UNCONTROLLED WHEN PRINTED
BBS amendment to DEP GEN 04.00.4076
AMENDMENT TO DEP GEN:
Wec : Veiligheidsrapport Veiligheidsrapport : WWW-Contract ors : Emergency plan : FCM related :
THERMAL INSULATION (PERNIS/MOERDIJK)
Objective / scope
No No Yes No No
Comm. Index Risk Classification Classificat ion HSE critical
: : : :
B/C L Unrestricted Yes
Objective Application of thermal insulation of equipment, above ground piping and tanks. Design requirements and execution of an insulation system should be such that:
Corrosion under insulation due to ingress of rainwater or condensation of water vapour is prevented.
Heat loss of equipment and piping is minimised, if economically justified.
Personnel protection is provided viz. surfaces with a temperature of 60°C or higher, if these present a danger.
Damage to equipment and piping from exposure to freezing conditions is prevented.
Condensation, solidification or a too high viscosity is avoided.
Scope This BBS document specifies the requirements and gives recommendations for the engineering and application of insulation.
Parties involved
Suppliers, principals, engineers, supervisors, consultants and contractors
Checked by
DMS/746 (SPFP - CEA)
G. Ritzema
DMS/71VP4 (DPFP - CEA)
E. Karam
DMS/946
R. Heemskerk
Risk
This document is, according to the Risk Matrix, potential (L)ow. The risk is covered by this document and by training and application of this document.
Revision info
Last revision
Date
Reason
D
08-10-2012
Harmonized with Thermal Insulation DEP and updated insulation tables
More revision information
Table of contents
1
SUMMARY........................... ............. ........................... .......................... ......................... .......................... .................... ...... 3
2
CONTEXT AND REFERENCES .......................... ............. .......................... .......................... ............. 3
3
GENERAL REGULATIONS ........................... .............. .......................... .......................... ................... ...... 3
4
AMENDMENT TEXT DEP 30.46.00.31-GEN 30.46.00.31-GEN......................... ............ ..................... ........ 4 4.1 4.2 4.3 4.4 4.5
Filename: 04004076.docx
REF. CHAPTER3.2, CHAPT ER3.2, MATE RIALS .......................................................... .......................................................... 4 REF. CHAPTER 3.1.2.1, 3.3.2, 3. 3.2, 4.3.2SURFACE PREPARAT ION ......... ......... 4 INSULATION THICKNESS FOR PIPING AND EQUIPMENT WITH TRACING (HOT INSULATION) .............................................................. .............................................................. 6 INSULATION THICKNESS FOR STORAGE TANKS (HOT INSULATION) .......................................................... ......................................................................................... ............................... 6 INSULATION THICKNESS CELLULAR GLASS, (COLD INSULATION) 7 Rev.: D
Custodian: DMS/746, DMS/946 Owner: Chairman BBS process 04
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BBS amendment to DEP GEN 04.00.4076
4.6 4.7
5
INSULATION CODES .................................................................. 10 5.1 5.2 5.3
5.4
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REF. APPENDICES, APPENDIX F, INSULATION THICKNESS PUR/PIR (COLD INSULATION) ............................................................. 8 REF. PART III, AMENDMENTS/SUPPLEMENTS TO THE CINI HANDBOOK ............................................................................................ 9
GENERAL ............................................................................................. 10 INSULATION CODES FOR HOT INSULATION MATERIALS ............. 10 SPECIFICATION COLD INSULATION FOR PIPING FOR THE TYPICAL DETAILS OF THE CONSTRUCTION OF COLD INSULATION SEE FIGURE 1 ..................................................................................... 10 SPECIFICATION COLD INSULATION AROUND EQU IPMENT ......... 11
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BBS amendment to DEP GEN 04.00.4076
1
SUMMARY This specification is an amendment to DEP 30.46.00.31-GEN and is applicable for the installation of thermal insulation at Shell Pernis/Europoort and Moerdijk.
2
CONTEXT AND REFERENCES This specification is based on the CINI Manual “Insulation for Industries” (Eng lish, latest version). This specification is an amendment to: DEP 30.46.00.31-GEN
3
Thermal Insulation
GENERAL REGULATIONS Engineering For new construction projects and major rejuvenation/maintenance works the engineering contractor or the project department shall submit an engineering instruction at the kick-off meeting 03.05.3000 (P) / 03.03.3000 (M) reflecting the basis of design of insulation systems and specification. The insulation instruction shall be approved by the Civil Engineering Section. The economic insulation thickness for hot insulation shall be determined by means of the data of the table below. For those cases where this is not applicable the insulation thickness as indicated in the tables of paragraph 5 shall be used. The following design criteria shall be used to determine the (economic) insulation thickness: Hot insulation
Cold insulation
Average ambient temperature :
8C
Max. ambient temperature
:
25C
Wind velocity
:
5 m/s
Wind velocity
:
1.4 m/s
Capital charge
:
17.5%
Humidity
:
85%
Heat cost
: € 8/GJ 1)
Emissivity
:
0.3
Drawings The required thermal insulation and finishing materials for piping and equipment shall be indicated and specified on the drawings, including all details with respect to the required mechanical provisions. The insulation details for cold insulation (supports of piping and equipment) shall be completely indicated on drawings, including all necessary required mechanical provisions and shall be submitted to the Civil Engineering Section for approval.
Materials All materials indicated on the drawings shall be specified with the codes mentioned inDEP 30.46.00.31-Gen. The use of individual engineering contractor codes is not allowed. Nano/micro porous insulation material not to be used without explicit permission of Civil Engineering Department (DMS/746 - DMS/946).
Insulation collars Waterproof insulation collars to avoid water ingress shall be fitted around all protruding parts of tanks, vessels and columns with operating temperatures between ambient and 175ºC or with intermittent operation. These collars shall be executed in accordance with standard drawing S-10.056. For existing equipment (maintenance), alternative solutions should be submitted to the Principal for approval, e.g. cellular glass collars (ref. Figure 2 and 3) in case welding on existing equipment is not allowed.
1)
Heat costs to be confirmed by the p rincipal at the start of the project.
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BBS amendment to DEP GEN 04.00.4076
Existing piping and equipment When modifications are made to existing pipe work and equipment, the existing insulation thickness shall be applied.
Electrical tracing In case electrical tracing has been applied under the insulation, the electrical tracing shall be switched off (by others) prior to remove and/or install the insulation system. Deviation is only possible with an approved work instruction or TRA.
Asbestos/Ceramic fibres containing materials One should take into account that existing insulation materials may contain asbestos and/or ceramic fibres. To determine the presence of asbestos samples shall be tested by a Shell approved laboratory (e.g. Daniel C.Griffith Holland B.V.) The handling of asbestos and or ceramic fibres shall be in accordance with 05.03.1021 / 05.05.1021 „Minerale vezels (asbest en MMMF)‟.
4
AMENDMENT TEXT DEP 30.46.00.31-GEN
4.1
REF. CHAPTER3.2, MATERIALS The hot insulation material on stainless steel piping and equipment, shall be of AS Quality in accordance with EN 13468 (maximum contents of leach able chloride ions is < or = 10 mg/kg of insulation material).
4.2
REF. CHAPTER 3.1.2.1, 3.3.2, 4.3.2SURFACE PREPARATION The paint system shall be in accordance with: BBS Maintenance painting 04.00.4053. BBS Painting and coating of new equipment 04.00.4054. BBS QA/QC Conservering 04.00.1028. BBS QA/QC Isolatie 04.00.1029. Ref. appendices, appendix D en E, INSULATION thickness (hot insulation).
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INSULATION THICKNESS IN MM Normal operating temperature in °C diameter. < 1"
type
<50*)
51100
101150
151200
201250
251300
301350
351400
401450
451500
501550
551600
"A"
30
30
30
30
40
40
50
50
60
60
70
70
30
30
30
40
50
60
40
50
50
60
60
70
30
30
40
40
50
60
50
60
60
70
80
80
30
30
40
40
50
70
60
60
70
80
80
90
30
40
40
50
50
70
70
70
80
80
90
90
30
40
40
50
60
80
70
80
90
90
100
100
30
40
50
50
60
80
90
90
100
100
100
120
30
40
50
60
70
80
100
100
110
120
130
130
30
40
50
60
80
80
100
100
110
120
140
140
40
40
60
70
80
100
100
110
120
140
140
140
40
50
60
70
80
100
110
110
120
140
150
150
40
50
60
70
80
100
110
120
120
150
150
150
40
50
60
70
90
100
120
120
150
150
150
150
40
50
60
70
90
100
120
120
150
150
150
150
40
50
60
80
90
100
140
160
180
180
200
200
40
50
70
80
90
100
"B" 1"
"A"
30
30
30
30
40
"B" 1,5"
"A"
30
30
30
40
50
"B" 2"
"A"
30
30
40
40
60
"B" 3"
"A"
30
30
40
50
60
"B" 4"
"A"
30
50
50
60
60
"B" 6"
"A"
50
50
50
70
70
"B" 8"
"A"
50
50
60
80
90
"B" 10”
“A”
50
50
70
80
90
“B” 12"
"A"
50
50
70
80
90
"B" 14"
"A"
50
60
70
90
100
"B" 16"
"A"
50
60
70
90
100
"B" 18"
"A"
50
60
80
100
120
"B" 20"
"A"
50
70
80
100
120
"B" > 20"
"A"
50
80
100
110
130
"B" Equipment
"A"
Equipment
"B"
50
80
100
110
130
140
160
180
180
200
200
25
25
25
40
40
50
70
80
90
100
70 80 90 90 100 120 130 150 150 150 150 160 160 200 200
"A" Economic insulation thickness. "B" Personnel protection.
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4.3
INSULATION THICKNESS FOR PIPING AND EQUIPMENT WITH TRACING (HOT INSULATION) Heat medium
Run pipe
Insulation thickness
< 3"
50 mm
4" en 6"
50 mm
8" … 20"
50 mm
Equipment
50 mm
< 3"
60 mm
4" en 6"
60 mm
8" … 20"
80 mm
Equipment
60 mm
< 3"
50 mm
4" en 6"
50 mm
8" … 20"
50 mm
Equipment
50 mm
LP-steam tracing
MP-steam tracing
Electrical tracing
4.4
INSULATION THICKNESS FOR STORAGE TANKS (HOT INSULATION) INSULATION THICKNESS IN MM Storage tanks Tank walls
Normal operating temperature in °C < 50
51-100
101-150
151-200
50
80
100 2)
120 2)
140
80 2)
80 2)
80 2)
Tank roofs
2
)
201-250 2
)
To be executed in two layers. Uit te voeren in twee lagen.
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4.5
INSULATION THICKNESS CELLULAR GLASS, (COLD INSULATION) Ambient temperature
:
25C
Humidity
:
85%
Wind velocity
:
1.4 m/s
Emissivity
:
0.3
INSULATION THICKNESS IN MM Diameter
Operating temperature C 20
0
-20
-40
-60
-80
-100
-120
-140
-160
-180
½”
12
14
23
30
37
43
48
53
57
61
65
¾”
12
15
24
32
39
46
51
56
61
65
69
1”
13
16
26
34
41
48
54
59
64
69
73
1½”
14
17
28
38
46
53
59
65
70
76
80
2”
14
18
30
40
48
56
63
69
74
80
85
3”
15
19
32
43
53
61
69
76
82
88
94
4”
16
20
34
45
56
65
73
81
87
94
100
6”
17
21
36
49
60
71
80
88
96
103
109
8”
17
22
38
52
64
75
85
93
101
109
116
10”
17
23
39
54
67
78
89
98
106
115
122
12”
18
23
40
55
69
81
92
101
110
119
127
14”
18
23
41
56
70
82
93
103
112
121
129
16”
18
24
42
58
72
84
96
106
115
125
133
18”
18
24
42
59
73
86
98
108
118
128
136
20”
18
24
43
60
74
86
100
111
120
130
139
24”
19
25
44
61
76
90
103
114
124
135
144
Vessel
19
26
46
64
106
126
145
162
178
195
209
Notes
Thickness may be rounded off to the nearest higher manufacturer's thickness (min. thickness 25 mm).
All piping over 24 inch shall be insulated in accordance with the thickness specified for vessels.
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BBS amendment to DEP GEN 04.00.4076
4.6
REF. APPENDICES, APPENDIX F, INSULATION THICKNESS PUR/PIR (COLD INSULATION) Ambient temperature
:
25C
Humidity
:
85%
Wind velocity
:
1.4 m/s
Emissivity
:
0.9
INSULATION THICKNESS IN MM Diameter
Operating temperature C 20
0
-20
-40
-60
-80
-100
-120
-140
-160
-180
½”
7
18
26
33
43
53
63
69
75
80
84
¾”
7
19
27
35
45
56
67
73
79
84
89
1”
8
20
29
37
48
59
70
77
83
89
94
1½”
8
21
31
40
52
65
77
85
91
97
103
2”
8
22
33
43
55
68
81
89
96
103
108
3”
9
24
35
46
60
75
89
98
106
113
119
4”
9
25
37
49
64
79
95
104
112
120
127
6”
9
26
40
52
69
86
103
114
123
131
138
8”
10
27
41
55
73
91
109
120
130
139
147
10”
10
28
43
57
75
95
114
126
136
146
154
12”
10
28
44
58
78
98
118
130
141
151
159
14”
10
29
44
59
79
99
120
132
143
153
162
16”
10
29
45
60
80
102
123
135
146
157
166
18”
10
29
46
61
82
103
125
138
149
160
169
20”
10
30
46
62
83
104
127
140
151
162
172
24”
10
30
47
63
84
107
130
143
155
167
177
Vessel
11
31
50
69
94
123
153
171
188
203
218
Notes
Thickness may be rounded off to the nearest higher manufacturer's thickness (min. thickness 25 mm).
All piping over 24 inch shall be insulated in accordance with the thickness specified for vessels.
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BBS amendment to DEP GEN 04.00.4076
4.7
REF. PART III, AMENDMENTS/SUPPLEMENTS TO THE CINI HANDBOOK Tab 1
General Requirements + Installation Instructions
CINI 1.3.01
General requirements for the thermal insulation of "hot" pipelines and equipment.
4.4 Application of the metal Add to this clause: finishing layer. Sealing of furrowed edges in the cladding is not required for hot-insulation. Paragraaf 4.4.4 The cladding shall be installed such that moisture at the inside can be drained. At horizontal piping, in the middle between two supports, at the lowest point, drain holes shall be provided, min. 1 hole⁄6 m1, diam 10 mm and at the lowest point of vertical bends, connections etc. In practice it will not always be possible to work without sealing by means of mastic or tape, but this must be very selectively. Example:
Horizontal equipment and piping in the vicinity of water spray systems, no sealing shall be applied to the bottom segment (between 4 and 8’o clock), and certainly not to the longitudinal joints in this segment
CINI 1.3.02
General requirements for the thermal insulation of "cold" pipelines and equipment.
1.1
Replace this clause by:
3.2.1
3.5 Metal finishing materials.
The ambient temperature is 25C.
The following materials shall not be applied without approval of the Civil Engineering Section:
flexible elastomeric foam (FEF).
cellular glass (CG)
Add to this clause:
Aluminium cladding shall not be applied. For cold insulation only aluminised steel cladding Type 2 shall be applied.
CINI 1.3.10 … CINI 1.3.37
Installation instructions for the thermal insulation of "hot" pipelines, fittings and equipment.
1.1
The following materials shall not be applied without approval of the Civil Engineering Section:
polyisocyanurate (PIR) and polyurethane (PUR)
cellular glass (CG)
Tab 3
Finishing materials + auxiliary materials
CINI 3.2.01… CINI 3.2.05
Weather resistant mastics.
Page 1 of 1
The following materials shall not be applied without approval of the Civil Engineering Section:
Filename: 04004076.docx
weather resistant ethyl vinyl acetate based mastic,
weather resistant latex based, vapour barrier mastic,
weather resistant elastomer based, vapour barrier mastic,
weather resistant bitumen based vapour barrier mastic,
contact adhesive.
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5
INSULATION CODES
5.1
GENERAL For engineering and contracting-out purposes the various insulation systems shall be indicated with insulation codes.
5.2
INSULATION CODES FOR HOT INSULATION MATERIALS Insulation codes shall be applied for the selection of hot insulation materials as per DEP. 30.46.00.31-GEN.
5.3
SPECIFICATION COLD INSULATION FOR PIPING FOR THE TYPICAL DETAILS OF THE CONSTRUCTION OF COLD INSULATION SEE FIGURE 1
The insulation material shall consist of pre-formed PUR/PIR sections in accordance with the requirements of CINI 2.7.01, type TARECPIR CR40 (Supplier Coolag Holland B.V. or equal). The total insulation thickness shall be made up of one or two layers, depending on the insulation thickness. Transverse and longitudinal joints shall be overlapping ("ship lapped") in the case of single layer insulation. The inner and outer layer of multi-layer insulation can be butt jointed, seams of multiple layer systems shall be staggered. The outer surface of the inner layer shall be covered with a secondary vapour barrier foil (no overlaps), Mylar Multiplex Foil type TF3/50, or equal. The vapour barrier foil shall be in accordance with the requirements of CINI 3.3.05.
The seams of the secondary vapour barrier foil shall be taped off with 50 mm wide InsuW-Rapid Multifoil Alu tape.
Each layer of insulation shall be fixed with Scotch 3M filament tape type 895 or equal, three (3) tapes per meter pipe length.
The outer primary vapour barrier on both one and two layer systems shall be Insu-W-Rapid IWR 701 Instant Butyl Sealing tape with aluminium backup (300 mm wide minimum for straight lengths of pipe) or TEMBUTIL-ALU PLUS. Overlap shall be at least 50 mm.
In piping systems at each interruption (a.o. at support locations, valves, flanges etc.), vapour stops shall be installed in accordance with CINI 1.3.53 par 3.3 and CINI 5.1.08.
Where boxes are used the inside of the box shall be lined with the composite vapour barrier (see above).
Protective jacketing shall be aluminised steel plate. The cladding of straight lengths of pipe shall be fixed with stainless steel tension bands (19 x 0.5 mm). DO NOT use parkers. The seams need not be sealed.
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5.4
SPECIFICATION COLD INSULATION AROUND EQUIPMENT
Supply and application of pre-formed PUR/PIR slabs, type TARECPIR CR40 (Supplier Coolag Holland B.V. or equal). The total insulation thickness shall be made up of one or two layers. Transverse and longitudinal joints shall not be overlapping ("ship lapped"). The outer surface of each layer shall be covered with a secondary factory applied vapour barrier foil (no overlaps) (Mylar Multiplex Foil type TF3/50, or equal). The vapour barrier foil shall be in accordance with the requirements of CINI 3.3.10.
For the insulation of spherical shaped parts of equipment (heads of heat exchangers, columns, tanks, etc.) factory shaped segments (spherically and tangentially shaped) shall be applied. All insulation layers shall be sealed-off on the outside with a vapour barrier foil.
The PUR/PIR-slabs shall not be glued to the equipment.
The joints of secondary vapour barrier foil shall be taped-off with 50 mm wide Insu-W-Rapid Multifoil Alu tape.
On other insulation layer 19 mm wide Filament tape CR 110 shall be applied with a centre to centre distance of 25 cm.
The outer insulation layer shall be fixed with 19 mm stainless steel straps.
On both the one layer system as well as the two layer system a vapour barrier layer of TEMBUTIL-ALU-PLUS shall be applied on top of the outer vapour barrier foil. Overlap shall be at least 50 mm.
The complete system shall be finished with aluminised steel plate. The cladding shall be fastened by means of stainless steel bands (19 x 0,5 mm) instead of parkers and/or blind rivets.
The use of dispersed PUR/PIR in situ shall be limited as much as possible. For valves and flanges, removable covers are preferred; if this is not possible or desirable, dispersed PUR/PIR in situ may be considered. The quality of the foam shall be in accordance with CINI 2.7.01. In order to facilitate future removal of in situ dispersed PUR/PIR, valves shall be wrapped in a rockwool blanket in accordance with DEP 30.46.00.31-GEN, , prior to dispersing the PUR/PIR. For the same reason it is recommended to apply a non-stick coating to the interior of covers used in this application.
The cladding of spherical heads/fronts shall be fixed with blind rivets. For the fixation of cladding on tank roofs the cladding shall be fixed to a specially designed supporting structure. The joints of cladding do not need to be sealed.
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BBS amendment to DEP GEN 04.00.4076
Figure 2: Insulation detail T-bracket
UNCONTROLLED WHEN PRINTED
BBS amendment to DEP GEN 04.00.4076
Figure 2: Insulation detail T-bracket
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BBS amendment to DEP GEN 04.00.4076
Figure 3: Insulation collar detail (alternative to S10.056)
back to front page
Revision information Revision
Date
Reason
0
2001-03-01
First issue
A
2002-09-15
Added figure 2 and 3
B
2003-07-14
Specification changes in para 6.3 and 6.7
C
2005-09-13
Changed: revisions DEP 30.46.00.31 Gen incorporated
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