DEPARTMENT: FEG

DOCUMENT NO: 44AC9100-000/V.02/0110/A4

DOCUMENT TITLE: GENERAL SPECIFICATION FOR INSULATION

PROJECT NO: 44AC9100

PROJECT LOCATION: DUMAD/IOCL-JR, Gujarat

PROJECT TITLE: EPCM/PMC Services for Acrylics/Oxo-Alcohol Project

at Gujarat Refinery & Dumad Complex

CLIENT: Indian Oil Corporation Limited

(WHERE APPLICABLE)

APPROVALS

Rev No. Issue Date Page Revision Description Prepared Checked Approved
B 7-Jan-20 50 Issued for Bid RC PNG MG

Entire Document DOCUMENT ISSUED FOR: (please
as applicable)

Issued this Revision
In-house Review
Purchase

Revised Pages Only  Client Approval
Construction
Issued this Revision  Bid
Design

This document is developed by JACOBS Engineering India Pvt Ltd and the information it contains is property of Indian Oil
Corporation Ltd. It shall not be used for any purpose other than that for which it is supplied.

CONFIDENTIAL – Not to disclose without Authorization

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TABLE OF CONTENTS

1.0 SCOPE
2.0 REFERENCE STANDARDS
3.0 DEFINITIONS
4.0 DESIGN - GENERAL
5.0 DESIGN - PIPING INSULATION
6.0 DESIGN - EQUIPMENT
DESIGN - TABLE 1 - INSULATION & PROTECTION SYMBOLS,
7.0
CLASSIFICATION AND GENERAL CONDITIONS OF USE
8.0 DESIGN - TABLE 2 - INSULATION, CLADDING E SECURENIENT
9.0 DESIGN - TABLE 3 - HEAT CONSERVATION
10.0 DESIGN - TABLE 4 - PERSONNEL PROTECTION
11.0 DESIGN - TABLE 5 - PERSONNEL PROTECTION
12.0 DESIGN - TABLE 6 – ACOUSTIC INSULATION
13.0 DESIGN - TABLE 7 – COLD INSULATION
14.0 MATERIALS
15.0 MATERIALS - THERMAL INSULATION
16.0 MATERIALS - ANCILLARIES
17.0 MATERIAL - ACOUSTIC INSULATION
18.0 APPLICATION
19.0 APPLICATION - PIPING - INSULATION
20.0 APPLICATION - PIPING - CLADDING
21.0 APPLICATION - EQUIPMENT - INSULATION
22.0 APPLICATION - EOUIPMENT - CLADOING
23.0 ACOUSTIC INSULATION AND CLADDING
24.0 FIRE HAZARD PROTECTION - INSULATION - EOUIPMENT
25.0 REMOVABLE INSPECTION PORTS (WINDOWS)
26.0 DOCUMENTATION
27.0 INSPECTION

28.0 FIGURES & DIAGRAMS

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1.0 SCOPE

1.1 General

This Specification covers the use of thermal insulation for above ground, external insulation of
piping and equipment operating between Ambient Temperature and 600oC for the purpose of
Heat Conservation, Process Stabilization, Temperature Maintenance, Acoustic Attenuation,
Personnel and Fire Protection.

The insulation requirements of this Specification are suitable for use in both indoor and outdoor
service with normal process plant atmospheres. Alternative designs and materials shall be
considered if necessary for highly corrosive atmospheres or potential leaks and spills of
chemicals.

This Specification is intended to cover Jacobs / IOCL / LSTK Contractor engineered piping,
pressure vessels and circular ducting; Jacobs / IOCL / LSTK Contractor rated heat exchangers
and mechanical equipment.

Cold service insulation shall be provided elsewhere in the contract document.

This Specification does not cover ‘vendor designed insulation for Boiler or Fired Heater packages
including Air heaters, Economizers, Gas Flues and Air Ducting. The Specification is intended to
cover Jacobs / IOCL / LSTK Contractor supplied insulation for parts of such packages except for
rectangular ducting.

Piping and equipment requiring insulation shall be specified on the following project documents:

1) Process St Instrumentation Diagrams (P&IDs} and Line Lists.

2) Piping General Arrangements and Isometrics
3) Instrument Piping Details
4) Project Specific Vessel and Exchanger Drawings
5) Equipment Suppliers General Arrangement Drawings for equipment items and Jacobs /
IOCL insulated package plant.

2.0 REFERENCE STANDARDS

International Standards

API 521 : Pressure-relieving and De-Pressuring Systems

ASTM B209 Standard Specification for Aluminium and Aluminium-Alloy Sheet and Plate
ASTM C547 Mineral Fibre Preformed Pipe Insulation
ASTM C612 Mineral Fibre Block and Board Thermal Insulation
ASTM C929 Handling, Transporting, Shipping, Storage, Receiving, and Application of
Thermal Insulation Materials for use in Contact with Austenitic Stainless
Steel
ASTM C692 Standard Test Method for Evaluating the Influence of Thermal insulations
on External Stress Corrosion Cracking Tendency of Austenitic Stainless
Steel
BS 2972 Methods of Test for inorganic Thermal Insulating Materials
BS 3533 Glossary of Thermal Insulation Terms
BS 3958 Thermal Insulating Materials
BS 476 Fire tests on building materials and structures
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BS 5970 Code of Practice for Thermal Insulation of Pipework and Equipment in the
Temperature Range -100°C to +870°C
BS 5422 Method for Specifying Thermal Insulating Materials for Pipes, Tanks,
Vessels, Ductwork and Equipment Operating within the Temperature Range
-40oC to +700oC
OISD-STD-177 Inspection and Maintenance of Thermal Insulation
OISD-STD-111 Process Design and Operating Philosophies on Fired Process Furnace
OISD 15665 Acoustics - Acoustic insulation for pipes, valves and flanges
NFPA 55 Liquefied Petroleum Gas Code

3.0 DEFINITIONS
'APPLICATOR' shall be defined as the party that is responsible for installation of insulating
materials.
‘Manufacturer’ shall be defined as the party supplying the insulation, cladding or fixing materials.
'IOCL' shall be defined as Indian Oil Corporation Limited (Client).
‘Project’ shall be defined as the entire scope of work on the Acrylic / Oxo Alcohol Project,
IOCL-Dumad.
‘Consultant’ shall be defined as Jacobs Engineering India Pvt. Limited
‘Contractor’ shall be defined as LSTK Contractor and his sub-contractor (if any)
4.0 DESIGN - GENERAL

4.1 General

4.1.1 In this Specification, insulation for the prevention of heat loss is designed to provide economic
thicknesses such that resulting cold face surface temperatures do not exceed 60°C with ambient
temperature in still air conditions min. 11°C max. 42°C

4.1.2 Insulation shall comprise a layer(s) of heat resisting fibre material enclosed within protective
metal cladding sealed against the ingress of moisture and designed to allow differential
expansion

4.1.3 Internal refractory lined piping and equipment shall not be insulated. Over these areas personnel
protection shall be achieved by the use of stand-off metal guards

4.1.4 Personnel protection shall be achieved on surfaces having either a continuous operating
temperature of 60°C to 200°C or is in intermittent service using stood off metal cages. guards.
shields or railings. Design of personnel protection guards shall be agreed with Jacobs / IOCL

4.1.5 On surfaces with continuous operating temperatures greater than 200°C the use of insulation is
acceptable. Insulation shall be designed to yield a cold face temperature of 60°C or less under
ambient temperature and still air conditions.

4.1.6 Personnel protection for Fired Heaters based on OISD 111 requirement is covered elsewhere in
the contract document.

4.1.7 The purpose for which insulation is required is identified by the applicable symbols in Table 1.
Piping and Equipment to be insulated shall be identified by these symbols on P&ID and Line Lists.

4.1.8 Instruments and associated piping subject to operating flow and/or temperature conditions
approximating those in the piping or equipment to which they are connected. shall be insulated to
the same requirements as that piping or equipment. The insulation requirements shall be
classified by symbols in accordance with Table 1.
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4.1.9 Carbon steel and low alloy piping and equipment shall be protected against corrosion by painting
in accordance with Project Specifications

4.1.10 All insulated austenitic stainless-steel piping and equipment shall be protected against external
stress corrosion cracking by the application of a sacrificial aluminium foil system.

4.1.11 To assist corrosion prevention, insulation materials shall be of the correct chemical nature and
shall include the following requirements
1. Carbon Steels - Insulation to be chemically neutral or slightly alkaline.
2. Aluminium - Insulation to be chemically neutral or slightly acidic.
3. Stainless Steels - Insulation shall be as free as possible of soluble chlorides (20 ppm
maximum).
5.0 DESIGN - PIPING INSULATION

5.1 General

5.1.1 Insulated piping systems shall have straight pipe. bends, tees and non-flanged pipe fittings
completely insulated

5.1.2 All valves and flanged joints shall be insulated only in the following services:
• Steam services
• Trace heated or covered services
• Closed Condensate services
5.1.3 Where insulation is used for Acoustic Attenuation, Class B and C, the system shall be completely
insulated including equipment items, valves, flanged joints, pipe fittings and manways

5.1.4 "Bucket" and "Float type" steam traps shall be traced and insulated together with the inlet piping.

5.1.5 Insulation on inlet piping to Thermostatic and Thermodynamic steam traps shall terminate a
minimum of 450mm from the trap leaving the remainder of piping and the trap un-insulated.

5.1.6 Steam trap outlet piping shall not be insulated except for Personnel Protection considerations

5.1.7 Insulation shall not be applied to the following unless otherwise specified for Acoustic Attenuation
(Class B & C), Personnel Protection or other special reasons:

1. Piping which becomes hot intermittently. such as relief valves. vents. steam-out and
snuffling steam systems, flare and blow down systems and by-passes at control valves.
2. Supports for piping
3. Steam Traps. (except as noted in paragraph 5.1.4 / 5.1.5).
4. Valves, including control valves and flanges in process piping systems (except as noted
in paragraph 5.1.2)
5. Pipe union fittings
6. Thermowell bosses and pressure tappings
7. Expansion joints. hinged joints and hose assemblies
8. Sight flow indicators
5.1.8 Piping shall be designed to provide an absolute minimum clearance of 25mm between the
outside surface of any insulation finishing material and adjacent surfaces.

5.1.9 Where insulated horizontal piping is supported on steel shoes, the height of the shoe shall be
such that the underside of the insulation finishing material is clear of the supporting structure
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upon which the shoe rests by 25mm minimum.

5.1.10 Vertical piping insulation shall be supported by bolted collars at intervals. (see figure 1 detail].
Collars shall be supplied, fabricated and fitted by the APPLICATDR.

6.0 DESIGN - EQUIPMENT

6.1 General

6.1.1 Support skirts of insulated vertical vessels greater than 1200mm diameter shall be insulated both
internally and externally for a minimum distance of 500mm below the bottom tangent line. On
skirts which do not require fireproofing the insulation shall terminate not less than 300mm above
the support concrete or steelwork. Where support skins are to be fireproofed the insulation shall
extend to the top of the fireproofed areas and galvanized steel finishing material shall be used to
protect the area of skin insulation below the bottom tangent line.

6.1.2 Support skirts of insulated vertical vessels of 1200mm diameter and less shall be insulated
externally only, as described in paragraph 6.1.1 above

6.1.3 Bottom heads of insulated vertical vessels fully enclosed by a support skirt shall be insulated
without weatherproof cladding finishing material and shall be insulated only when the vessel
outside diameter is greater than 1200mm.

6.1.4 Liquid ends of positive displacement pumps and casings of centrifugal pumps shall be insulated
only when heat traced or covered.

6.1.5 Insulation shall not be applied to the following equipment unless otherwise specified for Acoustic
Attenuation (Class B&C), Personnel Protection, Fire Hazard Protection or other special reasons.

a) Pumps with operating temperatures below 200°C unless pumped fluid has a pour point
above minimum design ambient temperatures.
b) Fans. compressors. blowers or other rotating or reciprocating equipment.
c) Internally insulated or refractory lined equipment unless specially designed for metal
temperature control
d) Heads of vessels fully enclosed by support skirts with vessel diameters 1200mm and
less.
e) Internal surfaces of fully enclosing support skins of insulated vessels with vessel diameter
1200mm and less.
f) Exchanger channel covers.
g) Nozzles. manholes and hand holes. and flanges of equipment.
h) Surfaces of coolers and condensers.
i) Nameplates on all equipment items.
j) Thermowell bosses and pressure tappings

External Insulation for vessels and similar equipment shall be adequately supported or
suspended. dependent on insulation material form, with clips and support lugs, welded on at
internals around the equipment item and positioned in accordance with Project Specific
Specifications. Contractor / Vendor shall supply all clips and supports required in order to attach
insulation to the Equipment.

Vacuum stiffening rings on equipment shall be fully and independently insulated. The insulation
finishing metal sheeting shall be sealed and allow for differential expansion. The sheeting shall be
shaped to shed water.
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DESIGN - TABLE 1 - INSULATION & PROTECTION SYMBOLS, CLASSIFICATION AND

7.0
GENERAL CONDITIONS OF USE
Symbol Classification Insulation table Insulation Notes
thickness Table selection
No. Reference consideration
IH Heat Conservation Table No. 3 Normal Operating Each section of the equipment having
(Process lines) temp. of process defined sections operating at differing
Where required for fluid and nominal temp. may be insulated to suit its
process reasons. pipe Size individual temp. For Shell and Tube
Exchangers Shells and Channels use
HS Fleet Conservation
the higher of the inlet and outlet
(Steam and
temperatures
Condensate Lines)
PS Process Stabilisation Special Consideration Special Piping and equipment subject to
to assist process Consideration Special specific considerations to
control. determine Insulation thickness and
design which shall be clearly indicated
on the P&lDs and Line lists.
IT Steam tracing Table No. 3 Normal operating Insulation where operating plant
temp. of process requires a protective heating system
SS IT with spaces fluid and one pipe to protect piping, equipment and
SC IT with heat transfer size greater than instruments against the effects of
cement parent pipe. ambient temperatures (including
hydrate formation. condensation,
IE Electric Tracing viscosity change and pour point
Hot water or Solvent suppression
LT
Tracing (liquid)
OT Hot Oil tracing

W Steam Covering Table No. 3

Hot water or liquid
covering
Hot oil covering

FP Fire hazard Table No. 5 or special Special Insulate to prevent fast boil-off of
protection consideration but no consideration liquids. Galvanised steel / stainless
greater Table No.3 steel protective cladding to be used
over insulation in place of standard
aluminium sheet metal cladding.
PP Personal Protection Table No. 4 Nominal pipe size Over unlined piping and equipment
(Insulation) and normal insulate or provide open mesh metal
operating temp. guards on operating plant would
Only applicable to normally be left un-Insulated and
operating Temp which may be accessible during the
>200“C performance of routine duties by
operating not maintenance only}
PG Personnel Protection -- Operating Temp
personnel. SEE NOTE*
[Stood-off metal- <200'C
guard]
IA – A Acoustic attenuation Table No. 6 Acoustic Category The selected acoustic insulation
for noise control at attenuation symbol shall be added to any other
IA – B various levels of subject to thermal insulation symbol which
IA – C requirement calculated applies e.g. HCA or STB or PPC etc.
insertion loss If no other insulation symbols are in
requirements. use, Acoustic symbols A, B or C shall
be used alone.
IC Cold Insulation Table No. 7 Normal Operating Equipment & piping having defined
temp. of process sections operating at differing temp.
fluid and nominal may be insulated to suit its individual
pipe Size temp. For Shell and Tube Exchangers
use the lowest of the in / out temp.
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NI Not insulated -- If no other symbol applies NI to be

used for definition & clarity for MTO
Notes:

The intent of P&IDs, Line Classification lists, Insulation Summaries etc. which designate
insulation for types PP and PG is to call attention only to the eligibility of such service. The actual
extent of such insulation shall be determined by Field Construction Personnel and/or operating
personnel using the following criteria:

* Pipe and Equipment designated for personnel protection (‘PP’ or ‘PG’) shall be fully painted in
accordance with Project Specific Specification.

** Exposed surfaces operating above 60oC and located with 600mm horizontally or 2100mm
vertically of a normal access. walkway, or work area.

8.0 DESIGN - TABLE 2 - INSULATION, CLADDING E SECURENIENT

INSULATION AND METAL CLADDING, FORM AND SECUFIEMENT METHOD

Item Nominal Size Insulation Material form Insulation securing method

Straight pipe Upto 200mm Preformed Pipe Sections I2mm min. diameter stainless
(6”) steel tie (lacing) wire
Straight pipe 250 (10”) to Preformed pipe section or 12mm wide stainless-steel
500 (20”) multi-segments. bends.
Straight pipe Above 500mm Multi-segments 20mm wide stainless-steel
(20”) bends
Welded valves, butt- All sizes As per straight pipe cut and As per straight pipe
welded tees & shaped to fit
reducers
Flanged Valves All sizes Suitable preformed Prongs. studs, rivet, Adhesive
flanged joints necessary to secure to
removable cladding.
Bends & elbows All sizes As per straight pipe cut and As per straight pipe
shaped to fit
Equipment Heads All sizes Preformed Blocks, Slabs cut 20mm wide stainless-steel
(except bottom heads and shaped to fit bends
of vertical equipment)
Equipment shells All sizes Preformed pipe or multi-pipe 20mm wide stainless-steel
segments or Slabs cut and bends
shaped to fit
Vertical Equipment All sizes As per equipment heads 20mm wide stainless-steel
Bottom Heads without bends
Skit
Vertical Equipment All sizes over As per equipment heads Wire Netting and Lacing
Bottom Heads with 1200mm (4ft)
Skit
Casing of pumps All sizes Preformed slabs cut to suit Prongs. studs, rivet, Adhesive
Turbines Compressor lining necessary to secure to
etc. Manholes and removable cladding.
handholes and where
required Exchanger
channels
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Item Insulation metal OD of thickness Cladding Insulation securing

cladding over insulation thickness method
Straight Pipe Flat metal* Upto 150mm 0.6 mm 12mm wide stainless-
steel bands
Straight Pipe Flat metal* 150 to 450mm 0.8 mm 12mm wide stainless-
steel bands
Straight Pipe Flat metal* 450 mm and 1.0 mm 12mm wide stainless-
above steel bands
Welded valves, butt- Flat metal* All sizes As per As per straight pipe
welded tees & reducers straight pipe
Flanged Valves flanged Flat metal* All sizes 1.0 mm 12mm wide stainless-
joints Removable steel bands and quick
claddings release toggle dips
Bends & elbows Flat metal* straight Upto 80mm As per As per straight pipe
pipe or pressed straight pipe
elbows
Flat metal* 80mm or larger As per Screws & rivets
fabricated mitre straight pipe
bends
Equipment Heads Fiat Metal* ‘Orange All sizes 1.0 mm Screws & rivets
(except bottom heads of Peel’ Fabrication
vertical equipment)
Equipment shells Flat metal* All sizes 1.0 mm 20mm wide stainless-
steel bands
Vertical Equipment Flat metal* All sizes 1.0 mm Screws & rivets
Bottom Heads without fabricated to suit
Skit
Vertical Equipment Not required All sizes 1.0 mm --
Bottom Heads with Skit
Casing of pumps Flat metal* All sizes 1.0 mm 20mm wide stainless-
Turbines Compressor Removable steel bands
etc. Manholes and claddings
handholes and where
required Exchanger
channels

Notes:

• For fire hazard protection galvanised steel cladding shall be used.

• All other areas to be glad in aluminium sheet
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9.0 DESIGN - TABLE 3 - HEAT CONSERVATION

INSULATION THICKNESS FOR HEAT CONSERVATION

NORMAL OPERATING TEMPERATURE (oC) AND THICKNESS (mm)

101 201 250 351 401 501 551
Nominal Upto 151 to 301 to 451 to
to to to to to to to
Pipe size 100 200 350 500
150 250 300 400 450 550 600
TH
MM THK THK THK THK THK THK THK THK THK THK
K
15 25 25 30 40 50 55 65 75 90 100 115
20 25 25 30 40 50 60 70 85 95 110 125
25 25 25 30 50 60 70 80 95 100 115 130
40 25 25 40 50 60 70 85 100 110 125 140
50 25 25 40 50 60 70 90 105 115 130 150
65 25 25 40 50 60 75 95 110 120 140 160
80 25 30 40 50 70 80 95 115 125 150 170
100 25 30 40 60 70 80 100 125 140 160 180
150 25 30 40 60 70 90 105 130 150 170 190
200 25 30 50 60 80 95 110 140 160 180 200
250 25 30 50 60 80 95 115 140 160 190 210
300 25 40 50 70 80 100 120 150 170 190 215
350 25 40 50 70 80 100 120 150 170 200 220
400 25 40 50 70 90 100 125 150 170 200 225
450 25 40 50 70 90 105 125 150 175 200 230
500 25 40 50 70 90 105 130 150 190 205 240
Over 500
25 40 50 70 100 125 160 190 230 270 320
and flat
SINGLE LAYER MULTI LAYER

Design Basis:

Maximum Heat Loss = 150w/m2

Ambient Temp = 31°C
Wind speed = 11.5 m/sec
Emissivity = 0.15
Mineral wool preformed pipe section = 140 kg/m3
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9.1 Multi-Layer Thickness Table

Thickness 1st layer 2nd layer 3rd layer

55 30 25 --
60 30 30 --
65 40 25 --
70 40 30 --
75 50 25 --
80 40 40 --
85 60 25 --
90 60 30 --
95 70 25 --
100 50 50 --
105 80 25 --
110 80 30 --
115 90 25 --
120 90 30 --
125 100 25 --
130 100 30 --
135 100 35 --
140 100 40 --
145 100 45 --
150 100 50 --
160 100 30 30
170 100 40 30
175 100 50 25
180 100 50 30
185 100 60 25
190 100 60 30
195 100 70 25
200 100 50 50
205 100 80 25
210 100 80 30
215 100 90 25
220 100 90 30
225 100 100 25
230 100 100 30
240 100 100 40
250 100 100 50
260 100 100 60
270 100 100 70
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10.0 DESIGN - TABLE 4 - PERSONNEL PROTECTION

INSULATION THICKNESS OVER PROCESS PIPING AND EOUIPMENT FOR

PERSONNEL PROTECTION PURPOSES

Normal Operating temperatures (0oC) with still air at 31oC

to give surface temp. not greater than 60oC
Nominal Pipe 201 to 301 to 401 to 501 to
60 to 200 550 and over
size 300 400 500 550
MM THK THK THK THK THK THK
15 40 55 80 90
20 40 60 90 105 Personnel protection at
25 50 65 95 110 elevated temperatures
shall be subject to
40 50 80 105 120 calculation and special
50 50 85 110 130 consideration.
65 60 90 120 140
80 60 95 125 150
100 Personnel 60 100 140 160
150 protection 70 105 150 175
200 shall be by 80 110 160 190
guards
250 80 120 180 200
300 80 125 180 200
350 90 130 180 200
400 90 140 180 200
450 90 140 180 205
500 90 140 180 210
Over 500 and 180
90 140 210
flat
SINGLE LAYER MULTI-LAYER

Design Basis:

Maximum cladding temp. = 60°C

Ambient Temp = 31°C
Wind speed = 0 m/sec
Emissivity = 0.15
Mineral wool preformed pipe section = 140 kg/m3

Multi-Layer shall be constructed with layer thickness in accordance with the heat conservation
layer thickness in section 9.1.
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11.0 DESIGN - TABLE 5 - PERSONNEL PROTECTION

MINIMUM INSULATION THICKNESS OVER EOUIPMENT FOR FIRE HAZARD

PROTECTION PURPOSES

Item Minimu Insulation Protection finish Notes

m material
thicknes
s mm
‘FP’ Refer to Mineral Rock Galvanized Steel / For vertical steel vessels, i.e. towers,
specified Table-3 Fibre Fire Batts stainless steel tall drums etc., that require
equipment applied in two sheeting with fireproofing, the fireproofing insulation
layers secured with shall be applied to a height of 12m
stainless steel from grade or the nearest solid
bands to be used in platform where a pool fire could form
this service

When credit factors, per API RP 521, for the insulation in determining the minimum pressure
relieving device sizes for fire exposure are to be considered, galvanized steel/stainless steel
cladding shall be used. Insulation applied to bottom heads of vertical vessels in an enclosed skirt
shall be fully clad with stainless steel jacketing

The Fire Proofing insulation system shall be capable of withstanding the force of fire hose stream
impingement. Fire hose stream tests are described in NFPA SB. Appendix H-3.

12.0 DESIGN - Table 6

MINIMUM THICKNESS OF ACOUSTIC INSULATION

The level of acoustic attenuation is indicated by the Class Symbol below as required by Table 1.
Where acoustic attenuation symbol A, B or C is combined with thermal insulation symbols the
selected insulation thickness shall be the greater of the two requirements.

When the following acoustic insulation cladding thickness requirements differ from the thermal
insulation protection sheeting requirements of the greater of the two thicknesses shall be
selected.

CLASS MINIMUM THICKNESS ACOUSTIC INSULATION CLADDING MATERIAL

OF POROUS LAYER CLADDING THICKNESS
INSULATION (mm) (mm)
A 50 0.7 Aluminium or Galvanized
steel
B 100 0.7 galvanized steel only
C 100 (in two 50mm layers) 1.4 (in two 0.7mm layers) Galvanized steel only
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13.0 DESIGN - Table 7

COLD INSULATION

Insulation for Cold Insulation (IC) for operating temperatures below 10 0C and dual temperature
(cold/hot) service where upper temperature limit is 120 0C shall be as given below:

POLYURETHANE FOAM

The physical requirement of bulk density, chloride content, thermal conductivity and pH value of the
material shall be as follows:

Preformed pipe sections and radial lags (for higher diameter pipe) of polyurethane foam of self-
extinguishing type in accordance with ASTM C591 TYPE –II Grade 2 shall be used as cold insulation
material. PUF & PIR materials as per IS-12436 meeting the technical requirement specified is also
acceptable.

High density polyurethane foam block of bulk density more than 300 Kg/m3 shall be used for supports
in cold lines.

Adhesive for bonding sections shall be Foster Fire Resistive Adhesive 81-33 or blown bitumen type
85/25 shall be used.

Vapor seal like Foster Fire Retardant Mastic 60-30 or equal shall be used.

Filler material shall be PUF dust or mineral wool mixed with specified adhesive shall be placed lightly so
as to fill irregular voids and at flashing of insulation shall be Foster Foam Seal Sealer 30-45. Glass
cloth to be used for vapor barrier reinforcement, shall be open weave 10 mesh having glass fibre
thickness of 5 mils. Aluminium sheets shall be used for cladding of vapor barriers.

Bulk density : 35.0 to 40.0 kg/m3

Chloride content : 20ppm (max)

Thermal conductivity : 0.221 Mw/cm oC at mean temp. 10oC

PH Value : Neutral

Closed cell content : 95% (min)

High density polyurethane foam block of bulk density more than 300 Kg/m3 shall be used for supports
in cold lines.

Adhesive for bonding sections shall be Foster Fire Resistive Adhesive 81-33 or blown bitumen type
85/25 shall be used.

Vapor seal like Foster Fire Retardant Mastic 60-30 or equal shall be used.

Filler material shall be PUF dust or mineral wool mixed with specified adhesive shall be placed lightly so
as to fill irregular voids and at flashing of insulation shall be Foster Foam Seal Sealer 30-45. Glass
cloth to be used for vapor barrier reinforcement, shall be open weave 10 mesh having glass fibre
thickness of 5 mils. Aluminum sheets shall be used for cladding of vapor barriers.
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POLYISOCYNAURATE (ASTM C 591 type II & III)

Rigid Polyisocyanurate foam block pipe fittings insulation shall be manufactured with polyester or
polyether resins, flammability retarding agents, special catalysts and fluorocarbon blowing agent. This
is suitable for use upto 125 0C. Selection of samples for testing shall be as per ASTM C 390(Class IV
frequency).

The physical requirement of bulk density, chloride content, thermal conductivity and pH value of the
material shall be as follows:

Bulk density : 40 to 64 kg/m3 (Tested as per ASTM C303 and C302)

Chloride content : NIL
Thermal conductivity : 0.238 mW/cm oC at mean temp. 10 oC
0.245 mW/cm oC at mean temp. 24 oC
0.252 mW/cm oC at mean temp. 38 oC
pH Value : Neutral

Other properties shall be as per applicable ASTM specification for the insulation

Proper expansion/contraction joints shall be provided to allow movement of pipe or vessel without
producing random cracking of all the insulation.

Vapor barrier shall be applied on all the vessels and equipment in cold services and also for services
upto 1250C.

Hot insulation over Stainless Steel surfaces shall be inhibited by Sodium Silicate.

DESIGN - TABLE 7 – COLD INSULATIONON

Operating Temperatures, 0C
Nominal -8 to - -19 to -33 to -46 to -61 to -76 to -91 to -101 to -121 to -131 to -146 to -156 to
>5 4 to-7
Dia (In) 18 -32 -45 -60 -75 -90 -100 -120 -130 -145 -155 -170
0.5 25 30 35 45 50 60 70 80 85 95 100 105 110 115
0.75 25 30 40 45 55 65 75 85 90 100 105 115 115 125
1 25 35 40 50 60 70 80 90 95 105 110 120 125 130
1.5 25 35 45 55 65 75 85 100 105 115 125 130 135 145
2 30 40 45 55 70 80 90 105 110 125 130 140 145 150
3 30 40 50 65 80 90 100 115 120 135 145 155 160 165
4 30 45 55 65 80 95 110 120 130 145 155 165 170 180
6 35 50 60 75 90 105 120 135 145 160 170 180 185 195
8 35 50 65 75 95 110 125 140 150 170 180 190 200 210
10 35 55 65 80 100 120 135 150 160 180 190 200 210 220
12 40 55 65 85 105 125 140 155 165 185 195 210 215 225
14 40 55 70 85 105 125 140 160 170 190 200 210 220 230
16 40 55 70 85 110 130 145 160 170 195 205 215 225 235
18 40 55 70 90 115 130 145 165 175 200 210 220 230 240
20 40 60 70 90 115 135 150 165 180 200 210 225 235 245
24 40 60 75 90 115 135 150 170 185 205 220 235 240 255
26 40 60 75 90 120 140 155 175 185 210 220 235 245 260
28 40 60 75 90 120 140 155 175 190 210 225 240 250 260
30 & >30 40 60 75 95 120 140 155 175 190 215 225 240 250 265
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14.0 MATERIALS

All material shall be to the described form (Design Table 2} and the following and shall be of
high quality and good appearance.

Insulation materials shall be of low chloride content, chemically inert, non-sulphurous, rot proof,
vermin-roof, impervious to hot water and steam, non-injurious to health and non-corrosive to
steel or aluminium. {even if soaked with water at ambient temperatures for extended periods}.

Insulation materials containing ASBESTOS in any form are not permitted

Insulation and cladding materials backed with paper or other flammable material are not
acceptable.

Insulation materials shall be stored, transported, handled and applied as per ASTM C929.

15.0 MATERIALS - THERMAL INSULATION

15.1 General

insulating material shall be Fibrous Preformed {Mineral Fibre with resin binder} insulation and
shall be of long fibred rock material processed from a molten state into fibrous form and
bonded with a binder suitable for the intended operational temperature range

Preformed materials shall satisfy the minimum requirements of quality standard in accordance
with BS 3958 (Parts 4 and 5), ASTM C547 and ASTM C612

The insulation material shall be supplied plain faced in Manufacturer's Standard sizes and the
average measured length, width and thickness shall not differ from the standard dimensions
specified by more than plus or minus 3mm.

Insulation shall conform to the following physical requirements:

Density - minimum : 140 kg/m3

Alkalinity (approx.) PH Between : 6 and 10
Combustibility : Non-combustible
Non-combustible minimum at 10%
: 100-320 kg/m2
deformation
Hygroscopicity % volume : 0.20 maximum
Linear shrinkage (av. max} : Below 2%
See Fig. 1 ASTM C795 wicking type of
Chloride content not to exceed 20 ppm :
Insulation over Stainless Steel
Sodium plus Silicate content : To exceed 40ppm

Mean temperature Average ‘K’

oC W/m oC
50 0.043
100 0.052
200 0.064
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250 0.078
250 0.093
300 0.110

* Mean temperature = (Hot face temp + Cold face temp)/2

15.2 Material - Weatherproof Cladding

The selection of Aluminium material in both coil and flat sheeting form for use as the thermal
insulation protective metal cladding shall take precedent over other metallic cladding with the
exception of fire hazard protection where stainless steel/galvanized steel cladding shall be
used.

Aluminium cladding shall he flat mill finished commercial grade of alloy AL-Mn which shall
comply with BS 1470 or ASTM B209 under the following material designations: BS 1470 - NS 3
- H6 ASTM B209 Alloy 3003 - H14 or H16 Galvanized steel cladding required for fireproofing
purposes shall be flat mill finished grade 2B of steel to comply with BS 1449 or ASTM A167,
A40 Steels to be SS304 or SS316.

Aluminium metal cladding shall be supplied with factory applied reflective and protective barrier
coating of polyethylene and aluminium foil which shall comply with B5 476 Class 1 (Surface
Spread of Flame). The backing shall be directly laminated to the aluminium without use of
adhesives or glue. Thicknesses shall be as indicated in Table 2.

16.0 MATERIALS - ANCILLARIES

16.1 General

16.1.1 Aluminium foil shall be 0.06 mm thick with a chemical composition of 98% minimum aluminium
and shall not have an adhesive backing.

16.1.2 Binding and tie wire used where indicated to secure insulation materials and sacrificial foil over
stainless steel surfaces shall be 18% Cr - 8% Ni stainless steel wire having a minimum
diameter of 1.22mm. The wire shall be fully annealed.

16.1.3 Banding for use over insulation and over metallic finishing cladding shall be in hand able coils
ready to be cut to required lengths at site. Bands shall be as shown in Table 2 of this standard
20mm or 12mm wide x 0.5mm thick - fully annealed 18% Cr - 8% Ni stainless steel.
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16.1.4 Expansion sections of banding where required to cater for differential expansion shall be of the
same size and material as the fiat bands and shall be of the ‘Expand-R-Strap’ type or
‘Techalloy' Breather spring type or an approved equivalent.

16.1.5 Banding clips for use with securing bands shall be of the same stainless-steel material as the
banding and shall be of the ‘Butterfly' type similar to ‘Band-it-Valstrap Clips’.

16.1.6 Rivets required for metal cladding fabrication shall be the expanding Monel 'pop' blind eye type,
9.5mm long x 5mm diameter

16.1.7 Screws required for metal cladding fabrication/securing shall be stainless steel slotted pan head
self-tapping type A No. 8 dia. x 12mm long to BS 4174 complete with neoprene washers under
the head

16.1.8 The material requirements of normal insulation accessories shall be as follows:

1. 'S' and 'J’ clips - Formed from 20mm wide stainless-steel banding.
2. Removable cover fastenings - Shall be of the quick release, spring shackle lock type,
material identical to the removable metal cladding.
3. Metal cleats - Used as supporting angles on weatherproofing cladding shall be of similar
material as described for the cladding material in paragraphs 8.2. 8.3 and 8.4. The size
shall be 65mm high x 50mm wide with the returned angle toe 13mm less than the
insulation thickness. The cleats shall be 6mm thick.
4. Floating rings - Shall be 10mm dia. carbon steel rod conforming to BS 4360 Grade 43A.
5. Sacrificial foil - Use as a barrier material between stainless steel piping and equipment
surfaces and insulation material shall be 0.06mm thick aluminium foil for operating
temperatures of 5000C and below. and stainless-steel foil at operating temperatures more
than 500oC.

16.1.9 Sealing compound for use as metal sealant, sealing overlaps of metal cladding shall be a
suitable flexible non-setting compound having properties which render materials waterproof,
weatherproof, chemically resistant and fire resistant.

17.0 MATERIAL - ACOUSTIC INSULATION

17.1 Sound absorbent insulation material in use as the porous layer shall be preformed semi-rigid
mineral fibre shapes as described for thermal insulation in Section 12.

17.2 The impermeable outer cover sound barrier material in use as the cladding is described for
weatherproofing and protection in Section 12.2. Acoustic attenuation Classes B and C (See
Table 6) shall use Steel cladding to the exclusion of aluminium.

17.3 The anti-vibration seals used to prevent metal-to-metal contact shall be a closed cell
polyurethane foam strip with pressure sensitive adhesive backing. The strip shall be a minimum
of 3mm thick by 50mm wide and possess the following characteristics:

Density 90 kg/m3
Water ‘vapour Transmission >0.167 metric-perms
Combustibility Self Extinguishing Service From (-) 40°C to +32°C
Temperature Range
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17.4 Where anti-vibration seals are incompatible with operating temperature, such seals shall
comprise of compressed porous layer material weatherproofed with a flexible mastic
compound.

18.0 APPLICATION

18.1 General

18.1.1 The requirements of application, given in this specification in no way absolve the APPLICATOR
from responsibilities of applying an insulating system that will give a satisfactory operational
performance and the requirements given herein shall be regarded as directives and guidelines
for the acceptable minimum. The APPLICATOR shall carry out the work in accordance with the
best practices of insulation application with the minimum of waste and debris and the final job
shall present a neat, efficient and workmanlike appearance.

18.1.2 All hydrostatic tests on piping and equipment, including steam tracing systems, shall be carried
out before insulating material is applied. The APPLICATOR shall only insulate those sections of
the plant that have been specifically released by an authorized agent of the IOCL for such work.
If however, it has been planned and decided to insulate prior to other trades work and before
tests have been completed, insulation shall terminate a suitable distance before and alter
welded and flanged joints and sealed against water ingress and protected from mechanical
damage which may be caused by other trades and during subsequent testing.

18.1.3 Surfaces to be insulated shall be clean, dry and free from loose rust scale. It shall be the
insulation Applicators responsibility to remove the loosely adhering scale and dirt by an
appropriate method which does not scar, score or damage the metal surface.

18.1.4 Insulated carbon and low alloy steel piping and equipment require protective coatings as
specified in Project Specification.

18.1.5 Where coatings are applied, repairs if necessary shall be carried out by the appointed Painting
Applicator and the coatings shall be the subject of inspection by an authorized agent of the
IOCL prior to the commencement of insulation application.

18.1.6 Insulated stainless steel piping and equipment shall be wrapped with sacrificial foil prior to
insulation application. The foil shall be secured with stainless steel tie-wires at sufficient
intervals to ensure the foil remains in place throughout the service life of the insulation- The
supply and application of foil shall be the responsibility of the APPLICATOR.

18.1.7 The APPLICATOR shall NOT carry out any welding or drilling on piping or equipment, he shall
however be responsible to carry out a check and confirm that all insulation supports, as
indicated on fabrication drawings, have been installed and welded into position. The
APPLICATOR shall also confirm that a sufficient and satisfactory number of supports have
been provided in accordance with Figure 7 of this specification.

18.1.8 Insulation shall be finished, sealed and weatherproofed at all terminal points including either
side of temporary shop supports, lifting lugs, testing points etc. At these positions on shop
insulated items closure pieces shall be designed and fabricated, to fit exactly at a later date on
site, without impairing the weatherproofing. The Insulation Applicator shall remain totally
responsible for the finished insulation.
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18.1.9 Equipment nameplates shall remain visible after insulation has been applied. The surrounding
edges shall be efficiently sealed against water ingress.

18.1.10 The application of the insulation shall consider expansion movements of piping. and equipment
at normal operating temperatures and include provision within the insulating system for any
differential expansion anticipated.

18.1.11 Shop applied insulation shall consider not only thermal expansion and contraction movements
but also movements of flexing and vibration created by on-off loading and transportation. The
anticipated scope of these movements shall be outlined to the APPLICATOR by the item
Fabricator.

18.1.12 Thermowell bosses, pressure tappings and weep hole nipples shall not be insulated but left
accessible. the surrounding edges of insulation shall be positively sealed against water ingress.

18.1.13 Double layer construction shall be required when operating temperatures are over 316oC and/or
the insulation thickness is greater than 100mm. Insulation installed in two or more layers shall
be staggered joint construction and each layer shall be adequately secured in place.

18.1.14 Insulation shall be applied in large regular pieces cut to size where necessary and firmly butted
together to minimize voids, and to keep edges of material under compression. Circumferential
joints shall be staggered by one half sections.

18.1.15 Wet or damaged insulation shall not be used under any circumstances. Installed material
awaiting its protective cover shall be adequately protected from damage, rain, and
contamination by other trades such as oils, spent welding rods, paint etc.

18.1.16 A minimum clearance of 25mm between the outside surface of any insulation finish and
adjacent equipment. pipe or structural members shall be maintained. Care shall be taken where
insulation is shop applied to ensure this minimum clearance.

18.1.17 Where voids occur in the insulation they shall be filled with suitable fibrous loose fill material.
Loose fill used for shop applications shall be protected from possible damage during
subsequent lifting and transporting.

18.1.18 Where installed, expansion joints shall comprise of compressible mineral fibre of sufficient
density and composition to operate efficiently as both insulant and expansion facility at the
given operating temperatures.

18.1.19 Insulation supports shall not project proud of the insulation outer surface and shall be given
sufficient coverage of insulating material to avoid hot spots on the insulation metallic
weatherproof cladding at support positions.

18.1.20 Weather-proof cladding shall be designed and installed to shed water always. Flat horizontal
surfaces are not acceptable. It shall be borne in mind throughout shop application that sloping
planes in shop conditions may possibly become flat surfaces when finally positioned at site and
continuous care shall be taken to ensure that final orientation is known by the Insulation
Applicator.
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19.0 APPLICATION - PIPING - INSULATION

19.1 General

19.1.1 Preformed insulation shall be applied, supported and secured to straight length single pipe runs
using two half sections up to the maximum manufactured sizes, above this size piping shall be
insulated with the minimum number of cut segments.

19.1.2 Insulating material shall be applied to fit snugly against the contours presented to the applicator
and neatly cut and shaped only where necessary to achieve this requirement. The insulation
shall be carried out with the least number of material pieces as possible and all unavoidable
gaps, cavities, and voids shall be suitably filled with compatible loose fill material.

19.1.3 Shop fabricated piping shall be amply supported and positioned in such a manner that allows
complete all-round uninterrupted access to the work piece. At temporary support points during
shop fabrication, insulation shall be terminated and sealed, and closure pieces fabricated for
later installation at site.

19.1.4 The insulation materials shall be secured to the pipes by means of circumferential tie wires or
bands in accordance with Design - Table 2 of this Specification. Tie wires or bands shall be
positioned sufficient to provide three ties or securing positions for each length of pipe insulation
section. Ends of tie-wires shall be turned into the insulation material.

19.1.5 Each layer of insulation on piping requiring two or more layers shall be secured by the same
method as required by paragraph 16.1.4 above. Joints of each layer shall be offset by
staggering.

19.1.6 Where necessary the insulation on vertical or near vertical piping (i.e. greater than 45o angle
from horizontal) shall be supported by bolted-on metal clips provided and installed by the
Insulation Applicator who shall assume responsibility of adequate pipe insulation support.
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20.0 APPLICATION - PIPING - CLADDING

20.1 General

20.1.1 The piping insulation protective metal cladding finish shall provide a weatherproofed and
mechanical damage resistant cladding over the whole of the insulated areas and be applied
and fitted in such a manner as to provide a close fitting assembly without gaps.

20.1.2 Straight pipe shall have metal cladding cut and machine rolled (approx. 1 metre long) wrapped
around, with 50mm minimum overlaps on both longitudinal and circumferential overlaps. All
laps shall be arranged to shed water

20.1.3 A single bead shall be made on all circumferential overlaps. Longitudinal overlaps shall be
‘cracked’ with a 45o angle inward turn of the overlapping edge to ensure a tight metal to metal
contact

20.1.4 All the seams at overlap positions shall be rendered watertight using a metal seam sealer which
shall be applied between overlapping metal edges in sufficient quantity and care to ensure that
insulation remains dry and un wetted whether the possible water impingement is from rain,
hose, or fire sprinklers.

20.1.5 The metal cladding shall be secured tightly around the insulated pipe and held in place with
stainless steel bands on a maximum of 300mm centres. One band shall be located on each
circumferential lap and the distance between laps divided at equal band spacing. The band
securing seals shall be kept neatly in line and positioned away from viewing angles as much as
is possible.

20.1.6 Vertical overlaps on vertical or near vertical piping shall be staggered to provide overlaps at
‘North’ and ‘South’ positions in alternate sections of cladding.

20.1.7 Each section of metal cladding on vertical piping with insulation OD's larger than 250mm shall
be supported from the next lower section with two ‘S’ clips fabricated from banding material.
The ‘S’ clips shall be of sufficient length to allow the minimum overlap of 50mm

20.1.8 On vertical piping with insulation OD of 600mm and larger, the securing bands shall be
supported by ‘J’ clips fabricated from banding material. The ‘J’ clip spacing shall be a minimum
of two per band. All ‘J’ clips shall be screwed into position and secured.

20.1.9 Insulated bends and elbows in piping 60mm and larger. shall be metalled with ‘lobster back’
segments using 10mm minimum ball swage to assist shaping. The metal bands shall be
screwed with self-tapping screws and include metal sealants to provide a completely
waterproofed arrangement.

20.1.10 Insulated bends and elbows in piping smaller than 60 mm may use complete pressed humped
back flat metal elbows or fabricated ‘stove pipe’ elbows but these fitments shall be completely
and positively waterproofed.
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21.0 APPLICATION - EQUIPMENT - INSULATION

21.1 General

21.1.1 The insulation over equipment shall be supported by rings, bars, clips etc., welded and fitted to
the metal surfaces by the equipment fabricators. Maximum use shall be made of these
provisions by the Insulation Applicator.

21.1.2 Sections and slabs shall be cut and shaped to fit the equipment contours using the minimum
number of insulating pieces.

21.1.3 Heads of equipment shall be insulated with preformed material of a form best suited to the
curvature of the equipment.

21.1.4 Insulating material shall be secured to equipment items by means of 20mm wide stainless-steel
bands at 300mm maximum centres. Bands shall be machine stretched and tensioned to take
out slack only

21.1.5 Insulation securing bands on equipment larger than 2135mm outside diameter shall be
provided with expansion sections at I-'620mm maximum spacing.

21.1.6 On vertical equipment an expansion gap of approximately 25mm shall be allowed beneath each
support or stiffener ring. Expansion gaps shall be filled with an even distribution of compressed
mineral rock fibres.

21.1.7 Expansion gaps shall be provided on horizontal equipment with mineral fibre as described in
paragraph 18.1.6 above being compressed between joints of the equipment insulation at
3660mm maximum intervals.

21.1.8 Where specified equipment flanges. nozzles, channel covers, manway and handhole flanged
covers shall be insulated with lined removable prefabricated covers secured with bands or
quick release toggle clips. Design to be approved by Jacobs / IOCL as in 16.1.13 above.

21.1.9 Insulation shall be stopped short of un-insulated flanges and nozzles etc., a sufficient distance
to permit withdrawal of bolts without disturbing the remainder of the insulation. insulation shall
stop short by the bolt length + 50mm minimum. Insulation shall be weatherproofed and sealed
at these positions.

21.1.10 Insulated bottom heads of shop insulated vertical equipment with fully enclosed support skirt,
shall be provided with temporary weather resistant protection which shall efficiently prevent the
ingress of water and weather during transportation, storage and lifting.

21.1.11 The insulation over pumps, compressors and turbines shall be in the form of lined removable
metal covers. Design of the covers shall be submitted and approved Jacobs / IOCL prior to
fabrication. Removable covers shall be fabricated by the Insulation Applicator and be made up
in sizeable pieces designed to be quickly and easily taken apart and reassembled. In the fully
assembled state lined covers shall represent an efficient, weatherproof, waterproof and sound
resistant covering.
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22.0 APPLICATION - EOUIPMENT - CLADDING

22.1 General

22.1.1 The protective metal weatherproof cladding over vertical vessel shells shall be constructed of
rectangular sheet metal panels applied in a "wallpaper" pattern with the short width of panel in a
circumferential direction parallel to the equipment insulation support rings and the longer length
of panel in a parallel direction to the vessel centre line. The weight of the panel shall be taken
on the equipment insulation support rings, via angle brackets bolted to the panel in accordance
with Fig 3. There shall be a minimum of two brackets per panel. Shop applied insulation shall
ensure that angle brackets remain in contact with support rings. The short width of panel shall
be rolled to suit the outside curvature of the vessel insulation. The long side of panel shall be
cut to suit the distance between insulation support rings.

22.1.2 The panels shall be applied commencing at the bottom of the vessel. Each circumferential ring
of panels shall be tensioned by means of temporary tensioning bands until the final joint is
screwed tight. ‘S’ clips shall be used as sheeting support at unscrewed circumferential
overlaps. ‘S’ clips shall be riveted into position on shop applied systems, to prevent slippage
during transportation.

22.1.3 The panels shall be held tight over the vessel insulation by means of circumferential bands and
seals. The bands shall be positioned on all horizontal overlaps and at 450mm centres. Elands
shall be held in their relative positions with ‘J’ clips and be machine stretched and sealed to
remove slack only.

22.1.4 The panels shall have a minimum overlap of 60mm on both horizontal and vertical edges. The
overlaps shall be arranged to shed water always.
22.1.5 The vertical and horizontal overlaps shall be secured with self-tapping screws at 75mm pitch
except the horizontal overlaps pre-selected to act as expansion joints, these shall be
constructed with a 150mm overlap and shall remain unscrewed and left free to permit
expansion. All overlaps shall be rendered watertight by use of a metal sealant positioned
between overlapping metal edges.

22.1.6 All equipment projections such as nozzles shall have the metal cladding sealed using a metal
flashing cut to fit the projection and extend over the cladding by at least 75mm. The seal
between the flashing and cladding shall be made water tight by use of self-tapping screws and
metal sealing mastic.

22.1.7 Horizontal cylindrical equipment shall be finished with flat metal cladding arranged in
circumferential bands with the edge of the sheets with the longer dimension applied around the
circumference of the equipment insulation.

22.1.8 The panels shall have a minimum of 75mm overlap on both longitudinal and circumferential
edges, both overlaps being finished with a simple ball swage and rendered water tight with a
metal seam sealer applied between overlapping metal edges.

22.1.9 Horizontal overlaps shall be secured with No. 8 x 15mm long, self-tapping screws set in the
overlap at 75mm intervals and shall be so arranged that staggered bands of panelling encircle
the equipment. ‘vertical overlaps shall not be screwed.

22.1.10 The metal protective finish shall be banded and sealed at 450mm centres ensuring that one
band is set over each vertical overlap.

22.1.11 The insulated heads of vertical and horizontal equipment shall be fabricated from flat metal in
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an ‘orange peel’ construction with all radial seams overlapping a minimum of 50mm and
secured with self-tapping screws at 75mm centres. All overlaps shall be ball swaged and be
rendered water tight using metal seam sealer between metal overlaps.

22.1.12 Projections from the heads shall be sealed using metal flashings neatly cut to fit around the
projections and extending over the cladding for a minimum of 75mm. The seal between
flashing and cladding shall be weatherproofed with self-tapping screws and seam sealing
mastics.

22.1.13 Insulation on bottom heads of fully skirted equipment does not require weatherproofing. (See
para. 18.1.10 re-temporary shop insulated covering).

22.1.14 Heads of equipment 550mm DD and smaller shall be finished and waterproofed with square
ended fabricated covers.

22.1.15 On shop insulated items at temporary shop supports, the insulating system shall be terminated
and sealed, and closure pieces shall be designed and fabricated to fit the open positions.
Designs of closure pieces shall consider the insulating requirements together with support and
securement and the necessity of maintaining waterproofing and weatherproofing after closures
are in place. Design proposals shall be approved by Jacobs / IOCL before fabrication of
closures commences. Closure pieces shall be fitted at site by the site appointed Insulation
Applicator.

23.0 ACOUSTIC INSULATION AND CLADDING

23.1 General

23.1.1 Acoustic Insulation (noise control] requirements and thicknesses shall be as indicated by
classification symbols A, B or C shown in Table 1 and Table 6 of this specification

23.1.2 Application methods and materials shall be as described for thermal insulation with the
following additions and exceptions.

23.1.3 For Class ‘B’ and ‘C’ acoustic insulation all flanges, valves, manways, fittings supports etc. shall
be fully insulated.

23.1.4 The extent of acoustic insulation of shop insulated piping and equipment shall be identified to
the APPLICATOR by the item Fabricator prior to the commencement of insulation.

23.1.5 At positions where metal-to-metal contact would normally occur, anti-vibration seals shall be
applied. Seals shall have a minimum thickness of 3mm and a minimum width of 50mm. The
edges of the cladding or end cap shall be folded where resting on the anti-vibration seals.

23.1.6 Gaps between the outer metallic insulation cladding and unavoidable projections shall be
sealed with flexible. non-setting, impervious seals like. mastic or rubber} where operating
temperatures allow: otherwise metal projections shall be insulated for a minimum length of
300mm from the heat source allowing lower operating temperature seals to be used.

23.1.7 Shop fabricators shall inform the APPLICATOR of all operating temperatures where Acoustic
insulation is required.

23.1.8 Complete cover of the system with insulating material shall be achieved and special attention
shall be paid to ensure the prevention of noise leakage through gaps and voids in the insulating
porous layer. Thicknesses of insulation shall never be reduced without approval by Jacobs /
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IOCL.

23.1.9 Removable acoustic enclosures {e.g. for valves, flanged joints. etc.) shall have an outer surface
of cladding with a mass per unit area at least equal to that of the cladding of adjacent pipes and
equipment. The lining of porous layer material shall be like that used on the piping and
equipment and shall be retained by an inner surface layer of perforated metal sheeting with an
open area of about 30%. It shall be at least 10mm away from the surfaces of flanges or valves

23.1.10 Where acoustic enclosures are installed they shall be of sufficient length to overlap the ends of
the pipe and equipment cladding by at least 200mm.

23.1.11 If shop supports and/or access conditions, make it impossible to fit shop applied acoustic
insulation completely in an uninterrupted application, then reference shall be made to Jacobs /
IOCL via the piping or equipment shop fabricator for a decision of requirements.

24.0 FIRE HAZARD PROTECTION - INSULATION - EOUIPMENT

24.1 General

24.1.1 The method of application shall be in accordance with Sections 18 and 19 unless modified by
specific requirements in the following paragraphs.

24.1.2 The insulation thickness shown in Table 5 shall be regarded as the minimum and shall be
increased where necessary as in the case of elevated temperatures where there is an
overriding requirement for thickness to suit heat conservation. tracing or other requirements.

24.1.3 The insulation cladding shall be secured with 25mm wide stainless-steel bands and screws.

24.1.4 The bands shall be positioned on horizontal overlaps for vertical items or vertical overlaps for
horizontal equipment and at 150mm centres.

24.1.5 Bands on all equipment shall be held in their relative positions with ‘J’ clips which shall be
riveted into permanent position.

24.1.6 Insulation applied to bottom heads of vertical vessels in an enclosed skirt shall be fully clad with
stainless steel cladding.

25.0 REMOVABLE INSPECTION PORTS (WINDOWS)

25.1 General

25.1.1 Removable insulated inspection ports/windows will be required at strategic points on various
piping arrangements and equipment/vessels throughout the refinery.

25.1.2 Inspection ports shall be of a proprietary type and approved by Jacobs / IOCL prior to purchase

25.1.3 Locations of any such removable inspection port/window will be initially indicated on {isometric}
drawings. and subsequently physically marked with indelible ink/paint on piping or equipment
prior to release by CONTRACTOR for insulation.

25.1.4 All inspection ports shall be rendered water tight using correct tooling and seating seals.
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26.0 DOCUMENTATION

The APPLICATOR shall ensure that detailed method statements and quality plans are
submitted for IOCL review and agreement, covering all insulation activities and shall include,
but not be limited to, the following:

• Programme of work schedules in sufficient detail to allow inspection planning

• Safe storage and handling of materials, safe disposal of unwanted materials.
• Insulation system to be used
• Written information identifying selected materials and manufacturers. (see note 1)
• Copies of manufacturer's current data sheets for all materials
• Material delivery dates
• Documented experience list using the selected insulation system and materials (see
note 1)
• Proposed insulation, cladding and fixing expansion details
• Stood off personnel protection guard details. {see note 1)
• Removable flange and valve cover details for both metal box and flexible types. (see
note 1)
• OA/QC procedures for the work shall be as per approved
• Test and Inspection procedures and plans- (see note 1}
• Copy of proposed Inspection / Record Sheets.
• Written information regarding temporary protection arrangements in the event of
1) Outdoor or partial outdoor application
2) Application in the presence of other trades
3) Site storage

Note 1: This information shall also be submitted by the APPLICATOR for Jacobs / IOCL review
and agreement prior to contract award.

27.0 INSPECTION

27.1 General

27.1.1 CONTRACTOR and APPLlCATOR are fully responsible for all quality assurance tasks related
to the materials and application of the insulation systems and proper performance of the
installed systems. Such tasks shall also include initiating. organizing and maintaining full
documentation to verify compliance with this specification. The inspection requirements shall
include, but not be limited to the tasks detailed below:

27.1.2 Inspection Tasks

The insulation shall be inspected during the following stages:

• At the time of material receipt

• Before applying the insulation
• During insulation application
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• Before and during application of weatherproofing

27.1.3 Inspection activities shall include at least the following activities at the time of receipt of the
materials:

• Appropriate checks shall be made to verify materials received at the site are the same
as the specified or approved materials. Such checks shall include verification of labels,
material safety data sheets, delivery receipts, and thicknesses. Damaged, unspecified,
or unapproved insulation materials shall be removed from the site.
• Ensure materials are protected from being damaged by moisture, temperature, wind or
any other atmospheric factors

27.1.4 Inspection activities shall include at least the following prior to insulation application:

• Verify that surfaces to be insulated are clean, dry, and coated as required
• Verify that painting of protrusions through insulation has been carried out.
• Ensure that aluminium foil has been applied over insulated stainless-steel surfaces.

27.1.5 Inspection activities shall include at least the following during insulation application

• Make sufficient checks to verify that the materials applied are the same as the specified
or approved materials
• Verify the insulated item and insulation code are the same as marked on the P&lDs and
related drawings.
• Inspect the insulation supports for correct location, type, width, and length. Verify that
the insulation surface is uniform without gaps and voids
• Inspect for tightness of joints and fasteners.
• Verify that the joints of the insulation segments are properly staggered and tightly
installed.
• Verify the location, width, and installation of insulation expansion joints.

27.1.6 Inspection activities shall include at least the following prior to and during weatherproofing:

• Ensure that the insulation is clean, dry, and fit for its intended purpose before
weatherproofing is applied.
• Inspect size and direction of metal cladding overlaps
• Ensure cladding is properly fabricated and installed.
• Verify that the location of bands. screws. S-clips. and J-clips.
• Ensure that moisture protection and weatherproofing at cut-outs, protrusions, and
locations where moisture could enter the insulation has been appropriately installed.
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28.0 FIGURES & DIAGRAMS

Following figures & diagrams shall form the part of this specification.
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