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IPM-L0105
16.11.2005 1 of 13
(This Standard supersedes AA Standard Ljph-1 dated 10 February, 1994, Ljpt-8 dated 11 February, 1993 and Ljph-28 dated 31 July, 2005)
Inter Project management Co.,Ltd. Advance Agro Workshop Building , 1 Moo 2 Thatoom, Srimahaphote Prachinburi 25140 ,Thailand
THERMAL INSULATION Contents 1 2 3 4 5 6 7 8 9 General Scope of Work Standards Material Purchase and Supply Specification for Insulation Work Insulation of Equipment Control, Measurement and Acceptance of the Insulation Work Guarantee Reference Standards
Orig. Rev.
16.11.2005 Date
JPH/SL Author
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GENERAL The purpose of these stipulations is to specify the general requirements for the insulation of equipment and piping included in the purchase contracts, for the insulation enquiry and to standardize the insulation material and procedure with regard to erection and mill maintenance. Deviations from these instructions are permitted only on written agreement. The deviation must be expressly specified in the purchase Contract. Instructions in EN 563 and prEN 13202 shall be considered for safety insulation of equipment. In this document, reference has been made to Finnish Standards SFS 3975...SFS 3979. Particular attention shall be paid to the waterproofness of the insulation coating.
2 2.1
SCOPE OF WORK Extent of Work The extent of the insulation work shall be indicated in the machine, tank, piping etc. lists or drawings for each section and/or a separate list showing the whole scope of the work. The insulation work shall be carried out according to Finnish standard SFS 3978E.
2.2
2.3
Insulation Scope General insulation scope: Safety insulation of Class SI where required for the surfaces over 70 oC Insulation against thermal losses of Class IN (see item 5 below), for process piping when t > 50 oC where thermal losses are significant Normal process lines where the thermal losses are not decisive are not to be insulated The piping lines for the following media shall be insulated: steam condensate hot water
PROJECT STANDARD
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chilled water chlorine dioxide solution (to avoid warming up) and additionally all the traced piping 2.4 Removable Type Covers When flanges, valves, blind flanges and manholes are to be insulated, the cover shall be of removable type. These removable covers shall be made of metal sheets, lined with rigid insulation slabs or blankets with wire netting facing fastened to the inside of the metal cover. Covers for instrument parts shall be furnished with latches of stainless steel. The insulation of covers shall extend over the adjoining pipe insulation for a distance of at least the pipe insulation thickness, but never less than 50 mm. 2.5 Insulation Thickness of Flanges and Valve Boxes The thickness of insulation for fittings, flanges, valves etc. shall be the same as for the adjacent pipe insulation. 2.6 Valve Insulation The upper part of the packing gland of valves shall be kept outside the insulation cover. Generally only steam and condensate valves shall be insulated. 2.7 Pipe Movement The insulation shall allow free movement of pipes on the supports. 2.8 Tests before Insulation The insulation must not be made before pressure and other necessary tests have been made. The Supplier must get written permission from the Purchaser to start the insulation work. The insulation of flanged joints is to be made after the piping is in operation.
2.9
Surface to be Insulated The surface to be insulated must be clean and dry before starting the insulation work.
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2.10
Welding The Supplier must not do any welding on equipment (e.g. pressure equipment etc.) or piping on the site. If welding is required the Supplier shall refer the matter to the engineer. The welders shall be qualified as required for each type of weld. Note: No welding is allowed if the tank is marked: "INSIDE LINING - DO NOT WELD
2.11
Tight Insulation The insulation is to be made in such a way that there will be no openings or gaps in the joints and that the smoothest possible insulation is achieved. Longitudinal joints in horizontal pipe insulation shall be in the lower half. When there are several layers of insulation, the joints must be staggered.
2.12
Insulation Material The insulation materials shall fulfil the requirements presented in the standard SFS 3976. For detail specification see Tables 4 and 5 The insulation material for stainless steel piping must not contain any chlorides.
2.13
Distance Rings The insulation cover of pipes and tanks must be prevented from sagging or shifting by use of distance rings. Vertical insulation shall be supported by steel clamps with welded pins at distances shown in SFS 3978E, Fig.4. The Supplier is responsible for the design of welding on equipment as mentioned in item 2.10.
2.14
Tank Painting before Insulation For the tanks which may stay empty or at a low temperature, the painting before the insulation of the tank shall be investigated from case to case. In any case the tank shall be painted 1 m from the base.
STANDARDS If not otherwise stated in the Contract or drawings Finnish standards SFS 3975E...SFS 3979E. shall be followed.
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Slight modifications in the presented choice of insulation material density are allowed depending on the availability and the manufacturing program. Insulation measurements and inspection shall be done according to SFS 3979. 4 MATERIAL PURCHASE AND SUPPLY All materials for the insulation work shall be purchased and supplied by the Supplier, for example mineral wool, metal claddings, wire nets, support rings and clips etc., if not otherwise indicated in the enquiry.
5 5.1
SPECIFICATION FOR INSULATION WORK General Insulation of piping is divided into five classes. IN SI CO insulation against thermal losses, indoors and outdoors safety insulation insulation against condensation
5.2
Class IN - Insulation Against Thermal Losses, Indoors and Outdoors This shall be applied for lines with operation temperature t > 50 oC and where thermal losses are significant from the point of view of economy. When operation temperature t 140 oC, the following items of the line are not to be insulated unless otherwise stated in the Contract or the drawings: pumps valves on-line instruments flanged connections
The magnetic flow meters shall not be insulated. The insulation thickness shall be according to Table 1 for piping and Table 2 for tanks. The insulation material shall be according Table 4 for piping and according to Table 5 for tanks under very corrosive conditions the covering material shall be stainless steel. Fixing of the covering shall be done with stainless steel pop rivets.
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The seams of the covering shall be beaded Type A according to SFS 3978, Fig. 9. Compensation of thermal expansions with beading Type A, extended at expansion joints. The bends shall be insulated with factory-made sections.
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TABLE 1 Recommended Economical Insulation Thicknesses for Piping (IN Class) Ambient air temperatures are assumed - indoors +20 oC
Pipe Size Do 21,3 26,9 33,7 42,4 48,3 60,3 76,1 88,9 114,3 139,7 168,3 219,1 273 323,9 355,6 406,4 508 610 711 813 DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500 600 700 800
Operation temperature t, oC Insulation thickness s, mm <80 40 40 40 40 50 50 50 50 60 60 60 60 80 80 80 80 80 100 100 100 81.. 120 50 50 50 50 60 60 60 60 60 80 80 80 80 80 80 100 100 100 120 120 121.. 160 60 60 60 60 60 80 80 80 80 80 100 100 100 100 100 120 120 120 140 140 161.. 200 60 60 80 80 80 80 80 80 100 100 100 120 120 120 120 140 140 140 160 160 201.. 250 80 80 80 80 80 100 100 100 100 120 120 120 120 140 140 140 160 160 160 200 251.. 300 80 80 80 100 100 100 100 120 120 120 140 140 140 160 160 160 200 200 200 200 301.. 350 80 100 100 100 100 120 120 120 140 140 140 160 160 160 160 200 200 200 200 240 351.. 400 100 100 100 120 120 120 140 140 140 160 160 160 160 200 200 200 200 240 240 240 401 450 100 100 120 120 140 140 140 160 160 160 160 200 200 200 200 240 240 240 280 280 451.. 500 100 120 120 140 140 140 160 160 160 160 200 200 200 200 240 240 240 280 280 320
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TABLE 2
Economical Insulation Thickness, Tank and Equipment Insulations (IN Class) Insulation thickness (mm) __________________________________________________________________________________ Operating Temperature oC Tank Diameter or Main Dimensions 50.. 101.. 151.. 201.. 251.. 301.. mm 100 150 200 250 300 400 __________________________________________________________________________________ Sheets, cups Rock wool Rock wool wire net mat wire net mat M2.1 or M3.1 SFS 3976 M 3.2 SFS 3976 _____________________________________________________________ 1001...4000 80 100 120 140 200 320 _________________________________________________________________________________ 4001... Rock wool Rock wool slab wire net mat L5.1 or L6.1 SFS 3976 M 3.2 SFS 3976 ________________________________________________________________ Sheet 80 100 120 140 200 320 _________________________________________________________________________________ Rock wool Rock wool lamella mat with thin slab L5.4 or L5.5 aluminium sheet PV-100 VM ________________________________________________________________ Roofs 80 100 120 140 200 320 _________________________________________________________________________________
5.3
Class SI - Safety Insulation This class shall be applied only when needed for personnel protection purposes for surfaces with operation temperature t > 70 oC, unless otherwise stated in the Contract or the drawings. However, the following items are not to be insulated: parts of lines routing higher than 2.0 m above floor or service platform or otherwise in normally inaccessible places other components as for Class IN Insulation and cover materials are according to Class IN
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Insulation thicknesses: In Table 3 below, the highest allowable surface temperature under normal service conditions is 70 oC.
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TABLE 3 Safety Insulation SI Insulation thickness of safety insulation Temperature of insulation surface t < 70 C, dimension mm Insulation: Mineral Wool, mm
__________________________________________________________________
Pipe size DN Operating Temperature C D0 __________________________________________________________________ 71-140 141-160 161-200 201-250 251-300 17,1 21,3 26.9 33,7 42,4 48,3 60,3 76,1 88,9 114,3 139,7 168,3 219,1 273,0 323,9 355,6 406,4 508,0 609,6 711,2 812,8 10 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500 600 700 800 20 20 20 20 20 20 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 20 20 20 20 20 20 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 20 20 20 20 20 30 30 30 30 40 40 40 50 50 50 50 50 50 50 50 50 30 30 30 30 30 30 40 40 40 40 50 50 50 50 60 60 60 60 60 80 80 30 30 40 40 40 40 40 50 50 50 60 60 60 80 80 80 80 80 80 80 80
914,4 900 30 30 50 80 100 1016,0 1000 30 30 50 80 100 1220,0 1200 30 50 50 80 100 ________________________________________________________________ Flat Surface 30 50 60 80 120
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5.4
CO - Insulation Against Condensation This class shall be used if the temperature of the surface is lower than the ambient temperature e.g. cold and cooling water pipelines and tanks to avoid forming of condensate water on surface of the pipe. Insulation material polythene. The thickness of the condensation insulation shall be minimum 25 mm. The covering material shall be the same as in insulation class "IN". The insulation shall fulfil the requirements of standard SFS 4967, Insulation against Cold, for steam tightness.
5.5
Valve and Flange Insulation Boxes Valves with weld ends to be insulated straight over. In valve and flange insulation boxes the insulation material is rock wool lamella mat , density 100 kg/m3 covered with aluminium sheet. The coating material shall be according to the insulation class.
INSULATION OF EQUIPMENT The insulation material and thicknesses shall be selected according to Table 4 and Table 5.
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Temperat ure oC
Insulation material
Covering 1)
Remarks! Liquor department hotdip galvanised PVC 200 m coated steel sheet, P5 SFS 3976, flat, s = 0,7 mm
0 - +200
Flat aluminium sheet Al MnlH16 SFS 2585 P2 SFS 3976, de < 150 0,5 mm, de < 500 s = 0,8 mm.
- de > 500
0 - +200
Flat aluminium sheet Al MnlH16 SFS 2585 P2 SFS 3976, s = 1,0 mm. Valve, flange boxes s = 1,0 mm.
Polyethen K 2.2
Flat aluminium sheet Al MnlH16 SFS 2585 P2 SFS 3976, de < 150 0,5 mm, de < 500 0,8 mm, de > 500 , s = 1,0 mm.
de = outside diameter of insulation 1) In corrosive condition 0,5 mm austenitic stainless steel sheet
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Roof
0 - +200
Roof
0 - +200
Mineral. wool slab Rock wool PV SKL L5.4 tai L5.5Glass wool OL-P
Note: Aluminium covers shall be fastened with aluminium pop rivets and zinc steel coats with stainless/ monel pop rivets. Stainless steel covering and other heavy covering structures such as large tanks, always with stainless pop rivets. Detachable sheets with stainless self-tapping screws. Structures with heavy outside strain shall under normal coating material be used zinc 0,7 mm sheet (275E) 3/4 area.
CONTROL, MEASUREMENT AND ACCEPTANCE OF THE INSULATION WORK The control, measurement and acceptance shall be performed according to the standard SFS 3979 and the contract documents. The measurements shall be recorded on a form according to the standard SFS 4966, Appendix II. One copy of the form shall be given to the Purchaser and another to the Supplier. The acceptance of insulation work takes place with handing-over the delivery. For detection of thermal leaks a thermo camera or a surface thermometer can be used.
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GUARANTEE The precondition for the material is that insulation materials and thicknesses shall correspond to the given instructions and standards. The insulation work shall be performed so that the pipelines are tight against internal steam pressure and outwards against dropping and flowing liquid. The thermal expansions shall be taken into consideration. The insulation and the covering materials shall be tightly fastened and there shall not exist any heat losses which deviate from normal conditions. Quality control of insulation work is done by measuring surface temperature. The area, where surface temperature exceeds more than 5 oC, the mean temperature of the object may not exceed 0.5 % of insulated area.
REFERENCE STANDARDS This document refers to SFS standards. The standards are available also in English. For other information and orders of SFS standards contact: www.sfs.fi .