RFCC-T-PCGC-0155 Method Statement for Work of Insulation Rev.1.pdf

Cilacap Resid Fluid Catalytic Crackin g (RFCC) (RFCC) Proj Proj ect PT. PERTAMINA (Persero)

Doc. No. : RFCC-G-CS-PR-010 Rev. No. : 1 Page No. : 2 / 47

METHOD STATEMENT FOR WORK OF INSUL INSUL ATION REVISION HISTORICAL SHEET Rev.

Page / Paragraph

Item

1

P6 / 7.1.1

7.1.2.2

P7 / 7.1.2

71.2.3 7.1.2.6 7.1.2.7

1

P7

7.1.3

1

P8

8.5

1

P6 / 7.1.2

9.2.6 9.2.12 9.2.14 9.2.15 9.5 9.6 9.7

Descr Descr ipt ion of Change Change Revised phrase as per Doc No. RFCC-C-CS-SP-002. Added phrase Revised Phrase as per Doc No. RFCC-C-CS-SP-002. Revised Phrase as per MOM No. RFCC-M-GC/PC-0108

1

P9 / 9.2

1

P9

1

P10

9.3.3

Added phrase “ho rizontal and vertical equip ment”

1

P10

9.3.8

Added phrase

1

P11

9.3.13

1

P12

9.5 9.6 9.7

1

P14

Revised Phrase as per MOM No. RFCC-M-GC/PC-0108

Added phrase

Revised Phrase as per MOM No. RFCC-M-GC/PC-0108 Added phrase Added JSA for Insulation Work Using Man Basket

CONSORTIUM ADHI – GS E&C

Cilacap Resid Fluid Catalytic Cracking (RFCC) Proj ect PT. PERTAMINA (Persero)

METHOD STATEMENT FOR WORK OF INSULATION TABLE OF CONTENTS 1.

PURPOSE

2.

SCOPE

3.

REFERENCES

4.

DEFINITIONS

5.

RESPONSIBILITIES

6.

INSULATION CODES, TYPE & THICKNESS

7.

INSULATION MATERIALS

8.

EXTENT OF INSULATION

9.

APPLICATION PROCEDURE FOR INSULATION

10. INSPECTION AND REPORTING PROCEDURE 11. QA/ QC RESPONSIBILITY 12. HSE 13. JOB SAFETY ANAL YSIS FOR INSULATION WORK 14. ATTACHMENTS





METHOD STATEMENT FOR WORK OF INSULATION 1. PURPOSE

The purpose of this method statement is to ensure the insulation is carried out as per project specification and to facilitate to the execution team that they are using specified materials as it is required places. 2. SCOPE

The scope of this method statement is to define the guidelines/ procedures to carry out supply and application of Thermal Insulation and Cold Insulation works. Thermal Insulation works includes Hot Insulation works, Personnel Protection works, Electric Tracing and Steam Tracing works on various piping and equipment. All the insulation works shall be done in plant under construction or commissioning at Pertamina Resid Fluid Catalytic Cracking (RFCC) Project in Cilacap, Central Java, Indonesia. 3. REFERENCES

This method statement based on the following: 3.1 Project Specification No: RFCC-C-CS-SP-002. 3.2 Inspection and Test Plan No: RFCC-ITP-PA-0001. 4. DEFINITIONS 4.1

Owner The Owner means Indonesia PT. PERTAMINA (Persero), who is the owner of this project.

4.2. Contractor The Contractor is the employer for whom the sub-contractor is working in the case: ADHI-GS E&C CONSORTIUM. 4.3. Sub Contractor The Sub Contractor is the organization who is performing Insulation Works on this project for Contractor, in this case Sub Contractor is PT. KRAZU NUSANTARA.




METHOD STATEMENT FOR WORK OF INSULATION 5. RESPONSIBILITIES 5.1 Site Manager He will be responsible for overall control of work according to this approved method statement in line with requirement of Health, Safety and Environment. He will coordinate with client for the scheduling and progress of work. He will assist his site team for completing the scope as per project requirement. 5.2 Constr uct ion Manager He will be responsible for coordinate with the concerned supervisor and inspectors and to carry out the job as per schedule. 5.3 HSE Manager He will responsible for safe implementation of this method statement for completing the scope as per project Health, Safety and Security, environment requirement. 5.4 QA/QC Inspect or He will be responsible for maintaining the quality of work as per project specification, for the implementation of quality plan and the project requirement, and for the management of nonconformance and quality audit. As per Project Doc. No. RFCC-ITP-PA-0001. 5.5 Supervisor He will be responsible for day to day activity as per planning and instruction of Site Manager. Manpower and equipment planning, daily progress of work shall be his main responsibilities.

6. INSULATION CODES, TYPE & THICKNESS Category Hot service insulation

Cold service insulation Other service insulation

Insulation Codes Ih ST TW TO JW SJ ET C JC A P / Is M

Insulation Type Normal heat conservation insulation Steam tracing insulation Hot water tracing insulation Hot medium tracing insulation Hot water jacketing insulation Steam jacketing insulation Electric tracing insulation Normal cold insulation Cold medium jacketing insulation Anti-sweat insulation Personal protection insulation Dual temperature Service

Following insulation codes based on Project Spec. No. RFCC-C-CS-SP-002. Section 2.1.1




METHOD STATEMENT FOR WORK OF INSULATION 6.1

Thick ness In Drawing The insulation thickness as given in the isometrics drawing shall be considered as final and with cross reference with table 2 and 3 and based on this thickness, the work will be executed.

7. INSULATION MATERIALS

All the insulation materials following ref. Project Spec. No: RFCC-C-CS-SP-002. Section 3, insulation materials shall be part of material submittal and is to be approved by owner. The insulation materials delivered at site shall be inspected by QA/QC for it is package and damage conditions, batch no., manufactures certificate, storage and expiry, etc. and recorded in ITP for verification of owner. The materials to be used shall be follows: 7.1

HOT AND PERSONNEL PROTECTION INSULATION

7.1.1

1

7.1.2

1

1

Insul ation Material 7.1.1.1 Calcium silicate pipe section having density of 220 kg/m³, shall be used for piping NPS 2” and above refer Project Spec. No: RFCC-C-CS-SP-002 (ASTM C533, Type I). 7.1.1.2 Mineral wool blanket backed one side with galvanized mesh having density of min. 93 kg/m³ and max. 128 kg/m³ (ASTM C592, Type I, II & III) shall be used for equipment insulation with operation temperature up to 370° C and mineral wool blanket backed one side with stainless steel wire mesh shall be used above 370° C operating temperature and on austenitic stainless steel surfaces. 7.1.1.3 Mineral wool pipe section having density of min. 100 kg/m³, shall be used for piping size NPS 1.5” and below and for socket type (ASTM C547, Type II & III). 7.1.1.4 Ceramic fibre blanket having density 128 kg/m³ (ASTM C892, Type III Grade 8) shall be used for pipe and equipment with temperature above 700 °C. 7.1.1.5 Mineral wool blanket loose (ASTM C553 type VII). Jacketi ng Material The sheet metal jacketing shall be aluminum alloy sheet with moisture retarder which consist of polyethylene or polysurlyn. 1060 Al 99.5 with manganese composition limits max. 0.03. Or AA 3003 with manganese composition limits min. 1.0 and max.1.5 (per cent), and as per ASTM B209M and C1729 (refer Project Spec. No: RFCC-C-CS-SP-002, section 3.6). 7.1.2.1 Flat sheet with a minimum thickness of 0.3mm for insulation below NPS 30” (ASTM B209M). 7.1.2.2 Flat sheet with a minimum thickness of 0.4mm for insulation NPS 30” and above, and for equipment insulation with equipment OD below 760mm (ASTM B209M). 7.1.2.3 Flat sheet with a minimum thickness of 0.6mm for horizontal equipment insulation with equipment OD 760mm and above (ASTM B209M). 7.1.2.4 Flat sheet with a minimum thickness 0.8mm for valve and flange boxes NPS 10” and below (ASTM B209M). 7.1.2.5 Flat sheet with a minimum thickness of 1.0mm for valve and flange boxes NPS 12” and above (ASTM B209M). 7.1.2.6 Corrugated sheet with a minimum thickness of 0.6mm for vertical equipment insulation with equipment OD 760mm and above. (ASTM C1729).




METHOD STATEMENT FOR WORK OF INSULATION 7.1.2.7 1

7.1.3

1

7.2

Weather proofing mastic, for bottom head of small equipment, body of insulated valve 20” and above (Ih type only) and for unfitted metal jacketing portion.

Auxi li ary Materials 7.1.3.1 Galvanized tie wire swg #20 for fastening of insulation material NPS up to 12”, and galvanized tie wire swg #18 for fastening of insulation material NPS 14” up to 18”, with interval max. 300mm, for tacking of circumferential and horizontal of wire mesh blanket, and shall be used for floating ring of insulation. Stainless steel wire shall be used for fastening insulation material to austenitic stainless piping and equipment. 7.1.3.2 Galvanized strapping band 13 X 0.4mm and wing seal for fastening of insulation material for NPS 20” and above, and for cylindrical equipment with OD below 760mm. Galvanized strapping band 19 X 0.5mm and wing seal for fastening of insulation material for cylindrical equipment with OD 760mm and above. 7.1.3.3 S/s strapping band 13 X 0.4mm and wing seal for fastening jacketing material for all piping, and equipment OD below 760mm. S/s strapping band 19 X 0.5mm for fastening jacketing equipment with OD 760mm and above. 7.1.3.4 S/s self tapping screws as per ASTM A167, 4.8 X 13mm and 4.8 X 19mm for fittings area and equipment jacketing securing. 7.1.3.5 C/s flat bar 30 X 3mm for insulation support ring of vertical pipe and equipment. 7.1.3.6 Blind rivets aluminum 2 X 10mm. 7.1.3.7 Silicone sealant for metal jacketing 7.1.3.8 G/i and s/s bolts and nuts M8. 7.1.3.9 Glass cloth (10 X 10 mesh) for application weather proofing mastic. 7.1.3.10 Glass fiber tape/ ceramic rope (for loop of tracer lines and Instrument tubing insulation). 7.1.3.11 Aluminum foil sheet 20µ and aluminum foil tape (Jacketing of instrument tubing insulation). 7.1.3.12 S/s toggle clips shall be used for valve and flange removable boxes according to size. 7.1.3.13 S/s 304 welded wire mesh 25 X 25 X 3mm for wire mesh barrier of personnel protection on austenitic stainless steel surface. 7.1.3.14 S/s 304 flat bar 30 X 3mm for support ring wire mesh barrier of personnel protection on austenitic s/s stainless steel surface. 7.1.3.15 Insulating cement for filling gap of calcium silicate (gap above 3mm shall be filled by insulating cement) COLD INSULATION & ANTI-SWEAT INSULATION

7.2.1

Insul ation Material 7.2.1.1 PIR (Polyisocyanurate) performed pipe section in green & or natural color with density min. 40 kg/m 3. 7.2.1.2 Rigid preformed cellular urethane with density min. 40 kg/m 3. 7.2.1.3 Mineral wool blanket loose (ASTM C553 type VII).

7.2.2

Aux ili ary Material 7.2.2.1 S/s strapping band 13 X 0.4mm and 19 X 0.5mm.




METHOD STATEMENT FOR WORK OF INSULATION 7.2.2.2 7.2.2.3 7.2.2.4 7.2.2.5 7.2.2.6 7.2.2.7 7.2.2.8 7.2.2.9

Joint sealant. Vapor stop (mastic, foam seal, bond) Glass cloth (10 X 10 mesh) Multi flex foil 50µ. (vapor barrier) Multi flex tape 50mm wide. Butyl rubber sheet 1mm. Butyl rubber gum tape 1mm. Filament tape wide 25mm

8. EXTENT OF INSULATION

1

Extent of insulation following ref. Project Spec. No: RFCC-C-CS-SP-002. Section 2: 8.1 Name plates and stamping shall be left clear of insulation or shall be fitted on outside of the jacketing. 8.2 Expansions/ construction joints. 8.3 Pumps area. 8.4 Compressors and auxiliary boilers 8.5 Insulation of valves and flanges box cover in insulated piping for steam lines service and steam tracing lines service (ST). For valves of insulated line (Ih) 20” and above, body of valve shall be insulated with mineral wool blanket with galvanized mesh, covered with glass cloth and weather proofing mastic.

9. APPLICATION PROCEDURE FOR INSULATION 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6 9.1.7 9.1.8

General Appl icati on Procedur e

Check that the surface to be insulated are clean, dry and free from dust, dirt, grease and oil. The surround area is free from obstacles and debris. Verify insulation system is defined on the work release and attached working isometric or drawing and suitable against the referred temperatures and process class. Check the insulation materials are of the correct type and size for application as per project specification. All calcium silicate and mineral wool pipe section shall be visually checked to ensure edges are not damaged. Damaged area shall be cut back neatly prior to use, wherever practical. Where insulation is secured using wire, the cut ends shall be twisted and turned into the insulation. Fabrication of insulation and jacketing materials shall take place under controlled conditions in suitably equipped workshop situated on the project. Without exception, activities in the field shall commence only after the issue of necessary work permit and TBM. Insulation works shall not be started until it has been ascertained that all appropriate testing has been completed and application of the specified protective coating system is completed and that any damaged areas have been properly repaired.




METHOD STATEMENT FOR WORK OF INSULATION 9.1.9 The insulation shall only be started from mechanical and piping team. 9.2 Insul ation for Hot Insulat ion and Person nel Protect ion Codes Ih, ST, JW, SJ, ET, P / Is 9.2.1 9.2.2 9.2.3

9.2.4 9.2.5 9.2.6 1

9.2.7 9.2.8

9.2.9 9.2.10 9.2.11 9.2.12 1

9.2.13

9.2.14 1

9.2.15

The insulation code and thickness shall be verified from isometric drawing or from project specification No. RFCC-C-CS-SP-002. For pipe NPS 1.5” and below, insulation shall be used mineral wool pipe section, and NPS 2” and above insulation shall be used calcium silicate pipe section. On vertical pipe length approximately 4000mm shall be fixed with one support ring for insulation material and fabricated with c/s flat bar 30 X 3mm. And expansion joint with mineral lose wool shall be located under support ring. Support rings shall be isolated with direct contact of pipe or equipment by means glass fiber tape to prevent damage on pipe surface. Piping at slope between 45 o and 90o shall be considered as vertical. Mineral wool pipe section for NPS 1.5” and below (socket type) and calcium silicate pipe sectio n for NPS 2” up to 12” shall be secured with galvanized tie wire swg #20. For 14” up to 18” shall be secured with galvanized tie wire swg #18. Galvanized strapping band 13 X 0.4mm for pipe NPS 20” and above. wire and bands shall be located approximately 50 mm from the end of each section and at center interval of max. 300 mm. Bands shall be machine tensioned, tig htened and sealed. Longitudinal and circumferential joints in outer layers of multiple layer installations shall be sta ggered from those in adjacent inner layer. The insulation for calcium silicate shall include contraction joints as per project specification wi th max. 5700mm spacing for horizontal straight pipe or centre between two pipe shoe or as sp ecified by the vendor design on calculation. Construction joint space is 25mm and filling with mineral loose wool. In case of exposed area in tracer pipe it shall be wrapped with 30 X 3mm glass fiber tape or rope and covering with aluminum foil sheet and foil tape. Insulation on steam traced lines shall be oversized preformed calcium silicate pipe sections arranged to enclose both the line and its accompanying tracer. Bolt clearance shall be maintained on both side of flange, and minimum clearance shall be bolt + 50mm at least one side as per site condition. For equipment insulation shall be used by mineral wool blanket with galvanized wired mesh as per ASTM C592 Type I, II & III for temperature up to 370 oC, and mineral wool blanket with s/s wired mesh for equipment temperature above 370 oC and on austenitic stainless steel surfaces. For alternate insulation material is mineral wool board as per ASTM C612 type II and IV (Project Specification No. RFCC-C-CS-SP-002) In case of equipment Four Stage Cyclone Separator (101-V-511) with temperature 709 oC, insulation shall be covered with ceramic fiber blanket with density 128 kg/m³ as per ASTM C892 Type3 Grade 8. Insulation thickness 150mm with 6 layers of 25mm thickness ceramic fiber blanket, for 1 st, 2 nd, 4th, 5 th layer shall be secured with s/s 304 tie wire and for 3 rd and 6th layer shall be secured with s/s strapping band 19 X 0.5mm. Equipment insulation shall be secured with galvanized band 13 X 0.4mm for OD below 760mm, and galvanized band 19 X 0.5mm for OD 760mm and above , machine tensioned and sealed. Band shall be positioned at max. 300mm spacing centre on vertical equipment and horizontal equipment to avoid loosening of blanket. The adjacent joints of blankets shall be tack stitched with galvanized wire swg #18 or #20.




METHOD STATEMENT FOR WORK OF INSULATION 9.2.16 Insulation at equipment flanges shall be stopped short of the bolts. The bolt removal clearance left for all flanged equipment connections. The clearance at equipment shall be nut length plus 50mm. 9.2.17 Where the bending radius is too small to be neatly segmented, insulation shall be fitted in Tee piece form to receive metal jacketing. 9.2.18 Equipment insulation work shall start after completion of external mechanical work done. 9.2.19 Installation insulation shall be done before equipment installation if required. 9.2.20 Instrument tube shall be insulated with glass fiber tape or ceramic rope as per thickness requirement and shall be covered with aluminum foil sheet and shall be fastened with aluminum tape. 9.2.21 All insulation activities shall be completed in one day, if this is impossible, the insulation shall be covered temporarily with water proof film/ plastic, to be sealed at the outer ends of water resistance.

9.3 9.3.1

9.3.2

9.3.3 1

9.3.4 9.3.5 9.3.6 9.3.7

9.3.8 1

Jacketing Procedure of Piping & Equipment

The metal jacketing to be used over insulated piping, fittings and equipment shall be aluminum alloy sheet with moisture retarder which consist of polyethylene or polysurlyn 1060 Al 99.5 with manganese composition limits max. 0.03. Or 3003 with manganese composition limits min. 1.0 and max.1.5 (per cent ) and as per ASTM B209 and ASTM C1729. For pipe jacketing with flat sheet with moisture retarder which consist of polyethylene or polysurlyn 1060 Al 99.5 with manganese composition limits max. 0.03. Or 3003 with manganese composition limits min. 1.0 and max.1.5 (per cent ) and minimum thickness 0.3mm for pipe below NPS 30”, and minimum thickness 0.4 for NPS 30” and above. For vertical equipment jacketing with corrugated sheet with moisture retarder which consist of polyethylene or polysurlyn. 1060 Al 99.5 with manganese composition limits max. 0.03. Or AA 3003 with manganese composition limits min. 1.0 and max.1.5 (per cent ) with deep corrugated dimension 1-¼”x ¼” (32mmX6.3mm) and minimum and minimum thickness 0.6mm for OD 760mm and above. And OD below 760mm jacketing material shall be used flat sheet with minimum thickness 0.4mm. Overlaps of minimum 50mm shall be provided on circumferential and longitudinal joints. All jacketing shall be installed in watershed manner. Longitudinal seams of horizontal piping shall be staggered at 3 O’clock and 5 O’clock. Horizontal seams shall be concealed from view from the sides of pipe rack or pipe track. Longitudinal seams on vertical pipe jacketing shall be staggered and placed away from the prevailing wind direction. On piping jacketing circumferential lap joints shall not be screw fastened, piping shall be secured with s/s bands only, with 13 X 0.4mm for all piping, and shall be positioned at each overlap and at max. 300 mm centers interval. S/s self tapping screw shall be applied only for fittings area. S/s strapping band shall be applied on circumferential equipment jacketing with max. 300mm centers interval, on vertical equipment s/s strapping band shall be secured with ”J” clips to prevent loosing on circumferential. S/s 304 self tapping screws shall be used for securing the equipment jacketing at max. 150mm centers for equipment, every longitudinal and circumferential overlap.




METHOD STATEMENT FOR WORK OF INSULATION 9.3.9

9.3.10

9.3.11

9.3.12 9.3.13 1

9.3.14

9.3.15 9.3.16

9.3.17 9.3.18 9.3.19 9.3.20 9.3.21

9.4 9.4.1 9.4.2 9.4.3 9.4.4 9.4.5

Fabrication of elbows/ bends shall be swage in swage for OD up to 600mm, and for above OD 600mm with overlap, each segment shall be secured by s/s 304 self tapping screws with minimum two screws per segment along the longitudinal seam. Caps end shall be installed at insulation terminations. These shall be by disc and swage up to OD 200mm over insulation, and lock formed for insulation OD above 200mm. cap ends on vertical pipe shall be lock formed and conical to provide watershed. “S” clips fabricated from s/s 304 13 X 0.4mm or 19 X 0.5mm strapping band shall be introduced between individual length of metal jacketing on vertical pipe and vertical equipment to prevent telescoping. Metal jacketing shall be installed in watershed manner at all times. The cutted side shall be sealed by the application of a metal silicone sealant. Removable Metal box insulation shall be used for valves and flanges for steam lines service and steam tracing lines service. For valve size 20” and above shall be insulated on body valve only with mineral wool blanket with galvanized mesh, covered with glass cloth and weather proofing mastic (Ih code only) Removable Box shall be fabricated with thickness 1.0mm flat aluminum sheet for NPS 12” and above, thickness 0.8mm flat aluminum sheet for NPS 10” and below, box shall be riveted to the inside of the boxes with pop rivets and screws, and shall be incorporated circumferential and longitudinal lock seams. Removable type metal box shall be pre insulated inside with mineral wool blanket secured with pins or clips and the thickness insulation shall be same of pipe or equipment. Boxes shall be fastened by s/s 304 type quick release toggle fasteners. Toggle shall be minimum two numbers on each side of over laps, additional toggles shall be installed where necessary to neatly and firmly close the box with good seal. Personnel protection with steel welded wire mesh barrier shall consist of physical barriers shall extend to a height of 2000mm and 600mm either side of working platform or walking level. Spacing requirements for shields and cages shall be 50mm minimum, but shall not be less than the heat conservation insulation thickness. Gusset plate and steel ring shall be fabricated of cs or s/s 304 size 30 X 3mm and 25 X 25 X 3mm s/s welded wire mesh shall be installed. Gusset plate shall be isolated with direct contact of pipe or equipment by means of glass fiber tape to prevent damage to pipe surface. For jacketing at small bottom head equipment shall be wrapped with weather proofing mastic.

Insulation for Cold Insulation and Anti-Sweat Insulation Codes C, JC and A

Piping and equipment shall have all welding completed and shall be hydrostatically or pneumatically tested prior to application of insulation. For cold insulation it is essential that no water or water vapour penetrates in to the insulation. For cold insulation preformed PIR section shall be used according to table 3 of Spec No.RFCC-C-CS-SP-002. For piping and large cylindrical surfaces insulation preformed cylindrical section or segments shall be used. Vapor stop shall be installed at all pipe supports locations and applied between the pipe and insulation termination. Application shall be extended over the roughened pipe surface for




METHOD STATEMENT FOR WORK OF INSULATION

9.4.6 9.4.7 9.4.8

9.4.9 9.5 9.5.1 9.5.2

9.6

50mm. All vapor stops shall start from pipe or equipment surface and to step upward to outer surface to insulation with reinforcing membrane with a minimum overall DFT of 2mm. No reinforcement is required on underside of insulation to a depth of 50mm. Insulation shall be installed after vapor stops becomes dry to touch. Adhesive shall be coated on the dried vapor stop coating for the adjacent outer most layer joint of PIR. In multilayer system, in addition to the primary vapor barrier a secondary vapour barrier shall be applied between the outermost layer and the next insulation layer. The insulation system shall include contraction joints as per project specification. All insulation materials applied in one day shall have the vapor barrier applied the same day. If it is found impracticable to apply the vapor barrier, exposed insulation shall be temporarily protected with a black polyethylene sheet. For jacketing on cold insulation shall be done same system with hot insulation jacketing. Insulation Applicatio n for Piping

Piping insulation shall be done before pressure test except the welding joints on safe working condition. Welding joints in insulation application will be done after pressure test with safe working conditions (i.e. scaffolding, man lift, man basket with approval safety) Insulation Applicatio n for All Equipment

1

9.6.1 9.6.2 9.7 9.7.1 9.7.2

Equipment insulation work shall be done after completion of external mechanical work done. Insulation shall be done before equipment installation on ground if required. Rework on Damage or Open Portion for Piping and Equipment

Damaged insulation and open portion will be checked for extent of damage or open portion and shall be re-insulated with the same specification as required for the piping and equipment. Insulation will be done using scaffolding, man lift or man basket with safety approval.

10. INSPECTION AND REPORTING PROCEDURE

The QA/QC operative on site will carry out periodic and stage wise inspection. Once QA/QC operative is satisfied in all respects with the work, he shall offer the area to Contractor/ Owner for inspection. Inspection will be carried out as per the Inspection and Test Plan. The inspection report with all the finding shall be recorded and signed with all parties in the reporting formats in ITP (Project Doc. No. RFCC-ITP-PA-0001). 11. QA/QC RESPONSIBILITIES

All the insulation works on the project will be under QA/QC operative and main contractor inspection department. The QA/QC operative will be responsible for overall quantity of the work according attached ITP (Doc No. RFCC-ITP-PA-0001) and will fill all the relevant inspection forms which shall be signed off by each party. His specific responsibilities will include:




METHOD STATEMENT FOR WORK OF INSULATION 11.1 11.2 11.3 11.4 11.5 11.6

Ensure all the materials for the project are strictly in accordance with the specifications & WMS. Ensure correct materials are used for application. Delivery notes & test certificates/ certificate of compliance shall be reviewed during material inspection. inspected materials shall be used for site work. Inspect workmanship of work in progress, ensure all tools and equipments are in good condition. Responsible for recording on inspection findings and maintaining them for each item to obtain final completion certificate. Strictly follow ITP of the work and report management for any shortfall and non conformance report.

12. HSE

Full care and precaution shall be given by the field management for the safety and sanitation of the manpower in the field to prevent accident during the execution of works. Refer to the site safety for general site control. One of the main aspects of this procedure is Safety and Health Control. This is to control the prevention of incidents, personal injuries as well as damage to equipment and properties during the entire construction period. In order to ensure a safe working environment during the entire construction period, the following safety measures shall be implemented as follows: 12.1 12.2 12.3

12.4

12.5 12.6 12.7 12.8 12.9

All personnel involved in the insulation and other related activities should be inducted as per contractor/ owner safety requirement. Administrative control shall be applied for use to reduce the potential summer season. Provision of rest shelters/ recovery area or stand by vehicle for each group. Each worker shall be provided with drinking water during hot weather conditions during working hours. Toilet with urinal and wash area shall be provided. Drinking water station shall be in place with cold water. All workers shall be provided with and wear Personnel Protective Equipment ie. safety helmet, safety glasses (clear & dark), safety shoes/ boots and wear long sleeve shirt/ jacket or coveralls. Additional PPE requirements shall be provided to workers as work scope dictates ie. face shield (welding/ grinding/ fabrication), respiratory protection (dust mask/ respirator), full body harness (FBH) when working at height and as per MSDS requirements. All waste material will be collected on regular basis to be stacked in a designated location at site, this material should be removed periodically from site. Sufficient number of toilet units provided for workers in line with project regulations and units maintained in hygienic condition. All equipment should be inspected and approved by HSE officer of GS E&C. Tool box meeting shall be arranged before work activity and the same should be recorded. The work site should always be maintained clean and tidy.

13. JOB SAFETY ANAL YSIS FOR INSULATION WORK

As per attachment #1





14. ATTACHMENTS No.

1 1

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

Descr ipt ion

Job Safety Analysis for Insulation Job Safety Analysis for Insulation Work Using Man Basket Insulation Thickness for Hot Service (Mineral Wool) Insulation Thickness for Hot Service (Calcium Silicate) Insulation Thickness for Hot Service (Ceramic Fiber + Calcium Silicate) Insulation Thickness for Personnel Protection (Mineral Wool) Insulation Thickness for Personnel Protection (Calcium Silicate) Insulation Thickness for Cold and Anti-Sweat Insulation Inspection and Test Plan Inspection Format Forms Typical Details For Piping Insulation Typical Details For Valve Insulation Flange Insulation And Insulation Support Ring Details Insulation Details at Pipe Support Vertical Vessel Insulation (Blanket Insulation) Vertical Vessel Insulation (Block Insulation) Horizontal Vessel Insulation (Blanket Insulation) Horizontal Vessel Insulation (Block Insulation) Heat Exchanger Insulation Insulation Details For Vertical Vessel Head Flashing Details At Nozzle And “S” And “J”-Clip Details Wire Mesh Barrier for Personnel Protection Details Removable Insulation Cover for Pumps (Hot Insulation) Insulation for Body of Valve 20” and Above (“Ih” Insulation only)


Reference

Attachment #1 Attachment #2 Table 2 (1) Table 2 (2) Table 2 (3) Table 2 (4) Table 2 (5) Table 3 Attachment #3 Attachment #4 Attachment #5 Attachment #6 Attachment #7 Attachment #8 Attachment #9 Attachment #10 Attachment #11 Attachment #12 Attachment #13 Attachment #14 Attachment #15 Attachment #16 Attachment #17 Attachment #18

Doc. No. : RFCC-G-CS-PR-010

Cilacap Resid Fluid Catalytic Cracking (RFCC) Project

Rev. No. : 1

PT. PERTAMINA (Persero )

Page No. : 15 / 47

METHOD STATEMENT FOR WORK OF INSULATION Att achm ent #1.

JOB SAFETY A NAL YSIS FOR INSULATION

Prepared by:

Afendi Muslim

Approved by:

Cho In Seok

Reviewed by:

Yanam

Date

20 August 2013

Step No. 1

Description of Task Step Insulation Fixing & Removal

Control Measures/ Preventive Measures

Hazard Calcium Silicate, Glass wool. Sharp Objects. Dust. Skin Irritation.

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•

•

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•

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Falling object.

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•

Flammable gasses

•

•

Inadequate access

• •

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2

Fabrication Shop

• • • • •

Working at height Pinch point Sharp object Electrical tools Slip, trip and fall Machinery equipment

:

•

• • • • •

Proper PPE as per MSDS. Wear proper hand gloves, proper manual handling. Wear proper dust mask, good housekeeping. Agreed Lay down area for storage, proper PPE as per MSDS. Secure all loose insulation at storage area from high wind, secure all tools during working at height. Gas testing to be done at the start of insulation work on any line containing flammable gasses . Make sure that adequate access is available. If scaffold is used for access it should be inspected by a certified scaffolding inspector & scaff-tag should be installed 100% tied off full body harness. Wear proper hand gloves Proper manual handling, wear proper hand gloves Isolate power cable, secure with Lock Out Tag Out. Proper material arranging and good housekeeping. Equipment certification and Fire Extinguisher


Responsible Person

• • • •

Worker Worker Worker Worker

Worker

•

•

Authorized gas tester

Worker Scaffolding Inspector

• •

Worker

•

• • • • •

Worker Worker Worker Worker Safety Officer

Cilacap Resid Fluid Catalytic Cracking (RFCC) Project PT. PERTAMINA (Persero )


METHOD STATEMENT FOR WORK OF INSULATION Step No. 3

Description of Task Step Using Foam Spray for Insulation


Hazard

• •

• •

Chemical (Polyol + Iso-cyanide, Polyurethane) Pressured Injection gun Foaming machine

• • • • •

•

4

Wasting Insulation Material (Hazardous Substances)

•

Health Impairment

•

•

Fire / Explosion

•

•

•

Environmental Impact

•

•

Proper Gun maintenance Fire Extinguisher Wear proper PPE as per the MSDS (mater Workers should not play around with the tools Only competent workers are allowed to use the pressurized injection gun Operators must read the manufacturers for using the foaming machine Assessment on the hazards and risk to health by potentially harmful substances shall be carried out. Shall detail the control measures that will be taken to reduce risk to health. MSDS and assessment of the risk and necessary control measure shall be in place prior to the work being carried out. Personnel shall be instructed to take appropriate precautions to protect their health from the hazards. Training shall be given in the correct use and maintenance of PPE. Hazardous substances shall be stored in a safe manner. Materials shall be segregated in accordance with good practice, e.g. Keeping oxidizing and reducing agent apart. Contingency arrangements shall be in place to initiate the spillage of any hazardous substances.


Responsible Person Worker Safety Officer Worker Worker Worker

• • • • •

Worker

•

•

Worker & Safety Officer

•


•


•


•




METHOD STATEMENT FOR WORK OF INSULATION Step No. 5

Description of Task Step House Keeping


Hazard •

Can occur when particles of dust, debris or grit, etc. Are blown around the workplace or when such particles are dislodged from work areas above. I.e. from scaffolding

•

•

•

Personnel shall ensure that the highest levels of housekeeping are maintained at all times. The company operates a mandatory “Eye Protection” policy on all project locations. Personnel shall adhere to this strict policy at all times. Supervisors shall monitor the standards of housekeeping on a daily basis to ensure that they are acceptable and implement routine “Clean Ups” where necessary.


Responsible Person Worker

•

Worker

•

Supervisor

•



Rev. No. : 1


Page No. : 18 / 47

METHOD STATEMENT FOR WORK OF INSULATION 1

Att ach ment #2.

JOB SAFETY A NALYSIS FOR INSULATION WORK USING MAN BASK ET

Prepared by:

Afendi Muslim

Approved by:

Cho In Seok

Reviewed by:

Yanam

Date

11 January 2014

Step No. 1.

Description of Task Step Insulation Fixing & Removal


Hazard Inexperienced or incompetent operator/ riggers

Faulty lifting equipment

:

Crane Operators and Riggers shall be certified by Third Party Inspection and competent enough to perform Lifting Operations. Other personnel may assist in rigging operations (if experienced) however a Rigger shall examine all rigging prior to commencing a lift. Toolbox talks shall be held prior to all major or unusual lifts to ensure that all personnel are aware of the operations.

Responsible Person HSE Officer

•

•

•

•

•

•

Visually inspect all equipment priors to use to ensure it is free from any defects / Leaks and or damage. Color Coding and all test certificates by Third Party Inspection on Man-basket / Equipment shall be checked to ensure they are current. Ensure that the number of Person(s) allowed in Manbasket is stenciled on its side. All equipment shall be of adequate rating to perform operations. Any damaged equipment shall be quarantined and

Crane Operator/ Rigger

HSE Officer


•

•

•

•

•

•


•

•


•

•



HSE Officer



METHOD STATEMENT FOR WORK OF INSULATION Step No.

Description of Task Step


Hazard

reported to your Supervisor immediately. Outriggers shall be properly extended, set and locked where locking devices are provided. All equipment shall be properly maintained and inspected on a weekly basis.

Personnel injuries

Uncontrolled lifts

Responsible Person

•

•


•

•

HSE Officer/ Inspector

Leather Hand Gloves shall be worn at all times to protect the hands during lifting operations Workers shall wear Full Body Harness, which is connected to the lifeline that is attached to the Crane hook prior to lift. Loads or Man-basket shall not be moved or swing on top of workers. Workers shall use Grab Bar and keep all parts of their body inside the man-basket during Hoisting, Lowering and Positioning. The Crane Operator shall never leave the crane controls unattended while personnel are still working or the man-basket is suspended.

Worker

•

•

•

•

•

•

•

•

•

•

Single point lifting shall be avoided wherever possible If direct lifting is not possible, use of Taglines shall be utilized to avoid the load from swinging. Lifting/ rigging operations shall be carried out from approve codes of practice. Short cuts causes accidents, do not take risks

Worker


Worker


•

•

•

•

Crane Operator/ Rigger Crane Operator/ Rigger

•

•


•

•


Worker



METHOD STATEMENT FOR WORK OF INSULATION Step No.

Description of Task Step


Hazard

Barricade the area prior to commencing operations. A qualified signal person must be in the basket at all times when transporting personnel Where applicable, Method Statement shall be read to establish specific precautions necessary to the operations

High winds

Responsible Person

•

•

•

•

•

•

Maximum Wind velocity (25 Knots) must be considered during lifting operations. Check approved Anemometer wind velocity reading from the client. Slings and other lifting materials shall be inspected regularly from defects and properly tagged for colorcoded. Lifting operations shall be closely monitored and supervised by trained and competent Riggers

Crane Operator/ Rigger Crane Operator/ Rigger

All parties

•

•


•

•


•

•

HSE Officer/ Inspector

•

•




Cilacap Resid Fluid Catalytic Cracking (RFCC) Proj ect

Rev. No. : 1


Page No. : 21 / 47

METHOD STATEMENT FOR WORK OF INSULATION Table 2 (1) Insulation Thickness for Hot Service (Mineral Wool) Unit: mm SIZE

1/2

3/4

1

1.1/2

2

2.1/2

3

4

6

8

10

12

14

16

18

20

22

24 PLANE

100

25

25

25

25

25

25

25

25

30

30

30

30

30

40

40

40

40

40

40

150

25

25

25

25

25

30

30

30

40

40

40

40

40

40

40

50

50

50

50

200

25

25

25

30

30

40

40

40

40

50

50

50

50

50

50

50

50

50

65

250

25

30

30

40

40

40

40

50

50

50

50

65

65

65

65

65

65

65

75

300

30

30

40

40

40

50

50

50

65

65

65

65

65

65

75

75

75

75

90

350

30

40

40

50

50

50

50

65

65

65

75

75

75

75

75

75

75

75

90

400

40

40

50

50

50

65

65

65

75

75

75

75

75

90

90

90

90

90

100

450

40

50

50

50

65

65

65

75

75

90

90

90

90

90

100 100 100 100

115

500

so

50

50

65

65

75

75

75

90

90

100 100

90

100 100 100 100 115

125

550

50

50

65

6S

75

75

75

90

100 100 100 100 100 115 115 115 115 115

140

600

50

65

65

75

75

75

90

90

100 100 115 115 100 125 125 125 125 125

150

650

65

65

65

75

75

90

90 100 100 115 115 115 125 125 125 140 140 140

150

TEMP.

Notes : Density : As per ASTM Code. 128kg/m3 Max. - 93kg/m3 Min. (blanket ) ASTM C592 Type III 128kg/m3 Min.(board/slab) ASTM C612 Class II & IV 100kg/m3 Min. (pipe cover) ASTM C547 Class II & III




Rev. No. : 1


Page No. : 22 / 47

METHOD STATEMENT FOR WORK OF INSULATION Table 2 (2) Insulation Thickness for Hot Service (Calcium Silicate) Unit: mm SIZE

1/2

3/4

1

1.1/2

2

2.1/2

3

4

6

8

10

12

14

16

18

20

22

24 PLANE

100

25

25

25

25

25

25

25

25

30

30

30

30

30

40

40

40

40

40

40

150

25

25

25

25

25

30

30

30

40

40

40

40

40

40

50

50

50

50

50

200

25

25

25

30

30

40

40

40

40

50

50

50

50

50

50

50

50

50

65

250

30

30

30

30

40

40

40

50

50

50

50

50

65

65

65

65

65

65

75

300

30

30

30

40

40

50

50

50

50

65

65

65

65

65

65

65

65

75

75

350

30

30

40

40

50

50

50

50

65

65

65

75

75

75

75

75

75

75

90

400

40

40

40

50

50

50

50

65

65

75

75

75

75

75

75

75

90

90

100

450

40

'40

50

50

50

65

65

65

75

75

75

75

90

90

90

90

90

90

100

500

40

40

50

50

65

65

65

75

75

75

90

90

90

90

90

100 100 100

115

550

50

50

50

65

65

65

65

75

75

90

90

90

100 100 100 100 100 100

125

600

50

50

50

65

65

75

75

75

90

90

100

100 100 100 100 100 115 115

125

650

50

50

65

65

65

75

75

75

90

100 100

100 100 115 115 115 115 115

140

TEMP.

Notes : Density : As per ASTM C533 type I 220 kg/m³ Table 2 (3) Insulation Thickness for Hot Service (Ceramic Fiber + Calcium Silicate) (Temp. maximum 750 °C) PIPE SIZE

1st layer

2nd layer

(inch )

Ceramic Fiber

Calci um Silic ate

1"

25mm

40mm

1.5"

25mm

50mm

3"

25mm

50mm

30"

50mm

50mm

Plane

150mm

-

Remarks

For 4TH Stage Cyclone Separator

(1) Ceramic fiber Use of Density 128 kg/m³ (ASTM C892 Type3 Grade 8). (2) Maximum Thickness of Ceramic Fiber Blanket 25mm. (3) If the thickness required to 50mm, use of Two layer.




Rev. No. : 1


Page No. : 23 / 47

METHOD STATEMENT FOR WORK OF INSULATION Table 2 (4) Insulation Thickness for Personnel Protection (Mineral Woo l) Unit · mm SIZE

1/2

3/4

1

1.1/2

2

2.1/2

3

4

6

8

10

12

14

16

18

20

22

24

PLANE

100

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

150

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

200

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

250

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

300

25

25

25

25

30

30

30

30

30

30

40

40

40

40

40

40

40

40

40

350

30

30

30

40

40

40

40

40

40

40

40

50

50

50

50

50

50

50

50

400

40

40

40

40

40

50

50

50

50

50

50

65

65

65

65

65

65

65

65

450

40

40

50

50

50

50

65

65

65

65

65

65

65

65

65

65

65

75

75

500

50

50

50

65

65

65

65

65

75

75

75

75

75

90

90

90

90

90

90

550

65

65

65

65

65

75

75

75

90

90

90

90

90

90

100 100 100 100

115

600

65

65

65

75

90

90

90

90

100 100 115 115 115 115 115 115 115 115

140

650

75

75

75

90

90

90

100 100 115 115 115 125 125 125 125 140 140 140

165

TEMP.

Notes : Density : As per ASTM code 128kg/m3 Max. - 93kg/m3 Min. (blanket ) ASTM C592 Type III 128kg/m3 Min.(board) ASTM C612 Class II & IV 100kg/m3 Min. (pipe cover) ASTM C547 Class II & III




Rev. No. : 1


Page No. : 24 / 47

METHOD STATEMENT FOR WORK OF INSULATION Table 2 (5) Insulation Thickness for Personnel Protection (Calcium Silicate) Unit · mm SIZE

1/2

3/4

1

1.1/2

2

2.1/2

3

4

6

8

10

12

14

16

18

20

22

24

PLANE

100

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

150

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

200

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

250

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

300

25

25

25

25

25

25

30

.30

30

30

30

30

30

30

30

30

30

30

40

350

25

25

30

30

30

40

40

40

40

40

40

40

40

40

40

40

40

40

40

400

30

30

40

40

40

40

40

40

50

50

50

50

50

50

50

50

50

50

50

450

40

40

40

40

40

50

50

50

50

50

65

65

65

65

65

65

65

65

65

500

40

40

50

50

50

50

50

65

65

65

65

65

65

65

65

65

65

65

75

550

50

50

50

50

65

65

65

65

65

65

75

75

75

75

75

75

75

75

90

600

50

50

65

65

65

65

65

65

75

75

75

75

75

90

90

90

90

90

100

650

50

65

65

65

65

75

75

75

90

90

90

90

90

90

90

100 100 100

115

TEMP.

Notes : Density : As per ASTM C533 type I 220 kg/m³




Rev. No. : 1


Page No. : 25 / 47

METHOD STATEMENT FOR WORK OF INSULATION Table 3. Insulation Thickness for Cold and Anti-Sweat Insulation Unit· mm 1/2

3/4

1

1. 1/2

2

2. 1/2

3

4

6

8

10

12

14

16

18

20

24

26

30

36

42

48

PLANE

10

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

5

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

25

30

0

25

25

25

25

25

25

25

30

30

30

30

30

30

30

30

30

30

30

30

30

30

30

35

-5

25

25

25

30

30

30

30

30

35

35

35

35

35

35

35

35

35

35

35

35

35

35

40

-10

25

30

30

30

30

35

35

35

35

40

40

40

40

40

40

40

40

40

40

40

40

40

45

-15

30

30

30

35

35

35

40

40

40

40

45

45

45

45

45

45

45

45

45

45

45

45

50

-20

30

35

35

35

40

40

40

40

45

45

45

50

50

50

50

50

50

50

50

50

50

50

55

-25

35

35

35

40

40

45

45

45

50

50

50

50

55

55

55

55

55

55

55

55

55

55

60

-30

35

40

40

40

45

45

45

50

50

55

55

55

55

60

60

60

60

60

60

60

60

60

65

-35

40

40

40

45

45

50

50

55

55

60

60

60

60

65

65

65

65

65

65

65

65

70

-40

40

40

45

50

50

50

55

55

60

60

65

65

65

65

70

70

70

70

70

70

70

70

75

-45

45

45

45

50

55

55

55

60

65

65

70

70

70

70

70

75

75

75

75

75

75

75

80

-50

45

45

50

55

55

60

60

65

65

70

70

75

75

75

75

75

80

80

80

80

80

85

90

-55

45

50

50

55

60

60

65

65

70

75

75

80

80

80

80

80

85

85

85

85

85

90

95

-60

50

50

55

60

60

65

65

70

75

80

80

80

85

85

85

85

90

90

90

90

90

95

100

-65

50

55

55

60

65

65

70

75

80

80

85

85

85

90

90

90

95

95

95

95

95

100

105

-70

55

55

60

65

65

70

70

75

80

85

90

90

90

95

95

95

95

100

100

100

100

105

110

-75

55

60

60

65

70

70

75

80

85

90

90

95

95

95

100

100

100

100

105

105

105

110

115

-80

55

60

65

70

70

75

80

80

90

90

95

100

100

100

100

105

105

105

110

110

110

110

120

-85

60

60

65

70

75

75

80

85

90

95

100

100

105

105

105

110

110

110

110

115

115

115

125

-90

60

65

65

75

75

80

85

85

95

100

100

105

105

110

110

110

115

115

115

120

120

120

130

-95

65

65

70

75

80

80

85

90

95

100

105

110

110

110

115

115

120

120

120

125

125

125

135

-100

65

70

70

75

80

85

90

95

100

105

110

110

115

115

115

120

120

120

125

125

130

130

140

-105

65

70

75

80

85

85

90

95

105

110

110

115

115

120

120

120

125

125

130

130

130

135

145

-110

70

70

75

80

85

90

95

95

105

110

115

120

120

120

125

125

130

130

130

135

135

135

150

SIZE TEMP

60




Rev. No. : 1


Page No. : 26 / 47

METHOD STATEMENT FOR WORK OF INSULATION -115

70

75

75

85

85

90

95

100

110

115

115

120

120

125

125

130

130

135

135

140

140

140

155

-120

70

75

80

85

90

95

95

100

110

115

120

125

125

130

130

130

135

135

140

140

145

145

160

-125

70

75

80

85

90

95

100

105

110

120

125

125

130

130

135

135

140

140

140

145

145

150

165

-130

75

75

80

90

95

95

100

105

115

120

125

130

130

135

135

140

140

145

145

150

150

150

170

-135

75

80

85

90

95

100

105

110

115

125

130

130

135

135

140

140

145

145

150

150

155

155

175

-140

75

80

85

90

95

100

105

110

120

125

130

135

135

140

140

145

145

150

150

155

155

160

0.2

-145

75

80

85

95

95

100

105

110

120

125

130

135

140

140

145

145

150

150

155

155

160

160

180

-150

80

85

85

95

100

105

110

115

125

130

135

140

140

145

145

150

150

155

155

160

160

165

185

-155

80

85

90

95

100

105

110

115

125

130

135

140

145

145

150

150

155

155

160

165

165

165

190

-160

80

85

90

95

100

105

110

115

125

135

140

145

145

150

150

155

155

160

160

165

170

170

190

-165

80

85

90

100

105

110

110

120

130

135

140

145

145

150

155

155

160

160

165

170

170

175

195

-170

85

85

90

100

105

110

115

120

130

135

140

145

150

150

155

160

160

165

165

170

175

175

200

-175

85

90

95

100

105

110

115

120

130

140

145

150

150

155

155

160

165

165

170

170

175

180

200

-180

85

90

95

100

105

110

115

125

135

140

145

150

155

155

160

160

165

170

170

175

180

180

205

Notes:

1.

Table is based on thickness required to prevent condensation on surfaces with following design conditions:

Ambient temperature Relative humidity

30 °C

:

: 85 percent 2

Surface heat transfer coefficient: 8 W/(m2·K) [6.88 kcal/(m ·h·°C)] 2. Where other design conditions are used, thickness should be adapted to meet job requirements. 3

3. Bulk density : Min. 40kg/m




Rev. No. : 1


Page No. : 27 / 47

METHOD STATEMENT FOR WORK OF INSULATION Att achm ent #3.

INSPECTION & TEST PLAN FOR INSULATION No.

A 1

Reference ( Co de /S td /S pe c. /P ro c. )

Description of Inspection

2

Rev. No : 3 Date

:

Page

:

Inspection for R ep or t F or m. No .

Remarks Sc

C

Owner

M

W

I

M

W

I

M

W

I

M

I

I

c) Insulation material form & thickness

M

I

I

d) Extend of Insulation

M

I

I

e) Insulation support ring (Vertical Only)

M

W

I

f) Cool down system installation (Fiber optic Cable-by instrument)

M

I

I

INSULATION Material V erification

Project Specification

a) Verify the material/ Size/ Quantity & Physical Properties

P.O.Spec. / Vendor Documents Field Material Control Procedure

b) Check the damage

2 -1

Doc No : RFCC-ITP-PA-0001

Piping Insulation

Applicable drawing & Specification

Manufacturer's Certificate and Field Receiving Report

ITP-IN(CP)-001

P re -I ns ul at io n C he ck

a) Check the completion of welding, hydro testing and assembly b) Surface cleaning and touch up painting

S c : Su b- Co nt ra ct or ;

C : C on tr ac to r;

M : Execution;

W : Witness;

I : Spot Witness

R : Review Inspection


H : Hold

MIGAS



Rev. No. : 1


Page No. : 28 / 47

METHOD STATEMENT FOR WORK OF INSULATION INSPECTION & TEST PLAN FOR INSULATION No.

2-2

Reference (Code/Std/Spec./Proc.)


Verifying Document

Doc No : RFCC-ITP-PA-0001 Rev. No : 3 Date

:

Page

:

Intervention Sc

C

Owner

M

I

I

M

I

I

M

I

I

M

I

I

M

I

I

f) Expansion/ Construction Joint

M

I

I

g) Primary vapor barrier w/ Glass cloth

M

I

I

M

I

I

Insulation

Appicable drawing & Specification

ITC-IN(CP)-001

a) Anti-abrasive coating b) Joint staggered & fit up c) Insulation Segments (Approx 8" for 2' Long, Approx 12" for 3' Long) d) SUS band interval for outer layer (SUS 304, min. 0.4mm t x 13 mm w, max 225 mm centers) e) Joint Sealant (Outer layer only, wet film thickness App 3.5mm)

(Dry film thickness 3.0mm) h) Vapor stop ( Pipe Suports, Valves & Flanges)



M : Execution;

W : Witness;

I : Spot Witness



H : Hold

MIGAS

Remarks



Rev. No. : 1


Page No. : 29 / 47


2-3

Reference (Code/Std/Spec./Proc.)



:

Page

:

Inspection for Report Form. No.

Sc

C

Owner

M

I

I

M

I

I

M

I

I

d) Flange & Valve Box Installation

M

I

I

Final Inspection

M

W

W

M

I

I

M

I

R

c) Insulation material form & thickness

M

I

I

d) Extend of Insulation

M

I

R

M

I

R

Jacketing


MIGAS

ITP-IN(CP)-001

a) Jacketing installation (Longitudinal overlaps min. 50mm & 90 ° or 150 ° positions) (Circumferential overlaps min. 50mm) b) Jacket band interval ( 0,4mm t x 13mm w for NPS

≤ 24",

max. 300mm centers)

( 0,5mm t x 19mm w for NPS

> 24",

max. 300mm centers)

c) Metal Sealant (white color/ min. 4mm dry thickness)

2-4

3 3 -1

Equipment Insulation


ITP-IN (CE)-002

P re -i ns ul at io n c he ck a) Surface cleaning and touch up painting b) Check the completion of installation, Assembly and final inspection

e) Insulation support ring S c : Su b- Co nt ra ct or ;


M : Execution;

W : Witness;

I : Spot Witness



H : Hold

Remarks



Rev. No. : 1


Page No. : 30 / 47





:

Page

:

Inspection for R ep or t Fo rm. N o.

Sc

C

Owner

M

I

R

a) Anti-Abrasive coating

M

I

I

b) Joint staggered & fit up

M

I

I

M

I

I

M

I

I

M

I

I

f) Expansion/ Construction Joint

M

I

I

g) Primary vapor barrier w/ Glass cloth

M

I

I

M

I

I

f) Cool down system installation (Fiber optic cable-by instrument)

3-2

Insulation


ITP-IN(CE)-002

c) Insulation Segments (Approx8" for 2' Long, Approx,12" for 3' Long) d) SUS band interval for outer layer (SUS 304, 0.5mm t x 19mm w, max. 300mm centers) e) Joint sealant (Outer layer only, wet film thickness App 3.5mm)

(Dry film thickness 3.0mm) h) Vapor stop (Supports, Valves & Flanges)



M : Execution;

W : Witness;

I : Spot Witness



H : Hold

MIGAS

Remarks



Rev. No. : 1


Page No. : 31 / 47


3-3




:

Page

:

Inspection for R ep or t Fo rm. N o.

Sc

C

Owner

M

I

I

M

I

I

M

I

I

d) Manhole box installation

M

I

I

Final Inspection

M

W

W

ITP-IN(CE)-002


Jacketing

a) Jacketing Installation (Laps-min. 50mm for flat jacketing) b) Jacket band interval (max. 300mm centers) (0.5mm t x 19mm w ) c) Metal Sealant (white color/ min. 4mm dry thickness)

3-4



M : Execution;

W : Witness;

I : Spot Witness


H : Hold


MIGAS

Remarks

Cilacap Resid Fluid Catalytic Cracking (RFCC) Proj ect PT. PERTAMINA (Persero )

METHOD STATEMENT FOR WORK OF INSULATION Attac hm ent #4.








METHOD STATEMENT FOR WORK OF INSULATION At tac hm ent #5.

Typic al Det ails Fo r Pi ping Ins ul ati on

COATED WITH MOISTURE BARRIER

Note : All Dimensions are in mm.






Typi cal Details For Valve Ins ul ati on


FLANGED VALVES


VALVE OTHER THAN FLANGED





Flang e Ins ul ati on And In su lat io n Supp or t Ri ng Details


FLANGE INSULATION

INSULATION SUPPORT RING FOR PIPING


























Heat Exch anger In su lat io n


TYPICAL DETAIL AT PIPING HANGER


DOUBLE PIPE HEAT EXCHANGER





Rev. No. : 1


Page No. : 43 / 47

METHOD STATEMENT FOR WORK OF INSULATION Attachment #14.

Insulation Details For Vertical Vessel Head

max interval 150 mm COATED WITH MOISTURE BARRIER


WATERSHED MANNER OVERLAP





Flashi ng Details At Nozzle And “ S” And “ J” -Cli p Detail s


FLASHING DETAIL AT NOZZLE



“ S” AND :J” CLIP DETAILS





Wir e Mesh Bar ri er f or Pers onnel Protec ti on Details

steel welded wire mesh

* use s/s components on s/s pipe





Attachmen t #17.

Removable In su lat io n Cover fo r Pumps (Hot Ins ul ati on )

Filling with mineral wool

50mm


RFCC-T-PCGC-0155 Method Statement for Work of Insulation Rev.1.pdf

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