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1. GENERAL
Site
GENERAL 1.1. SCOPE
Sponsors
Pre-Shipment This Engineering Specification covers the
Inspection minimum requirement for design and
Third Party material of external cold insulation for
Inspection piping and equipment, for purpose of cold
heat conservation, low temperature
Vendor maintenance, for use in industrial plant.
Inspection
Commodity This Engineering Specification defines the

Inspection cold thermal insulation to be used for
equipment, and piping system including:
Inspection and
Test Plan
Insulation types.
Factory Insulation materials.
Acceptance Thickness to be applied.
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Fastening materials.
Jacketing systems for insulation
protection.
Technical application methods to be
used.
1.2. References - Cold Thermal Insulation

Specification
Throughout this Engineering Specification

the latest edition of the following codes,
standards and engineering specification are
recommended:
1.2.1 Codes & Standards
Unfaced Preformed Rigid Cellular

Polyurethane Thermal Insulation
ASTM C 591
Code of Practice for Thermal
Insulation of Pipe Work and
Equipment BS 5970 (In the
temperature range –100 °C to +870
°C)
Method of Specifying Thermal

Insulating Materials on Pipes,
Ductwork and Equipment BS 5422
(In the temperature range -40 °C to
+700 °C)
1.2.2 Engineering specification - Cold

Thermal Insulation Specification
Engineering Specification for Painting
Engineering Specification for Thermal

Insulation Hot
Note: Definition of terms used in this

engineering specification shall be in
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accordance with ASTM C 168.
2. DESIGN BASIS - Cold Thermal

Insulation Specification
2.1. DESIGN TEMPERATURE
Design ambient temperature for cold

insulation: Tac = +48 °C
Maximum direct sunshine temperature:

85º C
The temperature for which the piping to be

insulated shall be the operating
temperature indicated on the Line List.
The temperature for which the equipment is

to be insulated shall be the operating
temperature indicated on the equipment
Engineering Drawings.
2.2. INSULATION PURPOSES - Cold

2.2.1 Insulation shall be provided on all

equipment, piping and instruments etc.,
containing fluid or vapor, for which it is
necessary to:
(1) In order to maintain low temperature for

process control.
(2) Avoid surface condensation.
(3) Conservation of refrigeration.
2.2.2 The system, including the insulating

material, the method of fixing, and the
finishing material, has to be capable of
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giving effective service during the required

life period of the installation. At all times the
system shall have good resistance to
vibration, mechanical damage and thermal
movement, and it should retain its physical
effective mass and stability in service.
2.3. INSULATION CODE
Cold insulation shall be marked with code

M on relevant documents.
2.4. INSULATION DATA - Cold Thermal

2.4.1
Insulation data shall be indicated on the

following documents:
1) Equipment insulation : Equipment List
2) Pipe insulation : Line List
2.4.2 Piping, equipment, storage tanks and

vessels requiring insulation shall normally
be specified on the following project
documents:
1) Piping and Instrumentation Diagrams

(P&IDs).
2) Piping arrangements and Isometric

drawings.
3) Instruments Piping Details and

Schedules.
4) Vessel, Exchanger, Storage Tank

documents and Insulation Schedules.
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5) Line List
2.5. EXTENT OF INSULATION - Cold

1) Insulation around valves and instrument

shall be provided so that insulation does
not interfere its operation.
2) All pipes, valves, flanges, and fittings

shall be insulated.
3) Valves shall be insulated up to the

packing gland.
4) All equipment attachment and

projections such as vessel supports, steel
structures attached to vessels, piping
supports, instrumentation lines, equipment
trim line and instruments connections
directly, to be cold insulated up to a
distance of 4 times (minimum 300 mm) the
insulation thickness.
5) Insulation shall extend down the outside

of vessel skirt for a distance 4 time
(minimum 500 mm) the insulation thickness
as measured from inside bottom tangent
line.
6) All flanged joints, manhole covers, etc.

shall be cold insulated with removable box
insulation.
7) Insulation on exchangers shall be

stopped at a sufficient distance from each
flange to permit the removal of the flange
bolts and shall be finished with a bevel of
sealer.
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2.6. LIMITATION
The following piping components &

equipment parts shall not be insulated
unless otherwise specified.
(1) Visible parts such as code, inspection

and nameplate, stampings, sight glass and
level gauge.
(2) Parts having moving element, such as

expansion and swivel joint, and sliding
valves.
(3) The parts dislike cold exposing such

as gland of valves.
(4) Flange connections in hydrogen service.
2.7 CLEARANCES - Cold Thermal

(1) Insulation shall be designed to provide

an absolute minimum clearance of 25 mm
between the outside surface of any
insulation finishing material and adjacent
surfaces.
(2) Where insulated piping is supported on

steel shoes, the height of the shoe shall be
such that the underside of the insulation
finishing material is clear of the supporting
structure upon which the shoe rest by 25
mm minimum.
3. INSULATION MATERIAL - Cold Thermal

3.1 GENERAL
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1) All material (Insulation, Jacketing and

ancillary material) shall be of high quality,
new, and good appearance.
2) The insulation material shall be

resistance to degradation. This requirement
can have wide implications, from resistance
to vermin and fangoid attach, to freedom
from fire hazard. Also it will include
resistance to the required environmental
conditions, e.g., adequate weather
resistance for outdoor service as well as
resistance to accidental spillage of oil or
other chemicals. The insulating material
itself should not tend to dissociate nor to
disintegrate.
3.2 SELECTED INSULATION MATERIAL

- Cold Thermal Insulation Specification
Rigid Cellular Polyurethane as per ASTM

C-591 TYPE-2 shall be used as cold
insulation material.
3.3 INSULATION THICKNESS
The operating temperature shall be used to

determine the insulation thickness.
Multiple layers shall be provided for

thickness above 75 mm.
Annex 1 Thickness table for heat

conservation (cold) Rigid Cellular
Polyurethane.
3.4 COMMERCIAL FORMS TO BE USED
Panels, blankets, blocks, preformed shells,
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cut shells, slabs, etc. according to the

equipment and pipe sizes and forms.
Preformed insulation shall be used for

pipes up to 12” NPS.
3.5 INSULATION FASTENING

MATERIALS
3.5.1 Welded Pins (needles)
To maintain insulating materials on storage

tank storage shells.
They shall be made of black annealed steel

MARTIN types, : 3mm.
3.5.2 Plates
For attachment on needles and handling in

place insulating material.
They shall be made of black spring steel.
3.5.3 Wires
They are used to hold pipe insulation

materials in place.
Dimensions to be used:
N° 8 (1,3mm.)
Type: 304 stainless steel
3.5.4 Straps / Fasteners
They shall be suitable for the insulation

materials selected and the metal jacketing
used.
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Type: Stainless Steel type 304.
3.5.5 Metal Straps
They are used to hold the insulation

materials in position on, equipment and
materials and where it is no possible to use
needles.
Dimension to be used:
Width 12mm for pipes.
Width 19mm for equipment, ducts.
3.5.6 Strap Fasteners
They shall be adapted to the straps on

which they are used.
3.6 METAL JACKETING - Cold Thermal

3.6.1 Aluminum Jacketing
Aluminum jacketing shall be used as

weather protection cover, over the
insulation unless otherwise specified.
Thickness shall be:
(OD: external insulated diameter of

equipment or piping)
OD < 350 mm. = 0.6 mm.

350 mm < OD < 600 mm. = 0.8 mm.
600 mm < OD < 1600 mm. = 1.0
mm.
OD > 1600 mm. = 1.2 mm.
Flat sheet with 0.5 mm thickness for
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equipment head and transitions.
Type: ASTM B209 Alloy 3003-H16 or

approved equivalent, with factory applied
polykraft vapor barrier.
3.6.2 Aluminum Foil
Aluminum foil shall be used to protect

Stainless Steel surface.
Thickness shall be: 0.19 mm
For securing Aluminum foil on stainless

steel surfaces, Aluminum band 24 SWG
thickness with
19 mm wide shall be used.
3.6.3 Commercial Forms to be used
Flat sheets shall generally be used, but

corrugated cladding may be used on large
surfaces and storage tanks.
3.7 JACKET FASTENING - Cold Thermal

Blind rivets shall be used for attaching

metal jackets together and screws for fixing
metal jackets to insulation supports. The
material of blind rivets and screws shall be
adapted to the material nature of the metal
jacketing.
3.7.1 For Attaching Metal Jackets Together
Form: Blind rivet.
Size: Æ = 4mm x 10mm.
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3.7.2 For Jacket Fastening To Insulation

Supports
Form: Hexagonal heads with washers.

(Self-tapping type)
Type: Stainless steel 304 or 304L
Size: Æ: 7 mm. x 13 mm. long for Æ < 1500

mm.
Size: Æ: 7 mm. x 19 mm. Long for Æ >

1500 mm.
Washers:Æ: 19 mm. Neoprene 2 mm.

Thickness.
4. APPLICATION ON INSULATION - Cold

4.1. PRECAUTIONS PRIOR TO

APPLICATION
The following operations shall be performed

on equipment and materials prior to
application of insulation:
Supports installation
Satisfactory hydrostatic tests
Preparation of surfaces to be
insulated.
If insulation work proceeds in advance of

hydrostatic testing and inspection, welded
joints shall be left uninsulated until
hydrostatic testing is completed.
4.1.1. Supports Installation - Cold Thermal

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Generally insulation supports on equipment

shall be installed by the Vessel fabricators,
and on piping by the piping construction
contractor. Support field welding on tested
equipment or materials, shall be prohibited
unless expressly authorized by the
engineering contractor.
4.1.2. Surface Condition - Cold Thermal

All surfaces to be insulated shall be

cleaned in order to remove all
contaminates.
Insulation materials shall not be applied to

surfaces, which are wet.
4.2. APPLICATION OF INSULATION - Cold

4.2.1. General
1) The application methods, given in this

engineering specification are general in
nature. The construction contractor is
responsible for applying an insulating
system that to give a satisfactory
operational performance and the
requirements given herein shall be
regarded as the acceptable minimum. The
construction contractor shall carryout the
work in accordance with the best practices
of insulation application with the minimum
of waste and debris and the final job shall
have a neat, efficient and workmanlike
appearance.
2) Insulation supports shall be provided at

least 3700 mm intervals on vertical lines or
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lines inclined more than 45° from horizontal

supports shall be installed above all flanges
in vertical lines and located to allow
removal of flange bolts.
3) Contraction joints shall be provided on

long straight runs of piping at approximately
7 m intervals and shall be a 25 mm gap for
all temperature up-to 180ºC joints shall be
packed with glass fiber blanket and
adequately sealed.
4) Before applying weatherproofing,

insulation shall be inspected for open joints,
voids, cracks and defacing. Open joints,
voids, and cracks shall be adequately filled
with insulation and defacing made good to
the satisfaction of the inspector.
5) Special consideration shall be given to

application of insulation near pipe supports.
The insulation and weatherproofing shall be
applied in a manner, which does not restrict
thermal expansion or contraction of the
piping at its support points.
6) Piping insulation shall be continues at

guides.
7) Inner layers in multiple layers pipe

insulation and insulation on irregular
equipment surfaces (where use of bands
and seals is impractical) shall be secured,
using wire. The wire shall be drawn taut to
imbed it into the insulation. The ends shall
be firmly twisted and the excess cut off. The
twisted ends shall be bent over and
imbedded into the insulation.
8) Butt and expansion joints shall be
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staggered for single layer insulation and in

both directions all multiple layers of
insulation.
9) Hydrostatic tests on pipe, vessels and

equipment, if possible shall be completed
before insulation is installed. If insulation is
applied before testing, all weld and thread
joints shall be exposed until completion of
testing.
10) Care shall be taken to avoid contact

between dissimilar material, which might
causes galvanic corrosion.
11) Insulation, which needs to be removed

for maintenance purpose, shall be
fabricated in such a manner, that it is easily
removable and can be remounted with a
minimum of work. Quick opening boxes and
similar construction shall be used in this
case.
12) Single thickness sectional pipe

insulation shall be applied with longitudinal
joints staggered and shall be secured with
wire ties on 230 mm centers. Double
thickness sectional pipe insulation shall be
applied with all joints staggered and shall
have inner layer secured by at least two
wires per section with the outer layer
secured by wire ties on 230 mm centers.
13) External stiffing rings on vessel and

piping shall be insulated with the same
thickness as required for vessel or piping.
4.2.2. Application of Insulating Materials

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Only sound and dry materials having

the correct dimensions, and the
required quality shall be installed.
Cut outs in insulation shall be clean
cut.
When more than one layer is
provided, the components of each
layer shall be staggered and joints of
the second layer shall be off set from
those of the first layer.
Blanket (metal-mesh covered) shall
be secured by twisting together the
wire mesh or by means of a hook or
by tying them together with 0.8 mm
diameter wire.
Any beveled or rounded edges of
insulating component shall be
carefully square off before application.
Each layer of insulating blanket shall
be applied on circular equipment and
secured by steel wire or adapted
straps with an adequate spacing to
hold components in place. (Maximum
spacing: 250 mm from center to
center).
On any sharp angles, a small alloy
aluminum angle piece shall be
installed to prevent the metal strap
cutting into the insulating materials.
All insulation components shall be
carefully cut and adjusted to follow
the exact shape of surfaces, nozzles,
manholes, rings, supports, gussets,
etc.
Stiffeners shall be thoroughly
insulated to the required thickness.
4.2.3. Vapour Barrier & Weatherproofing

(Pipe-work)
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4.2.3.1 The entire outer surface of the

insulation shall be covered a tack coat of
vapour barrier mastic, 1.5 liters per 1.0 m2
with a minimum thickness of 1 mm unless
otherwise specified. And nylon fabric
embedded into the surface while still wet,
avoiding all wrinkles pockets, etc. and
overlapping the nylon fabric a minimum of
50 mm. A finish coat of vapour barrier
mastic shall then be applied to the whole
surface 3.0 liters per sq.m., with a minimum
finished and dried thickness of 3 mm unless
otherwise specified, care shall be taken to
ensure that all nylon fabric and bands are
completely covered. The surface shall be
then be smoothed off with a suitable
solvent if metal cladding is not to be
applied.
4.2.3.2 The vapour barrier mastic and nylon

fabric shall extend at least 150 mm beyond
the insulation at all metal projections to
ensure a good seal. Heavy fillets of mastic
shall be applied to all corners and crevices
where water is likely to collect. Vapour
barrier mastic shall also be used as flashing
at all possible sources of moisture
penetration such as intersections of
insulation, nozzles, building, walls, valve
bonnets tees and other protrusions through
the surface coating.
4.2.4. Vapour Barrier & Weatherproofing

(Equipment) - Cold Thermal Insulation
Specification
4.2.4.1 The entire outer surface of the

insulation shall be covered a take coat of
vapour barrier mastic, 1.5 liters per 1.0 m2
with a minimum thickness of 1 mm unless
16 of 24 5/12/2018 4:23 PM
otherwise specified. And nylon fabric

embedded into the surface while still wet,
avoiding all wrinkles pockets, etc. and
overlapping the nylon fabric a minimum of
50 mm. A finish coat of vapour barrier
mastic shall then be applied to the whole
surface, 3.0 liters per sq.m. With a
minimum finished and dried thickness of 3
mm unless otherwise specified. Care shall
be taken to ensure that all nylon fabric and
bands are completely covered. The surface
shall then be smoothed off with a suitable
solvent if metal cladding is not to be
applied.
4.2.4.2 At all metal flashing protrusions,

insulation terminals, corners and cervices a
sealant shall be applied prior to the mastic
and nylon fabric, which shall extend 150
mm beyond the insulation to ensure a good
seal. Heavy fillets of vapour barrier mastic
shall be applied to all corners and cervices
where water is likely to collect. Vapour
barrier mastic shall also be used at all
possible sources of moisture penetration,
such as intersections of insulation, nozzles,
building walls and other protrusions through
the surface coatings.
4.2.5. Application of the Metallic Jacketing
After equipment or piping insulation

has been applied in a satisfactory
manner the insulation shall be
immediately jacketed and
waterproofed.
If bare insulation cannot be jacketed
before the end of the working day the
system shall be protected with plastic
sheets or in shed to prevent water
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entering.
A basic rule concerns the orientation
of the metal jacket overlapping.
To prevent any ingress of water (or
other liquid) under the jacket, it is
essential for horizontal joints, that the
top sheet overlaps the bottom sheet
(like roof tiles).
In the case of vertical joints the
overlap shall be in opposite direction
of the prevailing wind.
Laps shall be swaged to increase
stiffness and seal efficiency.
On equipment, ducts, piping and
whenever it is possible, both
horizontal and vertical laps shall be
minimum 50mm wide, otherwise, they
shall be as large as possible.
Metal jackets shall be fixed together
by adequate screws spaced of
maximum 200mm. From center to
center.
To prevent thermal bridges, insulating
fabric bands shall be provided
between jacket and support on
equipments and at insulation
supports.
To allow movement due to the
differential expansion between
equipment or piping and jacket,
special arrangement shall be provided
(Example: a circumferential lap joint
located between 2 supports shall not
be fixed).
On accessories such as supports,
branch connections, nozzles,
manholes … where adjustment of
jacket is difficult and water infiltration
is most likely to happen finishing
sheet in 2 parts attached by screws,
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lapped and swaged shall be provided.

Sealing mastic shall also be used.
Jacket for vessel heads shall be in
section except for small diameters
where they may be either flat or
Chinese hat type.
The outer surface of insulation shall
have a regular and smooth finish.
4.2.6. Insulation of Equipments and Ducts

Insulation elements like blocks and slabs

shall be applied with their length parallel to
the greatest length of surface being
covered.
The base course shall be applied with

alternate length blocks so that all
successive end joints are staggered.
Skirts supporting equipments shall be

insulated outside as part of the equipment
area.
Vessel identification plates shall not be

insulated.
Finally metallic jacketing shall be applied.
4.2.7. Insulation on Piping - Cold Thermal

Straight Pipes
The edges of pipe insulation segments

shall be cut off square leaving a distance
between the insulation segment edge and
the flange bolt extremity equal to the bolt
length plus 25mm. To ensure enough
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clearance for bolt dismantling.
Bends
Generally, materials shall be cut into

suitable segments and joints shall be
carefully staggered.
Each section shall be held in position by a

metal strap and fastener.
Tees and Branch Connections
Elements shall be carefully cut and

adjusted.
When two layers (or more) of insulation are

provided, joints shall be staggered as
follow:
- 1st layer on secondary branch
- 1st layer on main pipe
- 2nd layer on secondary branch
- 2nd layer on main pipe.
Then metallic jacketing shall be applied.
Flanged Components
Flanged components shall be insulated by

means of prefabricated boxes or insulation
elements like blocks and slabs.
4.2.8. INSULATION ON INSTRUMENTS

For in-line instruments, gauge and up to
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block valve of local instruments such as

pressure gauges, extend and specification
of insulation shall be according to this
engineering specification.
For lubing impulse / analyzer line, insulation

extend and specification shall be in
accordant with Engineering Specification
for Control and Instrument.
Generally local instruments shall be

insulated by means of prefabricated
removable boxes or insulation elements like
blocks and slabs.
Insulation shall be applied as described in

paragraphs 4 for instrument pipes.
Insulation must enable controls and

adjustments.
4.2.9. Inspection Windows - Cold Thermal

Adequate number of inspection windows on

all strategic locations shall be provided for
checking metal corrosion by construction
contractor, which will be specified by field
engineer.
The removable window shall be of the

same basic material and thickness as the
rest of the insulation and of sufficient rigidity
to withstand handling.
5. INSPECTION REQUIREMENTS - Cold

5.1 All materials furnished and/or used in

connection with the insulation work shall be
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subject to inspection and approved by

Owner to assure the use of material of the
type and quality, which meet the
requirements of this specification. It is the
responsibility of insulation contractor to
ensure adequate percautions against
damage and deterioration are taken during
the storage of insulation materials.
5.2 Installation procedure shall be subject

to inspection by Owner or by his
representative and any material, which has
been improperly installed or excessively
damaged material shall be removed and
replace properly with undamaged material.
5.3 Inspection and approval of materials

and workmanship by Owner shall not
relieve insulation contractor of any his
responsibilities what so ever.
5.4 Prior to insulation work commencing on

any particular section, Owner or third party
should be satisfied that all insulation
supports on vessels, vertical pipelines have
been correctly installed. Additionally all
refrigerant tracing lines are properly in
place and all metals surface are clean and
free of foreign or spattered materials.
5.5 All insulation application shall be

performed during dry weather, uncompleted
and exposed surfaces should be protected
at all time against dampnest, condensation
or rain. Any exposed ends shall be
temporarily protected with weather proofing
insulation showing any evidence of
moisture shall be removed and replaced.
5.6 Prior to the release of any equipment
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and piping to the insulation applicator, all

valves, gauges, etc., shall be inspected,
tested and repaired.
5.7 Care shall be taken to ensure that all

moving parts (working parts) of instrument,
valves, and equipment are protected when
insulation is applied.
6. STORAGE - Cold Thermal Insulation

Specification
Insulating materials shall be packed in a

manner to ensure no moisture can enter
during transport, in transit, and storage at
site and also during application.
Preferably, the materials shall be fixed to

non-returnable pallets.
ANNEX 1
COLD INSULATION
HEAT CONSERVATION (CODE M)
INSULATING MATERIAL: Rigid Cellular

Polyurethane as per ASTM C-591 TYPE-2.
K = 0.019 W/m °C
AMBIENT TEMPERATURE (Max.): +48 °C
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Specification to Industrial Inspection
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Cold Thermal Insulation Specification http://www.inspection-for-industry.com/cold-thermal-insulation-specifica...

Home General Fix Equipment Rotary Equipment

E & I Equipment Get in Touch

Did you find this Cold Thermal Insulation Follow on

Commodity This Engineering Specification defines the

1.2. References - Cold Thermal Insulation

Throughout this Engineering Specification

1.2.1 Codes & Standards

Unfaced Preformed Rigid Cellular

Method of Specifying Thermal

1.2.2 Engineering specification - Cold

Engineering Specification for Painting

Engineering Specification for Thermal

Note: Definition of terms used in this

accordance with ASTM C 168.

2. DESIGN BASIS - Cold Thermal

2.1. DESIGN TEMPERATURE

Design ambient temperature for cold

Maximum direct sunshine temperature:

The temperature for which the piping to be

The temperature for which the equipment is

2.2. INSULATION PURPOSES - Cold

2.2.1 Insulation shall be provided on all

(1) In order to maintain low temperature for

(2) Avoid surface condensation.

(3) Conservation of refrigeration.

2.2.2 The system, including the insulating

giving effective service during the required

2.3. INSULATION CODE

Cold insulation shall be marked with code

2.4. INSULATION DATA - Cold Thermal

Insulation data shall be indicated on the

1) Equipment insulation : Equipment List

2) Pipe insulation : Line List

2.4.2 Piping, equipment, storage tanks and

1) Piping and Instrumentation Diagrams

2) Piping arrangements and Isometric

3) Instruments Piping Details and

4) Vessel, Exchanger, Storage Tank

2.5. EXTENT OF INSULATION - Cold

1) Insulation around valves and instrument

2) All pipes, valves, flanges, and fittings

3) Valves shall be insulated up to the

4) All equipment attachment and

5) Insulation shall extend down the outside

6) All flanged joints, manhole covers, etc.

7) Insulation on exchangers shall be

The following piping components &

(1) Visible parts such as code, inspection

(2) Parts having moving element, such as

(3) The parts dislike cold exposing such

(4) Flange connections in hydrogen service.

2.7 CLEARANCES - Cold Thermal

(1) Insulation shall be designed to provide

(2) Where insulated piping is supported on

3. INSULATION MATERIAL - Cold Thermal

1) All material (Insulation, Jacketing and

2) The insulation material shall be

3.2 SELECTED INSULATION MATERIAL

Rigid Cellular Polyurethane as per ASTM

3.3 INSULATION THICKNESS

The operating temperature shall be used to

Multiple layers shall be provided for

Annex 1 Thickness table for heat