8.

Specification for Hot and Cold

Insulation Work
8.1 Scope of Work

 The insulation contract includes supply of all necessary insulating materials, with accessories
including scaffolding / weather protection etc. as specified in this specification at the works
site.
 The Contractor shall supply and install the insulating materials on the respective surfaces as
described in these specifications.
 The Contractor shall supply all necessary skilled and unskilled labour and supervision
required for carrying out the insulation as per these specifications and good engineering
practice.
 The insulation applications details specified herein need not necessarily be conclusive. Any
additional information or deviation from these specifications to proposed practices of
insulation application shall be brought to the notice of the Owner / Consultant and
concurrence shall be obtained. These shall be supported by sketches, details and diagrams
for removable housings, insulation supports, flashing details, expansion joints etc.
 This specification covers design and material requirements for above ground, external
insulation of piping and equipment operating between ambient temperature and 250C for
the purpose of heat conservation, process stabilisation, temperature maintenance, and
personnel protection.
 The insulation work covered under this specification falls under the following categories:
a) Cold service insulation for pipelines (IS 14164, IS 8183, IS 9842).
b) Hot service insulation for pipelines (IS 14164, IS 8183, IS 9842).
c) Insulation for personnel protection.
 Hot insulation shall be carried out using Resin Bonded Rock Wool / Mineral Wool as
insulating material conforming to IS 8183. Insulation thickness shall be as per Table - 1 of
clause 11.
 Generally rigid preformed pipe sections and logs (IS 9842) shall be used. Unbonded fibrous
material shall not be used.
 For protection of stainless steel surfaces, aluminium foil of 0.1 mm thickness as per ASTM B
209 alloy 3003 H16 or IS: 737 designation 31000 condition H3 to be used, before applying
hot insulation materials on S. S. surfaces.
 The scope of work covers insulation for pipes, flanges, storage tanks, equipment, pumps,
columns, heat exchangers, valves etc. as per the requirement of Owner / Consultant /
Engineer In-charge.
8.2 General Requirements

 The schedule of delivery, fabrication and erection of insulating materials shall have the
approval of the Owner /Consultant /Engineer-in-charge.
 The insulation contractor shall procure, furnish and erect all necessary scaffolding and
runways for installation of insulation and dismantle and remove the same immediately after
the work is completed.
 It shall be the responsibility of the contractor to collect and dispose daily, the debris
accumulated while carrying out his work of insulation erection. Good house keeping practice
shall be followed all the time by the contractor. All health and safety measures shall be taken
care by insulation Contractor / subcontractor during work.
 The contractor shall be responsible for damages caused by him, his employees or his
subcontractors to the plant or property of Owner /Consultant /Engineer-in-charge, or other
third parties working at the site.
 Samples of insulating materials and accessories shall be submitted to the Owner /Consultant
/Engineer-in-charge for inspection and approval prior to delivery at site. Subsequent
deliveries shall strictly conform to approved samples.
 The insulation work shall be taken on hand on piping, tanks and equipment only after
execution of hydro test.
 “No Bulging” of insulation shall be accepted. Contractor shall re-do the same on his own cost.

 Piping insulation shall be in preformed pipe section in two halves or sizes upto 300 NB. In
bigger sizes multiple segments are preferable if manufactured. Otherwise mattress is
acceptable.
 Equipment name plates shall remain visible after insulation has been applied. This is to be
ensured by bevelling back the insulating material and carefully sealing the exposed edges to
prevent ingress of moisture.

 The insulation contractor shall only insulate those sections of the plant that have been
specifically released for such work.

 The lower layer of aluminium sheet shall be covered with bitumen before application.
 All piping where the operating temperature is below the average atmospheric temperature a
drying of moisture condensation shall be carried out before application of insulation.
 All valves, pumps, flanges, special pieces fittings are to be insulated as per instruction of
Owner/Consultant/Engineer-In-charge.
 Periodical checks for density, thickness, shape and size as per requirements shall be carried
out at site as per instructions of Owner/Consultant/Engineer-In-charge.
 Special attention is required for insulating material to ensure that its installed thickness shall
not be reduced due to compaction.
 All materials shall be of high quality and good appearance. Insulation materials shall be of
low chloride contents, echo-friendly, low flame transfer, chemically inert, no skin allergic, non-
injurious to health and non-corrosive to steel and aluminium.
 Thermowell boxes, pressure tapping etc. shall not be insulated but left accessible.
  Double layer insulation shall be required where the insulation thickness is greater than 75
mm. Insulation installed in two or more layers shall be staggered joint construction and
each layer shall be secured in place and details of fixing shall be same.
 Wet and damaged insulation shall not be used under any circumstances.
 Insulation supports shall not project out of insulation and shall be given sufficient coverage
of insulation material to avoid hot spot on the metallic cover at support position.
 Insulation material to be applied shall not be kept over bare ground to avoid water
absorption. Installed material awaiting its protective cover shall be adequately protected with
cladding at a minimum loss of time.
 While applying insulation, a minimum clearance of 25 mm between outside surface of any
insulation finish and adjacent equipment, pipe or structural members shall be maintained.
 Cold Insulation - All pipe supports shall be isolated from cold pipes by wooden box. / rigid
insulation.

8.3 Equipment’s & Services to be Provided Thermal Insulation Contractor

- To supply & delivery to site and apply thermal insulation for ducting equipment and piping as
per safety rules and regulations applicable and satisfactorily hand over whole system as per
attached Schedule and as specified in IS 14164, IS 9842, IS 8183.

- Arrange for all necessary inspection by owner / consultant /Engineer-in-charge at various

stages as needed.

8.4 Cold Service Insulation for Pipelines

 General

Insulation work shall be carried out for chilled water pumps, ducts and chilled water piping as per
latest BS/American or equivalent IS standards for thermal insulation materials and finishing
materials and also codes of practice for industrial applications.

 Material of Cold Insulation

Material for cold insulation shall be Polyurethane foam (Insitu Foam). The insulation shall be
cladded by 24 G aluminium or colour coated GI sheets.
All chilled water and Condensate drain piping shall be insulated in the manner specified here.
Before applying insulation; all pipe work and fittings shall be brushed and cleaned, and dust, dirt,
mortar and oil removed.
All MS pipes shall be provided with a coat of zinc chromate primer, followed by two coats of cold
setting adhesive compound. Thermal insulation shall then be applied as follows:
Premoulded pipe insulation sections shall be placed over the pipes, the longitudinal joints of these
pipe sections shall be sealed with the adhesive compound. The traverse joints shall also be sealed
with adhesive compound. The insulation shall be continuous over the entire run of piping, fittings
and valves.
 For all piping insulation shall be finished by 24 G Aluminium or GI colour coated sheet cladding.
Insulation shall be applied only after the piping system has been satisfactorily tested for leaks at
2.5 times the working pressure or at minimum 10 kg/cm2 G test pressure.
All insulation work shall be carried out by skilled workmen specially trained in this kind of work. All
insulated clad pipes shall be labelled and provided with 300 mm wide band of paint along the
circumference at ever 1200 mm distance for colour coding. Direction of fluid shall also be marked.
All painting shall be as per relevant BIS codes. All pipe supports shall be isolated from cold pipe
by wooden blocks / rigid thermal insulation.
Cladding of vapour barrier on the insulation.

Application Aluminium / Colour coated GI

Sheet Gauge
a) Pipes, vessels and equipment up to 500 mm 24 SWG
nominal dia.

b) Pipes, vessels and equipment above 500 mm 22 SWG

nominal dia.

c) For valves, flanges and other areas where 20 SWG

mechanical damage is likely to occur.

8.5 Hot Service Insulation for Pipelines

 The material shall be resin bonded Rockwool / mineral wool conforming to IS 8183 at a
maximum bulk density of 100 Kg/cubic metre for slab/mattress for tanks, vessels and
equipment and 140 to 150 Kg/cubic metre for pipe sections. The material shall be preformed
section. Slag wool is not acceptable. Preference shall be given to rock wool. The binder shall
be suitable for the intended temperature range from ambient to 250 deg. C. The insulation
material should be in the form of factory made/machine laid stitched mattress and preformed
sections.

 Unless otherwise specified herein, insulation material shall strictly conform to all the
requirements of quality standards listed below :

- Pre-formed pipe insulation IS: 9842

 - Metal-mesh covered bonded Rock Fibre
Mattresses and mattresses type pipe insulation
IS: 8183 for piping and equipment.
Faced on the side with 20 mm mesh
made of galvanised 24 SWG wire
mesh stitched through with 24 SWG
galvanised lacing wire.

- Mineral-fibre block and board thermal IS: 8183

insulation

Insulation shall conform to the following requirements and shall be tested and test certificates on
samples shall be furnished to Owner / Consultant / Engineer in-charge as per IS: 8183 / IS: 9842

- Density 140 to 150 Kg/cubic metre (Density

shall be within this range and density
test shall be as per IS:5688 /IS:3144.
- Shot Content (IS:3144) Shot Content Shot shall not be
more than 5 mm in any dimensions.
When sieved as follows, the shot shall
not exceed as indicated below :
IS Sieve (IS:460) Shot (Content
percent by mass
(Max.)

500 micron 5
250 micron 15
- Moisture content and moisture absorption (IS : Not more than 2%.
3144)
- Incombustibility (IS:3144) Incombustible, loss weight not more
than 5%.
- Thermal Conductivity Mean Temp. Thermal Conductivity
(IS : 3346) deg.C. mW/cm deg.c
50 0.43
100 0.52
150 0.62
200 0.68
250 0.80

- Sulfur Content (IS: 3144)
- Linear Shrinkage (IS:3144)
- Heat Resistance (IS:3144)
- Compressive
- Recovery after compression
(IS: 9842 Append. ‘A’).
- Alkalinity (IS: 8183)
- Chloride content (IS: 3144)
- Dimension
300 0.90
Not more than 0.6%
Not more than 2% when subjected to
soaking conditions of soaking heat at
the stated max. temperature of use (550
deg.C) for 24 hours.
When heated to max.temp. Resistance
(550 deg. C) sample shall (IS: 3144)
maintain its general form and shall not
suffer visible
deformation of the fibrous structure.
120 KG/sq.m. Strength (average) min.
at 10% deformation.
After compression to 75% of the original
thickness, recovery shall not be less
than 90% of original thickness.
pH of the solution of the material shall
be between 7.0 & 10.0.
Not to exceed 10 ppm
(0.01% of Chloride)
Pipe Section
Hollow cylinder, split length-wise on one
or both sides of the cylindrical axis
Thickness 24
40
50
60
75 mm
Tolerance in +/- 3 mm
length
Tolerance in +/- 3 mm
thickness
When installed on the pipe of the
specified size, sections shall fit snugly
and shall have tight longitudinal and
circumferential joint.
Blanket
Unless otherwise specifically required,
standard width shall be 600 to 1200
mm, standard
length 1500 to 2400 mm.
Tolerance on thickness
Positive : 3 mm, negative -3mm
Block & Boards (IS:8183)
 Lengths : 1000 to 1400mm
Widths : 500 to 1000mm
- Tolerance Width & Length : + / - 3 mm
Thickness : + / - 3 mm

 Plaster Specification:

20 mm hard setting cement plaster shall be applied over lagging in two layers. The composition should
be 4:1 (4 parts cement and one asbestos fluff) followed by flood cost of insulcoat.

 Weather Protection Jacket:

Aluminium Jacketing shall be used as weather protection over insulation unless otherwise specified
and shall be ASTM B209 alloy 3009 H16 or IS:737 designation 31000 condition H3 for flat sheets
and H4 for corrugated sheets. Cladding shall be coated on the side in contract with the insulation with
a bitumen anticorrosive paint.

 Finish Material (Cladding) (As applicable):

- For shells of vertical storage : 0.71 mm (22 SWG)

- Tanks & Vessels : Corrugated

- For tanks' roofs : 0.71 mm (22 SWG) Flat

- For Horizontal vessels shell : 0.71 mm (22 SWG) Flat

and heads; vertical vessel heads

- For removable covers : 0.71 mm (22 SWG) Flat

- For piping up to 24 inch : 0.56 mm (24 SWG) Flat

- For piping above 24 inch : 0.71 mm (22 SWG) Flat

 Ancillary Materials:

Aluminium Foil to protect stainless steel surfaces shall be 0.1 mm thick per ASTM B209 Alloy 3003
H16 or IS: 737 designation 31000 condition H3. Securement Bands/Wires If materials is Aluminium,
then specification shall be ASTM B209 Alloy 3003 H16 or IS: 737 designation 31000 condition H3.
For Securing Aluminium foil on Stainless Steel surfaces Band, 24 SWG thk. x 20 mm wide of
Aluminium. For securing fibrous insulation

- On Piping Band, 24 SWG thick x 12 (min.) wide, Aluminium

- On equipment Band, 22 SWG thick x 12 (min.) wide, Aluminium.

- On Vertical Storage Tanks Band, galvanised steel, 25 mm wide x 2 mm thick galvanising

per IS:277 Class-2. for securing cladding on insulation on fibrous materials.

- For Piping Band, Aluminium 12 mm (min.) wide x 24 SWG thick

 - On Equipment Band, Aluminium 20 mm wide x 22 SWG thick.

- On vertical storage tanks Band, Aluminium 25 mm wide x 24 SWG thick. Screws

required for metal jacket securement shall be cadmium plated steel self tapping type A
No.8 dia x 12 mm long to BS 4176 complete with neoprene washers under the head.

To ensure perfect water proofing, all the cladding joints shall be packed with sealing materials
which may either be in the form of an elastomeric sealing compound or fibre based bituminous felt
strips.
8.6 Other Requirements for Insulation Work

All insulation work shall be carried out by a reputable specialist contractor who shall always be
responsible to the Owner/Consultant/Engineer-In-Charge.
All materials delivered to site shall be new and dry and be maintained in good condition throughout
the progress of the work.
The Engineer-In-Charge shall not accept poor quality, badly finished work, or irregularities in the
thickness of insulation or in the protective finish. To ensure that the correct thickness has been
applied, one piece from each run of insulation shall be cut out at the discretion of the Engineer-In-
Charge. If the inspection reveals any defects, the contractor shall cut out a further two pieces for
inspection. If these also prove defective, then the insulation shall be removed and new insulation
and finishes as specified be applied at the contractor’s expense.
All pipework shall be insulated separately and adjacent parallel runs of pipework shall not be
married together in one insulation covering.
All insulating materials and associated products shall be applied strictly in accordance with the
manufacture’s recommendations and instructions and work failing to comply with these shall not
be accepted by the Engineer-In-Charge.
All joints, surface, edges and overlaps shall be neatly finished and where possible overlaps shall
be arranged to be on the blind side on the water shedding side as appropriate.
Where allowance has to be made for pipe/duct expansion or contraction the insulation shall be
finished in a neat and approved manner permitting easy access and disconnection of removable
items with disturbing the insulation.
On surfaces operating below ambient temperature a complete moisture vapor seal shall be
provided over the insulation by a continuous un-punctured vapour barrier jacket or coating.
No insulation shall be applied to any part of the work until that particular part has undergone
successful inspection and pressure testing.
The pipework shall be dry and clean and all pipework including copper pipework shall be painted
one coat of primer. Stainless steel pipework shall be wrapped in 0.6 mm thick aluminium foil prior
to being insulated.
The insulation on all items of plant shall be applied in a manner to enable removal of any
maintainable term, i.e. coil bundle from non storage calorifiers.

8.7 Performance Guarantee and Acceptance Test

(i) PERFORMANCE GUARANTEE

 The contractor shall guarantee that upon completion of the work all portions shall be in full
accordance with the requirements of the contract and shall be perfect as to materials and
workmanship and remain so far a minimum period of one year from the date of final acceptance by
the Owner. The Contractor shall also guarantee that the equipment shall operate satisfactorily and
the performance and efficiencies of the equipment when operating under normal conditions shall
not be less than the guaranteed values. The Contractor further guarantee that during defect liability
period, he shall repair / replace all defective work / material within reasonable period from the
detection thereof.

(ii) ACCEPTANCE TESTS

After the entire installation work has been completed, the Contractor shall make all required
adjustments until all guaranteed performance requirements are met. After the entire system is
adjusted, the Contractor shall conduct acceptance tests of the installation in the presence of Owner
/ Consultant / Engineer-in-charge, during which the installation shall meet the guaranteed
performance requirements. All instruments and services required for the tests shall be provided by
the Contractor. The test reports shall be submitted to Owner / Consultant / Engineer-in-charge for
approval before handing over the plant.
The test shall be carried out as per the detailed testing schedule/procedure approved by the
Owner/Consultant/Engineer-in-charge. All tools, tackles, equipment and instruments required for
erection, commissioning and carrying out acceptance tests shall be arranged by the Contractor.
He shall also be responsible for clearing out all debris during execution and after completion of
work.

8.8 Special Instructions for Contractors

The Contractor shall submit drawings giving method of application of insulation and get the same
approved before starting of work.
The Contractor shall make himself completely familiar with all requirements of this specification.
He shall ensure that his quotation is complete and is prepared in the form specified. Incomplete
quotations are liable for deviations and shall render the Bid liable for rejection.
The contractor shall be fully responsible for rules of safety to be followed during or after installation
of insulation.
Deviations if any from any of the clause or requirements of this specification shall be clearly
indicated with detailed calculations/descriptions and justifications as per Format clause 12.10.
Since the ducts & piping are to be installed in critical areas, a proper sequencing and co-ordination
with other agencies shall be required for installation & insulation.
The Contractor shall have to prepare detailed Work program/Bar charts clearly showing delivery of
equipment/materials & completion of various activities and has to get it verified/approved by the
Owner / Consultant / Engineer-in-charge. The Contractor is expected to adhere strictly to the
approved Bar charts.
The Contractor shall obtain approval from the Owner / Consultant / Engineer-in-charge in respect
of all materials/equipment and the same shall conform to the tender specifications / documents.
The contractor shall submit “Sample” insulation piece like bend, tamper or any critical item for
Owner / Consultant / Engineer-in-Charge approval before proceeding work.
 The quantities mentioned in the tender are indicative and subject to change upto  10%. Any item
may be deleted or introduced as needed by the Owner / Consultant / Engineer-in-charge to meet
with the site requirements.

8.9 Measurement of Insulation

Unless otherwise specified measurement for duct and pipe insulation for the project shall be on
the basis of centre line measurements described herewith:

a. Pipe insulation: Shall be measured in units of length along the centre line of the installed
pipe. The linear measurements shall be taken before the application of the insulation. It
may be noted that for piping measurement, all valves, orifice plates and strainers are not
separately measurable. It is to be clearly understood that for the insulation measurements,
all these accessories including cladding, valves, orifice plates and strainers shall be
considered strictly by linear measurements along the centre line of pipes and no special
rate shall be applicable for insulation of any accessories, fixtures or fittings, flanges
whatsoever.

b. Duct Insulation: Shall be measured on the basis of surface area along the centre line of
insulation thickness.

Thus the surface area of externally thermally insulated or acoustically lined duct shall be
based on the perimeter comprising centre line (of thickness of insulation) width and depth
of the cross section of insulated or lined duct, multiplied by the centre-line length including
tapered pieces, bends, tees, branches, etc. as measured for bare ducting. No special
measurement / extra allowance is to be made for tapers, transformations, flanges, dampers
etc.

8.10 List of Approved Makes

No deviation from this list is allowed without specific approval from the Owner / Consultant /
Engineer-in-charge.

Thermal Insulation
a) Mineral Wool : Rock Lloyd

b) Fibre glass : Kimmco / Owens Corning, UP Twiga

c) Elastomeric nitrile : Armaflex, Vidoflex, Trocellan,

rubber foam / equivalent Phenotherm / Aeroflex.

d) Polyurethene Foam : Lloyds Insulation / Poly Products /

equivalent

e) Phenolic Foam : Bakelyte Hylam.

8.11 Thickness of Hot Insulation

TABLE - 1

RECOMMENDED THICKNESS OF INSULATION

FOR HOT SERVICES USING GLASS / MINERAL WOOL

TEMP. DEG.C 61-100 101-150 151-200 201-250 250-300 300-400

DEG.F. 142-212 213-302 303-392 393-482
NOMINAL PIPE SIZE INSULATION THICKNESS IN MM
NB
15 mm (1/2”) 25 25 40 40 40 75
20 mm (3/4”) 25 25 40 40 40 90
25 mm (1”) 25 40 40 40 50 90
32 mm (1.25”) 25 40 40 50 50 100
40 mm (1.5”) 25 40 40 50 50 100
50 mm (2”) 25 40 40 50 50 100
65 mm (2.5”) 25 40 50 50 65 115
80 mm (3”) 25 40 50 50 65 115
90 mm (3.5”) 40 40 50 65 65 115
100 mm (4”) 40 50 50 65 65 115
125 mm (5”) 40 50 50 65 65 115
150 mm (6”) 40 50 50 65 75 125
200 mm (8”) 40 50 65 65 75 150
250 mm (10”) 40 50 65 75 75 150
300 mm (12”) 40 50 65 75 75 150
Flat surfaces 50 65 75 100 115 150

1. These thicknesses are indicative only. The vendor shall actually calculate and submit his
recommended thicknesses along with his calculations.

2. Variations in thickness: From (-) 5% to (+) 20%.

TABLE – 2

RECOMMENDED THICKNESS OF COLD INSULATION

Cold Insulation for Water at plus 5oC

Piping insulation: Polyurethane foam (Insitu Foam) / Phenotherm finished by 24 G aluminium /

colour coated G. I. cladding.

Pipe size (NB) Thickness (mm)

15 mm 30
20 mm 30
 25 mm 50
40 mm 50
50 mm 50
80 mm 50
100 mm 50
150 mm 50
200 mm 50
250 mm 50

NOTE: Hard support blocks at 2.5 - 3.0 mtrs. Distance required.

8.12 Technical Data Sheets (Cold Insulation)

Subcontractor shall submit all technical literature etc. and furnish following technical data filled,
after award of contract

THERMAL INSULATION
1. Manufacturer : *
2. Type : *
3. Service : *
4. Thermal Transmittance : Max. 0.04 W/moK
5. Thermal Conductivity ‘K’ Valve
(at 10oC mean temp.)
6. Density : *
7. Operational Range : *
8. Thickness : *
9. Compressive Strength : *
10. Finishing material : *
11. Adhesive tape : *
12. Water Vapour permeability : *
13. Fire Performance : Class 1 as per BS 476

* VENDOR TO INDICATE

8.13 Technical Data Sheets (Hot Insulation)

Subcontractor shall submit all technical literature etc. and furnish following technical data filled,
after award of contract.

THERMAL INSULATION
1. Manufacturer : *
2. Type : *
3. Service : *
4. Thermal Transmittance : As per IS: 3346-1980
5. Thermal Conductivity ‘K’ Valve : *
(at 10oC mean temp.)
6. Density : *
 7. Operational Range : *
8. Thickness : *
9. Compressive Strength : *
10. Finishing material : *
11. Adhesive tape : *
12. Water Vapour permeability : *
13. Fire Performance : Class 1 as per BS 476

 VENDOR TO INDICATE