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1. OBJECTIVE
This procedure outlines site installation inspection work items that are to be carried out
by Quality Control Inspector of insulation installation in a project to ensure all standard
requirements, project or CLIENT requirements are met.
2. SCOPE
This procedure outlines minimum requirements of insulation installation for
“…………………………” Project.
3. RESPONSIBILITY
3.1 The QA/QC Coordinator at site is responsible in ensuring all inspection items outlined
in this procedure be carried out in professional manner at site. He shall monitor and
assist/support the Related Inspectors at project construction site in performing the
inspection work outlined in this procedure also report directly and being consulted
by the QC Manager on quality control procedures, methods and application.
3.2 Inspector have responsible to perform the inspection work outlined in this procedure
at project construction site.
3.3 Coordination Construction Superintendent, Engineer in Charge and CLIENT inspector
at site is required.
4. DEFINITION
The following words shall have the meaning indicated when used herein:
PROJECT : …………………
CLIENT : …………………
CONTRACTOR : PT. …………………. Engineering, Procurement and Construction Company
selected by CLIENT to perform the detailed design engineering,
procurement and construction.
5. REFERENCE
The following standards and references shall become part of this procedure and contains
detailed requirements on quality and acceptance criteria’s.
……. : Inspection and Test Plan (ITP) for Piping Work
……. : General Specification for Hot Insulation
Manufacture’s or Vendor’s Instruction manual of installation including relevant
drawings (hereinafter called “Instruction Manual”)
6. INSULATION PROCEDURE
6.2 Preparation
Equipment, vessels and piping requiring insulation shall be cleaned, dry and
coated in accordance with approved surface preparation and painting. All NDE and
pressure testing shall be successfully completed before any insulation is applied.
Surfaces to be insulated shall be free from oil, grease, loose, scale or other foreign
matter before applying insulation.
All equipment, vessels and piping shall have been tested and inspected as required
by the relevant specification prior to the installation of insulation.
Insulation support rings, pins, clips, studs, and accessories shall be of materials
compatible with the components to which they are attached and if welded, shall
be installed by the fabricator prior to post weld heat treatment unless specifically
permitted by client.
Nameplates shall not be insulated and shall be attached with extended brackets
to give adequate clearance for full insulation thickness.
Manufacturer’s instructions and recommendations of insulation and vapor barrier
manufacturer’s shall be followed.
Insulation work shall be completed in a neat and workman-like manner.
6.3 Storage
All insulation materials shall be stored and maintained in covered, weather
protected areas above floor level and stacked in manner to prevent damage.
Insulation materials shall be stored and maintained in a dry condition. Any
Insulation that is wetted or damaged must be discarded and replaced.
6.4 Application
Insulation shall not be applied to damp surfaces.
Protective measures shall be taken to prevent moisture from working underneath
or into partially applied insulation.
Tie wire and/or band shall be drawn taut to embed them into the insulation face
with ends firmly twisted. Bands shall be jig stretched and sealed under tension.
6.5. ?? Cladding
Refer to General Specification for Hot Insulation material properties
……..
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6.5. ?? …………………….
Refer to General Specification for Hot Insulation
……..
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7. INSULATION ASSEMBLY
Application of the insulation shall not commence until all equipment, piping flanges,
valves or fittings requiring hydraulic tests have been tested for leakage and made
tight, in practical terms this means that piping spools shall not be insulated until
hydro tests have been completed and flange joints and valves shall not be insulated
until leak testing have been completed, unless removable flanges and valve boxes are
fitted.
Valves, flanges, and nozzles of piping and equipment shall be insulated, unless
otherwise stated. All surfaces which are to be insulated, shall be cleaned free of all
dirt and grease and construction dust, and shall be perfectly dry and any mechanical
damages on paint to be repaired as per procedure and contractor to arrange
inspection with all trades involved to proceed before application of the insulation.
Insulated flanges, fittings, valves and pipe support shall be provided with removable
non-metallic weatherproofing shield cladding.
The stuffing box gland or valves handle shall be kept outside of the insulation of
cladding. Insulation with the same thickness as that used for the piping shall be
secured to the inside of the boxes. The stuffing shall be secured inside the boxes by
hooks made from metal strips, or similar. Overlapping edges of the cladding shall be
furrowed and sealed with sealant.
For all covers, e.g. of heat exchangers and manholes, liable to comparatively frequent
removal, a box shall be made from metal sheet and lined with insulation to secure
the cover in position around protruding parts of vessels e.g. nozzles, brackets, cleats,
stack saddle, shall be sealed using adhesive to prevent moisture intrusion.
Mechanical methods such as banding or wiring are not permitted.
Vertical surfaces over 400 mm shall be provided with angular support rings: for rigid
insulation the rings shall be spaced at intervals of 2-4m and shall form a break in the
insulation to allow wall expansion.
For flexible insulation the rings shall be spaced at intervals of approximately 2 m.
Where possible, all equipment shall have insulation supports supplied by the
equipment fabricators prior to delivery or during erection at site.
All insulated equipment and piping shall be weatherproofed with non-metallic
material sheet. The sheets shall be in both longitudinal and circumferential direction
with a minimum overlap of 50 mm and sealed using sealant.
Insulation shall be applied in the minimum number of layers. All joints in the
insulation between successive layers and also between adjacent sections of
insulation shall be staggered.
Where insulation is applied in more than one layer the inner layer and final layer
should be glued over the entire surface.
Galvanized steel materials shall not be used for insulation of piping or equipment.
Insulation must be wrapped in plastic covers after application until the cladding can
be applied to keep insulation materials dry.
Before application of any insulation finish, the surface of the insulation shall be made
reasonably smooth and shall present a neat appearance.
When necessary pumps and other equipment shall be insulated using removable
prefabricated covers in accordance with vendor’s instruction and the equipment
insulation schedule.
For all insulation systems for equipment there shall be 15mm diameter drain holes in
all low points, and a minimum of one hole every 3 meters on horizontal runs. The
drainage hole shall be provided in such a manner that water cannot enter into the
internals of the cover and saturate the insulation material. The drainage holes shall
have silicone mastic between the reinforced ring and the silicone rubber sheets on
both sides of the jackets. Each tailor made jackets shall be provided with a hole for
drainage at its low point.
8. INSULATION APPLICATION
8.1 Insulation thickness
Refer to General Specification for Hot Insulation
………………..
Man-ways, valves, flanges and stiffening rings on vessels and heat exchangers shall
not be insulated unless specifically required by the equipment insulation schedule.
It is preferred that removable type insulation boxes to be fabricated and installed
on Manways, valves & flanges on vessels.
Valves and flanges in piping shall be insulated.
Heat exchanger surfaces shall be provided where possible with protective
insulation plates or where this is not possible or practical provided with warning
signs.