Insulation - RPMS ENGG SPC PP 012
Insulation - RPMS ENGG SPC PP 012
Insulation - RPMS ENGG SPC PP 012
Standard Specification
for
Hot and Acoustic Insulation
RPMS-ENGG-SPC-PP-012
Ajay Shrivastava
1 (Sub-Committee Chairman)
_____________________________ _________________ ___________
Anand Umakanthan
_____________________________ _________________ ___________
2
A. Srinagesh
_____________________________ _________________ ___________
3
S. Sammadar
_____________________________ _________________ ___________
4
Kuddallur Seshadri
_____________________________ _________________ ___________
5
RECORD OF REVISIONS
Contents
1. Purpose...................................................................................................................... 5
2. References ................................................................................................................. 5
3. Conflicts and Deviations ............................................................................................ 7
4. Abbreviations and Definitions................................................................................... 7
5. Technical and Design Requirements ......................................................................... 9
6. Basic Properties of insulation material ................................................................... 18
7. Application procedure............................................................................................. 22
8. Inspection and Testing ............................................................................................ 43
9. Vendor Data ............................................................................................................ 43
10. Packing, Preservation, shipment and Storage ........................................................ 44
11. Measurement Wastages Norms. ............................................................................ 44
12. Attachment.............................................................................................................. 46
Reliance Project Management System RPMS-ENGG-SPC-PP-012
Standard Specification for Hot and Acoustic Insulation Date: 25/08/2020, Rev. 0
1. Purpose
This Standard Specification is to ensure uniform and sound approach to the hot &
acoustic Insulation for Piping, Equipment and Storage Tanks etc. for all projects of
Reliance.
All tanks, vessels, columns, equipment and piping containing hot fluids or vapours
are to be insulated to meet one of the below requirements.
a) Conserve heat energy/Minimize heat loss.
b) Maintain temperature for process control or product
c) Provide personnel protection.
d) Maintain noise level within specified limit <85 db.
e) Fire protection
This Standard Specification covers minimum requirement for the manufacturing,
supply, application & quality control of thermal insulation for Tanks, Vessels,
Columns, Equipment and Piping operating in the temperature range from ambient
to 600 °C.
This specification is not applicable for cold service insulation. Refer RPMS-ENGG-
SPC-PP-013 for cold insulation.
2. References
The latest edition of following Codes and Standards are referenced in this standard
specification and all relevant provisions of these reference codes and standards
shall be applicable. Any deviation with respect to below mentioned codes and
standards shall be brought to the notice of Buyer for approval.
Standard Standard Description
ASTM B209 Standard Specification for Aluminum and Aluminum-Alloy
Sheet and Plate
ASTM C165 Test Method for Measuring Compressive Properties of
Thermal Insulations.
ASTMC168 Terminology Relating to Thermal Insulating Materials
ASTMC177 Test Method for Steady-State Heat Flux Measurements
and Thermal Transmission Properties by means of the
Guarded Hot-Plate Apparatus
ASTMC303 Test Method for Density and Dimensions of Preformed
Block-Type Thermal Insulation
ASTMC356 Test Method for Linear Shrinkage of Preformed High-
Temperature Thermal Insulation subjected to Soaking
Heat
Definitions
Parties responsible for complying with an Engineering Standard
Supplier/Vendor: Party which manufactures or supplies materials and services to
perform the function as specified by Buyer
Buyer: Owner (Reliance or Owner-appointed licensor, DEC or EPC who specifies
equipment and services for purchase from Supplier
Parties referred within body of Engineering Standard
Owner: Reliance Industries Limited or specified Reliance Group Company
DEC: Detailed Engineering Contractor
EPC: Engineering, Procurement and Construction Contractor
Contractor: DEC or EPC
Insulation Contractor: Supplier of insulation services
Applicator: The party contracted to install the insulation systems
Insulation Material Supplier: Supplier / Manufacturer of insulation materials
Standard Terminology Relating to Thermal Insulating Materials is defined in ASTM
C168.
5. Technical and Design Requirements
5.1. Basic Design and Engineering of an insulation system shall be governed by
following parameters.
▪ Heat conservation with economical thickness
▪ Avoiding of corrosion under Insulation (CUI).
▪ Compliance with safety requirements for personnel protection
(PP/PG).
▪ Compliance with process conditions / requirements.
▪ Acoustic requirements
▪ Fire safe requirements (FI)
5.2. Based on above criteria following are the type of insulation covered in this
standard specification.
• These Insulation codes to be used by all stake holder, DEC or Process licensors
for P&ID, ISO and PDS CAD modelling.
Note:1: For all other details of "DC" type insulation refer RPMS-ENGG-SPC-PP-013.
Note:2:Details of Insulation and material required against each type of insulation
shall be as per Table 1.
Note:3:Inside and outside diameters of pipe insulation shall comply with ASTM
C585.
Insulation thickness for piping and equipment shall be selected from above Table 3
and same shall be specified in equipment data sheet and piping isometric.
Thickness shown in Table 3, 10/40 means, combination of
• 10 mm Silica Aerogel
• 40 mm mineral wool
When operating temperature exceed 600°C, additional layer of ceramic fibre
blanket shall be provided on the hot face (Inner most layer) of piping or equipment
as per thickness mentioned below,
5.4.1.2. Provision of foil at interface of Silica aerogel and Mineral wool material.
• Foil shall be provided at Silica aerogel and Mineral wool Interface as per table
below.
Sr No Operating Temperature Type of Foil
1 300°C to 400 °C 0.19 mm Aluminum foil
2 Above 400 °C 0.1 mm SS foil
AIA 50 mm
AIB 100 mm (50 mm + 50 mm)
5.5.3.2. In case correct gauge of Aluzinc cladding is not available to achieve the required
mass as per Table 8, then the cladding may be composed of an outer layer of metal
for weather jacketing and an inner damping layer. The inner layer may be made of
PVC foil weighted with barium oxide to provide the additional mass or a high mass-
per-unit-area limp rubber or plastic sheet.
5.5.3.3. The total weight for the vinyl sheet and cladding shall comply with Table 8. The
material should be suitable for service between -29°C and 82°C and have the ability
to self-extinguish. Adhesive for laps shall be phenolic-based nitrile material,
compatible with the sheet and approved by the loaded vinyl manufacturer. The
loaded vinyl may be bonded to the insulation-facing side of the cladding.
6. Basic Properties of insulation material
Unless otherwise specified, materials shall be selected from those described in
Table 9. All materials shall comply with the relevant BS / ASTM or Indian standards.
Insulation materials can affect personal health. Guidance on the classification of
health and safety concerns associated with insulation materials and accessories is
defined in ASTM C930.
6.1.1. Properties of mineral wool material
Table 9- Insulation materials
Sr.
Properties Standard Acceptable values
no
1 Density
1.1 Mineral wool IS 8183 / IS-
144 kg/m³ ±10% Tolerance
mattress 3144
1.2 Mineral wool pipe IS 9842/ IS- 160 kg/m³ ±10% Tolerance
section 3144
Sr.
Properties Standard Acceptable values
no
1.3 IS 8183 / IS- 150 kg/m³ ±10% Tolerance
Mineral wool slab 3144
2 Dimensions
2.1 Length 1.5 meter +/-0.5%, width 0.6
Mineral wool meter +/-0.5%, Thickness -2/+5mm
mattress
6.1.2.2. Higher version of Silica aerogel -Pyrogel HPS from Aspen Aerogel may be used for
high temperature lines operating above 350°C, however higher version of silica
aerogel may be used on stand-alone basis (i.e. without Mineral wool combination)
with Core Engineering approval.
6.1.3.2. Gypsum Cement (Hydrocal B 11) shall be used as a bore coating. Thickness of
gypsum cement shall be ≥ 1.2 mm.
For approved supplier for Cellular glass & Ancillaries material refer RPMS-ENGG-
PRA-PP-040, No other equivalent material Shall be used without prior approval
from Core Engineering.
6.1.4. Properties for Aluminum Cladding material
• Insulation shall be protected from weather, oil spillage, mechanical wear or
other damage by Aluminum cladding with factory applied 75 microns thick
Polysurlyn moisture barrier heat laminated to inner surface of cladding.
Properties as Table 11.
Table 11- Aluminium cladding materials
Sr no Properties Standard Acceptable value
1 Plain Aluminium ASTM C Thickness 0.9 mm/ 1.2mm, Aluminum
Cladding 1729 shall be 5005, 3105, 3103 or 1100 alloys
with H14 tempered in accordance with
ASTM B209 or 19000 H2 as IS 737.
For approved supplier for Ceramic fiber blanket material refer RPMS-ENGG-PRA-
PP-040, No other equivalent material Shall be used without prior approval from
Core Engineering.
6.1.8. Ceramic Fiber rope properties
6.1.8.1. Ceramic fiber rope shall be used for impulse piping insulation purpose. Properties
shall be as Table 14
6.1.8.2. All other properties shall be as per ASTM C 892 Grade III, Type 8.
For approved supplier for Ceramic fiber rope material refer RPMS-ENGG-PRA-PP-
040, No other equivalent material Shall be used without prior approval from Core
Engineering.
6.1.9. Cladding for Fire Safe Services
6.1.9.1. For fire safe services the cladding shall be as specified by DEC/Process Licensors.
6.1.9.2. Generally, for Fire safe requirement Polysurlyn moisture barrier sheet is not
recommended as per standard practice.
6.1.10. Anti-Vibration Seal for Acoustic Insulation
The following materials are suitable for use in anti-vibration seals: -
1. Synthetic rubber.
2. Natural rubber.
3. Non-flammable felt.
4. Strip and Stick AR 300
5. Silica Aerogel material Strip
Where these materials are not compatible with the operating temperature, the seal
shall be made from suitable compressed porous-layer material.
6.1.11. Cladding Sealing Strip for Acoustic Insulation
6.1.11.1. All cladding joints shall be sealed with an elastomeric sealant. The material shall be
fiberglass reinforced sponge silicone tape such as “STRIP-N-STICK AR 300”
manufactured by Saint Gobain Performance Plastics or an approved equivalent.
Each strip shall be 13mm wide x 1.5mm thick minimum.
7. Application procedure
7.1. Surface Preparation prior to Insulation of tanks, equipment and piping.
7.1.1. All surface preparation, materials, and other work shall comply with all applicable
environmental and safety provisions, laws, regulations, ordinances, etc., of the
city, county, state, province, or nation pertaining to the work being performed
and the materials being used.
7.1.2. The surface to be insulated shall be cleaned free of oil, grease and all other
foreign matter and moisture prior to the application of any insulation. No
insulation shall be installed until completion of any stress-relieving, chemical
cleaning, coating application, pressure testing, tracer installation, and release of
the surfaces in writing by RMPG’s site representative.
7.1.3. Painting shall be as per RPMS-ENGG-SPC-PP-014 prior to the start of insulation.
7.1.4. Damaged painting, rusted surface shall be immediately reported to concern Buyer
representative for rectification.
7.1.5. Selection of foil over the hot surface (over pipe/Equipments) prior to insulation.
MOC Operating Temperature Foil Description
CS Above 400°C 0.19 mm Aluminum Foil
SS & Alloy Steel 201°C to 400°C 0.19 mm Aluminum Foil
SS & Alloy Steel Above 400°C 0.1 mm SS foil
• Securement of foils for Piping & equipments,
Pipe diameter 8” & below 1 mm diameter wire (SS304) @200 CC
Pipe diameter above 8” and all 0.2 mm thick X 10 mm wide SS304 bands @200
equipment CC
7.2. Application procedure for Personnel Protection (PP)/Standoff guard (PG)
7.2.1. Personnel Guards or “PG” insulation shall be applied for protection of O&M
personnel. Protection shall be provided for all exposed surfaces with operating
temperatures 56°C to 200℃ that are located.
▪ within 600 mm horizontally or 2000 mm vertically of normal access
areas
▪ around operating platforms, along the grade & walkway
7.2.2. Perforated guard shall be installed all along the pipeline / Equipment for all
normal accessible areas.
7.2.3. 5 mm thick Silica aerogel material strip shall be provided at each support location
for perforated guard beneath the support clip, to avoid galvanic corrosion. (Refer
Attachment No 9 & 11)
7.2.4. Flanges shall not be insulated. Perforated plate or expanded metal of 1.2 mm
thick shall be used for insulation of flanges. The perforated area shall be at least
35%, with a hole diameter max. 5mm in triangular pattern.
7.2.5. Distance between Hot surface and Perforated plate shall be as per Table 15.
7.3.1.7. All pipe insulation shall be provided with an aluminum metal cladding with a factory
applied Polysurlyn Moisture barrier, unless otherwise specified.
7.3.1.8. For hydrocarbon & process lines, ends of pipe runs at flanges shall be sealed with
Hard Set Cements (BD6 or CAT 9 Cement or approved equivalent) to prevent the
product from entering in to the insulations in case of leakages. (“Refer Attachment
No. 7”)
7.3.1.9. For utility lines which are insulated except for valves and flanges, ends of pipe runs
at flanges shall be sealed as above. (Refer “Attachment No. 7”)
7.3.1.10. Small bore Insulated utility lines (Except Hydrocarbon /process lines less than 2”),
end of pipe runs shall be sealed as per “Attachment No 27 A”.
7.3.1.11. Insulation contractor shall be aware of the health and safety issues associated with
insulation materials and shall follow the guidance provided in ASTM C930.
7.3.2. Installation of silica aerogel and mineral wool
7.3.2.1. Inner wrap shall be Silica aerogel blanket over hot face. The outer layer over silica
aerogel shall be mineral wool pipe section up to 24” OD of insulation and above 24”
OD of insulation, mineral wool slab shall be used.
7.3.2.2. Silica aerogel insulation shall be applied by “cigarette wrapping” around the pipe,
as illustrated in “Attachment No.15”. Insulation shall be applied square to the
longitudinal axis of the pipe / equipment and pulled tight around the
circumference.
7.3.2.3. For pipe sizes <4”, 5 mm thick Silica aerogel material shall be used, while for pipe
sizes ≥4” both 5 mm and 10 mm thick Silica aerogel can be used.
7.3.2.4. Where ever combination of 5 mm and 10 mm thick silica aerogel is specified, 5 mm
thick layer shall be installed first.
7.3.2.5. Circumferential & longitudinal joints of silica aerogel shall be tightly butted with no
visible gaps. For multi-layer installations, circumferential and longitudinal joints
shall be staggered by a minimum of 75 mm (3”) with respect to previous layer.
7.3.2.6. The Mineral wool insulation over silica aerogel shall be snugly fitted, with all joints
tightly butted with no visible gaps. All circumferential and longitudinal joints shall
be staggered as per “Attachment No. 15”. Before Application of Mineral wool
applicability of foil shall be check as per clause 5.4.1.2.
7.3.2.7. The insulation shall be secured firmly with tie-wire or band as mentioned in this
specification. Twisted ends of the wire shall be bent flush with the surface of the
insulation. When bands are used, it shall be secured with conventional wing seals.
7.3.2.8. For bends up to 24” OD of insulation, miter segments for insulation shall be cut
from mineral wool pipe section. Above 24” OD of insulation, elbows shall be
insulated with Mineral wool mattresses as shown on “Attachment No. 14”.
7.3.3. Securement for basic insulation will be as follows
7.3.3.1. Silica aerogel layer shall be secured layer wise. Initial and subsequent layers of silica
aerogel shall be secured with 1 mm SS 304 wire at C/C 225 mm . Final silica aerogel
layer shall be secured with 0.6 X20 mm SS bands at C/C 225 mm C/C.
7.3.3.2. Securement method for mineral wool over silica aerogel.
OD of insulated surface Securement method for mineral wool
7.4.1.1. Wherever insulation is specified in steam & condensate lines the insulation material
shall be silica aerogel + mineral wool mattress material.
7.4.1.2. Thickness of silica aerogel and mineral wool material shall be same as specified on
Piping as per Table 3.
7.4.1.3. The inner wrap shall be silica aerogel blanket over valves & flanges with 50 mm
overlap.
7.4.1.4. After application of Silica aerogel material, Mineral wool mattress application to be
completed as mentioned above with basic securement procedure as per clause
7.3.3. Application of foil shall be ensure as per Clause 5.4.1.2.
7.4.1.5. The insulation of valves and flanges where specified for steam and condensate
services shall be carried out by means of flexible, reusable, weather proofed covers
or insulation lined boxes in accordance with the valve and flange box details refer
“Attachment No. 8”.
7.4.2. Insulation of valves and flanges in Hydrocarbon / Process lines. (HC)
7.4.2.1. Process Licensors/DEC shall identify valves and flanges to be insulated for
hydrocarbon and process lines. The same shall be marked in LDT and Isometrics by
DECs.
7.4.2.2. For valve size ≥ 8” valve body shall be insulated with silica aerogel and mineral wool
mattress as per 7.4. Valve and bonnet flanges shall not be insulated, bolts shall be
left un insulated. (Refer “Attachment 19 Sheet 4 of 4”). Application of foil shall be
ensure as per Clause 5.4.1.2.
7.4.2.3. For valve size <8”, valve shall be insulated with removable pad type insulation as
per section 7.6. (Refer “Attachment 19 Sheet 3 of 4”)
7.4.2.4. Flanges of all sizes in hydrocarbon and process lines shall be insulated with
removable pad type insulation as per section 7.6.
7.4.3. Expansion Joints (HC)
7.4.3.1. Due to the difference in expansion coefficients of metals and insulating materials,
necessary allowance should be provided for differential movements between the
hot surface, the insulation material and the cladding. DEC to calculate the
differential expansion and provide the distance at which expansion joint shall be
provided.
7.4.3.2. If no guideline is provided by DEC, expansion joints shall be provided on insulated
lines operating at ≥400°C, at every 6 meters centers on horizontal lines and at each
insulation support ring on vertical lines/Equipments as per attachment No. 22.
7.4.3.3. Expansion joints shall be formed by 25 mm space between pipe insulation sections,
this space shall be filled with loose mineral rock fibers. Expansion joints in each
layer shall be offset at least 150 mm from each other in case of multilayer
insulation.
½” 150 °C 2 13 mm
¾” 150 °C 2 19 mm
½” 250 °C 2 19 mm
¾” 250 °C 2 19 mm
7.4.5.3. Beyond 250 °C operating temperature, impulse lines insulation thickness shall be
specified by DEC, considering touch temperature requirement as per this standard
specification.
7.5.3. Application of Insulation to Columns and Vertical Vessels > 900 mm Dia.
• For surface preparation refer clause 7.1.
7.5.3.1. The insulation shall be mineral wool beveled slabs applied over an inner wrap of
silica aerogel blanket. Applicability of foil at interface of Silica Aerogel and Mineral
wool Shall be according to Clause 5.4.1.2.
7.5.3.2. The slabs shall be snugly fitted with all joints firmly butted and circumferential
joints staggered.
7.5.3.3. Securement shall be provided by 0.6 x 20 mm SS bands at 300 mm C/C.
7.5.3.4. Exposed heads of vessels shall be insulated with mineral wool blanket faced with
expanded metal cut and shaped to conform to the contours of the head. All butting
edges of the expanded metal shall be tightly laced with 20 SWG SS wire. (Refer
“Attachment 16”)
7.5.3.5. The metal cladding to protect the shell insulation shall be of 0.8 mm corrugated
Aluminum cladding . Overlap at the longitudinal seam shall be one corrugation;
overlap at the circumferential seam shall be 75 mm. (Refer “Attachment 16”)
7.5.3.6. The sheets shall be supported at the circumferential lap by 0.6 mm x 25 mm S.S. ‘S’
clips spaced at 2 per sheet, to allow for vertical expansion. Screws are not required
on circumferential seams. (Refer “Attachment No. 10 Sheet 1& 2”).
7.5.3.7. The cladding shall be secured by 0.6 mm x 25 mm S.S. bands. On vessels exceeding
1800mm diameter the bands shall be fitted with compression springs to allow for
circumferential tensioning of cladding . The bands shall be spaced on maximum 450
mm centers. All bands will be supported on joggle clips at 1800mm centers. Bands
shall be secured with conventional wing seals.
7.5.3.8. Stainless steel “Childers” type flat expansion springs at 3mtr. C/C shall be provided
as mentioned below for securement of insulation.
1. <1800 mm dia. – No springs required
2. >1800 mm to 6000 mm dia. – 2” long expansion springs.
3. Above to 6000 mm dia. – 4” long expansion springs.
7.5.3.9. Vertical seams shall be secured by self-tapping pan head SS screws 12 mm long
(No.10) at 100 mm C/C. All screws on corrugated sheets shall be located at the
crown of the corrugation. Care shall be taken not to locate screws at any place
where they may pierce the circumferential lap.
7.5.3.10. Exposed heads of vessel shall be clad with petal construction segmental cladding,
which shall be overlapped to prevent moisture & water penetration. Self-tapping
screws shall be used for fastening cladding. Overlaps shall be sealed as noted in
clause 7.3.4.
7.5.3.11. Protected heads within a skirt shall be insulated in accordance with paragraphs
7.5.2.13.
7.5.3.12. For vessels operating at a temperature over 400°C, air space shall be provided at
the junction of the skirt to vessel head, where the following criteria are satisfied.
Up to 1800 150
1801 to 3000 200
3001 to 4250 250
4251 & above 300
NOTE:
“Z”- Air space shall under no circumstances be less than Z = Rt.
7.5.3.14. Paragraphs 7.3.4 shall be applied to for weather proofing of all penetration from
cladding.
7.5.4. Man way, Exchanger Shell Cover and Flange Boxes
7.5.4.1. The Insulation system and thickness shall be as that of equipment, with exception
that outer layer over silica aerogel insulation with mineral wool mattress in place
of MW slab.
7.5.4.2. Vessel Manways and their associated flanges, exchanger shell covers shall be
fabricated from minimum 0.9mm thick flat Aluminum cladding with factory bonded
polysurlyn moisture barrier and shall be made in sections (removable) of suitable
size to permit inspection.
7.5.4.3. All box construction seams shall be lock-formed, and individual erection joints shall
be located and arranged to give maximum protection from wind and rain.
7.5.4.4. The boxes shall be positioned on the vessel in conjunction with the vessel cladding
to prevent any ingress of moisture at the location of the box/cladding joint.
7.6.3. Procedure of pad fabrication for Valves size up to 6” and Flanges in Hydrocarbon
/Process lines
7.6.3.1. Inner cloth in contact with hot surface shall be High temperature silica cloth.
7.6.3.2. Outer cloth for weather protection shall be Silicon impregnated fiber glass cloth.
7.6.3.3. Thickness of ceramic wool/Silica aerogel shall be as per parent line insulation
thickness. Ceramic wool to be filled in bag prepared with above mentioned two
cloths’ and stitched properly with High temperature fiber glass thread to protect
ceramic wool. Density of loose ceramic wool shall be 128kg/m3.
7.6.3.4. Pad shall be fabricated in two parts with Box type construction and finally covered
with one more layer of Silicon impregnated fiber glass cloth to make it water tight.
7.6.3.5. All the mating surfaces with Pad shall be sealed with High temperature silicon
sealant up to 200°C to avoid any water ingress. Above 200°C no sealant shall be
applied.
7.6.3.6. These pads shall be fixed over valve body with fiber glass bands or any other
suitable removable type attachment. SS band shall not be used for fixation of pad
insulation.
7.6.3.7. Separate set of pads shall be prepared for insulating flanges in such a manner that
the bolts are not covered in insulation.
7.7. Application of Insulation for Tanks (HC, SP)
7.7.1. General requirement
7.7.1.1. Before application of insulation, bottom 400 mm of the external surface of tank
shell shall be painted as per RPMS-ENGG-SPC-PP-014.
7.7.1.2. Bottom 400 mm height from tank base plate shall be insulated with cellular glass.
Thickness of cellular glass material shall be calculated by DEC or Process Licensors
to maintain heat loss equivalent to silica aerogel +mineral wool combination.
7.7.1.3. The tank roofs will be insulated with cellular glass in two-layer construction. The
first layer thickness shall be such that the interface temperature does not exceed
80°C.Thicknes shall be provided by DEC.
7.7.1.4. Material used for insulation work shall be from the approved vendor Insulation
Material Supplier.
7.7.1.5. Thickness of insulation shall be as per thickness table provided in this specification
for heat conservation. The thickness of insulation shall be detailed in Project Tanks
Schedule.
7.7.1.6. Wet insulation shall not be used in any case. Installed Insulation materials over
tanks shall be protected from rain and any contaminants by suitable covering till
permanent cladding is provided.
7.7.1.7. Insulation Contractors are invited to propose either proprietary system such as
“Kitsons Kalzip”, Tyco – “Trac-Loc”, or Conventional Systems, such as detailed
herein. Regardless of system, the insulation contractor shall submit a full design
and detailed drawings for review and approval prior to application. Application of
Insulation with Tyco – “Trac Loc” system do not require any supports on the Tank
shell. Whereas for conventional application, support arrangements to the shell to
be provided (as shown in “Attachment No. 2 and 3”) by Tank Manufacturing
Contractor prior to release the tank for Insulation work.
7.7.1.8. Due regard shall be paid to the effects of wind loading. Calculations for strength of
banding and cladding shall be in accordance with BSI CP3 Chapter V, Part 2.
7.7.1.9. Roof insulation is not designed to support pedestrians. Access to all fittings shall be
via designated walkways only.
7.7.1.10. The insulation contractor shall keep his working locations in a tidy condition.
7.7.2. Surface preparation
• Refer clause number 7.1 for surface preparation.
• Any non-conformities found in painting application shall be reported by
insulation contractor to concern Buyer representative prior to start insulation
work.
7.7.3. Application of insulation over shell portion of tank
7.7.3.1. Inner wrap shall be of Silica aerogel blanket with 50 mm overlap for longitudinal
joints and outer layers shall be of mineral wool slabs.
7.7.3.2. Bottom 400 mm height from tank base plate shall be insulated with cellular glass in
two layers.
7.7.3.3. Insulation material shall be secured over the shell with 0.6 mm x 40 mm SS 304
bands. The bands shall be installed in such a way, that there is a minimum of 2
bands per slab, positioned 150 mm from each slab joint. (Refer attachment No.1).
7.7.3.4. Maximum band length shall be 15 meters. Stainless steel “Childers” type flat
expansion springs at 3mtr. C/C shall be provided on each 15-meter length of band
as mentioned below.
1. >1800 mm to 6000 mm dia. – 2” long expansion springs.
2. Above 6000 mm dia. – 4” long expansion springs.
7.7.3.5. This is to ensure equal tensioning and expansion over the entire tank. Ends of the
bands shall be anchored with 12 mm Ø vertical rod. (Refer “Attachment No.2”).
7.7.3.6. The cladding shall be secured to the vessel by means of 1.2 mm x 50 mm SS 304
bands, with minimum of 4 number of bands per 2-meter sheet. The top outer band
of each lift shall coincide with the horizontal sheet lap.
7.7.3.7. The bands will be supported by joggle clips riveted to the cladding. Material and
width of the clips shall be same as that of bands. Distance between two adjacent
clips shall be 1.8 meters.
7.7.3.8. The thermal movements of the tank will be transmitted through the bands to
suitable breather spring units (Mity spring).
7.7.3.9. The maximum circumferential pitch of the breather springs (Compression Spring)
will be 4.5 meters for cladding securement.
7.7.3.10. Horizontal end laps shall be arranged weather-wise and each sheet shall overlap
the lower sheet by 75 mm. Each lift will be supported by minimum three numbers
0.6 mm x 20 mm SS ‘S’ clips to allow vertical expansion. Screws are not required on
circumferential seams. (Refer “Attachment No.10”).
7.7.3.11. The vertical overlap per sheet shall be one corrugation, and each joint shall be
sealed with approved adhesive/sealer and secured with self-tapping screws or
rivets at 100 mm pitch.
Note: Each “lift” of cladding shall be independent of the one above and one below.
7.7.3.12. Each lift of cladding shall span a maximum circumferential distance of 15 meters.
At the junction of each span the cladding will be secured to the vertical support
anchor plates by “Cromp Arc” studs and nuts (supplied and fitted by the Insulation
Contractor) (Refer “Attachment No.3 and 4”).
7.7.3.13. A molded profile filler strip shall be used to seal the roof to shell junction.
7.7.3.14. All projections shall be cut around locally with close fit to protrusion, maximum gap
around protrusion shall be 3mm, all protrusion shall be neatly finished with flashing
overlapping 75 mm minimum to adjacent surface and sealed with metal sealant to
avoid any moisture or water ingress (Refer “Attachment No.6”).
7.7.4. Roof
7.7.4.1. The tank roofs will be insulated with cellular glass in two-layer construction.
7.7.4.2. If any undulation observed over tank roof, the same shall be filled with Hydrocal
B11 and Cellular glass dust to make the surface smooth.
7.7.4.3. The first layer shall be laid on to the dry and smooth roof plates. The second layer
shall be bonded to the first with PC 88 adhesive. All joints and edges in the second
layer shall be staggered relative to the first and shall be fully sealed with adhesive.
7.7.4.4. At the junction of roof to shell, loose mineral wool shall be used to tightly packed
the space between kerb plate and Cellular glass.
7.7.4.5. The whole system will be secured by means of 0.6 mm x 20 mm SS 304 bands tied
to a floating ring at the center of the tank and an outer ring at the kerb junction.
The bands shall be pitched at 300 mm C/C.
7.7.4.6. The insulation shall be finished with two coats of PC 404 acrylic coating reinforced
with PC 79 polyester cloth, applied in accordance with Pittsburgh Corning’s data
sheets (Refer “Attachment No.5”).
7.8. Application for Solar protection insulation (SP)
7.8.1. Wherever solar protection type insulation is required for Piping or equipments,
insulation material shall be mineral wool pipe section or slab material only.
7.8.2. Thickness of insulation material shall be calculated by DEC.
7.8.3. If no details are available 40 mm insulation thickness shall be considered for solar
protection insulation.
7.8.4. Application procedure is similar as mentioned in Section 7.3 for Piping and Section
7.5 for equipment.
7.9. Inspection Windows / Pockets
A. Piping
Plug type inspection windows of ellipsoidal shape shall be provided on all of the
insulated pipelines having diameter 2” and above. One inspection window shall be
provided at a distance of every 20 meters of straight length of pipe. It should be
provided at the bottom i.e. at 4-6-8 clock position whichever is convenient. There
must be at least one inspection window between two bends which are minimum
10 meters apart. At least alternate bends shall be provided with inspection
windows. The size of the inspection windows shall be as Table 18.
Table 18: Inspection window details for Pipelines
Pipe diameter 2” 35mm x 120mm
Pipe diameter 3” 45mm x 120mm
Pipe diameter 4” 75mm x 120mm
Pipe diameter 6” 100mm x120mm
Pipe diameter 8” 100mm x120mm
Pipe diameter >8” 120mm x120mm
B. Exchangers
All the heads shall be provided with four (4) inspection windows one in each
quadrant. Minimum four (4) inspection windows shall be provided on the shell side.
(Refer “Attachment No. 21” for Inspection window details).
C. Columns & Vessels
Heads shall be provided with four (4) inspection windows one in each quadrant.
Four (4) inspection windows shall be provided at 1.5m above every platform.
Minimum two inspection windows shall be provided on shell portion on either side
of the ladder wherever platforms are not available. (Refer “Attachment No. 21” for
Inspection window details).
D. Tanks
One inspection window shall be provided at each course of the tank and at the top.
(Refer “Attachment No. 21” for Inspection window details).
7.10. Application procedure of Acoustic Insulation
7.10.1. Surface preparation shall be as per Clause no 7.1 for Piping and equipment in
conjunction with RPMS-ENGG-SPC-PP-014.
7.10.2. Any non-conformities found in painting, insulation contractor to consult concern
Buyer representative.
7.10.3. Wherever insulation for only acoustic reason is specified (AIA/AIB/AIC) shall be
provided with only mineral wool material, basic application procedure for
insulation shall be same as per clause 7.3.
7.10.4. Insulation for AHA/AHB/AHC shall be provided with silica aerogel and mineral
wool material, basic application procedure for insulation shall be same as per
clause 7.3.
7.10.5. Voids and cracks in mineral wool insulation, which are larger than 2.3 mm, shall
be corrected by re-fitting the insulation unless filling with loose mineral wool has
been accepted in writing by Buyer.
7.10.6. In case correct gauge of cladding is not available to achieve the required mass for
particular acoustic class then alternatively Loaded vinyl sheet shall be applied
between the insulation and metal cladding. Circumferential and longitudinal
joints shall be overlapped a minimum of 50 mm. The loaded vinyl sheet shall be
cemented on both surfaces of the area overlapped.
7.10.7. All longitudinal seams shall be staggered on alternative sides (4 o’clock and 8
o’clock) of the pipe and laps shall be located to give maximum protection from
wind and rain. (Attachment no 15).
7.10.8. On vertical pipe insulation, metal cladding shall overlap 50 mm for circumferential
seams and 75 mm for longitudinal seams. Cladding shall be supported from
insulation support rings or from cladding below using 3 or more stainless steel "S"
clips. Circumferential joints shall be lapped to shed water. The longitudinal seam
shall be located on the leeward side from the prevailing storm wind direction if
possible. In any case, the joints shall be located so they are easily accessible for
caulking.
7.10.9. Cladding shall be held in place using banding placed on the circumferential
overlaps and by screws on 75mm centers along the longitudinal over-laps.
Longitudinal seams of vertical pipe cladding shall be caulked with Fiberglass
reinforced sponge silicone tape as clause 7.11.2.2.
7.10.10. Fiberglass reinforced sponge silicone tape as clause 7.11.2.2. shall be used to
caulk around all protrusions through the cladding. Protrusions with metal
temperatures above 360°C must rely on flashing to keep water out. Other
cladding to cladding seams not waterproof by virtue of their design shall be
caulked with silicone rubber sealant.
7.10.11. Expansion springs shall be fitted to bands that secure cladding on piping larger
than 710 mm. Bands shall not be located adjacent to cladding laps. Springs shall
be extended 1.3 times their original length when tensioned.
7.10.12. Joints in preformed Aluzinc covers shall be fastened with screws on 100 mm
maximum centers. Joints shall include an overlap of at least 50 mm. Bands shall
secure each end of the cover to the pipe cladding.
7.10.13. The acoustic insulation cladding shall not be in direct or indirect metal to metal
contact with the pipe or equipment surface. Any such contact will allow a
transmission of vibrations to the cladding which will reduce or nullify the noise
reduction by the insulation. It may even enhance the noise radiation because of
the greater surface area of the cladding. It is also important that there should be
no gaps in the insulation. Joints in the porous layer shall therefore be staggered at
least 200mm and the cladding shall overlap at all joint (Refer “Attachment No.27
&29”).
7.10.14. The length of pipe to be insulated and the class of insulation shall be as specified
by the Noise Control Engineer / Consultant/ Manufacturer responsible for the
acoustic design. The requirements shall be identified on the P&ID’s, LDT’s and
Isometric drawings. With vertical pipes, any supports which carry the weight of
the cladding shall contain resilient elements to reduce the transmission of
vibrations from the pipe. (Refer “Attachment No. 28”). Where necessary, these
resilient elements should contain mechanical stops to limit excess movement.
Resilient elements shall not be loaded to such an extent that their operational
range of deflection is exceeded.
7.10.15. Insulation of pipe supports; flanges and valves shall be in accordance with the
requirements of the noted class. (Ref. section 5.5.3). Otherwise, the specified
length of pipe or equipment shall be insulated to cover the whole of the noise
radiating area without gaps or voids.
7.10.16. At locations where metal to metal contact would normally occur, anti-vibration
seals shall be applied (Refer “Attachment No. 29, 30 and 31”). They shall have a
minimum thickness of 3mm and a minimum width of 50mm.
7.10.17. At all exposed flanges the acoustic insulation shall be terminated with an end cap.
(Refer “Attachment No. 27 & 29”). This shall be located as close to the flange as
possible and shall not interfere with the requirements for bolt removal. The end
cap shall be isolated from the pipe by means of an anti-vibration seal.
7.10.18. When the noise radiated from a valve has to be reduced, the equipment shall be
surrounded by an acoustic enclosure. Flanges may be surrounded by an acoustic
enclosure or by removable insulation. Acoustic enclosures shall be easily
demountable to provide access to the flange or valve. Joints shall be sealed to
prevent noise leakage (Refer “Attachment No. 25”). If it is required that a flange
should be ventilated for safety reasons, a special construction such as that shown
in “Attachment No. 25" sht. 2 of 2 shall be used. Demountable parts of acoustic
enclosures heavier than 25kg shall have lifting lugs.
7.10.19. The acoustic enclosure shall have an outer surface of metal sheet with a mass per
unit area at least equal to that of the cladding.
7.10.20. The porous layer shall be similar in material to that used on the piping cladding
and shall be retained by an inner surface layer with an open area of about 30 %,
For example, perforated metal sheet. The inner surface layer shall be at least
10mm away from the flange or valve.
7.10.21. Where acoustic enclosures are installed around flanged joints, they shall be of
sufficient length to overlap the end caps on the pipe cladding by at least 100mm
for class B and 200mm for class C.
7.10.22. Cladding shall be continuously bonded and earthed to prevent electrostatic
charging. Where the earth connection is made via pipe it shall be made with
braided wire and not rigid bar.
7.10.23. Special provisions shall be made to protect the acoustic insulation at locations
where it could be susceptible to mechanical damages. For example, separate
supported steps should be provided where insulation may be stepped on. Where
mechanical load cannot be avoided, the cladding should be reinforced by using
stiffer plate and additional distance rings.
7.11. Ancillaries
• There are several ancillary materials, which shall be used to ensure that the
insulation system forms an effective seal to prevent ingress of fluids, or for
other special applications. Approved Ancillaries are listed in Table 19.
Adhesive sealer strip for cladding in Saint Gobain /Mahavir Corporation or approved
acoustic insulation - Strip and stick AR equivalent
300/ MCSRF 400
Expansion / Compression springs Stainless Steel “Childers” type flat expansion/
compression springs to suit banding width.
Reinforcing cloth PC 79 Owens Corning or equivalent
High Silica cloth Ch-84 AVX Corporation/Urja Industries /Harsh deep
industries/Mahavir Corporation or approved
equivalent
Silicon impregnated cloth Alpha Maritex / Urja Industries /Harsh deep
industries/Mahavir Corporation or approved
equivalent
Profile filler strip B.S.R. Type. Grade S.E. (Internal and External) to suit cladding profile
Metal sealant 95-44/TIC 7030/ Loid Seal Fosters / TIC/ Capricorn Coating and Colours or
94A Approved equivalent.
Hard Set cement - BD6/CAT9 Limpet/ Newkem or approved equivalent
7.11.1. Hard Set Cements, (BD6 or CAT 9 Cement or Approved Equivalent).
7.11.1.1. An asbestos free composition consisting of Approved Portland Cement reinforced
with long, graded, glass silk fibers.
7.11.1.2. It provides a low cost protective coating with a hydraulic set and gives a high degree
of mechanical protection. It should be used for sealing ends of pipe runs at flanges
in hydrocarbon service even where the flanges are being insulated. It can also be
used over mattresses on heat exchanger end covers, pumps etc.
7.11.2. Sheeting Sealants.
7.11.2.1. For sealing joints in metal sheeting, mastic sealants such as Foster Elastomeric 95-
44, TIC 7030, Loidseal 94A or approved equivalent shall be used.
7.11.2.2. Fiberglass reinforced sponge silicone tape 13mm wide x 1.5mm thick minimum
manufactured by from Saint Gobain/Mahavir Corporation or approved equivalent.
7.11.3. Silicon impregnated fiber glass cloth and High silica cloth.
7.11.3.1. This material shall be particularly used for Pad type removable insulation.
• For each insulated valve/venturi /steam traps/ strainers including flanges and
body, up to 300 mm line size 1.5 linear meter of piping of the connected parent
line and 2.00 linear meters for Line size above 300 mm shall be taken in to
account.
• For each pair of insulated flanges including orifice plate & flanges, 0.80 linear
meters of parent piping shall be considered.
11.3. Mode of measurement for Equipment
11.3.1. For insulation of equipment, measurement shall be taken in square meter over
the insulated equipment surface. The surface area for the nozzles, manholes,
projections will be derived as per relevant code of IS 14164:2008.
11.3.2. Surface area for ancillaries if indicated separately for payment viz., SS foil
wrapping shall be measured over the actual surface of application.
11.4. Wastage norms for hot insulation
SR No Insulation Commodity Wastage
1 MW pipe section, MW slab, MW 3%
Mattresses
2 Cladding material + Overlap 75 MM 2.5%
3 Silica Aerogel material 5 MM thick and 10 2.5 %
MM thick
4 Cladding Metal sealant 5% over actual
consumption
12. Attachment
Typical Tank shell Bottom insulation with
Attachment 1
Cellular glass
Attachment 2 Typical Tank Shell insulation Installation