ALPHA PROJECT SERVICES PRIVATE LIMITED

BARODA

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : I : 0 :01/0 / 2000

0
REV. NO.

01/09/2000
DATE

Issued For Const.

DESCRIPTION

R.V. Patel
PREPARED B REVIE!ED B APPROVED B

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : II : 0 : 01/0 /2000

CONTENT
SECTION 1.0 2.0 3.0 4.0 5.0 6.0 7.0 #.0 9.0 10.0 SCOPE GENERAL REQUIREMENTS INSULATION MATERIALS ANCILLARY MATERIALS APPLICATION APPLICATION OF INSULATION ON PIPING, VESSELS & EQUIPMENT IN UAL TEMPERATURE SERVICE COL INSULATION OF PIPING SU!"ECTE TO FOOT TRAFFIC SAFETY GUARANTEE ATTAC$MENTS TA!LE%I & INSULATION T$IC'NESS FOR COL INSULATION FOR ANTI CON ENSATION ( PIPING TA!LE%II & INSULATION T$IC'NESS FOR COL INSULATION FOR ANTI CON ENSATION ( VESSELS & EQUIPMENTS 25 21 22 22 23 24 TITLE PAGE 1 2 3 7 9 20

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 1 OF 2! : 0 : 01/0 /2000

1.0 SCOPE
This specification covers technical requirement and procedure for the application of selfextinguishing type insulation (expanded polystyrene, rigid polyurethane foam) and mineral wool to vessels, equipments, heat exchangers, pumps, piping and instruments.

2.0 GENERAL REQUIREMENTS

a) Insulation shall be provided on all vessels, equipments, heat exchangers, piping and instruments etc. ontaining fluids or vapour, for which it is necessary to ! I. "aintain low temperature for process control. II. #void surface condensation. b) #ll applications of insulation shall be made in accordance with this specification contractor shall submit with his proposal, information on intended practices of insulation application, which are not covered in this specification, for approval of the engineer-incharge. This information shall include all the details and s$etches including these for the following ! I. II. %emovable insulation housings &lashing details

III. #dditional insulation supports I'. 'essel head insulation supports '. (xpansion )oints 'I. 'essel insulation details 'II. (xchanger removable housing 'III. "achinery removable housings etc. "# P$%&'"&(%) %* +,&'$(,-. /0$()1 .&%$,1' Insulation materials must be protected against any damages, from delivery to finish cladding, dec$ing and covering with tarpaulins alone are not considered sufficient protection from weather for any length of time and shall not be permitted. Insulation material slabs and sections shall be stored on a flat surface in a hori*ontal position. Insulation materials shall beaver be stac$ed directly on the ground. The contractor shall provide covered storage for insulation materials as directed by the engineer-in-charge.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 2 OF 2! : 0 : 01/0 /2000

/# P$%&'"&(%) %* 2,$&(,--3 "%+2-'&'/ 4%5. #ll precautions shall be ta$en to ensure that each day+s wor$ is vapour sealed and cladded during erection and before being left over-right to prevent seepage of water into the materials and getting trapped. The system shall be protected by tarpaulins, water shed and other protective means. '# H3/$%.&,&(" &'.& Insulation shall be applied on vessels, heat exchangers, piping and other equipment only after successful completion of hydrostatic test. In case insulation wor$ starts before completion of hydrostatic test, all welded and mechanical )oints shall be left exposed for testing and subsequently insulated after successful completion of the hydrostatic test. *# C%-%$/(),&(%) 6(&7 %&7'$ ,1')"('. ontractor shall wor$ in close co-ordination with the erection contractor. ,herever temporary supports are provided the contractor shall remove these and provide the necessary insulating wood blac$s. 2.1 E8&')& %* ().0-,&(%) 2.1.1 I&'+. $'90($()1 ().0-,&(%) : a) Items requiring insulation are specified in the piping line schedule and equipment- vesselheat exchanger data sheets. b) #ll attachments and pro)ections such as vessel supports, structural steel attached to vessels, piping hanger supports, instrument load lines, branch lines li$e vents, drains and instrument connections connected directly to cold insulated piping, vessels and equipment, shall be cold insulated upto a distance of . times the ad)oining insulation thic$ness. c) #ll flanged )oints, manhole covers, etc. shall be cold insulated with removable box insulation. &or insulation of manhole covers refers sheet no. /0 of .1. 2.1.2 I&'+. )%& $'90($()1 ().0-,&(%) : a) 2onnet of valves above the pac$ing glands. b) 3ameplates, stampings and code inspection plates on vessels 4 equipment.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : : OF 2! : 0 : 01/0 /2000

3.0

INSULATION MATERIALS

GENERAL #ll materials used for insulation, fixing, sealing and protection shall be new and shall conform to the details given below and clause ..5. #ll insulating materials whether dry or wet shall be non-corrosive to the surfaces insulated. a) Insulation material for insulating piping, vessels and equipment in cold and dual temperature (cold- hot) service shall be as given below. O2'$,&()1 T'+2. $,)1' -160 -160 to 785 to 71:5 I).0-,&(%) M,&'$(,9olyurethane foam or polystyrene 9olyurethane foam. ;owever an initial lagging of resin bonded or lightly resin bonded mineral wool with polystyrene -/5 to 71:5 can be used as an alternative. 9olyurethane foam or polystyrene (upto 785 only) or resin

bonded- lightly resin bonded mineral wool slabs- mattresses, which are factory made, machine laid and machine stitched. b) Insulation material for piping, li$ely to be sub)ected to foot traffic shall be polyurethane. In case of non-availability of polyurethane, the following material shall be adopted. O2'$,&()1 T'+2. $,)1' -160 -160 to 785 to 71:5 I).0-,&(%) M,&'$(,9olystyrene # layer of resin bonded mineral wool cladded with polystyrene c) &oam of insulation shall be as follows ! 9ipes upto .55 32 9ipes upto above .05 32 'essel shells 'essel heads (quipments 9reformed pipe sections 9reformed pipe sections- radial logs %adial logs 9reformed pipe sections or slabs contoured to the profile of vessel heads. %adial logs or slabs as applicable to form contour of the surface to be insulated.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 4 OF 2! : 0 : 01/0 /2000

d) <imensions of preformed sections for piping insulation shall be defined by the outside diameter and insulation thic$ness. Tolerances for preformed sections shall be under ! =utside diameter oncentricity 2ore ?ength, width and thic$ness of slabs -5>, 70> /> =.<. 7: mm -5 mm : mm

e) The nominal used shall not disintegrate, settle, and change its form of composition, in a detrimental way, at the service conditions. f) The insulating material shall be chemically inert, moisture free, rat and vermin proof. g) 9erformed half sections and slabs shall be provided having their longitudinal and circumferential faces flat and smooth so as to mate with the mating sections at the whole face area. (nds of the preformed half sections shall be flat end perpendicular to the center line. :.1 E;PANDED POL<ST<RENE a) The insulation material shall be self extinguishing, preformed, expanded polystyrene with closed cell structure, in accordance with I@-.AB1, type @(. 5# C%+2%.(&(%) The insulation material shall be expanded polystyrene foam prepared from styrene homopolymer or copolymer containing an expanding agent. The finished foam in the form of slabs or half sections shall be of uniform closed cell structure free from. Cnreacted materials, shrin$age and distortion. "# D').(&3 The applied density of the expanded polystyrene shall be as under 9reformed pipe sections @labs :5 to :: $g- m/ 1A to 18 $g- m/

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : = OF 2! : 0 : 01/0 /2000

/# T7'$+,- "%)/0"&(>(&3 Thermal conductivity of insulation material of density 18 $g- m/ shall be as given below "ean temperature 5 15 :5 Thermal onductivity D, cal.-hr. m c 5.5:0 5.5:B 5.5:8

'# ?,&'$ >,2%0$ 2'$+',)"' ,ater vapour permeance of insulating material shall not be more than 5.. gm-m: :. h mm ;g as per I@!AA1 or / germ inch as per #@T" *# F-,++,5(-(&3 The insulating material shall be self extinguishing type when tested by the method prescribed in appendix-( of I@!.AB1. g) The expanded polystyrene shall be free from leachable chlorides. :.2 POL<URETHANE FOAM a) The insulation material shall be rigid preformed cellular urethane foam of self extinguishing type in accordance with #@T" circumstances shall cause fire to spread. 5# C%+2%.(&(%) The insulation material shall be produced by reacting polyisocyanates with ployhydroxy compounds and expanded with a fluorocarbon-blowing agent. The finished foam in the form of slabs or half sections shall be of uniform closed cell structure, free from unreacted materials, shrin$age and distortion. "# D').(&3 The density of finished foam shall be within /0.5 $g-m/ to /6.6 $g-m/ and shall be determined in accordance with #@T" -/5:. /# T7'$+,- "%)/0"&(>(&3 Thermal conductivity of the polyurethane foam slabs and sections shall not exceed 5.516 Dcal-hr. m F (5.1A 2TC- ft: hr. F&- in) at 15 F mean temperature after aging. The thermal conductivity shall be tested by the method prescribed in #@T" -//0. 061, type-II, Erade-:. The foam shall be formulated in such a way that it shall be of a self-extinguishing quality which under no /00 dessicant method.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : ! OF 2! : 0 : 01/0 /2000

'# C-%.'/ "'-- "%)&')& The closed cell content shall be at least 60> by volume. :.: MINERAL ?OOL "aterial spec. for mineral wool shall be as specified in clause /.5 of hot insulation spec. no. #9@-"T-.51, sub)ect to the specific requirements laid down in clauses /.a 4 b of this specification density of mineral wool shall be 155-1:5 $g-m/. (xcept for piping sub)ected to foot traffic where it shall be 105 $-m/.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : @ OF 2! : 0 : 01/0 /2000

4.0

ANCILLIARY MATERIALS

,# ?($'-)'&&()1, -,"()1 A 5()/()1 6($' ,ire netting shall be galvani*ed :. @,E x :5mm to secure insulation bloc$s. ?acing and stiching wires shall be :5 and :: @,E galvani*ed iron wire respectively. 5# B,)/. 2ands shall be of aluminium, of dimensions :5mm , x :. @,E, unless specified otherwise. "# A/7'.(>'. I. &or polyurethane The adhesive to be used for bonding polyurethane sections shall be foster fire resistive adhesive 81-//. In case of non availability of foster+s adhesive, blown bitumen, type 80- :0 conforming to I@!B5: shall be used as on alternative. II. &or polystyrene and mineral wool 2lown bitumen shall be used as adhesive and shall be 80- :0 type conforming to I@!B5:. /# V,2%0$ S',I. &or polyurethane The vapour seal for polyurethane insulation shall be foster fire retardant mastic A5-/5 or equal. In case of non-availability of foster+s mastic, 2itumen emulsion mastic Ginsul$oteH, grade T-1: or equivalent shall be used as an alternative. II. &or polystyrene 4 mineral wool 'apour seal for polystyrene insulation and mineral wool shall be bitumen emulsion mastic GInsul$oteH, grade T-1: or equivalent. '# F(--'$ +,&'$(,I. &or polyurethane 9olyurethane foam dust or mineral wool mixed with specified adhesive shall be pac$ed tightly so as to fill all irregular voids and at contraction )oints. II. &or polystyrene 2lown bitumen mixed with polystyrene beads shall be used to fill all irregular voids and at contraction )oints.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : B OF 2! : 0 : 01/0 /2000

III. &or mineral wool ?oose mineral wool shall be used to fill all voids and surface irregularities and at contraction )oints. *# J%()& S',-'$ The )oint sealer to be used for sealing polyurethane insulation )oints and at flashing of insulation shall be foster foam seal sealer /5-.0. &or polystyrene and mineral wool insulation, the adhesive specified shall be used to seal all )oints. 1# G-,.. C-%&7 The glass cloth to be used for vapour barrier reinforcement shall be open weave 15 mesh glass cloth having glass fiber thic$ness of 0 mils. 7# A-0+()(0+ .7''&. *%$ "-,//()1 %* >,2%0$ 5,$$('$ %) &7' ().0-,&(%). A22-(",&(%) A-0+()(0+ .7''& 1,01' I. 9ipes vessels and equipment upto 055mm nominal dia. :A @,E II. 9ipes vessels and equipment above 055mm nominal dia. :. @,E III. &or valve, flanges and other areas where mechanical :: @,E damage is li$ely to occur. (# A)&(-"%$$%.(>' 2,()& @hop 9rimer Type omposition #pplication <rying time =ver coating 9ractical covering capacity %ed oxide *inc chromate primer ! @ingle pac$, #ir drying ! # water resisting phenolic resin medium pigmented with *inc chromate red oxide. ! 2y brush or spray ! .-A hours ! 1A hours ! 15-1: sq. meters per liter at a <&T of :0 microns

# primer coat of red oxide *inc chromate shall be applied on all carbon steel and alloy steel piping and equipment before application of cold insulation. Items made of stainless steel and other non-ferrous alloys shall not be painted but shall be wrapped with 5.1mm #luminium foils before application of cold insulation. 4# B(&0+()(C'/ $%%*()1 *'-& 2itumini*ed self finishing roofing felt shall conform to I@-1/::, type-/, grade-1.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : : 0 : 01/0 /2000 OF 2!

5.0 APPLICATION
GENERAL The following applies to all types of cold insulated equipment and piping. ,# S0$*,"' 2$'2,$,&(%) The surfaces of tan$s, vessels, piping and valves etc. on which cold insulation is to be applied, shall be free of dust, loose paint or any other foreign matter. The surface irregularities shall be filled up with the approved filler. =ne coat of anticorrosive primer (as per clause ..i) shall be applied over the carbon- alloy steel surfaces to be insulated and allowed to dry before application of insulation. 5# I).0-,&(%) &7("D)'.. ,)/ -(+(& Insulation thic$ness shall be in accordance with the equipment data sheets and piping line schedule. &or piping- vessels to be insulated for anti-condensation, the insulation thic$ness shall be as per table-I and II. Insulation thic$ness on item covered in clauses :.1.1.b 4 c shall be equivalent to that an ad)oining piping and equipment. =.1 V,2%0$ 5,$$('$ a) 9olyurethane insulation # /mm (wet) thic$ coating of vapour seal mastic shall be applied to the surface of the insulation as soon as possible after erection, to reduce the time the insulation is exposed to the weather to a minimum. ,hilst this coat is still wet, glass cloth shall be laid over the surface and embedded in the mastic. are shall be ta$en to ensure that the glass cloth is laid smooth and free from wrin$les, and that no poc$ets of air are trapped beneath the surface. #t )unctions in the glass cloth, the overlap shall not be less than B0mm. # second /mm thic$ coat of mastic shall be applied after approximately twelve hours. ,hen dry this coating shall be a minimum of 1.05mm thic$. are must be ta$en, however to ensure that the individual coats are not greater than /mm (especially in corners), otherwise some crac$ing of dried coat may result. The total dry film thic$ness of vapour seal shall not be less than :.0mm with a tolerance of I5> to 705>. The mastic shall not be applied over wet insulation or until the adhesive is dry. <uring this drying time the insulation shall be protected from the weather by J#l$athene+ film, tarpaulin or similar materials approved by the engineer-in-charge. ,here )oints have been left uninsulated, a complete vapour seal as specified above shall be applied to the exposed end of the insulation and flashed weather tight on to the metal.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 10 OF 2! : 0 : 01/0 /2000

b) 9olystyrene and mineral wool insulation # vapour barrier meant to prevent moisture penetration into polystyrene and mineral wool insulation shall be applied over the insulation in accordance with the following steps. I. =ne coat of bitumen emulsion (:.0mm thic$ when dry) shall be applied on the insulation. II. Elass cloth shall be applied, with minimum overlap of 05mm, over the first coat of bitumen emulsion when the later is not fully dried. are shall be ta$en to ensure that the glass cloth is laid smooth and free from wrin$les and that no poc$ets of air are trapped beneath the surface. #t )unctions in the glass cloth, the overlap shall not be less than B0mm. III. #nother coat of bitumen emulsion (1.0mm thic$ when dry) shall be applied over the glass fabric, to form a smooth and even finish. c) 'apour barrier shall be protected by cladding with aluminium sheets. Koints in aluminium sheet shall be staggered and suitably sealed with an approved sealer. #luminium cladding shall bot be applied untill the vapour barrier has completely dried and its solvents have dissipated. @elf-tapping screws shall not be used to secure aluminium cladding as they may puncture the vapour barrier. /# E82,).(%)/ C%)&$,"&(%) 4%()&. ,hen specified on a pipe line or vessel drawing or where deemed necessary to allow movement and contraction of the pipe or vessel without producing random crac$ing of the insulation, contraction )oints shall be provided in the insulation. #t contraction )oint location, provision shall be made in aluminium cladding to accommodate contraction of pipe or vessel The following steps shall be ta$en ! I. 2ath longitudinal and circumferential )oints in insulation shall be staggered. II. ontraction )oints shall be provided at an interval depending on pipe or vessel material contraction- expansion co-efficient and temperature. Cnless otherwise specified contraction )oints shall be provided at an interval of A.5m on straight run of pipes or vessels operating at temperature. I.5F 4 below.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 11 OF 2! : 0 : 01/0 /2000

III. ontraction )oints in hori*ontal vessel insulation shall be close to support points while on vertical pipes 4 vessels, the same shall be provided at support ring location and at an interval of ..5 " straight run. I'. # contraction )oint shall consist of 1:.5mm gap in the insulation, loosely pac$ed with filler material, as applicable described under clause ..e to a depth of A.5mm less than the ad)acent insulation thic$ness. A.5mm gap thus left shall be filled up by approved non-setting compound (foster foam seal /5-.0 sealer of equivalent) and finished smooth with the surface of insulation. 'apour barrier which shall cover the )oint shall be applied only after the compound has dried. (xpansion- contraction )oint details are given in sheet /A of .1. '# S&,()-'.. .&''- 2(2()1 A '90(2+')& #ll pipes, vessels and equipment of stainless steel construction shall be wrapped with 5.1mm thic$ aluminium foil with an overlap of 05mm having barium chromate sealer interposed in the )oint prior to application of insulation. &oil shall be secured in position by aluminium bands, ta$ing every precaution to avoid formation of pinholes or crac$ing in the aluminium foil. ladding shall be done after the insulation and vapour barrier exactly the same way as for other pipes and equipment. f) &or all pipes, vessels, equipment etc. lying in a corrosive environment where sulphur dioxide or other corrosive media are li$ely to be present, stainless steel bands- clips shall be used to secure aluminium cladding in position. 1# F('-/ 6'-/()1 &ield welding of clips or other insulation supports on any vessel or piping, sub)ected to the pressure of operating fluid shall not be permitted. ;owever field welding on non pressure parts, to install insulation supports etc. can be permitted with prior approval of the engineer-in-charge, but extreme care shall be ta$en so that welding does not result in decrease of metal thic$ness or excessive during of metal. =.2 APPLICATIN VESSELS A EQUIPMENT GENERAL Individual vessel and tan$ drawings indicate the location of insulation supports furnished by the owner. ;owever additional supports or anchorage, wherever required, to facilitate application of insulation and securing of insulation shall be provided by the contractor at his own cost.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 12 OF 2! : 0 : 01/0 /2000

#ll surfaces shall be prepared as described in clause 0.a before application of insulation. ,# S()1-' -,3'$ ().0-,&(%) Insulation radial lags- preformed sections of handy si*es shall be installed on to the surfaces of vessels adhering to each other with applicable )oint sealer and secured in position by E.I. wire netting and aluminium bands at an interval of ::0mm. There shall be no through )oints and the insulation shall not be bonded to the vessel. 5# M0-&( -,3'$ ().0-,&(%) The inner layer of insulation shall be bonded to the vessel with the applicable adhesive. @ubsequent layers of insulation shall be banded to the preceding layer, with the applicable adhesive. The )oint sealer shall be applied to the ends and edges of all sections, including those in the inner most layer to seal all )oints. are shall be ta$en to ensure that the adhesive is evenly spread over the entire surface of application and the insulation is closely butted to each other both longitudinally and circumferentially. #ll the layers except the final shall be secured in position by metallic bands at an interval of ::0mm while the final layer shall be first secured with E.I. wire net and then with metallic bands at an interval of ::0mm. 2ands shall be staggered on successive layers. There shall be no through )oints in the insulation. "# F(--()1 #ll the crac$s and voids in the main insulation shall be filled up with applicable filler material, as described under clause ..e. =.: VERTICAL VESSELS ,# S7'-- EC3-()/$(",-# @labs in handy si*es as given below shall be applied resting onto the supports with )oints tightly butted, staggered 4 adhereing to each other with applicable adhesive and secured in position by circumferential metallic bands at a pitch of ::0mm. &or vessels upto :.0m =.<. I %adial lags of suitable width. &or vessels over :.0m =.<. I %adial lags. ;owever the procedure given below can be used as an alternative. &lat insulation slabs of width not more than /55mm shall be cut longitudinally to have notch (es) of suitable si*e spaced at suitable spacing, so as to form a radial segment suitable for the profile of the vessel shell. ;owever extreme care shall be ta$en to ensure

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 1: OF 2! : 0 : 01/0 /2000

that no air poc$ets are formed in the finished insulation. #ll insulation )oints shall be sealed with applicable )oints sealer. ,here more than one layer is used, each layer shall be banded separately as given in clause 0.:.b. "ethod of application shall be as given in sheet :0 of .1. ,hen mineral wool insulation is used, notches shall not be cut as the insulation itself is semi rigid and can be pressed to form contour of the shell. 5# T%2 H',/. @haped insulation sections shall be installed on top head, banded and butted tightly to each other. Insulation shall be held in position by ma$ing use of galvani*ed iron floating ring (:0mm x 5.Amm) placed over the insulation and positioned in the center of the head so as not to touch the no**le at the vertex. The insulation shall be held in position by use of radial metallic bands, one end of which shall be fastened to the floating ring and the other end shall be anchored to the band (s) placed around the cylindrical section close to the head. %adial bands shall be spaced on /55mm centers measured around the circumference of the vessel. The final layer of insulation shall be held in position also by metallic wire net laced at the no**le location by :-/ loops of 15 @,E galvani*ed wire and to the wire net over insulation on the shell at the cylindrical section close to the head. ,hen there exists no no**le at the top of the vertex, the insulation shall be held in position by wire netting and metallic bands stretched over the head and anchored on the cylindrical section close to the head by circumferential metallic band (s) on the shell and near the head. "# B%&&%+ H',/. In all the s$irt-supported vessels, insulation supports are provided inside the s$irt as indicated in the equipment drawing sheet .1 of .1. &loating ring and wire loops around the no**le and bands shall be used to support downward lacing of insulation. @uch a floating ring shall be positioned centrally around the no**le but over the insulation by radial bands anchored to the lagging support angle ring fixed inside the s$irt at a pitch at /55mm measured over the support angle ring.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 14 OF 2! : 0 : 01/0 /2000

If no**le does not existing, metallic bands shall be stretched across the bottom head and anchored with lagging support angle ring inside the s$irt. #ll the wire ends of wire netting shall be cut short and turned into the insulation. =.4 HORIFONTAL VESSELS The insulation radial lags of handy si*es shall be installed in close contact with the face to be insulated and held in position by E.I. wire netting and metallic bands at a pitch of ::0mm. ,here more than one layer is required, each layer shall be banded separately. The bands for successive layers shall not coincide with each other. ,ire netting on the final layer shall be applied and ends shall be laced together by lacing wire before putting the metallic bands as per clause 0.:.b. Insulation sections on the vessel heads shall be secured in position by wire netting and metallic bands stretched across the heads and anchored to circumferential metallic band (s) on the shell near the heads. #nchoring of bands measured on the circumference of shell shall be at a pitch of ::0mm max. "ethod of application of insulation shall be as given in sheet :A of .1. =.= TANG INSULATION "aterial and method of application for tan$s shall be the same as specified for vessels. &lat aluminium, sheets for weather proofing shall be used exactly in the same manner as specified for other vessels. =.! SPHERICAL VESSELS Insulation of spherical vessels shall be preformed as shown in sheet :8 of .1. 2efore commencing the application of insulation, the contractor shall ensure that exterior surfaces have been prepared in accordance with clause 0.a @haped insulation to fit curvature of sphere shall be banded to the vessel with applicable adhesive. #ll insulation )oints shall be sealed with applicable )oint sealer. This inner layer of insulation shall be held in position by :5mm L :5 @,E aluminium bands at /55 mm max. center at the equator. These bands are tied up with floating rings of 185 mm dia. made of 10 mm dia. @.@. rod at top and bottom of the sphere. The bands staggered on successive layers and the clips of the bands being recessed into the insulation. =ver the outer layer galvani*ed wire netting shall be spread over and laced together. =.@ VAPOUR BARRIER

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 1= OF 2! : 0 : 01/0 /2000

'apour barrier shall be applied on all the vessels described above as per the procedure outlined in clause 0.1.

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 1! OF 2! : 0 : 01/0 /2000

=.B

METAL SHEET FINISHING ,# H%$(C%)&,- V'..'-. The insulation shall be covered with aluminium sheeting with all the longitudinal and circumferential )oints having an overlap of minimum 05mm. #ll longitudinal and circumferential )oints shall be sealed with suitable approved bitumen*ed mastic sealer. #luminium sheeting shall be secured in position by metallic bands on the shell at a max. pitch of .:0mm. #ll the longitudinal )oints with overlap of 05mm in the aluminium sheet shall be $ept below the hori*ontal plane passing through the axis of the vessel to prevent water or other spillage from entering into the insulation. Kac$eting for dished heads shall be fabricated from radial segments with the radial overlap of minimum 05mm. The sheeting shall be secured in position by radial tensioned metallic bands stretched over the heads. =ne end of each band is anchored to the circumferential band (s) on the shell while the other is fastened (pop riveted) by Amm dia. floating rod ring which can be replaced by Amm thic$ strip (E.I.) rolled in the form of a ring. %adial metallic bands, measured over the circumference of shell, shall be at a pitch of /55mm. #ll the sheet metal )oints shall be properly sealed with approved sealing mastic. 5# V'$&(",- V'..'-. The aluminium sheeting shall be adequately rolled and installed over the insulation such that all the longitudinal )oints are staggered. #ll the longitudinal and circumferential )oints shall have an overlap of 05mm minimum and suitably sealed with approved mastic sealer. #luminium sheeting shall be secured in position by tensioned metallic bands installed circumferentially at a max. pitch of .:0mm. I. T%2 7',/.. Insulation shall be covered with flat aluminium )ac$et fabricated in segmental form with lapped )oints properly sealed with approved mastic sealer. =ver-lapping of sheet metal )oints shall not be less then 05mm. #luminium )ac$et shall be secured in position by radial tensioned metallic bands anchored to the circumferential band (s) of vessel on one side and fastened to Amm dia. floating for ring, centrali*ed of the vertex of head on the other side Amm thic$ metallic. (E.I.) strip rolled into a ring can be the substitute for Amm dia. rod. 9itch of radial bands measured over the circumferential bands of shell shall be max. /55mm

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STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 1@ OF 2! : 0 : 01/0 /2000

II. B%&&%+ 7',/. #luminium sheeting shall be installed exactly in the same manner as indicated for top heads. "# S27'$(",- V'..'-. ladding of each hemisphere of spherical vessel shall be done with aluminium sheets placed hori*ontally and a thic$ circumferential tensioned band (Amm thic$) shall be used at the equator to hold the radial metallic bands. /# O&7'$. =penings in metal )ac$ets for no**les, manways, brac$ets etc. shall be cut as close as possible for a snug fit. =. FLASHING #ll openings through insulation finish shall be flashed weather tight particularly where connections are not insulation. &lashing shall be carried out as per details given in sheet .5 of .1. @$irt supported vessels shall have the s$irt insulated inside and outside for at least A55mm below the tangent line or such that temp. of ad)acent non insulation surfaces of the s$irt shall not be below dew point. 9roper flashing and sealing shall be done on s$irt where insulation and subsequent metal finish terminates as given in sheet .1 of .1. =.10 E;CHANGER INSULATION (xchanger shells except for channels cover and channels shall be insulated and weather proofed as specified for vessels. (xchanger channels and channel covers including flange bolting shall be insulated with removable aluminium covers lined with insulation slabs of required thic$ness. =.11 MACHINER< In general, removable aluminium boxes lined with slab insulation of required thic$ness shall be used for insulation of machinery after giving a coat of anticorrosive paint. The contractor shall submit details of individual pieces of equipment depending on the nature of items to be insulated to the engineer-in-charge at site for approval. =.12 APPLICATION-PIPING G')'$,Insulation shall be applied only after ensuring that piping to be insulated is properly installed, supported and tested. %efer sheet :6 of .1 for application of insulation.

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STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 1B OF 2! : 0 : 01/0 /2000

,# H%$(C%)&,- 2(2()1 I. 9iping surface shall be cleaned of loose rust, mill scale, grease, dust or any other foreign contaminants. @urface preparation shall be done in accordance with clause 0.a. II. The insulation shall be applied to pipes in half round sections in reasonably handy si*es. ,here insulation thic$ness required is greater than 05mm or that the metal temp. is below-.5F , multi layer construction shall be followed with all the )oints staggered in successive layers. III. The inner layer of insulation shall be banded to the piping with applicable adhesive. @ubsequent layers of insulation shall be bonded to the preceding layers with the above adhesive. Koint sealer shall be applied to the ends and edges of all sections, for sealing all longitudinal and circumferential )oints. #dhesive shall be applied evenly and the half sections shall be closely butted to each other both longitudinally and circumferentially. I'. #ll the insulation layers except the final shall be secured in position by metallic bands at an interval of ::0mm, while the final layer shall first be secured with E.I. wire netting and then with metallic bands at an interval of ::0mm. 2ands shall be staggered on successive layers. '. Insulation at piping shall be stopped short of flanges to allow for withdrawal of bolts. &or fittings, the insulation shall be completed by applying. ut segments of the some insulation sections used for pipes. 'I. #ny crac$s or irregularities in the external surface of insulation sections shall be filled up by applicable filler material, as described under clause ..e. 'II. &or long run of pipes, the ends of insulation sections shall be sealed off at 1:m intervals and vapour barrier. arried down upto the metal surface. 'III. ontraction )oints shall be provided at an interval of Am unless otherwise specified as per clause 0.1.d. 5# V,2%0$ 5,$$('$ 'apour barrier shall be applied over the insulation as outlined in clause 0.1.

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STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 1 : 0 : 01/0 /2000 OF 2!

"# M'&,- .7''& *()(.7()1 'apour barrier (after it has dried) shall be protected by cladding it with specified aluminium sheeting. #ll )oints between ad)acent aluminium sheets shall be staggered and grooved with a minimum overlap of :0mm, and suitably sealed with approved sealer. The longitudinal )oints shall have single grooves while the circumferential )oints shall have two grooves. #luminium or E.I. bands- clips at an interval of .:0mm shall be used to secure the aliminium cladding in position. @elf-tapping screws shall not be used. &or pipes, vessels and equipments lying in a corrosive environment where sulphur dioxide in li$ely to be present, stainless steel bands- clips spaced at intervals of .:0mm shall be used to secure the aluminium cladding in position. /# V'$&(",- 2(2()1 Insulation, vapour barrier and metal sheet finishing shall be performed as specified for hori*ontal piping. ontraction )oints shall be provided in accordance with clause 0.1.d. Insulation supports- spacer rings shall be provided at an interval of ..5m (if other insulation supports are not already existing on the pipe) as shown in sheet /1 of .1. '# P(2' .022%$&. A 7,)1'$. In all the supporting arrangements of both hori*ontal and vertical piping, dry hard wood pipe support bearing bloc$s coated with fire retardant paint- mastic shall be used. "etal cradles, metal pipe supports and hangers shall be attached to outside of the pipe support bearing bloc$s and not directly to bore pipe. 9rovision shall be made to prevent seepage of water into the insulation from pipe hangers. *# F-,)1'. A >,->'. %emovable covers shall be provided over all flanges and valves. Insulation shall be preformed as per the details given in sheet // 4 /. of .1. ?oose fill mineral wool bac$ed up by slab insulation of thic$ness equal to that an ad)acent pipe shall be applied. #luminium covers over the valves and flanges shall be fitted with quic$ release clips. This application shall be proposed for each case by the insulation contractor and approved by the engineer-in-charge. 1# R'*$(1'$,)& &$,"'/ -()'. I. The lines to be refrigerant traced shall be given in the line schedule and also shall be given in layout drawings and isometrics.

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STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 20 OF 2! : 0 : 01/0 /2000

II. ,hen lines are traced with one or more tracers, insulation shall be of sufficient si*e to house the assembly without distortion or damage to the insulation. III. The refrigerant traced assemblies shall be first wrapped with specified wire netting, thus ensuring tracer pipe gearing tightly against the line refrigerant-traced. I'. #pplication of insulation shall be exactly the same as for piping described earlier and as given in sheet no /6 of .1. '. #pplication of vapour barrier and cladding with aluminium sheet shall also be some as for piping described earlier.

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STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 21 OF 2! : 0 : 01/0 /2000

6.0 APPLICATION

OF

INSULATION

ON

PIPING,

VESSELS

EQUIPMENT IN DUAL TEMPERATURE SERVICES !COLD" HOT#

a. Insulation material for dual temperature service shall be selected in accordance with clause /.a. ,hen, polyurethane or polystyrene or mineral wool is the material of insulation, application of the same shall be in accordance with the procedure laid down in clause 0.5 for piping, vessels and equipment as applicable. A.1 ,hen a combination of mineral wool and polystyrene is used, its application shall be carried out in accordance with the procedure laid down in the following clauses. %efer sheet no :6 of .1 for schematic arrangement. a) #ll surfaces of piping- vessels to be insulated shall be prepared in accordance with clause 0.a. #fter the anticorrosive paint has dried, mineral wool pipe sections- mattresses with specified E.I. wire netting and a thic$ness such that the maximum temperature on the outside of insulation is A5F , shall be applied on the surfaces to be insulated. The insulation shall be applied without any adhesive and all the insulation )oints shall be tightly butted against each other so that insulation fibers interloc$ both along longitudinal and circumferential )oints. "ineral wool insulation along with E.I. wire netting shall be held in position by metallic bands located of a pitch of ::0mm. b) # first layer of vapour barrier shall be applied over the mineral wool insulation, in accordance with the procedure outlined in clause 0.1.b. c) #fter the vapour barrier has fully dried, the polystyrene pipe sections- radial lags, as applicable, shall be applied with all the longitudinal and circumferential )oints tightly butted and sealed with applicable )oint sealer. The insulation shall be held in position by E.I. wire netting and metallic bands spaced at ::0mm intervals. d) # second layer of vapour barrier shall be applied exactly the same way as the first layer of vapour barrier. e) Insulation and vapour barriers for vertical piping shall be applied in exactly the same way as for hori*ontal piping except that support rings shall be provided to hold the insulation at an interval of ..5 ". f) #luminium sheeting shall be applied on the final layer of vapour barrier accordance with clause 0.8 or 0.1:.c, as applicable.

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STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 22 OF 2! : 0 : 01/0 /2000

$.0 COLD INSULATION OF PIPING LOCATED AT OR %ELO& GROUND LEVEL AND &HERE THERE IS A LI'ELY HOOD OF FOOT TRAFFIC
a) "aterial of insulation shall be preformed sections of polyurethane, as indicated in clause /.b. ;owever polystyrene and a combination of mineral wool and polystyrene, as applicable, may be used as on alternative as per provision of clause /.b. b) ,hen polyurethane or polystyrene is the material of insulation, application of the same shall be carried out in accordance with the procedure specified in clause 0.5. &or piping, vessels and equipment, as applicable, except that instead of providing aluminium cladding over the final layer of vapour barrier, the procedure laid down in clause B.d shall be adopted. c) ,hen a combination of resin banded mineral wool pipe sections and polystyrene is to be used, application procedure shall be as specified in clause A.1. ,ith the only exception that instead of providing aluminium cladding over the final layer of vapour barrier, the procedure specified in clause B.d shall be adopted. d) 2itumini*ed self-finishing roofing felt shall be wrapped over the final layer of vapour barrier after it has fully dried with an overlap of minimum 05mm both on longitudinal and circumferential )oints. I. The roofing felt shall be secured with the specified galvani*ed iron wire netting, laced with :5 @,E galvani*ed iron wire. II. # /mm thic$ bitumen emulsion mastic, in accordance with clause ..d.II, shall be applied for water and weather proofing. III. ,hen bitumen emulsion has completely dried, the surfaces shall be painted with two coats of bitumen based aluminium paint.

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STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 2: OF 2! : 0 : 01/0 /2000

(.0 SAFETY
The insulation contractor shall provide adequate protective appliances li$e hand gloves, mas$s, glasses etc. to the wor$men carrying out the insulation wor$, to protect them from inhaling and touching insulation dust and fibres.

).0 GUARANTEE
a) The insulation contractor shall submit along with the tender, authentic test certificates confirming that the insulation materials offered conform to the requirements of this specification and the standards mentioned therein. #ny deviation shall be clearly stated. b) The insulation contractor shall guarantee the following. I. The insulation and ancillary materials are new and unused and conform to the standards mentioned in the specification. II. The operating thermal conductivity shall be as specified. III. The wor$manship in execution of the insulation wor$s shall be in accordance with sound engineering practice.

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STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 24 OF 2! : 0 : 01/0 /2000

10.0 ATTACHMENTS
S$. N%. 1. :. /. .. 0. A. B. 8. 6. 15. 1:. D'."$(2&(%) 'ertical vessels I cold insulation with aluminium cladding on shell, tops and bottom heads. ;ori*ontal vessels I cold insulation with aluminium cladding. old insulation for spherical vessels. Typical cold insulation on hori*ontal pipes. old insulation of dual temperature service piping (#lternate method). old insulation supports for vertical pipes "ethod of insulating feet of vessels Typical cold insulation for flanged )oints. Typical cold insulation for valves. old insulation for manholes. lips on heads and inside of s$irt for bloc$ insulation. @heet :B of .1 @heet :8 of .1 @heet :6 of .1 @heet /5 of .1 @heet /1 of .1 @heet /: of .1 @heet // of .1 @heet /. of .1 @heet /0 of .1 @heet /A of .1 @heet /B of .1 @heet /8 of .1 @heet /6 of .1 @heet .5 of .1 @heet .1 of .1 D$,6()1 / S7''& N%. @heet :A of .1

11. <etails of contraction )oint. 1/. <etails of spacer ring. 1.. %efrigerant tracing insulation 10. "ethod of insulating branches of vessels 4 flanged )oints (flashing details). 1A. old insulation of vessel s$irt.

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STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 2= OF 2! : 0 : 01/0 /2000

TABLE-I
=?< I3@C?#TI=3 &=% #3TI =3<(3@#TI=3 I 9I9I3E Table of thic$ness for expanded 9olystyrene- 9olyurethane Insulation N%+. P(2' D(,+'&'$ ++ :5 :0 .5 05 85 155 105 :55 :05 /55 /05 .55 .05 055 A55 NOTES:1. <(@IE3 2#@I@ #mbient Temp. %elative ;umidity (missivity onductivity .1F 86> 5.6 5.:B0 ",-cm. <egree at I00F 5.:6 ",-cm. <egree at I.5F 5./1/ ",-cm. <egree at I:0F 5./: ",-cm. <egree at 5./. ",-cm. <egree at :. /. Thic$ness do not include finish thic$ness. "aximum single layer insulation thic$ness 05mm. ,herever thic$ness exceeds 05mm two layers of insulation shall be used for higher thic$ness several layers shall be used. 5F :5F I)"7 /-.H 4 under 1H 1 MH :H /H .H AH 8H 15H 1:H 1.H 1AH 18H :5H :.H 4 over .0 .0 05 05 00 A5 A5 A0 A0 A0 B5 B0 85 85 85 T7("D)'.. () ++

ALPHA PROJECT SERVICES PVT. LTD. BARODA

STANDARD SPECIFICATION FOR COLD INSULATION OF VESSELS, PIPING AND EQUIPMENTS

DOC. NO. : APS-MT-402 SHEET REV. DATE : 2! OF 2! : 0 : 01/0 /2000

TABLE-II
=?< I3@C?#TI=3 &=% #3T =3<(3@#TI=3 I '(@@(?@ 4 (NCI9"(3T Table of thic$ness for expanded 9olystyrene- 9olyurethane Insulation V'..'- D(,+'&'$ Cpto 1 " 1 " to 1.0 " 1.0 " to : " : " to / " / " to ..0 " =ver ..0 " 4 &lat NOTES:1. <(@IE3 2#@I@ #mbient Temp. %elative ;umidity (missivity onductivity .5F 86> 5.6 5.:0B ",-cm. <egree at I00F 5.:6 ",-cm. <egree at I.5F 5./1/ ",-cm. <egree at I:0F 5./: ",-cm. <egree at 5./. ",-cm. <egree at :. Thic$ness do not include finish thic$ness. /. "aximum single layer insulation thic$ness 05mm. &or insulation thic$ness in excess of 155mm minimum three insulation layers shall be provided. 5F :5F T7("D)'.. () ++ 1:5 1:5 1:5 1:5 1:5 1:5 1:5