Bearings Rotating Equipment Couplings Rotating Equipment Shafts Lubrication fittings Pressure gauges Gauge glasses Motor starters Instrument dials Vents Exposed linkages Valve stems Light bulbs Light bulb enclosures Light reflectors Air intakes Rubber parts and plastic

SURFACE PREPARATION A.

Surfaces shall be thoroughly cleaned of any material conducive to premature failure of the paint coating. The method of surface preparation used shall be compatible with, and suitable for, the prime coat of paint.

B.

Prior to solvent cleaning, soil, cement spatter, salts, or any other foreign matter (other than oil or grease) shall be removed by a steel fiber brush, wire brush, or by scraping.

C.

Oil, grease, or similar substances shall be removed by solvent cleaning, scraping or brushing. Rust, mill scale, or oxides may be removed by pickling, hand or power tool cleaning, or blast cleaning.

D.

Exercise care in the use of tools, to prevent excessive roughening of the surface and the formation of ridges and burrs. Excessive power wire brushing produces a burnished slick surface not suitable for coating.

E.

Power sanding or water washing shall be used when cleaning of a zinc-rich primed surface is required prior to application of topcoat.

FWUSAC


SPECIFICATION No: 126158-83A1 Page: 9 OF 23 REV No: 1

PAINTING F.

Blast cleaning with grit or synthetic abrasives is preferred to sand. For blast profile requirements, see Table A. Steel surfaces shall not be blasted when surface temperature is less than 5oF above the dew point, relative humidity is greater than 85% or there is a possibility that the blasted surface will be subject to wetting before the first coat of primer can be applied. Surfaces shall be blown, wiped or vacuumed free of blasting abrasive and dust before they are primed.

G.

Since freshly blasted surfaces are subject to immediate corrosion, particularly in high humidity or salt atmospheres, no more surfaces shall be blast cleaned than can be primed before visible or detrimental rerusting occurs. Blasted surfaces shall be primed no later than the end of the same work day.

H.

A 12”(300 mm) wide strip of uncoated, blasted surface shall be left between primed and unblasted surfaces to prevent damage to the newly dried prime coating. When blast cleaning is resumed, the strip of previously blasted surface will require only a light brush blast, accomplished by holding the cleaning nozzle in a direction away from the coated surface, to remove any rust that may be present.

J.

Following methods.

K.

is

a

tabulation

of

acceptable

SYSTEM

SSPC METHOD

Solvent Cleaning Hand Tool Cleaning Power Tool Cleaning White Metal Blast Cleaning Commercial Blast Cleaning Brush-Off Blast Cleaning Pickling Near-White Blast Cleaning Power Tool to Bare Metal Ultra High Pressure Water

SSPC-SP1 SSPC-SP2 SSPC-SP3 SSPC-SP5 SSPC-SP6 SSPC-SP7 SSPC-SP8 SSPC-SP10 SSPC-SP11 SSPC-SP12

cleaning

and

inspection

VISUAL COMPARISON NACE SSPC-VIS1 NACE #1 NACE #3 NACE #4 NACE #2 -

St.2 St.3 Sa.3 Sa.2 Sa.1 Sa.2 1/2 -

Surfaces shall be primed after cleaning before any rusting occurs (if rust forms after cleaning, the surface shall be recleaned before painting).



PAINTING L.

Nonferrous and Nonmetallic Surfaces Certain nonferrous and nonmetallic surfaces require additional preparation to that specified in the SSPC Painting Manual. A listing of these surfaces and their requirements follows. 1.

Galvanized Surfaces Galvanized surfaces shall only be painted where required by the client. When required, these surfaces shall be cleaned by one of the following methods:

2.

a.

Solvent clean

b.

Wash with a solution of 1-1/2 ounces ( 45 mililiter) of trisodium phosphate and 1-1/2 ounces ( 45 mililiter) of soap chips to each gallon of water, followed by thorough rinsing with clean water.

c.

Allow surface to weather for 2 to 4 months, depending on exposure, for removal of oily deposits.

d.

Wash surface with phosphoric acid solution, allow to dry and remove all crystalline deposits with a stiff brush, followed by a rinse with clear water. Any chemicals allowed to remain on the surface will be detrimental to paint adhesion.

Wood Interior surfaces shall be sanded to a smooth finish. Exterior surfaces shall be sanded only if the surface is very rough. Nail holes and joints in wood members shall be primed, puttied and sanded to a smooth, flush surface. Plastic wood may be used in lieu of putty, especially on interior surfaces. Window sashes shall be primed before glazing. Putty or plastic wood shall not be applied until the primer has dried.

3.

Plaster and Wall Board Plaster shall not be coated until it has dried completely. Large cracks shall be cut out and patched. Cracks which show up after the application of the first coating shall be spackled and sealed. When lime is present it shall be neutralized by washing with a solution of 3 pounds of zinc sulphate to 1 gallon of water. The crystals so formed shall be dusted off after drying.



PAINTING V.

PAINT APPLICATION A.

Paint shall be applied by one, or a combination, of the following methods: 1. 2. 3. 4. 5.

Brushing. Roller Coating. Air Spraying. Airless Spraying. Paint Mitt (for small diameter piping and so forth).

B.

The method of application shall be governed by the paint manufacturer's recommendation for the particular paint being applied. For application techniques, requirements and precautions, SSPC-PAl shall be used as a general reference.

C.

Conventional solvent-base paints shall not be applied to exterior surfaces in humid weather, when the air temperature is below 40oF or when the surface temperature is less than 5oF above the dew point. Chemically cured paints shall not be applied at air or surface temperatures below 50oF or when relative humidity is above 85%. Water-base paints may be applied to damp surfaces. Wetting of exterior surfaces is recommended during hot weather application. Water-base paints shall be applied at air temperatures above 50oF. (Paint manufacturer's recommendations shall be consulted in each case for possible special temperature requirements). No paints shall be applied to a surface at a temperature that will cause blistering, porosity or otherwise be detrimental to the life of the paint.

D.

Contact surfaces shall be painted as follows: 1.

The faying surfaces of connections specified to be slip critical shall be blast cleaned and coated with a paint which has been qualified as Class A (slip coefficient 0.33) by test in accordance with Test Method to Determine the Slip Coefficient for Coatings Used in Bolted joints as adopted by the Research Council on Structural Connections. A certified copy of the test report shall be included in the manufacturer’s certification.

2.

Steel coated before erection shall not be coated within 2”(50mm) of edges to be welded.

3.

Steel surfaces in direct bonded contact with concrete, embedded in concrete, or coated with concrete, normally shall only be painted in specific cases where corrosion of the steel is expected to be a problem.

4.

Steel to be embedded in brick or other masonry shall be given at least one prime coat of Universal Primer (P-100).



PAINTING

VI.

5.

Steel surfaces in contact with aluminum surfaces shall be given at least one prime coat of coal tar epoxy (P-209).

6.

Wooden surfaces (exterior wooden members only) in contact with any other surfaces shall be prime coated.

7.

Surfaces not in direct bonded contact, but inaccessible after assembly, shall receive the full specified paint system before assembly.

E.

Surfaces shall not be recoated until the preceding coat has properly dried or cured. The surface may be considered ready for recoating when the next coat can be applied without the development of paint film irregularities, such as lifting or loss of adhesion of the undercoat. However, the minimum or maximum drying or curing time specified by the paint manufacturer shall be the acceptable recoat period. Paint shall not be force-dried under conditions which will cause cracking, wrinkling, blistering, formation of pores, or which will be detrimental to its condition or appearance. Newly painted surfaces shall be protected to the fullest extent practicable from rain, condensation contamination, snow and freezing until the coating has dried.

F.

Successive coats of paint, preferably, should be of different colors. However, if they are of the same color, alternate coats shall be tinted to produce sufficient contrast to ensure complete coverage and specified film thickness of each coat. The final finish coat shall not be tinted. Tinting material shall be compatible with the paint and shall not be detrimental to its service life.

G.

Sprayed coatings shall be cross-spray-applied coverage, free of runs and sags.

H.

When not otherwise specified, prime coats shall be a minimum of 1.5 mils dry-film thickness per coat; finish coats shall be a minimum of 1 mil dry-film thickness per coat. Where the required thickness is not achieved, additional coats shall be applied until the proper thickness is obtained. Application shall be such that the film thickness will not affect appearance or service life of the paint.

J.

The type of paint to be used and the number of coats to be applied shall be in accordance with Paragraph IX and Table A.

to

insure

uniform

PAINTING OF PREVIOUSLY PAINTED SURFACES (MAINTENANCE PAINTING) A.

Surfaces to be painted shall be cleaned by blasting, power tools, hand tools, or solvents, or by a combination of these methods. All grease,



PAINTING oil, dirt, foreign material, rust, and loose, cracked, brittle, or nonadhering paint shall be removed. B.

E.

The remaining sound paint on the surface shall have the edges feathered by sanding prior to painting. Any paint that curls or lifts after the application of the spot or priming paint shall be removed and the area repainted. C.

Surfaces coated with cement-type paints, preferably, shall be blast cleaned wherever possible; alternatively, the surfaces may be scraped and power brushed to a sound, solid substrate prior to painting. Chalked surfaces of exterior walls shall be completely removed by hand wire brushing and washing with water.

D.

Glossy surfaces shall be roughened by light sanding or a trisodium phosphate wash to provide a bond for successive coats of paint.

The minimum coating requirement for spot painting shall be as follows: 1.

No Rusting, Prime Coat Exposed - Apply 1 or 2 finish coats to regain specified mil thickness.

2.

Rusted Area or Prime Coat Damaged - Clean damaged or rusted area to base material and apply prime and finish coats to regain specified mil thickness.

F. Existing paint coatings shall be checked or tested for compatibility with the paints with which they are to be overcoated to ensure that lifting or wrinkling of the existing coating will not take place.

VII.

FIELD PROTECTION, CLEANUP & INDUSTRIAL HYGIENE A.

The paint applicator shall fully protect all equipment, walls, floors, ceilings and other surfaces from damage and shall provide the necessary drop cloths or other protection required to fully protect all surfaces from dust, paint droppings, paint mist, other contaminants during the execution of his work.

B.

While painting around switches and controls, painters shall be careful to avoid tripping of switches. It is imperative that all switches remain unmoved and undisturbed by painters.

C.

Shipping tags, wires, strings and other means of temporary or shipping identification on surfaces to be painted shall be removed, but only after checking with and receiving authorization from FWUSAC's representative.



PAINTING

VIII.

D.

The paint applicator shall clean all surfaces which have been spotted with paint such as window glass, floors, walls, equipment, etc., leaving the premises clean to the satisfaction of FWUSAC.

E.

The paint applicator shall provide a temporary shelter for storage and mixing of paint materials. Applicator shall provide adequate fire fighting equipment, satisfactory to FWUSAC, for the temporary shelter and at all locations where painting work is in progress.

F.

A protective hood with a positive fresh-air supply shall be used during blast cleaning operations.

G.

A filter-type dust mask shall be used during hand tool or power tool cleaning operations in enclosed areas or in other situations where excessive concentrations of dust result.

H.

Protective clothing, such as gloves, goggles and aprons, shall be worn during pickling or solvent cleaning operations. Hands should be cleaned with a waterless hand cleaner after exposure to solvents. Clothing or protective equipment wet with solvents or paint should be promptly removed and laundered before reuse.

J.

Prior to the start of daily work, the contractor shall ascertain that all necessary tests have been made for toxic gasses, chemicals or explosives mixtures (see API Publ 2015). The safety conditions covered by OSHA, as well as those deemed necessary by the contractor, shall be met.

K.

Particular care must be exercised when working in close or confined spaces, especially when spraying. The paint contractor shall ascertain that all necessary tests have been made for oxygen sufficiency and hydrogen sulfide. The Threshold Limit Value (TLV) and Volatile Organic Content (VOC) as prescribed by OSHA or local government agencies for the particular solvent vapor in the air shall not be exceeded unless fresh-air masks, as approved by the National Institute of Occupational Safety and Health (NIOSH), are worn by workmen. When volatile solvents are flammable, the concentration in the air shall be kept to one-quarter or less of the lower explosive limit (LEL) by adequate exhaust or ventilation facilities.

INSPECTION A.

Surfaces prepared for painting are to be inspected and approved as satisfactory by the Owner's representative or paint inspector before any paint is applied by the contractor. The contractor shall also inspect all surfaces after cleaning and shall notify the Owner's representative of any defects, improper material or workmanship, or other conditions which in his opinion will affect the satisfactory performance and permanency of his work. Where such defects have been pointed out to, or by, the contractor, no painting shall be started



PAINTING until all such faulty conditions have been corrected or until a written agreement has been made with the Owner's representative regarding any subsequent defects which may develop because of the conditions noted.

IX.

B.

The Owner's inspector shall monitor wet and dry film thicknesses of the paint and shall compare his findings with those recommended. In cases of inadequate film build, the contractor shall be required to recoat the surface at his own expense.

C.

The inspector shall determine the adequacy of: 1.

Surface preparation using blast cleaning by comparison with NACE TM-01, "Visual Standards" prior to application of the first coat of paint.

2.

Dry film thickness by measurement of each coat and of the total system by procedures specified in SSPC-PA-2.

SELECTION OF PAINT A.

Paint system selection is based upon environment, humidity, location, presence of chemical fumes, splash and spillage, and other special factors.

B.

The following surfaces are not normally painted. shall be painted as follows: 1.

2.

When specified, they

Wood a.

Exterior - One coat of oil alkyd primer (P-103) and one coat of alkyd resin medium gloss enamel (P-206).

b.

Interior - One coat of oil alkyd primer (P-104) and one coat of alkyd resin medium gloss enamel (P-207).

Concrete a.

Concrete block walls (interior and exterior) - One coat of silicone water repellent (P-106) as primer and one coat of (P-106) as finish coat.

b.

Precast concrete roof members (interior) & gypsum board walls - One coat of latex flat (P-107) as primer and one coat (P-107) as finish coat.

c.

Concrete block walls in toilet rooms and laboratory - One coat of fill coat (P-108) and one coat of tile coat (P-208).



PAINTING 3.

Galvanized Steel a.

C.

For field touchup of galvanized steel, remove weld spatter, round off welds, hand tool clean and paint with one coat, 2.5 mils DFT minimum, organic zinc (P-105) or equal.

Paint systems are shown in Table A and Table C, and are applicable for the environment noted. Paint manufacturers should be consulted for recommendations before selecting systems for areas where paints will be subject to acid, alkali, solvent, etc., fumes, spillage, immersion or any other environment than that noted. A listing of primers and paints is given in Table B and Table D as a guide; equivalent paints are acceptable, subject to approval by FWUSAC. Where coatings in Table B and Table D do not meet local VOC rules, low VOC equivalent coating shall be submitted for approval by FWUSAC.



PAINTING TABLE A - PAINT SYSTEMS

Environment: Mild refinery/chemical plant/industrial service. Mild atmospheric conditions Not recommended for: Immersion in water, acid or alkali spillage or immersion, prolonged exposure to mineral and organic acids. PAGE 1 OF 2

SYSTEM

APPLICATION

NO.

BCS-1A

Uninsulated c.s.

SURFACE

PAINT TYPE

TEMP. LIMITS

(in order of application)

Up to 200°F

Inorganic Zinc primer High build, epoxy sealer

equipment including structural steel,

Vessels, heaters, Stacks, tanks, etc. Uninsulated c.s. equipment including structural steel,

BCS-3A

piping, exchangers, vessels, heaters, stacks, etc. Uninsulated c.s.

ICS-1A

Equipment including structural steel, piping, exchangers, vessels, heaters, stacks, etc. Insulated c.s.

ICS-2A

equipment including Exchangers, vessels, heaters, stacks etc. Insulated c.s. equipment including exchangers, vessels, heaters, stacks etc.

NUMBER

DRY FILM

COATING

OF COATS

THICKNESS EACH COAT (MILS) 3.0 – 5.0

NUMBER

1

P-101 PRIMER P-203

Heat exchangers,

BCS-2A

SURFACE PREPARATION SSPC ANCHOR STD. PROFILE (MILS) SP - 6 1.0 2.0

ABOVE

High build, acrylic

1

4.0 – 6.0

polyurethane

1

2.0 - 4.0

1

2.5 - 3.0

1

1.5 - 2.0

1

2.5 - 3.0

1

0.8 - 1.5

1

4.0 - 6.0

1

2.5 - 3.0

Inorganic Zinc

SP - 6

1.0 2.0

INT P-210 FINISH

P-101

200F - 350°F Silicone Acrylic

ABOVE

Inorganic Zinc

SP - 6

1.0 2.0

P-204

P-101

350F – 1000°F Silicone

Up to 300°F

ABOVE 300°F

Epoxy Mastic

SP - 6

Inorganic Zinc

SP-6

1.0 2.0

1.0 2.0

P-205

P-109

P-101 (for

(continuously )

Overseas Shipping)

FWUSAC



PAINTING TABLE A - PAINT SYSTEMS PAGE 2 OF 2 SYSTEM

APPLICATION

NO. ICS-3A

BP-1A

Insulated C.S. equipment including exchangers, vessels, heaters, stacks etc. Uninsulated C.S.

SURFACE

PAINT TYPE

TEMP. LIMITS

(in order of application) Silicone

Normally below 300°F but with Intermittent excursions to 1000ºF Up to 200°F

Piping IP-1A

Insulated C.S.

Up to 300°F

Piping IP-2A

Insulated C.S. Piping

ISS-1A

Insulated Austenitic Stainless steel and Duplex SS equipment and piping

UMS-1A

Misc. equipment that requires field upgrade of manufacturers standard coating system

ABOVE 300°F (continuously ) Up to 300 °F

Per Man. Standard

SURFACE PREPARATION SSPC ANCHOR STD. PROFILE (MILS) SP - 6 1.0 2.0

Inorganic Zinc Alkyd Resin

SP-6

Inorganic Zinc Epoxy Mastic

SP-6

Inorganic Zinc

SP-6

Epoxy Novolac

EPOXY Finish coat type and thickness to match adjacent equipment

SP-10

SP-6

NUMBER

DRY FILM

OF COATS 2

THICKNESS EACH COAT MILS) 0.8 – 1.5

1

2.5 – 3.0

1

1.5 – 2.5

1

2.5 - 3.0

1

4.0 - 6.0

1.0 2.0

1

2.5 - 3.0

2.0 to 3.0

2

4 to 6

N.A.

1

2.0 - 3.0

1.0 – 2.0

1.0 2.0

COATING NUMBER

P - 205

P-101 P-200 P-101 P-109 P-101

P-102

P-203



PAINTING

TABLE B - PRIMER MATERIALS

EXAMPLES OF ACCEPTABLE PRIMER MATERIALS Paint No.

(1) Type

Generic

Manufacturer's Identification

Acceptable Low VOC Equivalent

P-100

Universal Primer (lead free, chromate free)

Ameron 185 Carboline Multi-bond 150 Sherwin Williams Kem Kromik Metal Primer B50N2

Ameron 385 Carboline Multi-bond 150 Kem Kromik Metal Primer B50NZ6

P-101

Inorganic Zinc, Self Cure, Solvent Base, Multi-Package

Ameron Dimetcote 9 Carboline Carbo-Zinc 11 Sherwin Williams Zinc Clad II B69V3/B69D11

Ameron Dimetcote 9HS Carboline Carbo-Zinc 11 Sherwin Williams Zinc Clad II B69VZ1/VZ3/D11

P-102

Silicone (for stainless steel)

Carboline 4631WB (Black)

P-103

Exterior OilAlkyd Primer (Wood)

Carboline 4674 (Black) Dampney Thurmalox 70 (Black) Ameron 5105 Carboline Multi-bond 150 Sherwin Williams Y24W20 Ameron 5105 Carboline Multi-bond 150 Sherwin Williams B49W2

Ameron 5105 Carboline Multi-bond 150 Sherwin Williams B49WZ2

Ameron 68HS Carboline 858 Sherwin Williams Zinc Clad 4, B69A8/V8

Ameron 68HS Carboline 858/859 Sherwin Williams Zinc Clad 4, B69A8/V8

P-104

P-105

Interior Alkyd Primer (Wood) Epoxy, Zinc Rich

Ameron 5105 Carboline Multi-bond 150 Sherwin Williams Y24W20

P-106

Silicone, Water Repellent

Ameron 2011 Carboline Carbocrete 700

P-107

Latex, Flat

Ameron VG61 Carboline 3350 Sherwin Williams Pro Mar 400 B-30 Series

Ameron VG61 Carboline 3359 Sherwin Williams Pro Mar 400 B-30 Series

P-108

Tile Fill Coat

Ameron Amerguard 147 Sherwin Williams B42W46

Ameron Amerguard 147 Carboline Multi-Gard 954HB Sherwin Williams B42W46

P-109

Epoxy Phenolic Novalac

Sherwin Williams, Epo-Phen Hi Temp Coating

Sherwin Williams, Epo-Phen Hi temp Coating



PAINTING TABLE C INTERMEDIATE & FINISH MATERIALS

EXAMPLES OF ACCEPTABLE INTERMEDIATE & FINISH MATERIALS ( 2 PAGES)

Paint No. P-200

P-201

Generic Type

Sherwin Williams Epoxy Mastic Aluminum II

Sherwin Williams Epoxy Mastic Aluminum II Ameron 5405

Alkyd Resin (White)

Ameron 5450 Carboline Rustarmor 139 Sherwin Williams Tank Guard CL9255

P-202

P-203

High-Build Polyamide

P-204

SiliconeAcrylic

P-206


Polyamine Epoxy Aluminum filled

Alkyd Resin (Aluminum)

P-205


Silicone

Exterior Alkyd Enamel

Carboline Rustarmor 139

Ameron 5450 Carboline GP-62 Al/ Rustarmor 139AL Sherwin Williams B59S4

Sherwin Williams Tank Guard CL9255 Ameron 400AL Carboline Carbomastic 90 Sherwin Williams B59S4

Ameron 383HS Epoxy Carboline 890HB Sherwin Williams Multimil II B62 Series

Ameron 385 Carboline 890 Sherwin Williams Multimil II B62 Series

Ameron 892HS Carboline 1248 Sherwin Williams HeatFlex 450

Ameron 892HS Carboline 4631WB Sherwin Williams Heat-Flex 450

Ameron 878 Carboline 4674 Sherwin Williams B59S8

Ameron 892HS Carboline 4631WB

Ameron 5450 Carboline Rustarmor 139 Sherwin Williams B54 Series

Ameron 5405 Carboline Rustarmor 139 Sherwin Williams B54Z Series



PAINTING

TABLE C ( PAGE 2 OF2)

EXAMPLES OF ACCEPTABLE INTERMEDIATE & FINISH MATERIALS

Paint No. P-207

Generic Type

Interial Alkyd Enamel

P-208

Tile Glaze Coat

P-209

Coal Tar Epoxy

P-210

Aliphatic Polyurethane

P-211

High Build Aliphatic Polyurethane Satin or Modified Acrylic



Ameron 5450 Carboline Rustarmor 139 Sherwin Williams Pro Mar 200 Alkyd B34W200

Ameron 5405 Carboline Rustarmor 139 Sherwin Williams Pro Mar200 Alkyd B34WZ2000

Ameron 72 Carboline Multi-Gard 954HB Sherwin Williams B62 Series/B60V70 Ameron 78HB Carboline Carbomastic 14 Sherwin Williams B69B60/V60 Ameron 450 HS Carboline 134HG

Ameron 320HS Carboline Multi-Gard 954HB Sherwin Williams Tileclad HS B62WZ/B60VZ70 Ameron 78HB Carboline Bitumastic 300M Sherwin Williams B69B60/V60

Sherwin Williams B65W300/B60V30

Ameron Amershield Carboline 134HS/134HG Valspar V40 Series Sherwin Williams B65W300/B60V30

Ameron 450 SA Carboline 133HB (Polyurethane) Carboline 3359 (Acrylic) Sherwin Williams DTM B66WW1 (Acrylic) Sherwin Williams Corothane II B65200/B60V2 (Polyurethane)

Ameron Amershield SG Carboline 833 (Polyurethane) Carboline 3359 (Acrylic) Sherwin Williams DTM B66WW1 (Acrylic) Sherwin Williams Corothane II B65-200/B60V2 (Polyurethane)



PAINTING TABLE D ADDITIONAL EXAMPLES OF PAINT SELECTION

PAINT SYSTEM

NUMBER OF CAOTINGS

SHERWIN WILLIAMS

CARBOLINE

BP-1A

1st Coat Surface preparation DFT (mils) 2nd Coat DFT (mils) 3rd coat DFT (mils)

Zinc Clad II SP-6 ( 1.5 – 2.0) 3.0 – 5.0 Epoxy Mastic Aluminum II 4.0 – 6.0 None None

Carboline 859 SP-10 ( 1.0 – 2.0) 3.0 – 5.0 Carboguard 893 4.0 – 5.0 Carbothane 134HG 2.0 – 3.0

IP-1A

1st Coat Surface preparation DFT (mils) 2nd Coat DFT (mils)

Epo- Phen SP- 10(1.5 – 2.0) 7.0 – 9.0 None None

Carboguard 187 SP-10( 2.0 – 3.0) 5.0 – 6.0 Carboguard 187 5.0 – 6.0

BCS-2A


Zinc Clad II SP-6 ( 1.5 – 2.0) 3.0 – 5.0 Kem Hi-Temp Heat Flex II 450 AL 1.0 1.5

Carbozinc 11 SP-10( 1.0 – 2.0) 2.0 – 3.0 Thermaline 4900 AL( C901) 1.5 – 2.0

ICS-1A


Epo- Phen SP- 10(1.5 – 2.0) 7.0 – 9.0 Kem Hi-Temp Heat Flex II 450 AL 1.0 1.5

Thermaline 450 SP-10(1.0 – 2.0) 8.0 – 10.0 Thermaline 4900 AL( C901) 1.5 – 2.0

BCS-3A


Zinc Clad II SP-6 ( 1.5 – 2.0) 3.0 – 5.0 Hi-Temp 1000V AL 1.5 – 2.0

Carbozinc 11 SP-10( 1.0 – 2.0) 2.0 – 3.0 Thermaline 4700 AL( C901) 1.5 – 2.0

IP-1A

1st Coat Surface preparation DFT (mils)

Zinc Clad II SP-6 ( 1.5 – 2.0) 3.0 – 5.0

Carbozinc 11 SP-10( 1.0 – 2.0) 2.0 – 3.0



PAINTING REASON FOR CHANGES:

REV 1: Projectised per project requirements and FW procedure. Rev 0 is not issued on the project Since FW standard

is considered Rev 0.





D-3

Fire Proofing, 126158-84A1

Rev.1


FWUSAC


CONTRACT No. 126158-02 Page: 1 OF 17


FIREPROOFING The subject job specification is issued herewith. Please discard any previous issue of this specification. For convenience, the nature of the revision is briefly noted under remarks.


Date

By

Pages

Approved by

Reason for Issue

1

23RD AUG 2010

UVP/TC

17

SD




FIREPROOFING TABLE OF CONTENTS

SCOPE ........................................................................................................................................................................ 3 I. II. REFERENCES............................................................................................................................................................ 4 III. DEFINITIONS............................................................................................................................................................ 4 IV. REQUIREMENTS ...................................................................................................................................................... 5 V. MATERIALS.............................................................................................................................................................. 8 VI. APPLICATION OF CONCRETE FIREPROOFING ............................................................................................... 10 VII. APPLICATION OF OTHER FIREPROOFING MATERIALS............................................................................... 12 FIGURE 1: CONCRETE FIREPROOFING DETAILS ......................................................................................................... 13 FIGURE 2: CONCRETE FIREPROOFING DETAILS ......................................................................................................... 14 FIGURE 3: CONCRETE FIREPROOFING DETAILS AT SKIRT....................................................................................... 15 FIGURE 4: FIRED HAZAARD ZONE.................................................................................................................................. 16 REASON FOR CHANGES: ................................................................................................................................................... 17

FWUSAC



FIREPROOFING

REVISION INDEX PAGE

REV

DATE

REASON FOR REVISION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10 08/23/10

* Asterisk represents or will represent

I.

pages revised for this issue.

SCOPE A.

This job specification defines the basic requirements for design, materials, and application of fireproofing for steel structures, equipment, and supporting elements of piping and equipment located in fire hazardous areas of process plants.

B. The extent Summary

of fireproofing will Drawings and

be shown on Structural

Equipment Steel

Fireproofing Drawings.

C. The vendor or Contractor shall advise Foster Wheeler, in writing, of any conflicts between the requirements of this specification and other requirements. D. The latest editions of any federal, state or local codes, regulations, standards and guidelines that existed prior to January, 2010 or latest applicable to the project shall govern and supercede any prior federal, state or local codes, regulations, standards and guidelines referenced in this specification

FWUSAC



FIREPROOFING

II.

REFERENCES The latest editions and revisions of the following documents are referred to in this specification. A.

Job Specification 43A1, Foundations and Elevated Concrete Structures

B.

ACI 506, Recommended Practice for Shotcreting

C.

ASTM Standards: 1. 2. 3.

III.

ASTM C33, Specification for Concrete Aggregates ASTM C150, Specification for Portland Cement ASTM E119, Method for Fire Tests of Building Construction and Materials

D.

NFPA Code No. 30, Flammable and Combustible Liquids Code.

E.

UL Fire Resistance Directory

F.

ANSI/UL1709 Rapid Structural Steel.

Rise

Fire

Tests

of

Protection

Materials

for

DEFINITIONS A.

The following equipment is considered fire hazardous: 1.

Equipment containing hydrocarbons.

2.

Equipment in hydrogen service. Hydrogen service is defined as >50% hydrogen by volume or hydrogen partial pressure >100psia.

3.

Equipment which operates at or above the autoignition temperature of the liquid it contains.

4.

Equipment containing flammable or combustible liquids other than hydrocarbons as classified by NFPA Code Number 30 -Flammable and Combustible Liquids Code.



FIREPROOFING B.

Equipment not meeting the criteria for fire hazardous equipment in Paragraph A which is located from other fire hazardous equipment shall be considered non-fire hazardous.

C.

An area within a horizontal radius of 30’ (9 m) and 40’ (12 m) vertically upward from any fire hazardous equipment shall be considered a fire hazardous area. (Fig.4A)

D.

Fire Protection Ratings of fireproofing materials, in hours of protection on steel, shall be as listed by Underwriters Laboratories Inc. or other acceptable testing laboratory, using test procedures described in ASTM E 119 and UL1709. Where the words “shall be fireproofed” appear in this job specification, the fireproofing system shall be rated for a minimum of 3 hours per ASTM E119 or 2½ hours per UL1709. Hours of protection are defined as the number of hours of exposure to fire while maintaining steel temperatures below 1000°F (538°C).

IV.

REQUIREMENTS A.

General 1.

Structural elements supporting fire hazardous equipment shall be fireproofed.

2.

Structural elements supporting equipment which is not considered fire hazardous shall be fireproofed if one or both of the following conditions exist. a.

The equipment is essential for controlled shutdown of the plant.

b.

Failure of the equipment would damage fire hazardous equipment, or other equipment essential to controlled shutdown of the plant.

3.

Terminations of fireproofing on steel shall be sloped to shed water and sealed with mastic to prevent moisture from entering between the fireproofing material and the steel surface. Typical examples are top edges of fireproofing on horizontal beams whose top flanges are not fireproofed, top edges of fireproofing on columns, vessel legs, and vessel skirts of noninsulated vessels.

4.

Fireproofed members shall have their base plates and anchor bolting fireproofed unless otherwise noted on the drawings.

FWUSAC



FIREPROOFING B.

Structures Columns, beams and horizontal strut bracing of structural steel shall be fireproofed from grade to an elevation where the highest important equipment load is applied to the structure. All bracing except wind and earthquake bracing shall be considered as structural steel requiring fireproofing.

C.

Vessel Supports 1.

Vessel skirts 4' (1.2 m) in diameter and fireproofed on both the inside and the outside.

2.

Vessel skirts less than fireproofed as follows.

3.

4.

4'

(1.2

m)

in

larger

shall

be

diameter

shall

be

a.

Skirts with one access opening which is 16" (400 mm) diameter or smaller, and having only welded connections within the skirt, shall be fireproofed on the outside only.

b.

Skirts with an access opening larger than 16" (400 mm) in diameter, or more than one access opening, or with non-welded (flanged or screwed) connections within the skirt, shall be fireproofed on both the inside and the outside.

c.

Where the inside of the skirt is required to be fireproofed, bottom heads of uninsulated vessels shall be fireproofed using 4½” of calcium silicate insulation and stainless steel jacketing. Polyvinyl acetate mastic may be used for weatherproofing where it is impractical to use metal jacketing.

Extent of fireproofing on vessel skirts shall be as follows. a.

On insulated vessels, fireproofing foundation up to the insulation.

shall

extend

from

the

b.

On vessels having no insulation, fireproofing shall extend from the foundation to the top of the skirt. The fireproofing shall terminate in a 45° angle sloped downward and sealed with mastic. The top of the mastic shall be approximately 1" (25mm) below the skirt to shell weld (Figure 3).

Saddles supporting horizontal vessels and exchangers, measuring over 2' (610 mm) in height at their lowest point, shall be fireproofed in the same manner as vertical vessel skirts (Figure 3) on all surfaces.



FIREPROOFING

D.

5.

Legs, lugs, and brackets supporting vessels and exchangers shall be completely fireproofed.

6.

On supports of vessels and exchangers having slots in their base plates for thermal expansion, fireproofing shall not interfere with the sliding motion of these supports.

Fired Heaters Main structural members and bracing supporting fired heaters shall be fireproofed from the foundation to the floor of the heater.

E.

F.

Pipe Supports 1.

In fire hazardous areas, pipe rack bents supporting piping only shall be fireproofed to the first level, including horizontal members at the first level (Fig.4B) Pipe rack bents supporting fire hazardous equipment in addition to piping shall be fireproofed up to the point of support of the equipment (Fig.4C)

2.

Fireproofing of pipe supports is meant to include vertical and horizontal load-bearing members and load-bearing bracing. Top flanges of pipe-bearing beams, wind and earthquake bracing and longitudinal members which do not carry direct loads shall not be fireproofed.

3.

Where pipe racks require fireproofing, either precast concrete bents or fireproofed steel bents shall be used.

Instrumentation 1.

Aboveground instrument tubing and cable supported on pipe racks fire hazardous areas shall be enclosed in ladder type aluminum unperforated galvanized steel raceways. The raceways shall fireproofed with materials lighter than concrete for a minimum 1 hour protection per UL1709.

in or be of

2.

Critical instrumentation and power cable not covered by Paragraph 1 shall be protected so as to permit emergency function for at least 30 minutes under fire environment conditions as defined by UL1709. Critical instrumentation shall include but not be limited to the following.

FWUSAC



FIREPROOFING

3. G.

a.

Controls needed during emergency shutdown.

b.

Emergency block valves.

c.

Critical alarms

Alternative methods of fireproofing such as burying cable and/or routing cable around fire hazardous areas are acceptable.

Air Cooled Heat Exchangers Structural members supporting fireproofed as follows.

V.

air

cooled

heat

exchangers

shall

be

1.

All members of supports for exchangers handling flammable liquids shall be fireproofed.

2.

Only those structural members that are within fire areas, for exchangers handling nonflammable liquids fireproofed.

3.

Wind and earthquake bracing and longitudinal members which do not carry a direct load shall not be fireproofed.

hazardous shall be

MATERIALS A.

Concrete Components for concrete fireproofing shall be as follows: 1.

Cement shall be Type 1 Portland Cement conforming to ASTM C 150. Other cements may be used if required for special reasons, such as early strength or sulfate resistance.

2.

Sand shall be a commercial, high silica sand with clean, sharp, hard, durable particles conforming to ASTM C 33.

3.

For general purposes, aggregate shall be sharp and angular in nature, and range in size from ¼”(6 mm) to ½” (13 mm), and shall conform to ASTM C 33. Where light weight is essential, insulating type aggregates, such as perlite, vermiculite, expanded shale, or slag may be used.

4.

Water shall be free of substances injurious to desirable.

oils, acids, alkalis, salts or other concrete. Use of potable water is



FIREPROOFING

B.

C.

5.

Concrete mix shall be proportioned so that the minimum compressive strength of concrete after 28 days shall be 3,000 psi (210 kg/cm2).

6.

Welded galvanized steel wire mesh, 2" x 2" x 12 gage, (50 mm x 50 mm x 3 mm) shall be used for reinforcement.

7.

Lacing wire shall be No. 16 BWG (1/16", 1.5 mm) galvanized wire.

8.

Carbon steel rectangular welding studs, Nelson R6P or equal, shall be used for securing wire mesh reinforcement to steel. The length of the studs shall provide for ¾”(19 mm) to 1" (25 mm) spacing between the steel and the wire mesh. Carbon steel square or hexagonal nuts are also acceptable anchors for attachment of wire mesh.

9.

Mastic material for fireproofing terminations shall be waterproof, nonflammable when dry, durable under weather conditions, and able to withstand temperatures to 250°F (121°C).

Ceramic Fiber 1.

Ceramic fiber, 1½”(38 mm) thick, 8 lb/ft3 (128 kg/m3) density, may be used for fireproofing of instrument runs.

2.

Wire for holding ceramic fiber in place shall be annealed 18%Cr8%Ni stainless steel 16 BWG (1/16", 1.5 mm).

3.

Jacketing for ceramic fiber shall be 0.010" (0.25 mm) thick 18%Cr8%Ni stainless steel.

4.

Bands for securing jacketing on ceramic fiber shall be ½” (13 mm) wide, 0.020" (0.5 mm) thick stainless steel

Light Weight Proprietary Fireproofing Materials 1.

Several light weight proprietary materials are available for fireproofing steel structures and instrument trays for cables and conduits. They are cementitious, subliming, and intumescent coatings. They may be applied as described in Section VII or if available, in rigid panels.

These materials may be used in areas where exposure to damage from maintenance activities is minimal, and where considerable savings may result due to weight reduction of fireproofed structural



FIREPROOFING elements. Typical places include support legs and bracing for air cooled heat exchangers or similar equipment located on elevated structures such as pipe racks and other structural members at higher elevations. Panel shapes and intumescent coatings are especially suited for use on instrument trays (Paragraph IV.F.). 2.

Use of these materials is acceptable only if their manufacturers can document the fire endurance of the products backed-up by the acceptable laboratory tests and proven experience as well as ease of application and repair. Examples of acceptable materials are as follows. a.

Lightweight Cementitious: Carboline Company - Pyrocrete 240 series. Carboline Company - Pyrocrete 241 series ( 2 ½ hours Rating)

b.

Intumescent: Textron Specialty Materials - Chartek IV PPG Industries, Inc. - Pitt-Char XP Carboline Company - Nullifire System E

Foster Wheeler shall have final approval regarding the use of all proprietary materials.

VI.

APPLICATION OF CONCRETE FIREPROOFING A.

General 1.

Steel to be fireproofed shall be thoroughly cleaned to remove loose paint, grease, rust, and foreign matter which would impair the bond between the fireproofing and the fireproofed surface. Where fireproofing is applied to a painted surface, the paint shall be fully cured.

2.

Concrete fireproofing shall be applied to a minimum thickness of 2" (50 mm) in all cases to obtain the necessary protection. Typical details of fireproofing with concrete are shown in Figures 1, 2 and 3. Either pneumatic (shotcrete, gunite) or formed encasement application is acceptable.

3.

In certain instances, at the discretion of Foster Wheeler, it may be economical and feasible to fireproof structural members before they are erected. The joint connections shall be fireproofed



FIREPROOFING after erection to the same degree of protection as the structural member.

4.

Exposed concrete corners shall be chamfered or rounded.

5.

Reinforcement for Concrete Fireproofing Wire mesh shall be used for reinforcement and shall be supported on the member being fireproofed by means of welded studs or nuts on edge. Clearance between the mesh and the structural member shall be a minimum of 3/4" (19 mm). Edges of adjacent sheets of mesh shall lap a minimum distance of 2" (50 mm), and shall be secured with lacing wire spaced 18" (455 mm) apart.

6.

7.

Precautions a.

The surface to which the concrete is applied shall be kept free from frost and ice. Placing of concrete at temperatures below 40°F (4°C) is not permitted, unless facilities are available for keeping the concrete above this temperature during placing and curing.

b.

During operation, the application equipment shall be properly grounded to prevent static electricity, especially in areas where the atmosphere may contain flammable vapors.

c.

Surfaces and equipment adjacent to the member being fireproofed shall be shielded by screens, tarpaulins, or heavy paper covering to shield them from spatters and prevent excessive cleanup.

Curing The concrete shall be kept damp, but not dripping wet, to prevent loss of moisture, for at least 5 days after placement. Other suitable curing means, such as the application of resin based commercial compounds, may be employed.

B.

Pneumatic Application of Concrete The work shall be performed by qualified workmen experienced in the application of concrete by the method chosen. Application shall be in accordance with ACI-506, Recommended Practice for Shotcreting.

C.

Formed Encasement Application of Concrete



FIREPROOFING The form work, mixing, pouring and curing shall be in accordance with ENG STD 43A1.

VII.

APPLICATION OF OTHER FIREPROOFING MATERIALS A.

Required thickness of fireproofing materials other than concrete shall be obtained from the UL Fire Resistance Directory. In all cases thicknesses shall be sufficient to provide a minimum of 22 hours of protection per UL1709 unless otherwise allowed by this job specification. Materials shall be applied over reinforcement such as expanded metal lath, as recommended by the manufacturer or as called out in the UL Directory. The fireproofing subcontractor shall submit application details for approval with his quotation. Prior to application, the subcontractor shall prepare a sample of the same thickness as required for the project, to be approved by Foster Wheeler and the Owner. The finish of this sample shall be used as an inspection aid for acceptance of the work. The sample shall be on a 3' (1 m) long wide flange structural member.

B.

Intumescent and Subliming Coatings These materials are generally applied by spray method. Preparation of steel surfaces, application and finishing shall be in accordance with the manufacturer's written instructions and the requirements of Paragraph VII.A. above. The applicator shall be experienced in handling these materials and shall be recommended by the coating manufacturer. Priming of steel surfaces and painting of the finished work is required as recommended by the manufacturer.

C.

Light Weight Cementitious Materials These materials can be applied by spraying or troweling. If smooth surfaces are required, sprayed-on material shall be smoothed with a trowel, or trowelled application shall be used. A plastic nose corner bead shall be used on trowelled smooth boxed column design to ensure regularity and trueness of corners. Metal surface preparation, reinforcement, application, and finishing shall be in accordance with the manufacturer's recommendations and the requirements of Paragraph VII.A. above. The applicator shall be experienced in handling these materials and shall be recommended by the manufacturer.


FIREPROOFING FIGURE 1: CONCRETE FIREPROOFING DETAILS



FIREPROOFING FIGURE 2: CONCRETE FIREPROOFING DETAILS



FIREPROOFING FIGURE 3: CONCRETE FIREPROOFING DETAILS AT SKIRT



FIREPROOFING FIGURE 4: FIRED HAZAARD ZONE




FIREPROOFING REASON FOR CHANGES:

REV 1: Projectised per project requirements. Rev 0 is not issued on the project Since FW standard considered Rev 0.

for the preparation of this specification is





D-4

Flake Glass Polyester (Carboline Carboglas 1601SG), 126158-83A9

Rev.1




JOB SPECIFICATION 126158 - 83A9

FLAKE GLASS POLYESTER (CARBOLINE CARBOGLAS 1601SG) The subject job specification is issued herewith. previous issue of this specification.

Please discard any


Date

By

Pages

Approved by

Reason for Issue

1

10/5/2010

UVPATEL

10

SDemko

ISSUE FOR BDP



FLAKE GLASS POLYESTER (CARBOLINE CARBOGLAS 1601SG)

CONTENTS

REVISION INDEX

3

I.

3

SCOPE

II. REFERENCES

4

III. MATERIALS AND DESIGN

4

IV. PERFORMANCE OF THE WORK

5

V. SAFETY PRECAUTIONS

5

VI. SURFACE PREPARATION

5

VII. COATING THICKNESS AND APPLICATION

6

VIII.CONFLICTING INSTRUCTIONS

9

IX. PRESERVATION OF WORK

9

X. CLEANING AND STORAGE

10




REVISION INDEX PAGE

REV

1 2 3 4 5 6 7 8

1 1 1 1 1 1 1 1

*

I.

DATE

REASON FOR REVISION

10/5/2010 10/5/2010 10/5/2010 10/5/2010 10/5/2010 10/5/2010 10/5/2010 10/5/2010

complete revision-SPEC Projectised

Asterisk (when noted) will represent page content revised for this issue.

SCOPE A.

General 1.

This job specification (JOB SPEC) covers the requirements for a shop or field applied internal non metallic lining for decoking water storage tanks and other tanks when noted in order to insure the materials and workmanship necessary to produce a quality tank lining.

2.

The work entails the preparation, coating and inspection of the tank interior surfaces.

3.

The vendor or Contractor shall advise Foster Wheeler, USA in writing, of any conflicts between the requirements of this JOB SPEC and vendor requirements

4.

The latest editions of any federal, state or local codes, regulations, standards and guidelines that existed prior to September 2010 , shall govern and supercede any prior federal, state or local codes, regulations, standards and guidelines referenced in this JOB SPEC.

5.

The vendor or Contractor shall advise Foster Wheeler, USA in writing, of any conflicts between the requirements of this JOB SPEC



FLAKE GLASS POLYESTER (CARBOLINE CARBOGLAS 1601SG) II.

REFERENCES A.

III.

Steel Structures Painting Council (SSPC) 1.

SSPC-SP 5/NACE #1

White Metal Blast Cleaning

2.

SSPC-PA 2

Measurement of Magnetic Gages

Dry

Paint

Thickness

with

B.

U.S. Federal Documents - Occupational Safety and Health Specifications (OSHA)

C.

National Association of Corrosion Engineers (NACE) Recommended Practice RP0178.

MATERIALS AND DESIGN

A. Coating shall be CARBOLINE CARBOGLAS 1601SG for DECOKING WATER TANK and for the other tanks when noted. This is Flake Glass Polyester coating from CARBOLINE only. B.

A specific lining guarantee is required to be supplied to the owner by the applicator insuring the lining will be free from failure caused either by poor workmanship, application or material failure for a minimum period of 2 years. The applicator shall form a liaison with the coating manufacturer in order to ensure that not only is the surface preparation and application guaranteed, but the lining as well.

C.

All coating materials shall be delivered to the jobsite in the original and unopened containers, plainly marked with the proper designation of the product, as well as the name of the manufacturer.

D.

The coatings shall be used and applied per coating manufacturers’ most recent printed instructions without being extended or modified. The correct surface preparation and condition of the surface to be coated shall be rigidly adhered to.




IV.

E.

All coating materials at the jobsite shall be subject to inspection by the resident engineer or inspector.

F.

The minimum tank nozzle diameter shall be 3 inch ( 76 mm) in order to facilitate lining application.

G.

Tank design and fabrication details shall be in accordance with NACE RP0178. All sharp edges and welds shall be ground smooth to a rounded contour in accordance with NACE weld preparation designation “C”. All weld splatter shall be removed prior to abrasive blasting.

H.

Butt welded joints shall be used in lieu of lap-type joints.

PERFORMANCE OF THE WORK All work shall be performed in strict accordance with this specification and the coating manufacturer's current application instructions. The applicator shall furnish all labor, equipment, appliances and materials and shall ensure that all work is performed in a safe and workmanlike manner. All phases of the work shall be available to the coating manufacturer and the resident engineer or inspector for observation or inspection at any time.

V.

SAFETY PRECAUTIONS All pertinent OSHA safety regulations shall be adhered to rigidly. In addition, all safety precautions noted on the manufacturer's product data sheets and application instructions shall be observed.

VI.

SURFACE PREPARATION A.

General 1.

2.

All surfaces to be coated shall be prepared in a workmanlike manner with the objective of obtaining a clean, dry and properly prepared substrate. No coating work shall begin before the prepared surfaces have been inspected and approved.




B.

VII.

Steel Surfaces 1.

Remove any oil or grease from surfaces to be coated using clean rags soaked in toluol. Any chemical contamination shall be eliminated by means of neutralization, flushing or both, prior to additional surface preparation. Solvent and rags shall be changed frequently to ensure their cleanliness.

2.

All surfaces to be coated shall be abrasive blast cleaned to white metal in accordance with SSPC-SP 5/NACE #1.

3.

The proper abrasive to obtain the specified profile (anchor pattern) designated in the coating manufacturer's most recent printed application instructions shall be used. Abrasive blasting shall be performed using grit or synthetic abrasives. After abrasive blasting, dust and spent abrasive shall be removed from the surfaces by brush or vacuum. The coating shall be applied as soon as possible after the blasting operation is finished and always before the surface starts to rust. No abrasive blasted surface shall stand overnight before coating.

4.

Only unused fresh abrasive shall be used. oil, grease, chlorides, copper and clay.

5.

Imperfections in surfaces to be coated shall be repaired by grinding or welding prior to abrasive blasting.

Abrasive shall be free of

COATING THICKNESS AND APPLICATION A.

General 1.

Coatings shall be applied in accordance with the instructions of the coating manufacturer. Coating thickness shall be 40 mils minimum.

2.

All coatings shall be applied under favorable conditions by an applicator with successful previous experience applying the same coating.




3.

All blast-cleaned metal shall be coated, as specified, within the same day of cleaning to prevent new rusting or oxidation of cleaned surfaces. Any oxidation or rusting of cleaned surfaces shall require reblasting to a white metal finish.

4.

The application shall leave no sags, brush marks, pinholes, or other defects.

5.

Drying time between coats and for final cure shall adhere to the coating manufacturer's recommendations with conditions of temperature, humidity and ventilation taken into consideration.

6.

Cleaning and coating shall be scheduled so that dust and other contaminants from the cleaning process will not fall on wet, newly coated surfaces.

7.

All coating shall conform to the following conditions: a.

The dry film thickness of each coat and of the entire system shall follow the coating manufacturer's recommendations.

b.

All equipment shall be maintained in good working order and shall be comparable to that described in the coating manufacturer's application instructions. Equipment shall be thoroughly cleaned and inspected daily. Worn spray nozzles, tips, etc. shall be replaced regularly. Effective oil and water separators shall be used and serviced on all air lines.

c.

Thinning shall be done only if necessary for the workability of the coating material and then, only in accordance with the coating manufacturer's application instructions. The approved manufacturer's supplied thinner shall be used.




d.

B.

No coatings shall be applied when the air temperature is below 60°F or above 100°F, or when the temperature of the surface to be coated is below 60°F, unless allowed in the coating manufacturer’s application instructions. No coatings shall be applied if a predicted temperature of 60°F or lower is forecast within 24 hours of application unless the coating area is enclosed and heated. No coatings shall be applied when the surfaces may become damaged by rain, fog or condensation or when it is anticipated that these conditions will prevail during the drying period, unless suitable enclosures to protect the surface are used. Where heat is necessary, it shall be supplied by the applicator and shall be of such type that it will maintain a minimum air and coated surface temperature of 70°F during the coating period. The heater shall be of such type as not to contaminate the surface area to be or being coated with combustion products. The responsibility for supplying utilities to run electric or gas heaters shall be carried by the owner.

Inspection 1

Visual inspection for pinholes, holidays, dry spray, sags and other flaws shall be performed after each coat is applied. All such flaws shall be corrected before the next coat is applied.

2

After the final coat is applied and visually inspected, a holiday detector, equivalent to a Tinker Rasor Model AP-W (3000 to 3500 volts) or approved equal, shall be used over the entire tank interior to ensure no holidays exist in the coating. The coating shall set for a minimum of 48 hours at a minimum temperature of 70°F before high voltage holiday inspection is performed.

2.

Coating thickness shall be inspected in accordance with SSPC-PA 2.




VIII. CONFLICTING INSTRUCTIONS

IX.

A.

Copies of both this specification and coating manufacturer's most recent printed application instructions shall be at the jobsite.

B.

Resolution of conflicts between these documents shall be provided in writing by the coating manufacturer.

PRESERVATION OF WORK A.

During construction, the applicator shall assume the responsibility for preservation of all his work against damage.

B.

The applicator shall complete the coating work and subject it to inspection by the resident engineer, inspector and/or a representative of the owner.

C.

All work which is rejected or which must be retouched shall be redone by the applicator at his expense.




X.

CLEANING AND STORAGE A.

B.

Cleaning 1.

All work not to be coated, or previously coated, shall be carefully protected during the coating of adjacent work.

2.

Any coated surfaces which were not specified to be coated and/or any coating materials not per this specification shall be thoroughly cleaned and the original or specified finish restored at the applicator's expense.

3.

Name and data plates on equipment shall not be coated and shall be left clean and legible upon completion of the project.

4.

Upon completion of the project the jobsite shall be left neat and clean.

Storage All coating materials shall be stored under cover in a controlled atmosphere as recommended by the coating manufacturer.





D-5

External Insulation, Hot Service, 126158-82A1

Rev.1




JOB SPECIFICATION 126158 - 82A1 EXTERNAL INSULATION – HOT SERVICE The subject job specification is issued herewith. previous issue of this specification.

Please discard any


Date

By

Pages

Approval

Remarks

1

5th Oct 2010

Udayan Patel

28

S. Demko



FWUSAC Specification No. 126158 - 82A1 Page: 2 OF 28

Rev No: 1

EXTERNAL INSULATION – HOT SERVICE

REVISION INDEX PAGE REV

DATE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010 10/05/2010

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

REASON FOR REVISION Entire specification is projectized

* Asterisk, when noted, will represents page content revised for this issue

I.

SCOPE A.

This job spec defines the requirements for the external insulation of piping and equipment in hot service (above ambient temperature), for the purpose of conserving heat and protecting personnel. This job spec does not define insulation for systems operating above 1200°F (649°C).



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE B.

The insulation described in this job spec is suitable for use in outdoor service with normal process plant atmosphere. Where the atmosphere and/or potential spills or leaks contain chemicals that will react with standard insulation materials, specialized insulation systems shall be developed. The vendor or Contractor shall advise Foster Wheeler, USA in writing, of any conflicts between the requirements of this JOB SPEC. The latest editions of any federal, state or local codes, regulations, standards and guidelines that existed prior to September, 2010 shall govern and supercede any prior federal, state or local codes, regulations, standards and guidelines referenced in this JOB SPEC

C.

Requirements regarding the extent of insulation, based on the intended service, shall be specified on the following project documents: 1.

Engineering Flow Diagrams / Piping and Instrument Diagrams

2.

Line Classification Lists

3.

Piping Isometric Drawings

4.

Instrument Piping Details

5.

Equipment Insulation Summary



Rev No: 1


II.

REFERENCES The following documents are referred to in this job spec. A.

ASTM Standards 1.

ASTM B 209 Specification Sheet and Plate.

for

Aluminum

and

Aluminum-Alloy

2.

ASTM C 195 Specification for Mineral Fiber Thermal Insulating Cement.

3.

ASTM C 449 Specification for Mineral Fiber Hydraulic-Setting Thermal Insulating and Finishing Cement.

4.

ASTM C 533 Specification for Calcium Silicate Block and Pipe Thermal Insulation.

5.

ASTM C 547 Specification for Mineral Fiber Preformed Pipe Insulation.

6.

ASTM C 592 Specification for Mineral Fiber Blanket Insulation and Blanket-Type Insulation (Metal Mesh Covered).

7.

ASTM C 610 Specification for Expanded Perlite Block and Pipe Thermal Insulation.

8.

ASTM C 612 Specification for Mineral Fiber Block and Board Thermal Insulation.

9.

ASTM C 795 Specification for Wicking-Type Thermal Insulation for use over Austenitic Stainless Steel.

10. ASTM C 892 Specification for High-Temperature Fiber Blanket Thermal Insulation. 11. ASTM C 1086 Insulation.

Specification

for

Glass

Fiber

Felt

Thermal



Rev No: 1


III.

DESIGN A.

B.

The service or purpose for which insulation is required shall be classified and identified as follows. For insulation thickness requirements refer to Tables 1 through 4. 1.

HC - Heat Conservation Insulate where heat loss is not desirable.

2.

PP - Personnel Protection The extent of protection for PP shall be within 2' (610 mm), horizontally of normal working areas or access ways for a height of 7' (2.1 m) above grade or a platform.

The normal operating temperature of the fluid shall be used to determine insulation requirements, with the following clarifications: 1.

Where an equipment item has sections operating at different temperatures, each section may be insulated as required to suit its operating temperature.

2.

For heat traced items, the normal operating temperature of the process fluid shall be used.

3.

For jacketed items, insulation requirements shall be based on the temperature of the fluid in the jacket.

C.

Instrument components subject to flow and/or temperature conditions approximating those in the piping/equipment to which they are connected shall be insulated using the same criteria as the connected piping/equipment.

D.

The following items shall not be insulated. 1.

Equipment and piping where heat loss is desired.

2.

Internally insulated items. Such items shall have a conspicuous warning note painted on external surfaces stating that external insulation is prohibited.

3.

Flanged joints, except those listed in Para. III.E.

4.

Valve bodies, including control valves, whose temperature is between ambient and 300ºF (149ºC).

operating



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE 5.

Items which become hot intermittently, such as relief valves, relief systems, vents, drains, pump-out and blowdown systems, steam-out and purge steam systems.

6.

Pipe union fittings

7.

Strainers and filters

8.

Steam traps

9.

The bellows portion of expansion joints, hinged joints and hose assemblies

10. Sight flow indicators 11. Nameplates on vessels, exchangers and machinery 12. Supports for piping or equipment. Note: If the support skirts for vertical vessels are not fireproofed, insulation on vessels shall be carried below the tangent line for a distance of 2' (610 mm), but it shall end not less than 1' (305 mm) above support concrete or steel. If the skirt is fireproofed, the insulation shall extend to the top of the fireproofing. E.

The following flanged joints shall be insulated. For insulated flanges, bolt and flange material stresses must be acceptable at the increased temperature. 1.

Those in steam service.

2.

Those heated by a tracer or jacket.

Insulation applied to flanged joints shall be removable and reusable. It may be fabricated as shown in Detail "H" or it may be of prefabricated blanket type as described in Paragraph V.B. F.

Bodies of flanged valves, including control valves, in insulated lines which operate at temperatures over 300ºF (149ºC), shall be insulated using the same insulation thickness as the pipe. Valve bonnets shall not be insulated. Screwed or welded valves shall be insulated with insulating cement and weatherproofed with mastic.

G.

Uninsulated expansion loops and cross-overs in heat tracer tubing shall be wrapped with waterproof fiberglass cloth tape to a thickness of 1/4" (6 mm).



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE H.

Insulated piping in pipe racks shall be supported on steel shoes. The height of the shoe shall be such that the bottom of the insulation is at least 1" (25 mm) above the support upon which the shoe rests.

J.

Tanks shall be equipped with the same type of insulation and supports as vessels. Requirements for tank insulation shall be determined for the specific tank and incorporated on the tank drawing.

K.

Compressors, pumps, and other mechanical equipment shall be insulated on an individual basis with consideration given to the requirements for process access and equipment maintenance. The equipment manufacturer shall be consulted prior to the insulation of each piece of equipment.

L.

Insulation shall be protected by a metal jacket from the weather, spillage, mechanical wear, or other damage. Weatherproofing mastic may be used on irregular surfaces or on surfaces for which metal jacketing is not practical.

M.

Insulation support rings shall be provided on vertical vessels. The spacing of the rings shall coincide with the insulation expansion joints. Vertical vessels shall have a minimum of two insulation support rings; one at or below the bottom tangent line and one at the top tangent line. Additional rings shall be added as required by the expansion joint spacing.

N.

Support rings, studs, clips, etc. shall be fabricated using the same material as the equipment item and shall be welded in place by the fabricator. Carbon steel rings shall be bolted to the clips. See Figure 2 detail "B".



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE P.

Clamp type support rings shall be furnished and installed by the insulation contractor at the lower end of vertical piping (piping inclined more than 45º from horizontal) and above each flange, ell, tee, etc. for pipe sizes greater than NPS 3. Intermediate support rings shall be supplied for uninterrupted vertical runs as follows:

Pipe Diameter (D)

Length of Run (L)

NPS 3 < D ≤ NPS 16

L < 30’(9m) 30’ ≤ L <40’(12m) L ≥ 40(12m)

# of Intermediate Supp’ts. NOTE 1 0 1 >1

L < 20’(6m) 20’ ≤ L < 30’(9m) L ≥ 30’(9m)

0 1 >1

D > NPS 16

NOTE

Q.

Spacing

N/A 20’(6m)max. 1 supp’t. every 20’(6m) N/A 15’(4.5m)max 1 supp’t. every 15’(4.5m)

1 Where only one intermediate support is required, the support shall be placed as close to the midpoint of the run as possible. Where more than one is required, the supports shall be placed at equal intervals.

Clamp type support rings shall be manufactured from 3/16" (4.5mm) to 1/4" (6mm) thick plate and shall match the piping material. The clamp shall be coated to resist corrosion if the piping is coated. Galvanized clamps are not permitted on alloy steel, stainless steel or items operating above 700ºF (370ºC).



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE R.

Support rings at flanges shall be located a minimum of 1" (25 mm) above all welds and a minimum of one bolt length plus 1" above the back face of the top flange. Support rings at fittings (ells, tees, etc.) shall be located at least 6" (150 mm) above the pipe to fitting weld.

S. Expansion joints in the insulation shall be used to provide for differential thermal expansion between the insulation material and the piping or equipment material. Expansion joints shall be packed with a loose fiber insulation material. On vessels, a 1" (25 mm) wide space packed with loose insulating fiber shall be provided around all nozzle and manway necks, and any other attachment to the vessel wall in addition to the required expansion joints. Maximum spacing for circumferential and longitudinal expansion joints on equipment and piping shall be as follows:

TEMPERATURE Up to 250°F (Up to 121°C) 251 to 400°F (122 to 204°C) 401 to 600°F (205 to 316°C) 601 to 900°F (317 to 482°C) 901 to 1200°F (483 to 649°C)

MAX. JOINT SPACING 30’ (9m) 15’ (4.5m) 12’ (3.6m) 9’ (2.7m) 6’ (1.8m)

On vertical piping and vessels, expansion joints shall be located under the insulation support rings where such rings are required.

FWUSAC


Specification No. 126158 - 82A1 Page: 10 OF 28

Rev No: 1

EXTERNAL INSULATION – HOT SERVICE IV.

MATERIALS A. All insulating materials shall be asbestos-free, non-corrosive to the metal being covered, and where applicable, shall comply with OSHA requirements. B. Acceptable follows.

insulation

APPLICATION Heat Conservation and Steam Tracing Personnel Protection Prefabricated Blanket Removable Covers (Para. V.B.1)

materials

for

specific

TEMPERATURE ≤150°F (65°C) 151-300°F (66-149°C) >300°F (149°C) ≤150°F >150°F ≤1000°F >1000°F

(65°C) (65°C) (538°C) (538°C)

applications

are

as

ACCEPTABLE MATERIAL(S) No Insulation Required Expanded Perlite Perlite, Mineral Wool, Calcium Silicate No Insulation Required Metal Shields1,2 Glass Fiber Ceramic Fiber (Hot Face Only)

1. If both heat conservation and personnel protection are required, metal shields shall be installed over insulation where necessary. 2. Where metal shields are not practical from a design or installation standpoint, acceptable insulation materials shall be in accordance with the Heat Conservation and Steam Tracing portion of the above table. C.

Insulation and accessory materials shall conform to the following requirements. Temperature limits listed by the manufacturers and in the applicable ASTM standards shall not be exceeded. 1. Calcium silicate block and preformed pipe insulation shall conform to the requirements of ASTM C 533 Type I. 2. Expanded perlite block and preformed pipe insulation shall conform to the requirements of ASTM C 610. 3. Mineral fiber insulation shall conform to ASTM C 547 Type II for preformed pipe insulation, ASTM C 592 Type II for blanket insulation, and ASTM C 612 Type IV for block and board insulation. 4. Ceramic fiber insulation shall conform to the requirements of ASTM C892 Grade 8 Type I. 5. Glass fiber insulation shall conform to the requirements of ASTM C1086. 6. Insulating material on austenitic stainless steel shall comply with the requirements of ASTM C 795. If a special grade of material must be manufactured to meet these requirements, the manufacturer shall make

FWUSAC



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE provisions to avoid the special grade materials.

possibility

of

interchanging

standard

and

7. All mastics, cements, binders, and other materials used in conjunction with insulation on austenitic stainless steels shall contain less than 50 ppm leachable chlorides. Potable water shall be used for mixing these materials. 8. Mineral fiber thermal insulating requirements of ASTM C 195.

cements

shall

conform

to

the

9. Mastic for weatherproofing shall be breathable asphalt, acrylic, or polyvinyl acetate. Mastic shall be weather and fire resistant and capable of withstanding surface temperatures of 200ºF (93ºC). An example of an acceptable weatherproofing mastic is Foster Products Company Sealfas G-P-M 35-XX/45-XX. 10. Combined insulating and finishing cement shall conform to ASTM C449 and shall be compatible with all materials with which it comes in contact. It shall be suitable for application to the required dry thickness in one operation and shall produce a smooth surface after being troweled. 11. Metal jacketing shall be 0.016” (0.4 mm) thick aluminum per ASTM B209 Grade 3003 or 3105 with H14 or H16 temper and a factory-applied bonded layer of moisture barrier on its inside surface. The moisture barrier may be polyethylene - kraft paper, polysurlyn, or other approved alternate. Jacketing on vertical cylindrical equipment shall be corrugated as follows. For outside diameters (including insulation) of 36" (915 mm) to 60" (1.5 m), pitch of corrugations shall be 3/16" (4.5 mm). For outside diameters (including insulation) larger than 60" (1.5 m), pitch of corrugations shall be 1-1/4" (30 mm). Metal jacketing for vessel heads, machinery, pipe and pipe fittings, horizontal vessels, vertical vessels less than 36" (915 mm) in diameter and other irregular surfaces shall be flat sheets. 12. Joint sealer for metal jackets shall be Foster Elastolar Sealant 95-44 or equal.

Childers

Chil-Joint

CP-70,



Rev No: 1


13. Accessory and attachment materials shall be as follows. a.

Wire for securing insulation shall annealed Type 18-8 stainless steel.

be

16

gage

(1.7

b.

Bands and seals for securing insulation and jacketing shall be 0.020" (0.5 mm) thick stainless steel. Width of bands on jacketing shall be ½” (13 mm) for jacket outside diameters ≤5’(1.5 m) and ¾” (19 mm) for diameters > 5’ (1.5 m). Width and spacing of bands on insulation shall be per Para. V.A.12.

c.

Expander-type bands shall be Gerrard Company or equal.

d.

Expansion springs for bands on insulation shall be Type 302 stainless steel INSUL-MATE ES-7 manufactured by RPR Products, Inc., CHIL-SPRING manufactured by Childers Products Company, Inc. or equal.

e.

Compression springs for bands on jacketing stainless steel Childers MITY-SPRING or equal.

f.

Screw fasteners shall be No. 8 (4 mm), stainless steel, 1/2" (13 mm) long, self-tapping panhead or hexhead.

g.

Reinforcing material for mastic finishes shall be 10 x 10 mesh glass fabric.

h.

Wire mesh shall be 1" (25 mm) hexagonal pattern annealed 18-8 stainless steel poultry netting with a minimum wire size of 0.036" (0.9 mm).

j.

"S" and "J" clips shall be 0.020" (0.5 mm) thick stainless steel.

k.

Flashing materials shall be 0.010" (0.25 mm) aluminum grade 3003 or 3105.

shall

be

mm)

fully

Type

302



Rev No: 1


V.

INSTALLATION A. General 1.

Equipment and piping surfaces shall be cleaned by brushing off all foreign matter, such as dirt, loose rust, loose scale, plaster, etc., and shall be wiped clean of oil and water to a dry condition before insulation is installed. Painted surfaces shall be insulated only after the paint has completely dried.

2.

Insulation shall not be installed over joints (welds, flanges, pipe threads, etc.) or tracers until required field testing has been completed and all such joints or tracers are proven tight.

3.

Dry insulation material which becomes wet prior to or during installation shall be thoroughly dried before proceeding with its installation.

4.

Working parts of valves, turbines, or other mechanical equipment shall be protected when insulation is applied. Until all insulation materials, including cement or mastic, have been removed from these parts (e.g., valve stems, governor linkages, etc.) the scope of insulation work shall be considered incomplete.

5.

Insulation up to 3" (75 mm) in thickness may be applied in a single layer with vertical joints staggered. Thicker insulation shall be applied in 2 or more layers with staggered joints. Adjacent insulation sections shall be butted firmly together. Preformed pipe insulation and preformed insulation fittings may be installed in one layer if available in the required thickness however, the maximum layer thickness in a multi-layer system shall be 3” (75 mm).

6.

Voids due to fitting of rigid insulation shall be filled with insulating-finishing cement. Cement shall not be used in contact with stainless steel components (including steam tracing), with electrical tracers or in insulation expansion joints. In these cases, rigid insulation shall be cut to eliminate voids.

7.

Insulating cement may be used on irregular surfaces where the use of insulation is impractical. The applied thickness of the insulating cement shall be 25% greater than the required insulation thickness.

8.

Pipe insulation shall be discontinued at flanged connections permit removal of the studs. The distance from the end of insulation to the back of the flange on both sides of connection shall be equal to one stud length plus 1" (25mm). ends of insulation shall be beveled at noninsulated flanges.

to the the The At



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE insulated flanges, the ends of the insulation shall be straight. In both cases, insulation terminations shall be weatherproofed using aluminum flashing. 9.

Stiffening rings on equipment shall be covered insulation thickness as the equipment itself.

with

the

same

10.

If blanket insulation is used on large vessels, fans, ducts, boilers, etc. it may be strapped on or it may be impaled on pins welded to the vessel as shown on Fig. 2 Detail "D." All welding required for installation of insulation supports shall be approved by the purchaser prior to welding.

11.

In cases where large diameter piping requiring heat conservation insulation passes through a vessel skirt, the insulation thickness may be reduced by the Detailed Design Contractor with the approval of the Owner to avoid increasing the size of the openings in the skirt. The resulting insulation thickness shall under no circumstances be less than 3” (75mm).



Rev No: 1


Insulation material shall be held in place with tie wires or bands as follows: INSULATION LAYER Single or Outer Layer Single or Outer Layer Inner Layer Inner Layer Any Layer Any Layer *

13.

INSULATION OUTER DIAM. <3 ft.(1 m) 3 to 6 ft. (1 to 2 m) <3 ft.(1 m) 3 to 6 ft. (1 to 2 m) 6 to 10 ft. (2 to 3 m) >10 ft. (>3m)

WIRE OR BAND SIZE Wire (Para. IV.Q.1) 0.5”(13 mm) Band Wire (Para. IV.Q.1) 0.5”(13 mm) Band 0.5”(13 mm) Band 0.75”(19 mm) Band

SPACING* 9-12” (225-305 mm) 12”-18” (305-455 mm) 12”-18” (305-455 mm) 12”(305 mm) 12”(305 mm) 12”(305 mm)

Not less than two wires or bands shall be used per standard length of insulation.

Bands over rigid insulation shall have expansion devices (Para. IV.Q.3 and IV.Q.4) as follows: Vessel OD <4'(1.2m) 4 – 8' (1.2-2.4m) 8 - 12' (2.4-3.6m) 12 - 20' (3.6-6.0m) >20'(6.0m)

400-600ºF (204-316ºC) 0 0

OPERATING TEMPERATURE 601-800ºF 801-1000ºF (317-427ºC) (428-538ºC) 0 1 1 1

1

1

1

1

2

2

2

3 3 NUMBER OF EXPANSION DEVICES

For vessels up to 8' (2.4m) in diameter, expansion devices may be deleted if the block is cut 1/2" (13mm) greater in circumference than the vessel. The blocks shall be secured in such a way that the tension of the bands produces a compression on the butt edges rather than the block surface. A cushioning blanket insulation layer (i.e., mineral fiber) is also an acceptable substitute for expansion devices on vessels up to 8' (2.4m) in diameter.



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE B. Construction of Prefabricated Blanket Removable Covers 1.

Insulating material shall be glass fiber or ceramic fiber blanket. Ceramic fiber shall only be used for the hot face and only at operating temperatures in excess of 1000ºF (538ºC).

2.

Insulation thickness shall be 1" (25 mm) at operating temperatures ≤ 350ºF (177ºC) and 2" (50 mm) at operating temperatures above 350ºF (177ºC). Where ceramic fiber is used the thickness of the ceramic fiber layer shall be 1" (25 mm).

3.

External jacketing over insulation shall be silicone-impregnated fiberglass fabric, 16 oz/yd3 (approx. 600g/m3). The inner surface ("hot face") shall be covered with the same material at operating temperatures up to 500ºF (260ºC). Where "hot face" temperatures exceed 500ºF (260ºC), the covering shall consist of 13 oz/yd3 (approx. 500g/m3) fiberglass fabric with 2 mil (0.05 mm) aluminum foil laminate or 16 oz/yd3 (approx. 600g/m3) fiberglass fabric bonded to 3 mil (0.075 mm) 304SS foil.

4.

In all cases, the hot face of the covers shall be lined with Type 302 or 304 stainless steel knitted wire mesh 0.011" (.28 mm) in diameter. Insulation covers shall be sewn with lock stitching using 10 to 14 stitches per inch (25 mm). Hog ringed seams are not permitted.

5.

Flaps shall be provided to cover mating edges of the cover to shed water. Ends of covers shall overlap fixed insulation by 3" (75 mm). Lacing with Type 18-8 stainless steel wire (16GA)(1.5 mm) shall be used to secure covers. Lacing hooks shall be on maximum 8" (200 mm) centers. Flaps overlapping fixed insulation shall be constructed thinner than the removable jacket to minimize gaps and flexibility problems during installation.

6.

All removable insulation shall have 1/2" (13 mm) diameter drain holes at low points.

C. Expanded Metal Shields 1.

Shields shall be galvanized steel and fabricated from flattened 1/2" (13mm) No. 18-20 expanded metal. Typical metal shields are shown in Figure 5.

2.

Expanded metal supports may be provided by structural steel supports anchored at the equipment foundation or by stainless steel clips banded to piping/equipment. Typical support clips are shown in Figure 6.

3.

Shields on flanged connections and equipment shall be designed for convenient removal for maintenance access.



Rev No: 1


Individual sections shall not weigh more than 40-50 pounds (18-23 kg).

5.

The insulation subcontractor in conjunction with field engineering shall have the authority to alter the shield and shield support design for the purpose of constructability.

6.

In all cases the shields shall be located a minimum distance of 3" (75 mm) from the hot surface. This distance may be increased as required by OSHA standards, plant safety requirements or other applicable codes.

D. Weatherproofing 1.

Metal jackets shall be installed in such a manner as to shed water. Longitudinal and circumferential seams shall have a 3" (75 mm) minimum overlap. Where jacket surfaces are cut to provide for protrusions, flashing shall be provided and installed in such a manner as to keep water from entering behind the jacket. Orange peel segments of head jackets shall be lapped a minimum of 3" (75 mm) and shall be sealed with joint sealer.

2.

Mastic weatherproofing shall be applied in two coats. sizes larger than NPS 2, and equipment, the mastic reinforced between coats with 10 x 10 mesh glass fabric.

3.

Transitions between metal jacketing and mastic cover protection, or terminations of either type of cover, shall be in such a manner as to provide for water runoff. This may be accomplished either by flashing or overlapping.

For pipe shall be

a.

For horizontal conditions, the mastic shall extend under the metal jacketing for at least 3" (75 mm).

b.

For joints at the top of vertical cylinders, the mastic or head jacketing shall overlap the outside surface of the metal jacketing, or flashing shall be used. The overlap, in any case, shall be at least 3" (75 mm).

c.

For joints at the bottom of vertical cylinders, the mastic or head jacketing shall be installed under the jacket of the cylinder.



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE d.

4.

In locations where mastic extends over the outside of metal jackets or steel rings, etc., masking tape shall be used during application of the mastic, and later removed to ensure an even termination of the mastic.

Metal jackets shall be held in place with bands and selftapping screws. a.

Bands shall be provided at each circumferential joint and at least one intermediate location. Maximum spacing shall be 12” (305 mm).

b.

Screws shall be used on longitudinal joints and for securing flashing. Spacing shall not exceed 6” (150 mm).

5.

On vertical piping and equipment, "S" clips shall be used to keep jacket sheets from sliding. "S" clips shall be spaced at 12" (305 mm) intervals. No less than two clips shall be used per sheet.

6.

"J" clips shall be used to support the bands on vertical piping and equipment over 10' (3 m) in diameter. "J" clips shall be attached to the jacket with self-tapping screws and shall be spaced about 6' (1.8 m) apart.

E. Vessels and machinery nameplates and code inspection plates shall not be covered with insulation. Insulation shall be beveled away from such markings and sealed against water entry. Cavities created by the absence of insulation over the nameplates, which are positioned so that water, dust, or other matter may accumulate in them, shall be fitted with removable plugs made from the insulation material. Such plugs shall be clearly and permanently marked with the word "NAMEPLATE". F. Typical insulation details are shown on the following pages. Deviation from these sketches requires prior approval.

G. Thickness and heat loss values in Tables 1 through 4 are based upon calcium silicate insulation with aluminum jacketing, 80°F (27°C) ambient temperature and no wind. The economic thickness for heat conservation was calculated based on an arbitrary fuel cost of $3/MMBTU and various inflation and economic factors. The maximum calculated jacket temperature for personnel protection is approximately 150°F (65°C). The thickness specified in the tables shall be used regardless of the insulation material selected. Where the thickness listed is not commercially available, the next larger commercially available thickness shall be used.



Rev No: 1




Rev No: 1




Rev No: 1




Rev No: 1




Rev No: 1




Rev No: 1


FWUSAC



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE TABLE 1 HEAT CONSERVATION - ENGLISH UNITS INSULATION THICKNESS AND HEAT LOSS OPERATING TEMPERATURE (°F) Pipe Size (In.) 0.5 th hl 0.75 th hl 1 th hl 1.5 th hl 2 th hl 2.5 th hl 3 th hl 4 th hl 6 th hl 8 th hl 10 th hl 12 th hl 14 th hl 16 th hl 18 th hl 20 th hl 24 th hl ≥30 th hl

151200 1.5 14 1.5 16 1.5 18 1.5 22 1.5 25 1.5 26 1.5 32 1.5 39 1.5 53 1.5 64 1.5 75 1.5 87 1.5 99 1.5 111 1.5 122 1.5 134 1.5 159 1.5 25

201300 1.5 28 1.5 32 1.5 35 1.5 44 1.5 49 1.5 51 1.5 65 1.5 77 1.5 106 1.5 128 1.5 150 2 144 2 162 2 181 2 201 2 220 2 259 3 28

301400 1.5 44 1.5 50 1.5 55 1.5 68 1.5 77 1.5 80 1.5 101 1.5 120 2.5 118 2.5 139 2 195 2.5 193 2.5 216 2.5 241 2.5 266 2.5 292 2.5 343 4 33

401500 1.5 61 1.5 67 1.5 76 2 78 2 93 2 98 2.5 107 2.5 125 2.5 165 2.5 194 3 208 3 238 3 264 3 294 3 325 3 356 3 417 4 46

501600 1.5 80 1.5 92 1.5 100 2 102 2.5 110 2.5 117 2.5 127 3 146 3 193 3 227 3 273 3 312 4 276 4 306 4 337 4 368 4 429 4 60

601700 1.5 100 2.5 89 2.5 101 2.5 117 2.5 138 2.5 147 2.5 176 3 184 3 243 3 286 4 284 4 323 4 347 4 385 4 424 4 462 4 540 4 76

701800 2.5 98 2.5 109 2.5 123 2.5 143 2.5 168 3 179 3 195 3 225 4 244 4 292 4 347 4 394 4 424 4 471 4 518 4 565 4 659 4 93

801900 2.5 117 2.5 130 2.5 147 2.5 171 3 185 3 214 3 233 3 269 4 292 4 349 4 415 4 471 4 507 4 563 4 620 4 676 4 789 4 111

9011000 2.5 137 2.5 153 2.5 173 2.5 201 3 217 3 252 3 274 3 316 4 343 4 411 4 488 4 555 4 596 4 662 4 729 4 795 4 928 6 90

10011100 2.5 159 2.5 177 3 187 3 216 3 252 3 269 3 318 4 314 4 398 4 477 4 566 4 644 4 692 4 769 4 846 4 923 4 1077 6 104

11011200 2.5 183 3 191 3 215 3 248 3 289 3 309 4 311 4 360 4 457 4 547 4 650 4 739 4 794 4 883 4 972 4 1060 4 1237 6 119

NOTES: 1. th = Nominal thickness of insulation (inches). Thicknesses listed on the last line, labeled "≥30" shall be used for vessels, exchangers, and flat surfaces. 2. hl = Heat Loss, BTU/lin ft/hr for pipe sizes less than 30"; BTU/ft2/hr for cylinders ≥30" diameter and for flat surfaces.



Rev No: 1


Pipe Size (In.) 0.5 th hl 0.75 th hl 1 th hl 1.5 th hl 2 th hl 2.5 th hl 3 th hl 4 th hl 6 th hl 8 th hl 10 th hl 12 th hl 14 th hl 16 th hl 18 th hl 20 th hl 24 th hl ≥30 th hl NOTES:

151200 1.5 14 1.5 16 1.5 18 1.5 22 1.5 25 1.5 26 1.5 32 1.5 39 1.5 53 1.5 64 1.5 75 1.5 87 1.5 99 1.5 111 1.5 122 1.5 134 1.5 159 1.5 25

201300 1.5 28 1.5 32 1.5 35 1.5 44 1.5 49 1.5 51 1.5 65 1.5 77 1.5 106 1.5 128 1.5 150 1.5 173 1.5 197 1.5 221 1.5 245 1.5 269 1.5 318 1.5 49

TABLE 2 PERSONNEL PROTECTION - ENGLISH UNITS INSULATION THICKNESS AND HEAT LOSS OPERATING TEMPERATURE (°F) 301401501601701801400 500 600 700 800 900 1.5 1.5 2 2 2.5 2.5 44 61 72 90 98 117 1.5 1.5 2 2.5 2.5 3 50 70 81 89 109 122 1.5 1.5 2 2.5 3 4 55 76 88 101 115 123 1.5 2 2 2.5 3 4 68 78 102 117 133 141 1.5 2 2.5 3 3 4 77 93 110 127 155 167 1.5 2 2.5 3 4 4 80 98 117 135 144 172 1.5 2.5 2.5 3 4 5 101 107 127 159 166 176 2 2.5 3 4 4 5 102 125 127 157 192 202 2 2.5 3 4 5 6 136 165 193 200 213 235 2 2.5 4 4 5 6 166 194 159 239 154 277 2 3 4 5 5 6 195 208 190 245 299 322 2 3 4 5 6 7 224 238 226 277 303 328 2.5 3 4 5 6 7 216 264 257 303 325 350 2.5 3 4 5 6 7 241 294 306 336 359 385 2.5 4 4 5 6 7 266 258 337 369 392 421 2.5 4 4 5 6 7 292 281 368 402 426 456 2.5 4 4 5 6 7 343 328 429 467 493 525 2.5 4 4 5 6 7 50 46 61 62 64 66

9011000 3 130 4 130 4 146 4 185 5 172 5 183 5 207 6 221 6 276 7 297 7 343 8 354 8 377 8 414 8 451 8 487 8 560 8 68

1001- 11011100 1200 4 5 138 147 4 5 151 161 5 5 147 179 5 6 176 194 5 6 199 214 6 7 204 219 6 7 525 240 7 7 237 272 7 8 294 314 8 9 319 343 8 9 367 392 8 9 410 437 9 9 406 465 9 9 444 510 9 10 483 516 9 10 521 556 9 10 596 635 9 10 71 73

1. th = Nominal thickness of insulation (inches). Thicknesses listed on the last line, labeled "≥30" shall be used for vessels, exchangers, and flat surfaces. 2. hl = Heat Loss, BTU/lin ft/hr for pipe sizes less than 30"; BTU/ft2/hr for cylinders ≥30" diameter and for flat surfaces.

FWUSAC



Rev No: 1


Pipe Size (In.) 0.5 0.75 1 1.5 2 2.5 3 4 6 8 10 12 14 16 18 20 24 ≥30

th hl th hl th hl th hl th hl th hl th hl th hl th hl th hl th hl th hl th hl th hl th hl th hl th hl th hl

6693

94149

TABLE 3 HEAT CONSERVATION - METRIC UNITS INSULATION THICKNESS AND HEAT LOSS OPERATING TEMPERATURE (°C) 150205261317372428204 260 316 371 427 482

40 15 40 17 40 19 40 23 40 26 40 27 40 33 40 41 40 55 40 67 40 78 40 91 50 103 50 116 50 127 50 139 50 165 50 26

40 29 40 33 40 36 40 46 40 51 40 53 40 68 40 80 50 110 50 133 50 156 50 150 65 169 65 188 65 209 65 229 65 270 75 29

40 46 40 52 40 57 40 71 50 80 50 83 50 105 50 125 65 123 65 145 65 203 65 201 65 225 65 251 65 277 65 304 65 357 100 34

40 63 40 70 40 79 50 81 65 97 65 100 65 111 65 130 65 172 65 202 75 216 75 248 75 275 75 306 75 338 75 370 75 434 100 48

40 83 50 96 50 104 65 106 65 114 65 122 65 132 75 152 75 201 75 236 75 284 75 325 100 287 100 318 100 351 100 383 100 446 100 62

50 104 65 93 65 105 65 122 65 144 65 153 65 183 75 191 75 253 75 298 100 296 100 336 100 361 100 401 100 441 100 481 100 562 100 79

65 100 65 113 65 128 65 149 65 175 75 186 75 203 75 234 100 254 100 304 100 361 100 410 130 441 130 490 130 539 130 588 130 686 130 97

65 122 65 135 65 153 65 178 75 193 75 223 75 242 75 280 100 304 100 363 130 432 130 490 130 528 130 586 130 645 130 703 130 821 130 116

483538

539593

594649

65 143 65 159 65 180 65 209 75 226 75 262 75 285 100 329 100 357 100 428 130 508 130 578 130 620 130 689 130 759 130 827 130 966 130 94

65 165 65 184 75 195 75 225 75 262 75 280 75 331 100 327 100 414 100 496 130 589 130 670 130 720 130 800 150 880 150 961 150 1121 150 108

65 190 75 199 75 224 75 258 75 301 75 322 100 324 100 375 100 476 130 569 130 676 130 769 130 826 130 919 150 1012 150 1103 150 1287 150 124

NOTES: 1. th = Nominal thickness of insulation (millimeters). Thicknesses listed on the last line, labeled "≥30" shall be used for vessels, exchangers, and flat surfaces. 2. hl = Heat Loss, W/m for pipe sizes less than 30"; W/m2 for cylinders ≥30" diameter and for flat surfaces.

FWUSAC



Rev No: 1

EXTERNAL INSULATION – HOT SERVICE TABLE 4 PERSONNEL PROTECTION - METRIC UNITS INSULATION THICKNESS AND HEAT LOSS Pipe Size (In.) 0.5

th hl 0.75 th hl 1 th hl 1.5 th hl 2 th hl 2.5 th hl 3 th hl 4 th hl 6 th hl 8 th hl 10 th hl 12 th hl 14 th hl 16 th hl 18 th hl 20 th hl 24 th hl ≥30 th hl NOTES: 1. th = line,

6693

94149

150204

40 15 40 17 40 19 40 23 40 26 40 27 40 33 40 41 40 55 40 67 40 78 40 91 40 103 40 116 40 127 40 139 40 165 40 26

40 29 40 33 40 36 40 46 40 50 40 53 40 68 40 80 40 110 40 133 40 156 40 180 40 205 40 230 40 255 40 280 40 331 40 50

40 46 40 52 40 57 40 71 40 80 40 83 40 105 50 106 50 142 50 173 50 200 50 233 65 225 65 251 65 277 65 304 65 357 65 52

OPERATING TEMPERATURE (°C) 205261- 317372260 316 371 427 40 63 40 73 40 79 50 81 50 97 50 102 65 111 65 130 65 172 65 202 75 216 75 248 75 275 75 306 100 268 100 292 100 341 100 48

50 75 50 84 50 92 50 106 65 114 65 122 65 132 75 132 75 201 100 165 100 198 100 235 100 267 100 318 100 351 100 383 100 446 100 63

50 94 65 93 65 105 65 122 75 132 75 140 75 165 100 163 100 208 100 249 125 255 125 288 125 315 125 350 125 384 125 418 125 486 125 65

65 100 65 113 75 120 75 138 75 161 100 150 100 173 100 200 125 222 125 160 125 311 150 315 150 338 150 374 150 408 150 443 150 513 150 67

428482

483538

539593

594649

65 122 75 127 100 128 100 147 100 174 100 179 125 183 125 210 150 245 150 288 150 335 175 341 175 364 175 401 175 438 175 475 175 546 175 69

75 135 100 135 100 150 100 193 125 179 125 190 125 215 150 230 150 287 175 309 175 357 200 368 200 392 200 431 200 469 200 507 200 583 200 71

100 144 100 157 125 153 125 183 125 207 150 212 150 546 175 247 175 306 200 332 200 382 200 427 225 423 225 462 225 503 225 542 225 620 225 74

125 153 125 168 125 186 150 202 150 223 175 228 175 250 175 283 200 327 225 357 225 408 225 455 225 484 225 531 250 537 250 579 250 661 250 76

Nominal thickness of insulation (inches). Thicknesses listed on the last labeled "≥30" shall be used for vessels, exchangers, and flat surfaces.

2. hl = Heat Loss, W/m for pipe sizes less than 30"; W/m2 for cylinders ≥30" diameter and for flat surfaces.





D-6 Notes to Detail Engineering Contractor and Vessel Fabricator for the Coke Drums, 126158-4-11-001

Rev.A


Job Specification 126158-82A3 Insulation of Coke Drum

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