Tuesday, October 5, 2010

Insulation Procedure

1.0 Scope
1.1 This procedure covers the installation of insulation on piping, vessels, and equipment operating in hot service or cold service. Underground piping is not covered by this procedure.

2.0 Codes and Standards
2.1 Contract documents
2.2 General specification provided by Owner.
PDOC-SP-MEC-014 - Specification for Insulation
ASME C533 Calcium Silicate Block and Pipe Thermal Insulation
ASME C547 Mineral Fibre Performed Pipe Insulation
ASME C612 Mineral Fibre Block and Board Thermal Insulation
Occupational Health and Safety Act

3.0 Material Control
3.1 All the material shall be verified as per material certification. Tag and nameplate being as per data sheet.
3.2 Items quantity and size of the material shall be as per P.O. and drawings.
3.3 All materials supplied shall be new and undamaged.
3.4 All insulation material shall be properly stored and protected from moisture in accordance with CONTRACTORS procedure PDOC-587B-PR-GEN-001 (Material, Handling Delivery And Storage Procedure) for material's loading, unloading, storage and distribution.
3.5 Use of materials other than those specified requires OWNER'S approval.
3.6 Insulation materials containing asbestos or polyurethane shall not be used.

4.0 Insulation Preparation
4.1 Check the materials as 3.1~3.5 to ensure that the type of the material and thickness are in accordance with relevant specification and drawings.
4.2 Insulation supervisor shall receive a copy of the pipe test acceptance to confirm that all the testing such as hydrostatic, X-ray , etc. have been completed and released on all piping and equipment involved
4.3 All surfaces to be insulated shall be cleaned and primed, and remained dry before insulation to be applied.
4.4 Inspect weather condition. Insulation shall not be installed during weather which might cause the pipe or insulation to become wet when the surfaces are less than 5ÂșC above dew point. Insulation to be installed over an extended period must be protected to ensure it remains dry until it has been properly sealed.
4.5 Heating tracing shall be installed, tested and tagged in accordance with relevant specification and drawings before insulation.
4.6 Insulation support installation shall be finished as required before insulation
4.7 Make sure that Insulation will not cover the face of gauge glasses, equipment name or data plates or tags, nor be applied so as to interfere with dynamic parts of instruments or equipment.

5.0 Piping Insulation
5.1 Insulation Construction shall be performed after all the insulation preparation have been finished and released.
5.2 Factory fabricated sectional pipe insulation shall be applied in staggered joint construction and secured with wire loops or bands on 225 mm centers. On multiple layer construction, all joints shall be lapped one-half of each section between layers. Each layer shall be secured separately. All joints shall be securely butted and all cracks, joints, etc. shall be filled with insulating sealant as appropriate.
5.3 Mastic sealer shall be used around pipe supports where the insulation is punctured by the support.
5.4 Heat traced lines shall be insulated to completely cover both line and tracing.
5.5 Where insulation is required on the outside of piping, vessels or equipment that extends through an exterior building wall or roof, the insulation shall not stop at the exterior of the building but shall be extended for 300 mm inside the building.
5.6 Any cracks or openings that occur in the insulation or weather-proofing are to be filled in with additional insulation or weather-proofing to provide a smooth sealed surface
5.7 At all flanges, unions, and pipe terminations, the pipe insulation shall be bevelled at a 45°angle to facilitate remove of flange bolts and union collars without damage to the main pipe insulation and metal jacketing. A screwed and sealed metal cover shall be installed.
5.8 All openings in metal jacketing for nipples, pipe supports, etc. are to be neatly cut to provide a tight fit and shall be thoroughly sealed and weather-proofed to prevent moisture from penetrating under the jacket. Openings shall be fitted with a metal collar or suitable flashing embedded in sealant and screwed firmly on place.
5.9 Insulation shall be covered with metal jacketing lapped a minimum of 50 mm on all seams and secured with screws and bands, locating one band at each lap joint and spaced a maximum of 450 mm on centre. Vertical jacketing shall be supported with “S” clips.
5.10 All insulation shall be clad with metal jacketing. Jacketing shall be installed so as to shed water and protect against wind and blowing rain.

6.0 Insulation on Fittings, Flanges and Valves
6.1 Fittings shall be insulated with standard factory formed insulation and secured with wire loops or bands, minimum two per section. All joints shall be filled with insulating sealant as appropriate. Insulation shall be covered with pre-formed metal jacketing.
6.2 Insulation and jacketing on valves, flanges and unions shall be installed so as to be removable without damage to the main pipe insulation.
6.3 Unless the piping is heat/electrical traced, valves, flanges and unions shall not normally be insulated unless specified by OWNER. All other fittings are to be insulated.

7.0 Insulation On Vessels and Equipment
Make sure that all the insulation preparation have been finished and released.
7.1 Vessels Insulation
7.1.1 Vessels shells shall be insulated with factory fabricated insulation curved or grooved to fit the vessel shell contour. If additional layers are required, insulation shall be installed with staggered joints.
7.1.2 Each layer shall be secured with bands; machine stretched, and fastened on 300 mm centres.
7.1.3 Insulation shall be clad with metal jacketing lapped a minimum 75 mm on all seams. Jacketing shall be installed so as to shed water and protect against wind and blowing rain.
7.1.4 All openings in metal jacketing for man-ways nozzles, nipples, pipe supports, etc. are to be neatly cut to provide a tight fit and shall be thoroughly sealed and weather-proofed to prevent moisture from penetrating under the jacket. Openings shall be fitted with a metal collar or suitable flashing embedded in sealant and firmly screwed place.
7.1.5 Jacketing shall be secured with metal screws on 150 mm centres on longitudinal seams and with bands, located at lap and spaced on a maximum of 450 mm on centre.
7.1.6 Vessel heads shall be insulated in the same manner as the shell. Insulation shall be covered with metal jacketing in a pie shaped or segmented arrangement.
7.1.7 Corrugated jacketing on vertical vessels shall be installed using the “S” clip method and lapped a minimum of two (2) corrugations on vertical seams.
7.1.8 A band shall be placed adjacent to heads of horizontal vessels and at the top sheet on vertical vessels to secure flashing between head and shell jackets.
7.1.9 Where insulation is required on the outside of piping, vessels or equipment that extends through an exterior building wall or roof, the insulation shall not stop at the exterior of the building but shall be extended for 300 mm inside the building.
7.1.10 Insulation and jacketing on exchanger flanges and heads shall be installed so as to be removable without damage to the main shell insulation.
7.2 Equipment
7.2.1 For equipment of irregular shape, insulation shall be of the same type and thickness as specified for vessels. Insulation and metal jacketing shall be installed so as to be removable.
7.2.2 Insulation cement, where required shall be applied in layers 20 to 25 mm thick. Every layer shall be reinforced with steel mesh. The outer surface of the insulation cement shall be finished with a smooth layer of finish cement.

8.0 The Detailed Insulation System
The detailed insulation system for hot service, cold service and personal protection and detailed material status shall conform to the MR & Manual that shall be reviewed and approved by OWNER.

9.0 Quality Record And Inspection Report
9.1 All quality records and report shall be accepted by CONTRACTOR. QC engineer and the OWNER’s representative.
9.2 All quality inspection records shall be coincident with the insulation construction. The recorded information shall be real and reliable.

10.0 Revision Note
This procedure shall be revised if it is found to be inadequate for purposed work upon completion of engineering/new construction practice / new site information or as requested by OWNER.

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