October 1997

Process Industry Practices Insulation

SAMPLE
PIP INSH2000 Installation of Hot Service Insulation Systems

NOT FOR COMMERCIAL USE

1/8/97 Draft 3

INEG1000 Insulation Design and Type Codes

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES In an effort to minimize the cost of process industry facilities, this Practice has been prepared from the technical requirements in the existing standards of major industrial users, contractors, or standards organizations. By harmonizing these technical requirements into a single set of Practices, administrative, application, and engineering costs to both the purchaser and the manufacturer should be reduced. While this Practice is expected to incorporate the majority of requirements of most users, individual applications may involve requirements that will be appended to and take precedence over this Practice. Determinations concerning fitness for purpose and particular matters or application of the Practice to particular project or engineering situations should not be made solely on information contained in these materials. The use of trade names from time to time should not be viewed as an expression of preference but rather recognized as normal usage in the trade. Other brands having the same specifications are equally correct and may be substituted for those named. All practices or guidelines are intended to be consistent with applicable laws and regulations including OSHA requirements. To the extent these practices or guidelines should conflict with OSHA or other applicable laws or regulations, such laws or regulations must be followed. Consult an appropriate professional before applying or acting on any material contained in or suggested by the Practice.

Process Industry Practices (PIP), Construction Industry Institute, The University of Texas at Austin, 3208 Red River Street, Suite 300, Austin, Texas 78705. PIP member companies may copy this practice for their internal use.

Not printed with state funds.

Process Industry Practices

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October 1997

Process Industry Practices Insulation

SAMPLE
PIP INSH2000 Installation of Hot Service Insulation Systems
Table of Contents
1.1 1.2 1.3 1.4

1. Introduction .................................. 2

Purpose ............................................. 2 Scope................................................. 2 Insulation Systems ............................ 2 Supporting Documents ...................... 2

NOT FOR COMMERCIAL USE

Data Sheets

5.11 Damage Considerations .................... 7 5.12 General Housekeeping ...................... 7

6. Extent of Insulation ..................... 8 7. Documentation ............................ 8

2. References ................................... 2
2.1 Process Industry Practices (PIP)....... 2 2.2 Industry Code and Standards............ 2

3. Definitions .................................... 3 4. Storage and Handling of Insulation Materials ..................... 3 5. Application of Insulation ............. 3
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 General .............................................. 3 Securement ....................................... 4 Metal Jacketing.................................. 4 Screws ............................................... 5 Expansion Bands............................... 5 Insulation Expansion Joints ............... 6 Supports for Vertical Piping ............... 6 Fitting, Flange and Valve Insulation .. 6 Mastic (PVA or Acrylic) Weatherproofing.............................................. 6

INSH2001 Extent of Insulation INSH2002 Documentation Requirements

5.10 Protection of Installed Insulation........ 7

Process Industry Practices

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October 1997

PIP INSH2000 Installation of Hot Service Insulation Systems

1.

Introduction
1.1 Purpose The purpose of this Practice is to provide requirements for installation of hot service insulation systems, ambient to 1200F (649C). 1.2 Scope This Practice covers requirements for storage and handling of insulation materials, application of insulation, extent of insulation, and documentation. 1.3 Insulation Systems

Systems requiring additional insulation specifications beyond PIP Practices shall be covered by Purchasers documentation. 1.4 Supporting Documents

SAMPLE

Use of this Practice for contractual purposes requires the Purchaser make specific choices and assemble additional supporting documents. Listing of or reference to supporting documents within this Practice does not imply suitability for specific designs.

2.

References

When adopted in this specification or in the contract document, the latest edition of the following codes, standards, specifications and references in effect on the date of contract award shall be used, except as otherwise specified. Short titles will be used herein when appropriate. 2.1 Process Industry Practices (PIP) 2.2 PIP INSH2001 - Extent of Insulation PIP INSH2002 - Documentation Requirements

NOT FOR COMMERCIAL USE

Industry Code and Standards American Society of Testing and Materials (ASTM)

ASTM C450 - Standard Practice for Prefabrication and Field Fabrication of Thermal Insulating Fitting Covers for NPS Piping, Vessel Lagging and Dished Head Segments API 521 - Guide for Pressure-Relieving and Depressuring Systems

American Petroleum Institute (API)

Process Industry Practices

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October 1997

PIP INSH2000 Installation of Hot Service Insulation Systems

3.

Definitions
For the purposes of this Practice, the following definitions apply: Contractor: Party responsible for furnishing and/or installing the insulation system Owner: Principal end user Purchaser: Owner or the owners authorized agent

4.

Storage and Handling of Insulation Materials

4.1 4.2 4.3 From delivery to installed finished product, insulation materials shall at all times be protected from the elements and have adequate drainage. Insulation materials shall be handled and stored per manufacturers printed recommendations. Mastics, adhesives, and sealers that are exposed to temperatures outside the recommended temperature ranges during storage shall be removed from the site and replaced with new material. Materials with expired shelf life and dates shall be removed from the site and replaced with new material.

SAMPLE

4.4

5.

Application of Insulation
5.1 General

NOT FOR COMMERCIAL USE

5.1.1 5.1.2 5.1.3

All materials shall be stored, mixed, thinned, and applied in accordance with the manufacturers printed instructions. All conflicts between this specification and the manufacturers instructions shall be brought to the attention of the Purchaser for resolution. Authorization to proceed with application of insulation shall be obtained in writing from the Purchaser. Unless otherwise specified, insulation shall not be applied until completion of the following has been verified: a. Required hydrostatic and/or pneumatic pressure testing b. Application of required substrate protective coating systems, including touch-up of previously applied coatings c. Installation and testing of required tracing systems d. Cleaning of surfaces that are to receive insulation

5.1.4

If required by the Purchaser, application of insulation may proceed before pressure testing is complete, provided that all welds and flanged and threaded connections are left exposed until the pressure testing is complete. Temporary terminations of installed insulation shall be adequately protected at all times.

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PIP INSH2000 Installation of Hot Service Insulation Systems

5.1.5

Where insulation has been specified on piping or equipment flanges that are to be hot bolted, the insulation shall not be installed until hot bolting has been accomplished and the flange determined to be leak-free. Unless otherwise specified, all insulation materials shall be installed in a single layer when the total thickness does not exceed 3 in. (75 mm). When applying single layer insulation, other then hinged pipe covering, the circumferential butt joints of each half section shall be staggered. Thicknesses 3-1/2 in. (90 mm) and greater shall be applied in multi-layers with staggered joints. Consideration shall be given to multi-layer insulation for operating temperatures over 600F (316C). When applying double or multi-layer insulation, each succeeding layer shall be staggered to the longitudinal and circumferential joint of the layer beneath. All joints of all layers shall be staggered.

5.1.6 5.1.7 5.1.8

5.1.9

5.1.10 Each layer of double layer or multi-layer insulation shall be held in place separately. 5.1.11 All insulation shall be smooth and free from cracks, voids, gaps and depressions greater than 1/8 in. (3 mm). All cracks, voids, gaps and depressions in the insulation greater than 1/8 in. (3 mm) shall be refitted not filled. 5.2

SAMPLE

NOT FOR COMMERCIAL USE

Securement 5.2.1 5.2.2 5.2.3

Insulation up to 12 in. (300 mm) outside diameter (O.D.) shall be held in place with 16 gauge Type 304 stainless steel tie wire, except cellular glass and polyisocyanurate foam insulation, which may be held in place with fiberglass reinforced pressure-sensitive tape or stainless steel tie wires applied over the tape. Insulation 12 in. (300 mm) O.D. to 24 in. (610 mm) O.D. shall be held in place with 1/2 in. (13 mm) wide by 0.020 in. (0.51 mm) thick Type 304 stainless steel bands and wing seals. Above 24 in. (610 mm) O.D., use 3/4 in. (19 mm) wide by 0.020 in. (0.51 mm) thick bands and wing seals. Metal jacketing 12 in. (300 mm) O.D. to 24 in. (610 mm) O.D. shall be held in place with 1/2 in. (13 mm) wide by 0.020 in. (0.51 mm) thick Type 304 stainless steel bands and wing seals. Above 24 in. (610 mm) O.D., use 3/4 in. (19 mm) wide by 0.020 in. (0.51 mm) thick bands and wing seals. All cut ends of wire shall be embedded into the insulation.

5.2.4 5.3

Metal Jacketing 5.3.1 Metal jacketing on vertical equipment 48 in. (1219 mm) and larger in diameter shall be aluminum sheets, 0.024 in. (0.61 mm) thick with 1-1/4 in. (32 mm) pitch corrugations, measuring approximately 33 to 48 in. (838 to 1219 mm) wide by 10 ft (3 m) long. The length of corrugated jacketing may be modified to minimize waste and cutting. Metal jacketing on horizontal equipment 48 in. (1219 mm) and larger in diameter shall be aluminum 0.024 in. (0.61 mm) thick. Finish shall be

5.3.2

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PIP INSH2000 Installation of Hot Service Insulation Systems

specified by purchaser, (i.e., smooth, corrugated, cross-crimped, embossed, coated, etc.) 5.3.3 Metal jacketing on all vessels, and piping, less than 48 in. (1219 mm) in diameter shall be aluminum, 0.016 in. (0.406 mm) thick and machine-rolled for circumferential fit. Finish shall be specified by the Purchaser, (i.e., smooth, corrugated, crossed crimped, embossed, coated, etc.). Vessel head segments, fittings, valves, etc., shall be fabricated from smooth metal. Stainless steel jacketing 0.010 in. (0.254 mm) or zinc-aluminum alloy coated steel 0.016 in. (0.406 mm) thick shall be used on equipment and piping when fire protection is required, to comply with API 521. When aluminum jacket is used on lines with an operating temperature exceeding 750F (400C), 0.010 in. (0.254 mm) thick stainless steel shall be used at points of contact. Exposed edges of metal jacketing shall be machine-bent or rolled to eliminate sharp edges.

5.3.4 5.3.5

5.3.6

5.3.7 5.4

SAMPLE

Screws Screws shall be self-drilling No. 8 by 1/2 in. (13 mm) stainless steel, with elastromeric washer. Heads may be hex, Phillips recessed round, round, or hexslotted or pan type.

5.5

NOT FOR COMMERCIAL USE

Expansion Bands

Banding on vessels over 8 ft (2.4 m) in diameter shall have 4 in. (100 mm) stainless steel springs. Springs shall be located every 30 ft (9.1 m) of band length. Each spring shall be installed and loaded in accordance with the manufacturers printed instructions. Expansion springs on external jacketing shall be compression type.

Process Industry Practices

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PIP INSH2000 Installation of Hot Service Insulation Systems

5.6

Insulation Expansion Joints 5.6.1 Insulation expansion joints for rigid insulation materials shall be installed in uninterrupted straight pipe insulation, spaced at the following intervals:
Pipe Maximum Operating Temperature F 200 400 500 700 Above 700 (C) (93) (204) (260) (370) (>370) Insulation Expansion Joint Spacing, Maximum Feet 60 30 12 9 6 (meters) (18.2) (9.1) (3.6) (2.7) (1.8)

5.6.2

SAMPLE

Insulation expansion joints shall be a minimum of 1 in. (25 mm) wide, packed tightly with mineral fiber blanket insulation compressed a minimum of 50%. Insulation expansion joints shall be installed in all layers of multiple layer insulation. Joints shall be staggered between layers. Insulation expansion joints shall also be installed below insulation support clips or rings on equipment and piping

5.6.3 5.6.4

5.7

NOT FOR COMMERCIAL USE

Supports for Vertical Piping Fitting, Flange and Valve Insulation 5.8.1 5.8.2

Vertical pipe insulation shall be supported by a pipe insulation support located directly above all elbows, flanges or flanged valves. Additional supports are required at a maximum of every 21 ft 1 in. (6425 mm) of uninterrupted length.

5.8

Molded insulation fittings shall be used when commercially available. Insulation for all fittings shall be fitted and assembled with tight joints. Cementing of prefabricated assemblies shall be done with fabricating cement. Insulation for fittings, flanges and valves shall be fabricated in accordance with ASTM C450 and the Adjunct. Pre-fabricated items may be used in lieu of field fabricated items.

5.8.3

5.9

Mastic (PVA or Acrylic) Weatherproofing 5.9.1 On flat, larger curved and irregular insulation surfaces, when mastic weatherproofing is specified, the surface shall be covered with a tack coat of mastic sufficient to embed reinforcing. The reinforcing shall be overlapped a minimum of 2 in. (50 mm). An application of insulation finishing cement may be required to obtain adhesion on fibrous materials. The weatherproofing mastic shall then be installed in accordance with the manufacturers printed instructions over the reinforcing, pressing it through

5.9.2

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October 1997

PIP INSH2000 Installation of Hot Service Insulation Systems

the mesh to obtain a good bond. Care shall be taken to completely fill and seal the mesh openings. 5.9.3 5.9.4 5.10 The combined thickness of the weatherproofing mastic and reinforcing shall be in accordance with the manufacturers recommendation. Mastic weatherproofing shall overlap adjoining metal surfaces to provide a weather-tight joint.

Protection of Installed Insulation 5.10.1 Insulation systems must be caulked and/or sealed at all possible points of moisture entry. Do not feather edge of caulk. 5.10.2 Installed insulation shall have the required permanent protection or temporary protection applied before the conclusion of that days work. 5.10.3 Installed insulation shall have temporary protection applied if the insulation can be damaged by rain or other forms of atmospheric moisture.

SAMPLE

5.11

Damage Considerations 5.11.1 Unless otherwise specified, insulation that becomes wet shall be removed and replaced with dry insulation, and the wet insulation shall be discarded.

5.12

NOT FOR COMMERCIAL USE

General Housekeeping

5.11.2 Damaged insulation shall be replaced if the nature of the damage will adversely affect the thermal performance of the system. Any disputes regarding the need for replacement of insulation shall be referred to the Purchaser for resolution.

5.12.1 Insulation materials shall be handled and disposed of in accordance with applicable federal, state, and local laws and regulations. 5.12.2 Insulation-related materials, such as mastics, shall be handled and applied with care to prevent splattering on adjacent facilities, such as concrete foundations, paving, structural steel, equipment, piping, gauge glasses, instruments, machined surfaces, valve stems, and packing. 5.12.3 All mastic over-spray and splatter shall be cleaned up as soon as it occurs. 5.12.4 Flammable materials shall be stored away from ignition sources such as welding operations. 5.12.5 Debris resulting from insulation application work shall be removed from the work area on a regular basis and placed in containers at the end of the work day.

Process Industry Practices

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October 1997

PIP INSH2000 Installation of Hot Service Insulation Systems

6.

Extent of Insulation
For extent of insulation see Data Sheet PIP INSH2001.

7.

Documentation
Documents required to define the scope of the work shall be listed on Data Sheet PIP INSH2002.

SAMPLE
NOT FOR COMMERCIAL USE

Process Industry Practices

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Installation of Hot Service Insulation Systems Data Sheet for Extent of Insulation

PIP INSH2001
PAGE 1 OF 2 JAN 97

PROJECT _________________________________________ DATE ___________________________ INSULATION REQUIREMENTS FOR PIPING AND EQUIPMENT (Note: Project piping and equipment insulation specifications may modify these requirements.) INSULATION CODES: HC - Heat Conservation PS - Process Stability ET - Electric Traced ST - Steam Traced SJ - Steam Jacketed HT - Hot Fluid Traced HJ - Hot Fluid Jacketed PF - Prevention From Freezing PP - Personnel Protection FP - Fire Protection Insulation FP (As Required by the Purchaser)

SAMPLE
ITEMS HC [1] AMB - 1200F (649C)
YES NO [4] NO [4] YES [5] NO Straight or bent pipe, socketweld, threaded or buttweld pipe fittings. Socketweld, threaded or buttweld valves. Pipe unions Steam traps, related strainers Flanged pipe fittings, flanged valves (excluding relief and control valves), flange orifice sets, piping flanges connected to equipment nozzles and flanged special items (i.e. strainers) Primary piping for instrument connections, sample piping, vent and drain piping. Expansion or rotation joints, slide valves, etc. Instruments and associated tube Relief valves Control valves Tee and inline strainers Vessels, shell and head surfaces Vessel handholes Vessel manways Vessel instrument trim Shell and tube heat exchangers, excluding flanged joints Heat exchanger flanged joints Pump casings NO [4] NO NO NO [2, 5] NO [2, 5] YES [4] NO [2, 5] NO [2, 5] NO

PS AMB - 1200F (649C)

YES NO [4] NO [4] NO [2, 5] NO

ET, ST, SJ, HT, HJ, & PF

YES NO [2] NO [2] YES [5] YES YES [5] YES NO YES [5] YES [5] YES N/A N/A YES N/A N/A YES [5]

NOT FOR COMMERCIAL USE

YES NO [2, 5] NO [2, 5]

NO [4] NO NO NO [2, 5] NO [2, 5] YES [4] NO [2, 5] NO [2, 5] NO

YES NO [2, 5] NO [2, 5]

Installation of Hot Service Insulation Systems Data Sheet for Extent of Insulation

PIP INSH2001
PAGE 2 OF 2 JAN 97

PROJECT _________________________________________ DATE ___________________________ INSULATION REQUIREMENTS FOR PIPING AND EQUIPMENT (Note: Project piping and equipment insulation specifications may modify these requirements.) INSULATION CODES: HC - Heat Conservation PS - Process Stability ET - Electric Traced ST - Steam Traced SJ - Steam Jacketed HT - Hot Fluid Traced HJ - Hot Fluid Jacketed PF - Prevention From Freezing PP - Personnel Protection FP - Fire Protection Insulation FP (As Required by the Purchaser)

SAMPLE
ITEMS HC [1] AMB - 1200F (649C)
Comments:

PS AMB - 1200F (649C)

ET, ST, SJ, HT, HJ, & PF

Steam turbines YES [3] [5] N/A Compressors [5] NO [2] N/A Blowers, fans [5] YES [4] N/A Internally insulated items NO [4] NO [4] N/A [1] Economics of insulating these items will vary dependent on climate, fuel cost, labor and material cost, and cost of money. [2] Insulate or guard only where required for personal protection. [3] Insulation shall be furnished by the equipment supplier. [4] Provide removable metal guards or suitable personnel barriers where required for personnel protection. [5] Removable/reusable covers should be considered. Personnel Protection (PP) shall be provided to 7 feet (2.13 meters) above grade or platforms and 3 feet (0.91 meters) horizontally from the periphery of platforms, walkways, or ladders.

NOT FOR COMMERCIAL USE

Installation of Hot Service Insulation Systems Data Sheet for Documentation Requirements

PIP INSH2002
PAGE 1 OF 3 JAN 97

PROJECT _________________________________________ DATE ___________________________ NUMBER

INEG1000 INGG1000 INSH1000 INSH2000 INSH2001 INEG1001 INEG1002 INEG1003 INEG1004 INEG1005 INEG1006 INEG1007 INEG1008 INEG1009 INEG1010 INEG1011 INEG1012 INEG1013 INEG1014 INEG1015 INEG1016 INEG1017

TITLE
Insulation and Type Codes Document Use Guidelines Requirements for Hot Service Insulation Materials Installation of Hot Service Insulation Systems Extent of Insulation Data Sheet YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO !

REV

DATE

NOTES

SAMPLE
SELECTED INSULATION THICKNESS TABLES
Thickness of Calcium Silicate Insulation for HC Thickness of Calcium Silicate Insulation for PP Thickness of Calcium Silicate Insulation - Combined Table Thickness of Cellular Glass Insulation for HC Thickness of Cellular Glass Insulation for PP Thickness of Cellular Glass Insulation - Combined Table Thickness of Fiberglass Insulation for HC Thickness of Fiberglass Insulation for PP Thickness of Fiberglass Insulation Combined Table Thickness of Mineral Wool Fiber Insulation for HC Thickness of Mineral Wool Fiber Insulation for PP Thickness of Mineral Wool Fiber Insulation - Combined Table Thickness of Expanded Perlite Insulation for HC Thickness of Expanded Perlite Insulation for PP Thickness of Expanded Perlite Insulation - Combined Table Thickness of Polyisocyanurate Insulation for HC Thickness of Polyisocyanurate Insulation for PP Piping - General Arrangement Piping - Layered Insulation Piping - Vertical Insulation Support Single Layer Piping - Vertical Insulation Support Multi-Layer Piping - Flange Insulation Piping - Insulation Connections Piping - Expansion Joint

NOT FOR COMMERCIAL USE

HOT INSULATION INSTALLATION DETAILS

INIH0001 INIH0002 INIH0003 INIH0004 INIH0006 INIH0007 INIH0008 YES ! YES ! YES ! YES ! YES ! YES ! YES ! NO ! NO ! NO ! NO ! NO ! NO ! NO !

Installation of Hot Service Insulation Systems Data Sheet for Documentation Requirements

PIP INSH2002
PAGE 2 OF 3 JAN 97

PROJECT____________________________________________________ DATE______________________ NUMBER

INIH0009 INIH0010 INIH0011 INIH0012 INIH0013 INIH0050 INIH0051 INIH0052 INIH0053 INIH0054 INIH0055 INIH0056 INIH0057 INIH0058 INIH0059 INIH0060 INIH0061 INIH0062 INIH0063 INIH0064 INSH1001 INSH1002 INSH1003 INSH1004 INSH1005 INSH1006 INSH1007 INSH1008 INSH1009 INSH1010 YES ! YES YES YES YES ! ! ! ! NO ! NO NO NO NO ! ! ! !

TITLE
Removable and Reusable Insulation Flexible Valve Cover Pipe Supports Hanger Rod Rain Shield Spacer Blocks for Typical Tracer Arrangements Vertical Vessels with Outside Diameters over 36" (915) Vertical Vessels with Outside Diameters 36" (915) and Less Vessel Composite Type 1 Vessel Composite Type 2 Vertical Vessel Bottom Head Insulation Top/Horizontal Head Nozzles Vessel Stiffener Insulation Detail Insulated Manhole Cover Rigid, Removable and Reusable Insulated Manhole Cover Typical Clip Details Nozzle Flashing Lap Seam Details Horizontal Vessels Application of Metal Gores on Horizontal Vessel Heads Horizontal Heat Exchangers Hot Service Insulation System for Project Specific Requirements Calcium Silicate Insulation System for Pipe and Equipment Expanded Perlite Insulation System for Pipe and Equipment Mineral Wool Performed Pipe Sections Insulation System Mineral Wool Board Insulation System for Equipment Mineral Wool Blanket Insulation System for Pipe and Equipment Glass Fiber Performed Pipe Sections Insulation System Glass Fiber Block and Board Insulation System Glass Fiber Blanket Insulation System Cellular Glass Block and Fabricated Sections Insulation System

REV

DATE

NOTES

SAMPLE
YES ! YES ! YES YES YES YES YES YES YES YES YES YES YES YES ! ! ! ! ! ! ! ! ! ! ! ! NO ! NO ! NO NO NO NO NO NO NO NO NO NO NO NO ! ! ! ! ! ! ! ! ! ! ! !

NOT FOR COMMERCIAL USE

YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! YES ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO ! NO !

SELECTED MATERIALS SYSTEM DATA SHEETS

Installation of Hot Service Insulation Systems Data Sheet for Documentation Requirements

PIP INSH2002
PAGE 3 OF 3 JAN 97

PROJECT____________________________________________________ DATE______________________ NUMBER

INSH1011 INSH1012 INSH1013 YES ! YES ! YES ! NO ! NO ! NO !

TITLE
Polyisocyanurate Insulation System Ceramic Fiber Blanket Insulation System Glass Fiber Needled Blanket Insulation System

REV

DATE

NOTES

SAMPLE
NOT FOR COMMERCIAL USE

OTHER