NUCLEAR POWR CORPORTION OF INDIA LIMITED

(A Government of India Enterprise)

In-House Training Program

on
INSULATION
FOR
NUCLEAR POWER PLANT PIPING AND COMPONENTS

BY

P.C. Katiyar
Addl. Chief Engineer (RAS)
Directorate of Procurement

ORGANISED BY :-

Knowledge Management Group

DIRECTORATE OF R&D AND KM, NPCIL

INSULATION

CONTENT
1.

INTRODUCTION

2.

MATERIALS

3.

REFERENCE STANDARDS FOR INSULATING

MATEIRALS

4.

INSUALATION THICKNESS

5.

APPLICATION PROCEDURES

6.

EXAMINATION AND TESTING

7.

QUALITY ASSURANCE PLANS

8.

SUBMISSION OF TECHNICAL DOCUMENTS & HISTORY

DOCKETS

9.

TENDER DOCUMENT FOR INSULATION PACKAGE

(A CASE STUDY OF RAPP-3&4)

Insulation
1.0

Introduction
Thermal insulation provides many useful purposes in both
industrial and commercial piping applications. In the
simplest of terms, thermal insulation serves the purpose of
reducing heat flow from one surface to another. For hot
(above ambient) piping applications thermal insulation
reduces heat loss.
On cold (below ambient) piping
applications the insulation generally serves the purpose of
minimizing heat gain.
By providing a medium for retarding heat transfer, thermal
insulation offers many useful functions in industrial and
commercial piping applications. In specifying an insulation
system, it is important to consider the parameters of your
process and application needs.
The following are some
common design criteria used in insulation system design for
piping application:

Controlling heat loss on hot piping.

Providing personnel protection.
Providing personnel comfort in commercial building.
Reducing heat gain on cold piping.
Limiting or retarding surface condensation.
Providing process control.
Economic optimization or energy conservation.
Providing fire protection.
Providing freeze protection.
Providing noise control.

Controlling Heat Loss on Hot Piping

The objective behind controlling heat loss on hot piping can be
very narrow in scope or very broad, with multifaceted purposes.
As already mentioned, insulation in any application serves one
primary function, to reduce the heat flow from one surface to
another.

Providing personnel protection

Providing personnel comfort in commercial building
Providing process control
Economic optimization or energy conservation
Providing freeze protection

Insulation, by itself, does not have the ability to Maintain or

hold temperature within a system. Insulation can only provide a
means for control. Insulation can limit, retard, reduce, or minimize
the rate at which heat flows through or out of the system, but it
cannot stop the process. Insulation is merely a resistor to heat
flow; it is not a barrier to heat flow.
Personnel Protection:
When providing for personnel protection, only enough insulation is
applied to protect individuals from getting burned by the heat of
the pipe surface. Traditionally the upper temperature limit of the
surface of the insulation used as a guideline for personnel
protection was 140 F. In recent years, however, a more
conservative design temperature for personnel protection is 125 F.

Reducing Heat Gain on Cold Piping

In cold piping applications the main objective of providing
insulation is the reduction of heat gain. This process is most often
evidenced in terms of providing process control and limiting or
retarding surface condensation. The most important controlling
factor in the effort to minimize heat gain on cold piping is the
prevention of moisture migration, or water intake, into the
insulation system. This type of moisture migration will have a
dramatic effect on the system performance.
Thermal insulation is provided for piping, equipment and ducting
to minimize the heat transfer from it. Apart from selecting good
insulation material, workmanship during pre-fabrication and
erection is also very important in insulation applications. Heat
leakage sources of all forms are to be identified and thermal
bridges are provided by deploying thermal breaks of Ceramic Fiber
paper wherever possible.
This course on Insulation covers requirements for the supply,
installation and performance guarantee of thermal insulation for
piping, equipment and ducting in the nuclear and conventional
portions of the Nuclear Power Plants

2.0

MATERIALS:

There are many different types of insulating materials

available for both commercial and industrial piping applications.
There are in fact too many to discuss in detail here. A few of the
more common commercial and industrial piping insulation types,
or classifications, are described here. The following list, contain
the material classifications most common to the industrial and
commercial piping industry:

Calcium silicate insulation

Cellular glass insulation
Elastomeric foam insulation
Fiber glass and mineral wool insulations
Perlite insulation
Phenolic foam insulation
Polystyrene foam insulation
Polyurethane and polyisocyanurate foam insulations

Cellular Glass Insulation

Cellular glass insulation is a high-strength versatile insulation
used in temperature services that range from -450 F upto
900F. Cellular glass insulation is all closed cell glass with
no organic binders or fillers. The closed cell glass structure
renders it impervious to liquid water and the driving force of
water vapour pressure. It is manufactured in flat blocks
which are then fabricated into any shape specified.
Fabrication techniques are governed by ASTM Standard
Recommended Practices for Inner and Outer Diameters of
Rigid Thermal Insulation for Nominal Sizes of Pipe and

Tubing. Cellular glass is applied to cold piping in single or

double layers and usually used with a joint sealant and then
covered with either a fabric reinforced mastic or a metal
jacket. On hot piping applications cellular glass is applied to
the pipe in single or double layers with metal bands. No
sealants are used on hot applications. It is then covered with
a metal jacket.
Elastomeric Foam Insulation
Elastomeric foams are used almost exclusively in
commercial, institutional, and residential facilities. They are
used primarily on hot water and chilled water lines or for
water and sewer lines for freeze protection. Elastomeric
foams are extruded into pipe dimensions and generally
available in in, -in, and 1-in thicknesses. They are also
available in sheet form for equipment. These foams are
usually taped, wired, or glued in place.
Fiberglass and Mineral Wool Insulations
Fiberglass and mineral wool are actually two separate and
distinct types of insulations; however, many of their
applications and physical properties are similar. These
products are generally used in hot applications but with
some restrictions can be used in cold applications as well.
Fiberglass is often used for chilled water piping, and other
piping, upto a maximum of 850F. Mineral wool has a peak
temperature limit of 1200F. Fiberglass is made from glass
fibers bonded together with resin binders. Mineral wool is
made from rock slag fibers and bonded together with resin or
clay binders. These materials are generally applied with
metal bands, wire, or tape and covered with a metal or

nonmetallic flexible jacket. On indoor applications they re

frequently covered with an all-service jacket.
Perlite Insulation
Perlite insulation is generally used in the same types of
applications as calcium silicate. It is somewhat lighter in
density and lower in compressive strength than calcium
silicate; however, it is usually treated with a water inhibitor
which tends to keep it drier than calcium silicate. Perlite
insulation is also made in molds to fit the range of pipe
covering shapes required by industry. It is usually applied
with metal bands and covered with a metal jacket.
Phenolic foam Insulation
Phenolic foam is a very low thermal conductivity organic
foam insulation used primarily for plastic piping in freeze
protection applications. Phenolic foam insulation is made in
a catalyst reaction bun and cut in a fabrication process to the
sizes needed for the applications. It is generally applied with
tape or wire and covered with all-service or metal jacket,
depending on the ambient condition and the geography.
Polystyrene Insulation
Polystyrene is a very inexpensive efficient thermal insulation
used almost exclusively in residential and food processing
applications. It comes in expanded boards and extruded
buns. The extruded buns are sometimes used to fabricate
pipe covering for chilled water lines or water and sewer lines.
In residences it is used in the wall panels. In food processing
it is used in the walls and on the roofs. It has a low
permeability rating and is easy to work with. It is applied
with bands, tape, wire, or glue depending on the application.

Polyurethane and Polyisocyanurate Foam Insulations

Polyurethane and polyisocyanurate foams are two chemically
different insulation materials; however, their cell structure
and physical properties are so similar that they are usually
lumped into a common category. This is probably not fair to
polyisocyanurate foam insulation because it generally tends
to be of higher quality. Both insulations have very good
thermal properties. They are used from about -200F upto
300F both indoors and outdoors. On cold applications they
require multiple layers because of their contraction
characteristics. These insulations are manufactured in batch
bun processing and then sold to fabricators where they are
cut into various shapes and sizes depending on the
applications. These insulation materials are usually applied
with tape or wire and covered with either a fabric-reinforced
mastic or a metal jacket.
ACCESSORY MATERIALS
The accessory materials referenced in the above paragraphs
are a necessary part of the insulation system. There are many
manufacturers and supplier of these materials and the quality
can vary dramatically from one to another. The following are
a few of the more common accessory materials used in
industrial and commercial insulation system specifications
with a brief description of each. See also Table given blow.

ASTM Specification Reference:

Material
Calcium silicate
Cellular glass
Elastomeric foam
Fiberglass and mineral wool
Expanded perlite
Phenolic foam
Polystyrene foam
Polyurethane/polyisocyanurate
foam
Acrylic latex mastic
Aluminium banding materials
Aluminium jacketing
ASJ jacketing
Asphalt cutback mastic
FRP jacketing
Hypalon mastic
Stainless steel banding materials
Stainless steel jacketing
6x6 polyester mesh fabric
10x10 glass scrim

ASTM specification
C533-85
C552-91
C534-88
C553-70
C610-85
C1126-89
C578-87a
C-591-85
C647-89
C921-89
C921-89
C921-89
C647-89
C921-89
C647-89
C921-89
C921-89
NA
C1668-86

Acrylic Latex Mastic

Acrylic latex mastic is a heavy bodied weather barrier coating used
primarily to cover rigid insulations such as cellular glass and
polyurethane. It is generally applied in two coats with a 6 x 6
polyester reinforcing fabric for impact and tear resistance. The
finished coating thickness is typically about 1/16 in thick. This material
does not provide vapour protection.

Aluminium Banding Materials

Aluminium bands are used as a securement for many types of
insulation materials. The most common sizes specified range between
, , and 1 in width and are 0.016 in thick. These bands are secured
in place with metal band clips or seals of common dimensions.
Aluminum bands should not be used in applications where the
insulation may be used for fire protection.
Aluminium Jacketing
Aluminium jacketing materials come in many different sizes and
configurations. In piping applications, either smooth or slightly
embossed jacketing of 0.016-in thickness is most common. When
specifying aluminium jacketing for use with permeable insulation
materials and calcium silicate in particular, it is important to specify
aluminium jacketing with a factory-applied moisture barrier liner.
ASJ Jacketing
ASJ jacketing stands for All Service Jacket. This material is a craft
paper/foil/scrim laminate material used exclusively on indoor
commercial applications. ASJ jacketing is usually factory applied and
serves the primary function of providing moisture protection. These
are not vapor barriers, but they can provide a water vapor retarding
effect when properly applied.
Asphalt Cutback Mastic
Asphalt cutback mastics are heavy-bodied asphalts that are cut with
mineral spirits so it can be put on with a trowel or sprayed on. When
applied, the mineral spirits dissipates and leaves behind a hard
asphaltic vapour barrier finish. It is generally applied in two coats
with a 6x6 polyester reinforcing fabric for impact and tear resistance.
The finished coating thickness is typically about 1/16in. Once applied,

asphalt cutback mastics are usually covered with a metal jacket for
aesthetic purposes.
FRP Jacketing
FRP stands for Fiber Resin Plastic or Fiber Reinforced Plastic. By
either definition it is a hard plastic membrane that is reinforced with
glass fibers. FRP jacketing can be used in many of the same
applications where aluminium is used. Also, due to its excellent
chemical resistance, FRP jacketing is often used where aluminium
cannot be used. FRP jacketing materials come in sheet or rolled from
and the laps are sealed with a resin sealant recommended by the
manufacturer.
Hypalon Mastic
Hypalon is a trade name for a Highly Flexible and Extremely Durable
vapour barrier Mastic material. There are numerous products on the
market today that use this product in their compositions to form what
are referred to as elastomeric membranes. These elastomeric
membranes are also referred to generally as hypalons. Hypalons are
usually reinforced with a 10 x 10 or a 10 x 20 fiberglass fabric to
provide impact and tear resistance.
Stainless Steel Banding Materials
Stainless steel bands are used to support or secure insulation materials
to piping. They are used in many of the same applications as
aluminium bands. Stainless steel bands are generally used in either
or -in widths and are 0.010 or 0.015 in thick. Stainless steel bands
are secured with matching seals or clips. Stainless steel bands should
be used whenever the insulation is being used in fire protection
applications or where other insulation securement materials are not
appropriate.

6x6 Polyester Mesh Fabric

6x6 mesh refers to the number of strands of the primarily fiber in 1 in 2
of fabric. A 6 x 6 mesh will have six primary stands going in one
direction and six primarily stands going perpendicular to that. In a
polyester mesh fabric, the primary strands are woven together in a
unique way to make a fabric which does not fray, pucker, or
fishmouth. This fabric is ideally suited to heavy-bodied mastics such
as asphalt cutback and acrylic latex.
Glass scrim
Glass scrims come in many different configurations. The most
common scrims used in industrial and commercial piping applications
are 10 x 10 x 20. As mentioned above, the numbers refer to the
number of primary strands in 1 in2 of fabric. Glass scrims are best
suited to light-bodied mastics, paints, and elastomeric membranes.
Spray Mineral Wool:
Spray mineral wool conforming to requirements of IS:9742 shall be
considered for application on irregular surfaces.
Other Materials:
Cold stickers, Vapour Barrier, Joint Sealant:
Cold stickers (e.g. MAS-83 compound) shall be used for adhering and
sealing insulation material.
Vapour barrier mastic shall be fire resistant, non-bituminous such as
MAS-131 fire resistant aluminium mastic and capable of being
applied by trowel or brush to the required thickness/covering capacity
as per manufacturers specification.

Joint sealant shall be a vapour barrier sealer available as a soft paste

capable of retaining flexibility between minus 40C to + 100C (e.g.
MAS 35).
Jacketing Material
Jacketing material on insulation on all pipes and equipment shall be of
GI sheet of minimum thickness 0.71 mm, drawing quality, coating
grade 250 or better conforming to specification IS:277.
For cold (anti-condensation) removable type insulation jacketing
material on equipment, valves and flanges shall be at least 0.91 mm
thick GI sheet.
Non-removable type of cold (anti-condensation) insulation: In-situ
applied polyurethane insulation cladded with galvanised steel
cladding would be the preferred arrangement for such duty.
Ancillaries:
Wire Netting:
Galvanized thicken wire netting of commercial quality of size 12.5
mm x 0.71 mm hexagonal construction shall be used.
Lacing wire:
Soft, annealed G.I lacing wire of minimum diameter of 0.80 mm shall
be used.
Screws:
Self tapping, rust proof screws shall be used for lap joints along with
EPDM washers if needed.
Steel Bands:
Galvanised steel bands of min. 12mm wide x 0.5 mm thick shall be
used for securing insulation.

Metal rods, clips and other supports for insulation except materials
which are to be welded to pipes, equipment and ducting to provide
support for the insulation.
For cleaning stainless steel surfaces, only acetone or superior kerosene
with a free chloride not exceeding 25 ppm shall be used. All the
cleaning agents shall be subject to the approval by the purchaser.
Epoxy paint e.g. Epilux-5 (Base & Catalyst) paint manufactured by
M/s. Berger Paints (India) Ltd. Or Equivalent.
The Contractor shall arrange for suitable material and tools required
for cleaning the surface to be insulated.
Only approved water proofing compound (MAS 94 OR EQV) shall be used
for sealing the GI jacketing at the outdoor locations.

3.0 Reference standards for insulating materials and method of testing

Following are the Reference
methods
IS:277
IS:3144
IS:3346
IS:5688
IS:5724
IS:8154
IS:8183
IS:9428
IS:9489
IS:9742
IS:9842
IS:12432
IS:
12436
IS:13205
IS:14164
ASTM
C-795

for insulating materials and testing

Galvanized steel sheets (Plain and corrugated)

specification.
Mineral wood thermal insulation materials methods of
tests.
Method of determination of thermal conductivity of
thermal insulation material.
Method of test for performed block type and pipe covering
type thermal insulation.
Methods of test for thermal insulating cements.
Preformed calcium silicate insulation (for temperature
upto 650 C.
Specification for resin bonded mineral wool.
Preformed calcium silicate insulation (for temperature
upto 950C).
Method of test for thermal conductivity of thermal
insulation by means of heat flow meter.
Code of practice for sprayed mineral wool for thermal
insulation.
Specification for pre-formed fibrous pipe insulation.
Code of practice for application of spray applied
insulation.
Preformed rigid polyurethane (PUR) and isocyurcthane
foams for thermal insulation.
Code of practice for the application of polyurethane by
insitu pouring method.
Code of practice for the application and finishing of
thermal insulating material at temperatures above 80 deg.
C and up to 700 deg. C.
Standard specification for thermal insulation for use in
contact with austenitic stainless steel.

Following table illustrates some of the properties of insulation

materials that are commonly referred to in the insulation material selection
process. It is important to remember that the properties of the material alone
should not control the specification process; the combined properties of the
insulation material and the corresponding accessory products that make up
the total system should control the process.
Insulation meterial

Compressive
strength (psi)
Calcium silicate
100
Cellular glas
100
Elasgtomeric foam
NA
Fiberglass/
25 at 10%
Mineral wool
10 at 10%
Expanded perlite
70
Phenolic foam
22 at 10%
Polystyrene foam
25
Polyurethane/polyisocyanurate 30
foams

Maximum
temp (F)
1000
900
200
850
1200
1000
300
165
250

Minimum
temp (F)
250
-450
-40
42
42
250
75
-65
-200

Preformed / In-situ Polyurethane/foam

Preformed/in-situ polyurethane shall conform to IS-12436. The thermal
conductivity of K value when determined as per IS 3346/IS 9489 shall not
exceed figures as given below:
Temp (Deg. C)
0
10
20

K In W/MK
0.021
0.022
0.024

Slabs and pipe sections shall have a normal density of 36 kg/m 3 and where
pipe supports are outside the insulation on 40mm nominal or larger diameter
pipes, polyurethane pipe sections of appropriate density (minimum 120
kg/m3) shall be used.
The comprehensive strength (at 10% deformation), water vapour
transmission. Dimensional stability and horizontal burning characteristics
shall be as per IS: 12436. materials shall be irradiation resistance.
The tolerances on slabs and pipe section shall be in accordance with
IS:12436
Resin Bonded Mineral Wool:
Resin bonded mineral wool mattresses conforming to IS:8183 having
normal density of 140/150 kg/m3 and thickness varying from 25 to 100 mm
shall be used. Material should conform to the requirements of IS:8183 in
respect of moisture resistance non-corrossivity, non-hygroscopity and shall
be proof against rot, vermin and fungus. These mattresses shall have
thermal conductivity as under:
Temp.
Deg.C
100
200
300

Thermal Conductivity
W/M-K
0.042
0.054
0.072

Resin bonded mineral wool mattresses shall not have chloride content more
than 25 ppm.
It shall be supplied in the form of mats which is enclosed on one side with
G.I wire netting of specification 12.5x0.71 mm hexagonal construction.

Tests for thermal material shall be carried out as per IS:8183 and IS:3144
and test certificate will be submitted with each batch of material. For all
austenitic steel surfaces, mineral wool insulation conforming to ASTM C795 shall be used.
Properties and Limitations of Insulation Materials
Insulation material
Calcium silicate
Cellular glass
Elastomeric foam
Fiberglass
Mineral wool
Expanded perlite
Phenolic foam
Polystyrene foam
Polyurethane/polyisocyanurate
foams

Maximum
temperature
1000
900
200
850
1200
1000
300
165
250

Minimum
temperature
250
-450
- 40
42
42
250
75
-65
-200

Resin bonded mineral wool shall also be incombustible and of fire

barrier quality, irradiation resistant, odourless, easy to cut and
maintain.
Snap-on Type Rigid Pipe sections of Resin Bonded Mineral Wool.
Pre-formed snap-on type rigid pipe section of resin bonded mineral
wool conforming to IS:9842 shall be used for all piping upto and
including 350 NB Pipelines larger than (350 mm NB) and special
area such as fittings would require insulation with bonded mattresses.
Pipelines larger than (350mm NB) and special are such as fittings
would require insulation with bonded mattresses.

The pipe section (snap-on type) shall be strong, durable, noncorrosive, non hygroscopic, water repellent, and odourless. The
insulation shall also be incombustible, rot, vermin and fungus proof.
If the insulation thickness requirement is higher than available pipe
section it can be supplemented with matters to achieve requisite
thickness.
Calcium Silicate (Asbestos Free):
Calcium silicate (asbestos free) with addition of insulation binders and
corrosion inhibitors shall be used in the form of blocks for regular
surfaces and wet cement for irregular surfaces, where use of preformed blocks is not possible. The material shall conform to IS:8154.
Thermal conductivity of the material shall not exceed 0.089 W/MK
at 300 deg. C mean test temperature when tested as per IS:3346.
Insulation should be suitable for application up to 600 deg. C.
Blocks made from calcium silicate powder or mixture of calcium
silicate fibers shall have a nominal density of 250 kg/m3 in dry state.
The compressive strength of the blocks at 10% deformation when
tested as per IS:5688 shall not be less than 1.5 kg/cm2 . Blocks shall
be fire resistant and thermally stable at temperature of 600 deg. C.
This insulation material and the primer shall not have soluble chloride
content more than 25 ppm. Water used for wet mixing shall be free of
halides.

4.0

INSULATION THICKNESS
The basis for selection of insulation thicknesses of various operating
temperatures and piping and equipment are given in Tables A and B.
The insulation thickness given in Table-A are for hot insulation and
Table B is for cold insulation.
TABLE-A
Insulation thickness (in mm) for hot insulation
Pipe Size
N.B (mm) Upto
100
15
25
20
25
25
25
32
25
40
25
50
25
65
25
80
25
100
25
125
25
150
25
200
25
250
25
300
25
350
25
400
25
450
25
500
25

Fluid Temperature (Deg.C)

101
to 151
to 201
to
150
200
250
25
40
50
25
40
50
25
40
50
30
40
60
30
40
60
30
50
60
30
50
60
40
50
70
40
50
70
40
60
70
40
60
80
40
60
80
40
60
80
40
60
90
40
60
90
40
70
90
40
70
90
40
70
90

251
310
60
60
70
70
70
80
80
80
90
90
100
100
110
110
110
120
120
120

to

550
25
600
25
600
& 25
Equipment,
flat surface

50
50
50

70
70
70

90
90
90

120
120
120

Insulation thickness given in Table A has been calculated based on the

following parameters.
Ambient temperature
Surface temperature
Wind velocity
Emissivity
Material

35 C
50 C
0 m/s.
0.60 (for GI Cladding)
Mineral wool Mats.
Kg/m3

150

TABLE-B
Insulation thickness (in mm) for cold insulation
Pipe Size
N.B (mm)
15
20
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450

Upto 20
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
25
30

Fluid Temperature (Deg.C)

20 to 11
10 to 0
-1 to -10
25
35
40
30
35
45
30
40
45
30
40
50
30
40
50
35
45
50
35
45
55
35
45
55
35
50
60
40
50
60
40
50
65
40
55
65
40
55
70
40
55
70
45
60
70
45
60
75
45
60
75

500
550
600
600 &
Equipment,
flat surface

30
30
30
30

45
45
45
45

60
60
60
60

75
75
75
80

Insulation thickness given in Table B has been calculated based on the

following parameters.
Ambient temperature
Relative humidity
Surface temperature
Wind velocity
Emissivity
Material
5.0

35 C
85%
32 C
0 m/s.
0.60 (for GI Cladding)
Polyurethane foam

APPLICATION PROCEDURES FOR INSULATION

Application Procedure for Preformed / Cast in-situe Rigid
Polyurethane :
Application and finishing of this insulation material, where used for low
temperature anti-condensation insulation of cold carbon steel piping GI
ducting and cold stainless steel piping and equipment covered under
this specification respectively, shall be in accordance with IS: 14164.
Application Procedure for Carbon Steel Pipes & Equipment & GI
& CS Ducting Non-Removable Type of Insulation with pre-formed
Polyurethane
(i)
(ii)

Surface to be insulated shall be cleaned and dried thoroughly

A coat of cold sticker shall be applied as per manufacturers
specification on the surfaces to be insulated and on the inside
surfaces and edges of all polyurethane sections for proper
adhesion, seal and cushion against vibration. The sections shall
be struck on tightly and joints shall be sealed with cold sticker

(iii)
(iv)

(v)

(vi)
(vii)

(viii)

(ix)

(x)

properly. Securement of insulation shall be carried out using

aluminium bands 24 SWG x 12 mm wide at center to center
distance of 300 mm.
The insulation section of insulation shall be pre-cast or cut and
carved with suitable tools.
Insulation of 60mm and larger thickness shall be applied in
multiplayer construction with staggered joints.
Between
successive layers of insulation a coat of sealant as applicable
shall be applied for proper adhesion and sealing of joints.
For very low temperature pipes operating at minus 20 or
below, a contraction gap of 15 mm shall be provided at every 6
meters filled tightly using 40mm thick annular cuts of resin
bonded mineral wool slabs, compressed to 15mm.
All gaps between polyurethane sections/blocks shall be filled
with joint sealant.
Pre-formed polyurethane blocks/pipe sections of minimum 120
kg/m3 density shall be used at pipe supports or hangers that are
on the outside of insulation on the 40mm or larger diameter
pipes. (For all such supports or hangers on all pipe sizes, metal
cradles 3 mm thick x 100 mm wide shall be fitted on the final
covering by the Purchaser).
Wherever, a nozzle is connected to an uninsulated line,
insulation shall not extend over the nozzle, Lugs, cradles, steel
beams or skirts that are directly on the pipe or equipment, shall
be considered to form a part of the item to be insulated. They
will receive the same insulation thickness as specified for the
body of the vessel and the insulation will be carried out in such
a manner that the temperature of the adjacent non-insulated
surfaces of the supports will not be lower than the dew point.
This length will be decided by the Purchaser.
Vapour barrier for insulation with preformed polyurethane shall
consist of two coats of approved mastic (e.g. MAS 131) with
open weave glass cloth (10x10 mesh) provided between the
two coats therein, for reinforcement.
Pipe hangers and clamps shall be covered with vapour barrier
mastic along with the pipe. The Contractor shall take care that
the threaded portion of the clamps are not covered with the
insulation.

(xi)
(xii)
(xiii)

For vertical piping M.S. Collars with the outstanding projection

from bare surface not exceeding 70% of the thickness of
insulation shall be spaced at not over 2.0 M from each other.
Jacketing, where specified shall be with galvanized steel sheet,
duly grooved and lapped with a minimum of 50 mm.
Bitumen and bituminous products shall not be used in any
indoor applications.

Application Prodecure for Carbon steel pipes and Equipment NonRemovable Type of Insulation with Cast in-situ Polyurethane
Surface Preparation
The Surface of piping to be insulated is wire brushed, and given a
coating of a Polyurethane (PU) compatable paint
PU Preparation
PUF Insulation is a mixture of two component, component A Polyol
blend and component B Isocynate (MDI). Component A is a mixture of
polyol flame retardant, catalyst and 141-B (blowing agent). The
proportions of these chemicals shall be as specified by the PUchemicals manufacturer to achieve desired properties of PUF insulation.
Foaming reaction takes place after mixing component A & component
B, and full foaming of PU mix is achieved by vaporization of mixed
foaming agent into tiny vapour pockets in the insulation matrix.
Application
Cut spacer rings 50mm wide of the same diameter and thickness of the
insulation to be provided from slabs or performed sections of
polyurethane.
Applying adhesive and fix the above spacer rings at a spacing of 850
mm from each other (typ.)
Secure and tighten the spacer rings using GI bands 12mm wide x 0.5
mm thick.

Fabricate cladding of specified thickness with grooves and beads.

Cladding shall be lapped to 50mm (min) and fitted tight with joint
sealant applied at all joints.
Fix cladding on the spacers using specified overlaps and screw spacing.
Joints to be provided with butyl rubber tape.
Drill pour and riser holes and inject metered quantity of polyurethane
chemical mixture.
Tape off pour and riser holes
Cut, trim and apply MAS 35 mastic or equivalent on pour holes
Application Procedure for Removable Box Type Insulation for
Carbon Steel Valves, Flanges and Equipment
(i) The adjacent pipe insulation shall be lap joint and finished, with
mastic vapour barrier and cladding as per this specification.
Clean and apply a layer of anti corrosive paint or aluminium
foil faced mineral wool insulation, 25mm thick to cover the
entire surface, including the bare part of the adjoining pipe.
(ii) Provide and fix external cladding as required, maintaining a gap
equal to the insulation thickness all around. This is achieved by
use of spacers of preformed polyurethane. This cover is in two
halves, with a parting plane along the vertical center line of
valve or flange. The entire inner surface of this fabricated
cover is coated with a release coating of soft wax. This
assembly is now ready for pouring of polyurethane chemicals to
form the insulation.
(iii) Drill pour holes for chemicals and also vent holes for exit of air
contained within.
Polyurethane chemicals, in correct
proportion are injected into the enclosure in metered quantity.
(iv) When the polyurethane is fully set, the external cover is removed
slowly. The release agent on the inner surface would prevent
adhesion to cladding and a clean block of polyurethane would
be seen.
(v) Using a sharp cutter, insulation is cut neatly along the parting plane
to result in two halves.

(vi) Mastic sealer and vapour barrier are applied as specified earlier.
The cladding is replaced and fitted, closing all points for
possible water entry.
The valves glands shall not be insulated.
For removable insulation on valves, flanges and equipment, proper care
shall be taken to maintain continuity of the vapour seal between the
fixed and the removable type of insulation.
Application Procedure for Stainless Steel Piping and Equipment
The insulation procedure for stainless steel piping and equipment shall
be the same as carbon steel piping and equipment except for cleaning of
surfaces to be insulated.
For cleaning of stainless steel surfaces shall be painted with at least two
coats of Epilux-5 manufactured by M/s. Berger Paints (India) Ltd. , or
equivalent (base & catalyst) and dried. Alternatively . Aluminium foil,
0.10 mm thick is wrapped carefully on bare pipe, insuring that there are
no points for water entry from the insulation system to the bare
pipe/equipment. Protection of SS surfaces to be insulated requires
careful workmanship and close supervision.
On the painted and dried surfaces, the insulation procedure shall be
same as for cold carbon steel piping and equipment (removable and
non-removable types).
Application Procedure for Bonded Mineral Wool Mattresses
General Requirements:
This material can be used for thermal insulation of hot carbon steel and
stainless steel piping and equipment specified. Application and
finishing of thermal insulation shall be in accordance with IS:14164.
Surfaces of pipes, ducts and equipment shall be thoroughly cleaned and
dried.

Bonded mineral wool and mattresses for large diameter piping and
equipment shall be used as far as practicable. On lines requiring more
than 80 mm insulation, the insulation shall be applied in two or more
layers. All joints shall be staggered and the inner layer shall have
minimum 50 mm thickness. All gaps shall be densely filled with loose
mineral wool.

The mineral wool mattresses to be used shall have a soluble chloride

content of less than 25 ppm. Stainless steel lines shall be covered with
a layer of aluminium foil of thickness of 0.1 mm before application of
insulating materials. A minimum overlap of 50mm shall be maintained
and the work shall be carried out with careful workmanship and close
supervision.
All pipes and equipment shall have suitable supports, which provide for
sufficient space around piping for required thickness insulation and
jacketing.
In continuous runs of 6M or more of vertical pipes and vessels, support
rings shall be provided at not more than 3 meter intervals. Such ring
shall encircle the pipe and the radial lugs thereon shall have a length
equal to 75 percent of the total insulation thickness.
Insulation at the support shall be jacketed with G.I sheets of 0.6 mm
thickness. Fastening shall be with pan head self tapping screws, size
No. 8, 12 or 18 mm long. Spacing of screws shall be suitable for close
fit-up, but not over 150mm.
The insulation on valves and flanges shall be covered with removable
GI boxes using 0.91 mm thick GI sheet.
Expansion joints shall always be insulated with mineral wool mats
(IS:8183). However, the convolution shall first be wrapped with
minimum 0.1 mm aluminium foil to allow free expansion and
contraction of pipes.

Application Procedure for pre-formed Mineral Wool Pipe Sections

and Resin Bonded Mineral Wool Slabs Insulation of Pipes and
Equipment
For insulation of piping and equipment, preformed sections tested in
accordance with IS:9842, shall be neatly applied with all edges tight
butted. Where gaps are un-avoidable in longitudinal or circumferential
joints, a strip of bonded mineral wool insulation shall be used to fill
such gaps. On multiple layers of insulation, both longitudinal and
circumferential joints of outer layers shall be staggered with respect to
those of inner layers.
For piping, each layer of insulation shall be secured firmly in place with
galvanized, annealed steel binding wire using not less than 3 loops of
wire per meter length of insulation on pipe size upto 200 mm inclusive.
The twisted ends of the wire shall be embedded in the insulation in all
cases. On piping above 200 mm diameter, 12mm x 0.5mm thick
stainless steel bands shall be used for securing the insulation.
All pipes and equipment shall have suitable supports for insulation and
jacketing.
Insulation sections / slabs shall be suitably cut to give a proper fit up on
pipe fittings, valves and flanges. The blocks shall be secured firmly in
place with annealed G.I Wire or stainless steel bands. Gaps and
irregularities of joints shall be filled by step of bonded mineral wool
insulation and smoothened by suitable insulating cement approved by
Purchaser. Valves, fittings and flanges of 250 mm and larger sizes
shall have a covering of 12.5 mm x 0.71 mm hexagonal galvanized
annealed steel wire mesh.
For equipment each layer of insulation shall be secured firmly with
12mm x 0.5 mm stainless steel band at 300mm center to center. On top
of the final layer of insulation 12.5 mm x 0.71 mm hexagonal
galvanized annealed wire mesh be tightly fixed. A leveling coat of
insulating cement shall be applied over the wire mesh. Layer of wire
netting and leveling coat of cement are not needed for resin bonded
mineral wool.

For all insulation cladding systems, GI sheets of minimum 0.71 mm

thickness shall be used for jacketing with self-tapping screws.
Removable parts of equipment, flanges, valves and name plates shall be
covered with removable type insulation with 0.91 mm cladding
thickness.

Application Procedure for Sprayed Mineral Wool:

Alternatively, spray mineral wool may be preferred wherever possible
(IS:9742). Application procedure shall be as per IS 12432 part 1.
Actual method to be employed as recommended by manufacturer shall
be submitted to Purchaser by the Contractor for approval.
Application Procedure for Calcium Silicate
These insulation materials shall be used for the turbine and associated
equipment, where specified, except for the insulation of reheaters and
expansion joints.
All surfaces shall be thoroughly cleaned and dried. The material shall
be applied as pre-formed blocks on equipment of regular shape as
quoted by the Contractor. For the equipment of irregular shapes, the
material shall be applied in the form of wet cement. Only pre-formed
pipe sections shall be applied on piping. Fire resistant paint shall be
applied over the insulated surface to prevent the oil soaking if any
slippage is there.
Application Procedure for wet cement
This procedure shall be applicable for the insulation of turbine and
associated equipment other than reheaters and expansion joints covered
under clause 4.4. The above can also be used for the insulation of
equipment with irregular surfaces, where use of pre-formed blocks is
not possible. The cement shall be tested in accordance with IS:5724.

The contractor shall mark the locations of the studs to be welded on the
equipment to be insulated. It is Purchasers responsibility to get the
studs welded on the equipment accordingly.
Dry power shall be mixed with suitable quantity of halide free water
and the wet cement shall be applied manually. The surfaces to be
insulated shall be coated with a suitable primer for the proper adhesion
of the first layer of insulation.

Over every 50mm thick insulation, one layer of chicken wire mesh
shall be fixed. Previous layer shall be thoroughly dried before applying
the next layer. When final insulation thickness is built up, studs
(welded by the Purchaser on the equipment surface) shall be bent into
the insulation and 12mm thick layer of suitable insulating cement
approved by the Purchaser shall be used to smoothen the surface.
When no cracks are observed after drying, the top surface shall be
jacketed with GI sheets (minimum 0.71 mm thick) with self tapping
screws.
Equipment/ Piping Under In-Service Inspection (ISI)
Some circumstantial weld joints for some of the piping and equipments
(viz steam generator etc. ) are required to be subjected to periodical inservice inspection. Removal insulation for piping, valves & flanges are
suggested below. However, contractor may suggest suitable insulation
at such location (including inspection area) which can be easily
removed and installed back with proper sealing of joints.
Provisions on Removable Pipe Insulation for Welded Joints
intended for PSI/ISI
All removable insulation shall be fabricated with outer envelop of 0.91
mm thick GI sheet. Internal insulation shall be mineral wool pipe
sections or light resin bonded flexible mats encased fully with close
seave glass fabric (7 mil thick). Removable insulation block shall be
mechanically fixed to outer cover for all pipe sizes to ensure that the
assembly can be removed and refitted easily in two halves. Latch and

buckles shall be provided to secure the halves together tightly. The

metal cladding shall have an extended overlap length on each side to
ensure that the removable insulation section is seated properly and
cladding joint gets sealed to the cladding on the line insulation against
ingress of water/oil etc. The length of such section shall be 300mm or
more such that adequate pipe surface is available on both side of weld
joint during PSI/ISI.

Removable Type Insulation on Valves & Flanges Etc. of Pipe Lines

& Equipments.
Thermal insulation (Box type) on all the pipe flanges, valves and
online equipments coming on piping and equipments shall be done.
Some heat exchangers required periodic ISI of tubes. Channel covers
of such equipments shall be suitably insulated to allow easy removal
and installation of channel covers without removal of insulation alone.
In such locations metal encapsulated insulation can be provided.
Insulation of Boiler Feed Pumps and Reheaters:
Boiler feed pumps and reheaters shall be insulated by preparing and
fixing of 50 m thick mineral wool blanket backed on both sides with
close twill weave glass fiber cloth and stitched with glass thread,
binding wire and then GI jacketing in the form of a box shall be used on
the bags.
Provision on Insulated Pipes for Areas Prone to Inadvertent Foot Step
Loading.
Insulted pipe lines/equipments are not be used as platforms as it may
damage the insulation. Suitable provision like cross over platforms are
to be provided access insulated pipe lines which come in passage of
personnel/material movement, wherever required. However, pipe lines
which are located at grade level or close to high maintenance areas are
vulnerable to inadvertent foot step loading during construction,

commissioning, operation and maintenance.

For such areas,
arrangement may be followed after reviewing the loading/requirement
of individual area.
Inspection to the insulation material used, double end (Z Shape) spacer
rings constructed of 30 mm x 3 mm thick galvanized flats shall be
provided at spacing not over 425 mm from each other. These spacer
rings may be constructed with Supercera thermal breaks or equivalent
to prevent direct condition. After application of insulation as per design
requirement, a cap plate of 1 m thickness shall be provided over the top
120 deg. Of the pipe circumference. This additional cap plate will be
pop riveted to the spacer ring. Normal metal cladding shall be provided
on the top of this arrangement as per this specification.
Additional Provisions on all Insulated area which are Vulnerable to Oil
Drips from Lubrication System / Hydraulic System etc.
In such areas, after provision of all elements of the insulation design
and prior to provision of metal cladding, an impermeable barrier of
supercera fabric (or equivalent) laminated to aluminium foil shall be
wrapped around, with all edges stitched and sealed with self adhesive
aluminium foil tape 75mm wide, so that oil does not get soaked in
insulation. Metal cladding shall be carried out on the top of above
barrier treatment. It is to be ensured that lap joint sealant MAS 94 or
equivalent is provided at all the metal joints to prevent oil ingress in the
insulation system. Mock-up shall be carried out to establish the
procedure at site and report shall be issued to Purchaser.
Insulation of Feeder and Header Insulation Cabinet (FHIC):
Insulation of feeder and header insulation cabinet is of panel type. Due
to the space limitation in the area of feeders and header, it is difficult to
insulate all individual components, and hence cabinet type arrangement
is provided. Mineral wool mattresses sandwiched between galvanized
sheets shall be used to make the panels.
There are penetrations in the various faces of the cabinet like:
-

Feeder supports are penetrating from lower rear face and top
central face of the cabinet.

- RTD cables, flow monitoring tubes, DN monitoring tubes are

penetrating from the upper front face of the insulation cabinet.
- End shield cooling pipe lines are penetrating from the bottom face of
the insulation cabinet
- Header outlets are penetrating from top face of the insulation
cabinet.
- Annulus gas monitoring butes are penetrating from the east and west
face of the cabinet.
- Part of the coolant channel end fittings are penetrating from the lower
front face of the insulation cabinet etc.
Details of all these penetrations are given in the respective drawings.
The insulation arrangement shall seal all these opening perfectly, so that
there shall not be any chance of air/head leakage from the insulation
cabinet.
Due to the lack of space for certain faces of the FHIC, wherever
insulation thickness is less than specification requirements,
Microporous insulation may be considered. For installation of FHIC,
the technical specification for FHIC shall be followed.
6.0

EXAMINATION AND TESTING

All materials required for thermal insulation, including jacketing and
other finishing materials shall be new and subject to the approval of the
Purchaser.
All the insulation material received at the plant site shall be stored in
the batches properly identified. The Quality Assurance Plan (QAP) for
material shall be submitted for approval of Purchaser prior to
commencement of work. All test certificates providing the proof of the
requirements shall be provided for each batch as per approved QAP.
Purchaser has the right to ask for additional testing at no extra cost in
order to satisfy himself.
The application of the insulation and finishing of the insulation work
shall be of first class workmanship subject to the approval of the
Purchaser.

In case of wet cement insulation, the Contractor shall specify the

proportion of various ingredients to be used for the mix. The same
proportions of ingredients shall be used throughout the job. Random
sampling and testing may be asked for if deemed necessary.

7.0 QUALITY ASSURANCE PLAN (QAP)

The supplier shall submit a detailed QAP for approval by the Purchaser,
Quality assurance plan for the work covered by this specification shall
meet the minimum requirements of control and tests as given below.
Final QAP as approved by the Purchaser shall be used during insulation
erection/installation.
Sl. Description
No

PROCEDURES

2
I

MATERIALS
MINERAL WOOL

II

POLYURETHEB
NE

III

Control and tests

Action by
supplier

Quality
Surveillance by
Purchaser or
his authorized
representative

Submission of insulation Submission

application
procedure, by supplier
inspection and test procedure

Approval by
Purchaser

Density, Dimensions
Recovery after compressive,
moisture content & moisture
absorption,
thermal
conductivity,
irradiation
resistance, chloride content,
incombustibility
Density, Dimensions
Dimensional
stability,
moisture absorption, closed
cell
content,
horizontal
burning, thermal conductivity,
compressive strength
Density, Dimensions

I
I

R,C
R

I
I

R,C
R

R,C

PREFORMED
FIBREOUS
INSULATION

Thermal conductivity, chloride I

content, moisture content and
moisture absorption test

Tensile test, bend

dimension, coating test

test, I

R,C

Consistancy of wet mixed I

thermal insulation cement,
covering capacity and volume
change upon drying of thermal
insulation cement
VI INSULATION
Compressive strength, thermal I
CEMENT
conductivity, linear shrinkage
(continue from
of preformed high temperature
pervious page)
thermal insulation subject to
soaking heat, adhesion of
dried
thermal
insulation
cabinet
VII SPRAY
Density, dimensions
I
MINERAL WOOL
I
Compressive strength, thermal
conductivity, adhesion, heat
resistance, incombustibility
CALCIUM
VII
Density, dimensions
I
SILICATE
Compressive strength, heat I
resistance, liner shrinkage,
flexural strength, alkalinity,
moisture content, chloride,
thermal conductivity
3 INSTALLA

R,C

R,C

IV GI SHEET
V

(JACKETING
MATERIAL)
INSULATION
CEMENT

TION
GENERAL

All insulation material is in I

close contact with the surface
to which they are supplied
Edges and ends of sections I
shall be join by lap joint.
Close to one another over their
whole surface except is
special application described
by Purchaser

R,C
R

R,C
R

R,C

Sl. Description
No

II

GENERAL
(continue from
previous page)

SURFACE
PREPARATION

Control and tests

Action by
supplier

Quality
Surveillance by
Purchaser or
his authorized
representative

In multi layer insulations, all

joints shall be staggered.
Each layer shall be separately
secured to the surface.
Fittings on the equipments and
vessels shall be covered with
an independent insulation to
allow easy access and removal
without disturbing the main
insulation
Suitable protective finish (e.g.
finishing cement, sheet metal
etc.) shall be applied over the
insulation.
Before the insulation of
fittings is taken up, insulation
of pipe with its protective
finish shall be completed.
Before application of the
insulation, surface shall be
cleaned to remove all dirt,
scale, oil etc. and dried.

R,C

R,C

R,C

R,C

R,C

Clean surface shall be coated I

with anti corrosive paints,
where ever specified by the
Purchaser.

R,C.H

Sl. Description
No

Control and tests

Action by
supplier

Quality
Surveillance by
Purchaser or
his authorized
representative

III COLD SUFACE

Each pipe shall be insulated

separately.
Proper care shall be taken
during application of cold
sticker, vapour barrier.
Gap
between
insulation
Section / Block shall be filled
with joint sealant.
While applying multiplayer
insulation, all joints shall be
staggered. The final two layer
shall be provided with
adequate vapour barrier.
Stiffener
angles,
weld
protrusions, ladder supports,
insulation support rings, pipe
hangers
or
any
metal
connection shall be insulated
if in direct contact with the
cold surface. The insulation
thickness over such protrusion
shall have at least 50% of the
thickness of the adjoining
section.

R,C

R,C,H

R,C

Sl. Description
No

Control and tests

Action by
supplier

III COLD SURFACE

Vapour seal material shall be

applied all over the exposed
edge of the insulation and
bonded to the surface of pipe
or vessel. At all such points
mastic fillet shall be provided
to round off the angle between
the insulation and the weld
surface.
Vapour seals on the fittings
shall be carried over at least
50 mm beyond the finish
vapour barrier of the main
insulation system and sealed
properly.
Vapour sealing material shall
be carried over expansion
joints or contraction breaks
without a joint
In case of jointly insulated
pipelines, each pipe lines shall
be insulated separately. This
is to avoid the effect of
differential expansion due to
difference in temperature.

R,C

R,C

R,C

R,C

(continue from
previous page)

IV HOT SURFACE

Quality
Surveillance by
Purchaser or
his authorized
representative

IV HOT SURFACE

Stiffener
angles,
weld I
protrusions, ladder supports,
insulation support rings, pipe
hangers
or
any
metal
connections shall be insulated
if in directed contact with hot
surface.
Thickness of the
insulation on such protrusions
shall be not less than 50% of
thickness of the main system.

R,C

Legend:
I
: Complete action and inspection by supplier on a 100% basis.
R

Review of test records, test reports, procedures, test certificates,

Records of process parameters etc.

Checking the actual component or witnessing the

Inspection/testing activity on a suitable percentage/random basis.

Hold point by Purchaser

8.0

SUBMISSION OF TECHNICAL DOCUMENTATION

The following documents shall be submitted by the contractor with

the bid

If alternate material is proposed, other than the specified material in

the specification, justification of it with technical details shall be
provided

Insulation application procedure in detail indicating step by step

complete activities for each job.

The following documents shall be submitted by the contractor for approval

by Purchaser after placement of the order and before taking up the job.

Insulation application procedure in detail indicating step by step

complete activities for each job.

Quality control/detailed QAP and procedures indicating step by step

complete quality control/inspection programme at all stages of each
job.

Inspection and test procedures.

Marking, identification and packaging procedures, if any.

History Docket
Contractors shall submit 5 copies of bound history docket containing the
following. The History Documents shall be approved by the Purchaser or
his authorized representative.
1.

Purchaser order/ Site Contract.

2.

Applicable Specification and Drawings.

3.

All approved application procedures,

procedures, inspection plant / QAP.

4.
5.

All material test certificates, all other test and inspection reports.
Design concession requests if any

6.

Performance Guarantee Certificate.

inspection,

testing

Approval of above technical documentation by purchaser shall not

relieve the contractor from full responsibility for correct interpretation of
purchasers specifications and drawing and for the completeness and
accuracy of contractors technical documentation. It shall be the total

responsibility of the contractor to ensure that the product supplied and

installed is in accordance with the governing specifications.
OTHER REQUIREMENTS
Insulation work on piping and equipment shall only be done when the
system has been completely tested and cleared for insulation work by the
Purchaser.
The term cleaning used in the Specification means that the surfaces to be
insulated shall be made free of all loose scale rust, grease, dust oil or any
other foreign matter. The surfaces thus cleaned shall be thoroughly dried
before proceeding with any insulation work. The procedure for cleaning
shall be subject to the approval of Purchaser.
Insulating material offered by the supplier shall have a proven record of
satisfactory service in Indian conditions for an acceptable period as
outlined in the Tender Documents. All insulation materials shall be rotproof, vermin proof, chemically inert and shall not cause corrosion when
applied on the metal surfaces.
The surface of GI jacketing in contact with insulating material on hot
insulation shall be protected with approved primer against corrosion
(moisture barrier). For example TUFKOTE ETCH PRIMER from M/s.
Shalimar Paints or Bison wash Primer from M/s. Burger Paint or
Amerlock-400 from M/s. Goodlass Nerolac or equivalent.
Insulation shall be neatly applied with all edges tightly butted and joins
shall be staggered. All joints and gaps shall be closely filled with the
respective insulating material. Circumferential joints shall be at least 150
mm apart between layer and longitudinal joints shall coincide with the
exist of pipes and equipment. Insulation subjected to vibration or/and
thermal expansion and contraction shall be reinforced with additional
supports and lacing.
The surface area of equipment and running lengths of pipes to be
insulated are estimated, in the schedule of quantities and rates in tender
document only for the guidance of the Bidders. However, the bidders
shall make their own assessment, with the help of the drawings issued
along with the tender.

Where roller type supporters are specified on the outside of insulation of

the piping, a suitable thickness of load bearing insulation like cellular
glass of 150 mm length on either sided of the saddle size.
Insulation Contractor shall not carry out any welding on the piping or
equipment.
The joints of GI jacketing shall be sealed with approved metal sealing
compound (e.g. MAS-94).
In the case of steam feed water lines exposed to atmosphere, the
longitudinal and circumferential joints of the jacketing material shall be
sealed with a suitable compound (MAS-94) to prevent entry of rain water
/ moisture in the insulation. Wherever hanger supports are located, the
gap between hanger support and line jacket shall be properly sealed to
prevent entry of rain water along hanger rods/ brackets. The procedure
for sealing for the above shall be submitted for approval of Purchaser
before taking up the work.
Weld joints below insulation over PHT system shall be marked suitably
on the surface of insulation to facilitate locating weld joints for in service
inspection.
The sand cement used for plastering in the case of cold insulation shall be
in the ratio of 1:3 with at least 2% by weight of CICO or IMPERMO.