02 - Ab-Pf1a-C000-B13-Spec-0007 - 02C2.1

PRODUCTION FACILITY (PHASE 1)
SPECIFICATION FOR INSULATION
AA0-0000-TAA-00-CS-SPC-0001
Document Owner: TAQA
Document Approver: Project Manager
Revision No: 000 Issue Date: Date 28-06-2013
Amendment Summary: Issued for Design

TAQA Atrush PRODUCTION FACILITY PHASE 1
TITLE DOCUMENT NO REV DATE PAGE
Specification for Insulation AA0-0000-TAA-00-CS-SPC-0001 000 28-06-13 Page 2 of 38

Revision Description Sheet
Rev Para. Revision Description

00A Issue for Review
00B Re-issued for Review
000 Issued for Design
Hold No Para. Description of Hold


Table of Contents
1. INTRODUCTION ....................................................................................................... 4
1.1 GENERAL .................................................................................................................. 4
1.2 PROJECT BACKGROUND ........................................................................................ 4
1.3 DEFINITIONS ............................................................................................................ 4
1.4 LIST OF ABBREVIATIONS ........................................................................................ 5
1.5 RESOLUTION OF CONFLICT ................................................................................... 5
1.6 UNITS OF MEASUREMENT ...................................................................................... 5
1.7 HEALTH, SAFETY AND ENVIRONMENT REQUIREMENT ....................................... 5
2. CODES AND STANDARDS ....................................................................................... 5
3. SCOPE OF SUPPLY / DESIGN.................................................................................. 8
3.1 SCOPE ...................................................................................................................... 8
3.2 DESIGN ..................................................................................................................... 8
3.3 EXTENT OF INSULATION ......................................................................................... 9
3.4 INSULATION THICKNESS CRITERIA ..................................................................... 11
3.5 VAPOUR BARRIER ................................................................................................. 18
3.6 METAL JACKETING ................................................................................................ 18
3.7 VAPOUR STOPS ..................................................................................................... 19
3.8 MATERIALS............................................................................................................. 19
3.9 INSTALLATION ....................................................................................................... 22
3.10 SHIPPING AND STORAGE ..................................................................................... 31
4. QUALITY ASSURANCE AND QUALITY CONTROL ................................................ 32
4.1 QUALITY ASSURANCE........................................................................................... 32
4.2 QUALITY CONTROL ............................................................................................... 32
4.3 INSPECTION ........................................................................................................... 32
5. DOCUMENT REQUIREMENTS ............................................................................... 32
5.1 GENERAL ................................................................................................................ 32
5.2 SCHEDULES AND REPORTS ................................................................................. 32
5.3 DATA AND CALCULATIONS ................................................................................... 32
5.4 DRAWINGS ............................................................................................................. 33
5.5 MATERIALS FABRICATION AND INSTALLATION .................................................. 33
APPENDIX 1 TYPICAL DETAILS OF INSULATION .............................................................. 34
1. INTRODUCTION
1.1 GENERAL
This specification covers the minimum requirements for the supply, design, materials and
installation of external thermal insulation for hot and cold services, applicable to piping,
equipment, vessels and storage tanks.
1.2 PROJECT BACKGROUND
TAQA Atrush (TAQA) has a production sharing agreement (PSA) with Kurdistan Regional
Government (KRG) and is the operator for block K4 (Atrush field) in Kurdistan, Iraq. TAQA
is planning to build a Production Facility (‘PF’) (Phase 1) in the Atrush concession block,
Kurdistan.
The proposed PF facilities shall include following units / systems (Non exhaustive List):
a) Flow lines from wells
b) Separation and oil stabilization
c) Gas Compression and Treatment
d) Sulfur Recovery Unit (optional)
e) Produced Water Treatment
f) Oil Storage Terminal
g) Pipeline connecting PF and Oil Storage Terminal
h) Export pumps and Truck Loading Bays
i) Power generation to minimize gas flaring
1.3 DEFINITIONS
Following Definitions shall apply for this document.
Shall - The word 'shall' is to be understood as mandatory.
Should - The word 'should' is to be understood as strongly recommended.
May - The word 'may' is to be understood as indicating a possible course of action.
Include, Includes, Including - If the word “include” or “includes” or “including” is used in
any document, it shall be taken as having the meaning “including but not limited to” and
shall not be considered as creating or inferring any limitation on the description that follows
if other components / equipment are required.
Company / Principal / Owner – TAQA
Consultant - A contracted party by TAQA who shall be responsible for providing Project
Management and other related consultancy services under the contract.
EPC Contractor - A contracted party by TAQA who shall be responsible for providing
design engineering, procurement and construction service under the contract.
Purchaser - A party, who places the order on, or requests tender from the Vendor /
Supplier. This can be the TAQA / EPC Contractor.

Vendor / Supplier - A party responsible for the supply of equipment, materials or product-
related services in accordance with this Specification and its referenced standards and
data sheets.
Sub Contractor – An authorized organization / personnel from EPC contractor / Vendor /
Supplier to carry out activity related to work.
Inspector - Any person / party certified as acting for and on behalf of TAQA or EPC
Contractor to inspect items to be purchased and / or the work done by the Vendor.
1.4 LIST OF ABBREVIATIONS
ASTM : American Society for Testing and Materials
BS : British Standards
ppm : Parts per million
1.5 RESOLUTION OF CONFLICT
In the event of any conflict between this specification and the Data Sheets or with any
applicable Codes and Standards, EPC Contractor / Vendor / Supplier shall inform the
TAQA and obtain written clarification or authorization from the TAQA before proceeding
with the work. Normally the most stringent specification shall prevail in case of conflict. In
general, the order of precedence for the document shall be:
 Purchase Order / Contract
 Data Sheet
 Project Specifications
 International Codes / Standard
 Vendor / Supplier Documentation
1.6 UNITS OF MEASUREMENT
In general SI units shall be used for the entire project except for piping dimensions where
ANSI standards shall be used.
1.7 HEALTH, SAFETY AND ENVIRONMENT REQUIREMENT
The Health safety and environment requirement remains the highest priority for all TAQA
projects. The local requirements shall prevail however, the most stringent will apply. The
supplier shall ensure that the item supplied is designed to operate safely at the prescribed
operating conditions at all stages of operation and shutdown.
2. CODES AND STANDARDS
The latest editions of the following codes and standards shall be deemed to be part of the
specification.
All recommendations shall apply unless specifically modified herein.
American Society for Testing and Materials (ASTM)
ASTM A 167 Stainless and Heat Resisting Chromium Nickel
Steel Plate, Sheet, and Strip
ASTM A 463 Specification for Steel Sheet, Cold Rolled
Aluminium Coated Type I and Type II

ASTM A653 Standard Specification for Steel Sheet, Zinc-
Coated (Galvanized) or Zinc-Iron Alloy-Coated
(Galvannealed) by the Hot-Dip Process
ASTM B209 Aluminium-Alloy Sheet and Plate
ASTM C165 Standard Test Method for Measuring

Compressive Properties of Thermal Insulations
ASTM C177 Test Method for Steady State Heat Flux

Measurements and Thermal Transmission
Properties by means of the Guarded Hot Plate
Apparatus
ASTM C 303 Standard Test Method for Dimensions and
Density of Preformed Block and Board-Type
Thermal Insulation
ASTM C355 Water Vapour Transmission of Thick Materials.
ASTM C411 Hot-Surface Performance of High Temperature

Thermal Insulation
ASTM C547 Mineral Fibre Preformed Pipe Insulation

ASTM C 549 Perlite Loose Fill Insulation
ASTM C 552 Cellular Glass Block and Pipe Thermal
Insulation.
ASTM C 591 Cellular Urethane Thermal Insulation
ASTM C 592 Mineral Fibre Blanket Insulation and Blanket -

Type Pipe Insulation (Metal-Mesh Covered)
ASTM C612 Standard Specification for Mineral Fibre Block
and Board Thermal Insulation
ASTM C640 Corkboard and Cork Pipe Insulation for Low
Temperature Thermal Insulation
ASTM D 1621 Compressive Properties of Rigid Cellular
Plastics
ASTM D 1622 Apparent Density of Rigid Cellular Plastics
ASTM D 2842 Water Absorption of Rigid Cellular Plastics
ASTM D 2856 Test Method for the Open Cell Content of
Cellular Plastics
ASTM E 84 Surface Burning Characteristics of Building

Materials
ASTM E 96 Water Vapour Transmission of Materials in

Sheet Form

ASTM C450 Prefabrication and Field Fabrication of Thermal
Insulation Fitting Covers for NPS Piping,
Vessels Lagging and Dished Heads
Segments.
ASTM C585 Practice for Inner and Outer Diameters of Ring
Thermal Insulation for Nominal Pipe and
Tubing
ASTM C647 Guide for Properties/Test of Mastic/Coatings
Finishes of Thermal Insulation
ASTM C1071 Standard Specification for Fibrous Glass Duct
Lining Insulation (Thermal and Sound
Absorbing Material)
British Standards (BS)
BS 3958 Thermal Insulating Materials
BS 5608 Preformed Rigid Polyurethane (PUR) and

Polyisocyanurate (PIR) Foams for Thermal
Insulation of Pipe work and Equipment.
BS 5970 Code of Practice for Thermal Insulation of Pipe

work and Equipment (in the Temperature
Range - 100°C to +870°C)
BS 2972 Inorganic Thermal Insulation Material
BS 5970 Thermal Insulation for Pipework and
Equipment
BS 5422 Method for Specifying Thermal Insulating
Materials for Pipes, Tanks, Vessels, Duct Work
and Equipment Operating within the
Temperature range -40 °C to +700 °C.
International Standards Organization (ISO)
ISO 9001-2008 Quality Management System – Requirements
Commission Industrial Insulation (CINI)

CINI Manual Insulation for Industries
Process Industry Practices (PIP)

PIP INEG 1000 Insulation Design and Type Codes
PIP INSR 1000 Insulation of Flexible, Removable / Reusable
Insulation Covers for Hot Insulation
PIP INTG 1000 Insulation Inspection Check List
TAQA’S Specification
AA0-0000-TAA-00-MC-SPC-0001 Specification for Surface Preparation and
Painting

AA0-0000-TAA-00-AA-BOD-0001 Project Design Basis
3. SCOPE OF SUPPLY / DESIGN
3.1 SCOPE
3.1.1 This specification covers the minimum requirements for the supply, design, materials
and installation of external thermal insulation for hot and cold services, applicable to
piping, equipment, vessels and storage tanks.
3.1.2 Hot insulation shall be required for the following purpose:
a. Heat Conservation
b. Steam Tracing
c. Steam Jacketing
d. Electric Tracing
e. Personnel Protection
f. To maintain process temperature, to protect from boiling or freezing
g. To prevent external condensation and subsequent moisture ingress
3.1.3 Cold insulation shall be required for the following purpose:

a. Limiting heat transfer into low temperature piping and equipment.
b. The prevention of condensation or icing on piping or equipment operating at
temperatures below the atmospheric dew point and below 5°C, but not
requiring low temperature conservation.
3.1.4 This specification also gives the requirements for metal jacketing used to protect hot
and cold thermal insulation. The insulation requirements of this specification are
suitable for indoor and outdoor service for normal process plant atmospheres.
Alternative materials may be considered for highly corrosive atmospheres.
3.1.5 This specification covers the requirements of vapour barrier for use over cold service
insulation.
3.1.6 This specification does not cover the requirements for vacuum jacketed cold
insulation, Vendor supplied cold boxes are also out of scope of this specification..
3.1.7 The Vendor / Sub-Contractor shall comply fully with the provisions laid down in this
specification. Any exception must be authorised in writing by TAQA.
3.1.8 This Specification together with applicable drawings, bill of quantities, codes and
standards referred herein shall form the part of material requisition.
3.1.9 Insulation codes shall be used on P&IDs, data sheets, piping isometrics, and other
project documents. The insulation type codes shall be as per PIP INEG 1000.
3.2 DESIGN
3.2.1 The Vendor / Sub-Contractor shall provide hot and cold insulation designed to
provide an economic thickness to prevent heat loss, so that the insulation cold face
surface temperature does not exceed 60°C in an ambient still air temperature of
20°C. The design shall also provide an economic thickness to conserve refrigeration
temperatures, and shall also prevent condensation and icing of piping and equipment
surfaces operating below the atmospheric dew point and temperatures below 5°C.

3.2.2 The hot insulation shall comprise of a layer or layers of a heat resisting material
enclosed within protective metal sheeting designed to prevent the ingress of moisture
and to allow differential expansion.
3.2.3 The cold insulation shall comprise of a layer or layers of Cellular Glass or Rigid
Polyurethane Foam. All Cellular Glass shall be enclosed by a bituminous non-
metallic vapour barrier; Polyurethane Foam shall be enclosed within a protective
metallic barrier. The insulation and vapour barrier, in both instances, shall be suitably
protected from external damage by outer metal jacketing.
3.2.4 Instruments and instrument piping that is subject to the process temperature
condition of the associated piping system or equipment shall be insulated to the
same requirement.
3.2.5 Surface preparation and Painting shall be in accordance with AA0-0000-TAA-00-MC-
SPC-0001. All insulated stainless steel piping shall be protected against chloride
attack by a suitable painting system.
3.3 EXTENT OF INSULATION
3.3.1 Piping
a. Hot and Cold insulation requirements for piping systems shall be included in the
P&I diagrams, line lists, piping General Arrangement drawings and isometrics
stating the type and thickness of insulation. Refer to Project Design Basis for
detailed nomenclature.
b. Personnel Protection Insulation
Piping systems that operate at temperatures above 65°C or below -29°C and do
not require insulation for heat conservation or process considerations shall be
insulated for personnel protection. The extent for the insulation required shall be
shown in the relevant drawings.
Personal Protection shall be provided to 2.13 m above grade or platforms and

0.91m horizontally from the periphery of platforms, walkways or ladders.
c. Flanges and valves, including valve bonnets, shall be hot insulated in insulated
lines
d. For Cold insulation, Flanges and all valves (including control valves), shall be
completely insulated including the valve bonnets, with the exception of extended
bonnets on valves in cryogenic service (see Appendix 1). Cold insulation on
valves shall have provision for accessibility to the packing gland. Vents, drains,
instrument connections and any other appurtenances shall be fully insulated.
e. The following piping items shall not be insulated:
Vent valves, steam traps, cooling water piping, expansion joints, hose
assemblies, start-up lines and other lines with normally no flow, blow down
piping from safety relief valves, except at boilers, snuffing steam lines beyond
the last block valve, thermo well bosses and pressure tapping, light flow
indicators, internally refractory lined piping, piping with personnel protected
metal grills.
3.3.2 Equipment Vessels, Drums, Reactors and Exchangers

The extent of insulation required for equipment shall be provided in the supplier drawings
and data sheets.
a. Cold Insulation
 All vessel man ways, nozzles and other appurtenances shall be fully insulated.
 Vessel mounted instruments shall be fully insulated, (see Appendix 1). Plexiglas
frost extensions on level gauges shall extend to a minimum of 50 mm (2") past
the insulation.
b. Following equipment and components shall not be insulated, unless otherwise
specified:
 Refractory lined or insulated equipment
 Heat exchanger channels and covers, except where required for personnel
protection or other special considerations,
 Man ways, Nozzles and Flanges except where required for personnel
protection or other special reasons
 Vessel Saddles and Support Legs, (these items may be protected with
fireproofing cement if required from fire hazard considerations)
 Any attachments for Platforms, Ladders and Pipe Supports
 Surfaces of Coolers and Condensers
 Nameplates which indicate design and/or operating data and warnings
 Torque Tube extensions for Vessel mounted Level Controllers (see Appendix
1).
3.3.3 Storage Tanks
a. Hot Insulation
Insulation requirements for the tank shell and roof shall be provided in relevant
drawings and data sheets. Man ways, nozzles and flanges shall not be insulated,
except where required for personnel protection. Attachments for stairways,
ladders, platforms and pipe supports shall not be insulated.
b. Cold Insulation
Insulation requirements for the tank shell and roof shall be provided in relevant
drawings and data sheets. Man ways, nozzles and flanges shall be fully insulated.
Attachments for stairways, ladders, platforms and pipe supports shall be insulated
as far as possible to prevent or minimize frosting.
3.3.4 Rotating Machinery
a. The insulation requirements for rotating machinery shall be determined from the
equipment Data Sheets and the equipment specifications.
b. Hot insulation for rotating machinery shall satisfy following requirements:
 Liquid ends of positive displacement pumps and centrifugal pump casings shall
be insulated only when it is heat traced or jacketed.

 Thermal insulation shall not be applied to fans, compressors and blowers
unless required from personnel protection, fire hazard protection or other
special considerations.
3.3.5 Steam Tracing
Insulation shall be applied to the outside diameter of the pipe covering the line and tracer
tubing. Flanges and valves in steam traced piping systems shall be thermally insulated.
3.3.6 Electrical Tracing
Electrically traced piping and equipment shall be completely insulated. No part of the
traced piping system or equipment shall be left bare. All flanges and valves, including the
valve bonnet, shall be insulated.
3.4 INSULATION THICKNESS CRITERIA
3.4.1 General
a. Economic thickness of insulation
The Economic thickness of insulation is the thickness above which the increased
cost of insulation does not give any significant savings for heat loss over a period
of time
b. Hot Insulation
The thickness of insulation shall be based on normal operating temperatures.
Insulation thicknesses shall not be designed for short-term elevated temperatures
such as steam-out conditions and regeneration temperatures at reactors. The
thickness of insulation shall be calculated based on the criteria listed below:
 The insulation material selected.
 The maintenance of heat conservation within specified economic values.
 The mean average ambient temperature.
c. Cold Insulation
The thickness of insulation shall be based on normal operating temperatures.
Insulation thicknesses shall not be designed for any short-term low temperatures
due to system depressurisation. The thickness of insulation shall be calculated
based on the criteria listed below,
 The insulation material selected,
 The maintenance of low temperature within specified economic values and
the prevention of surface icing.
 The mean average ambient temperature, wind speed and relative humidity
 Material and installation cost of insulation against the saving in
refrigeration energy.
3.4.2 Insulation Thickness
Insulation thickness calculations are based on site conditions. Thickness should be
rounded off to the nearest higher manufacture’s thickness. Insulation thickness
should be selected on the basis of normal operating temperature and nominal
diameter.
To determine the insulation thickness of oil-traced, steam-traced and hot water-

traced piping, the nominal diameter shall be the sum of pipe diameter and tracer pipe
diameter. The normal operating temperature shall be, highest of the process
temperature and the tracer temperature (condensation temperature of steam, if
steam tracing is applied).
Flanges, valves and expansion bellows shall have the same insulation thickness as
the piping and equipment concerned.
Insulation thickness selection in case of exchangers should be based on higher of
the inlet or outlet temperatures.

a. Hot Insulation
Tables 1 and 2 show insulation thicknesses (mm) for Piping, Pipeline and
Equipment – HEAT CONSERVATION.
Table 1. Insulation Thickness for Hot Service (Heat Conservation)
Material: Preformed Mineral Fiber
Maximum Operating Temperature
°F 300 400 500 600 700 800 900 1000

°C 150 205 260 315 370 425 480 535
Pipe
size Insulation Thickness (mm)
NPS
½“ 30 30 40 40 60 60 60 70
3/4 “ 30 30 40 50 60 60 60 70
1“ 30 30 40 50 60 60 70 70
1½” 30 40 50 50 60 60 70 70
2“ 30 50 50 60 60 70 70 80
3“ 30 50 60 60 70 80 80 100
4“ 80 50 60 70 80 80 100 100
6“ 50 60 70 80 100 100 100 120
8“ 60 70 80 80 100 100 120 130
10” 60 80 80 100 110 120 130 140
12 “ 60 80 80 100 110 130 140 140
14 “ 60 80 100 110 120 130 140 150
16 “ 70 80 100 110 120 30 140 150
18 “ 70 80 100 110 120 140 150 150
20 “ 70 80 100 120 120 140 150 150
Above
20" & 80 100 120 140 150 150 200 200
Flat
Table 2 . Insulation Thickness for Hot Service (Heat Conservation)

Material: Calcium Silicate
°F 300 400 500 600 700 800 900 1000

°C 150 205 260 315 370 425 480 535
Pipe
NPS
½“ 30 30 30 30 50 50 50 60
3/4 “ 30 30 30 40 50 50 50 60
1“ 30 30 30 40 50 50 60 60
1½” 30 30 40 40 50 50 60 60
2“ 30 40 40 50 50 60 60 70
3“ 30 40 50 50 60 70 70 80
4“ 40 40 50 60 70 70 80 90
6“ 40 50 60 70 80 80 90 100
8“ 50 60 70 70 80 90 100 110
10” 50 60 70 80 90 100 110 120
12 “ 50 70 80 80 90 110 120 120
14 “ 50 70 80 90 100 110 120 130
16 “ 60 70 80 90 100 110 120 130
18 “ 60 70 80 90 100 120 153 140
20 “ 60 70 80 100 110 120 13 140
Above
20” & 80 90 100 120 140 150 170 80
Flat

b. Cold Insulation-
Tables 3 and 4 show required insulation thicknesses (mm) for Piping, Pipeline
and Equipment – COLD CONSERVATION
Table 3. Insulation Thickness for Cold Conservation
Material: Cellular Glass

Minimum Operating Temperature
°F +40 +20 0 -25 -75 -125 -175 -225 -275

°C 5 -7 -18 -32 -60 -80 -115 -140 -170
Pipe
NPS
½“ 30 40 50 50 50 75 75 90 100
3/4 “ 30 40 50 50 50 75 75 90 100
1“ 30 40 50 50 75 75 90 100 115
1½” 30 40 50 50 75 90 100 115 130
2“ 30 40 50 65 75 90 100 115 130
3“ 40 50 65 75 90 100 130 140 150
4“ 40 50 65 75 90 115 130 140 150
6“ 40 50 65 75 100 115 140 150 170
8“ 40 50 65 75 115 130 150 170 *
10” 40 50 65 90 115 140 150 170 *
12 “ 40 50 75 90 115 140 170 * *
14 “ 50 50 75 90 115 140 170 * *
16 “ 50 50 75 90 115 150 170 * *
18 “ 50 50 75 100 125 150 170 * *
20 “ 50 50 75 100 125 150 170 * *
24” 50 50 75 100 125 150 170 * *
30” 50 50 75 100 140 170 * * *
36” 50 50 90 100 140 170 * * *
Above
36" & 50 50 90 115 150 170 * * *
Flat

Table 4. Insulation Thickness for Cold Conservation
Material: Polyurethane Foam
°F +40 +20 0 -25 -50 -75 -100

°C 5 -7 -18 -32 -45 -60 -73
Pipe
NPS
½“ 30 40 50 50 50 50 60
3/4 “ 30 40 50 50 50 50 60
1“ 30 40 50 50 60 70 70
1½” 30 40 50 50 60 70 80
2“ 30 40 50 60 65 70 80
3“ 30 40 60 70 80 85 90
4“ 30 40 60 70 80 85 90
6“ 30 40 60 70 85 95 100
8“ 30 40 60 70 90 110 110
10” 30 40 65 85 100 110 120
12 “ 30 50 65 85 100 110 120
14 “ 40 50 65 85 100 110 120
16 “ 40 50 65 85 100 110 125
18 “ 40 50 65 95 100 120 130
20 “ 40 50 65 95 100 120 130
24” 40 50 65 95 100 120 130
30” 40 50 65 95 115 130 150
36” 40 50 80 95 115 130 150
Above
36" & 40 50 80 110 125 140 150
Flat
Where polyurethane foam has been specified, the Vendor may propose other plastic
foams with a thickness calculated to provide equal or greater thermal resistance than
obtained using the specified thickness and material.
3.4.3 Personal Protection
Table 5 show required insulation thicknesses (mm) for Piping and Equipment –
PERSONNEL PROTECTION.

Table 5. Insulation Thickness for Hot Service (Personnel Protection)
Material: Calcium Silicate / Mineral Fibre
°F 500 600 700 800 900 1000

°C 260 315 370 425 480 535
Pipe
NPS
½” 30 30 30 30 30 30
¾” 30 30 30 30 30 30
1" 30 30 30 30 30 30
1½” 30 30 30 30 30 30
2“ 30 30 30 30 30 40
3“ 30 30 30 30 30 40
4“ 30 30 30 30 30 40
6“ 30 30 30 40 40 50
8“ 30 30 30 40 40 50
10” 30 30 30 40 40 60
12 “ 30 30 30 40 40 60
14 “ 30 30 30 40 40 60
16 “ 30 30 30 50 50 60
18 “ 30 30 30 50 50 70
20 “ 30 30 30 50 50 70
Above
20” & 30 40 40 60 60 80
Flat
3.4.4 Steam Tracing

Insulation thicknesses for steam tracing are determined by the operating temperature
of the process or 70% of the operating temperature of steam, whichever is the higher.
Thickness shall be in accordance with Tables 1 and 2.
3.4.5 Electric Tracing
Minimum insulation thicknesses for electric tracing shall be in accordance with Table
6. Additional thicknesses shall be provided for insulation boxes on valves, flanged
joints, pumps, etc. Thicknesses are based on mineral fibre insulation.

Table 6. Insulation Thickness for Hot Service (Electric Tracing)
Material: Calcium Silicate / Mineral Fibre

°F 50 100 200 300 400
°C 10 38 93 149 204
Insulation Thickness (mm)

Pipe size NPS
½” 30 30 30 40 40
¾” 30 30 30 40 40
1“ 40 50 65 80 90
1½” 40 50 65 80 90
2“ 40 50 65 80 90
3“ 40 50 65 80 90
4“ 40 50 65 80 90
6“ 40 50 65 80 90
8“ 40 50 65 80 100
10” 40 50 65 90 100
12 “ 40 50 80 90 100
14 “ 50 65 80 90 100
16 “ 50 65 80 90 100
18 “ 50 65 80 90 100
20 “ 50 80 90 100 100
Above 20” &

50 80 90 100 115
Flat
3.5 VAPOUR BARRIER

A continuous vapour barrier shall be provided over the cold insulation prior to installing
the metal jacketing. Acceptable types of vapour barrier and their limitations of use are
provided in Section 3.8.5.
3.6 METAL JACKETING
Metal jackets shall be provided over cold insulation following the installation of the
vapour barrier. Metal jackets shall be of galvanized / aluminized steel / aluminium sheet /
stainless steel.
Aluminium sheet shall not be used for piping and equipment requiring passive fire
protection.

Stainless steel jacketing shall be used for all towers, drums and exchangers.
Galvanised steel should be avoided in coastal areas due to the risk of corrosion.
3.7 VAPOUR STOPS
All piping and equipment shall be cold insulated as a unit with a vapour stop at each
interruption including, but not limited to, valves, flanges, elbows, tees, supports, hangers
and other protrusions.
3.8 MATERIALS
3.8.1 General
a. Insulating materials covered in this specification are mineral fibre, calcium silicate,
cellular glass and polyurethane foam for hot and cold services respectively.
The Vendor shall select the insulating material considering the following criteria:
 For operating temperatures between 20 C and 760 C, mineral wool shall be
used.
 Cellular glass, loose, shall be used for insulated flanges and valves (01 meter
on both sides) in oil service, for operating temperatures between -260 C and
425 C.
 For operating temperatures between -183 C and 149 C, Polyisocyanurate rigid
foam (PIR/PUR) shall be used. For buried piping/pipeline material shall comply
with ASTM C591 grade 1 Type V with a minimum insulation density of
60Kg/m3.
 All HVAC ductwork shall be insulated with rigid Mineral Fibre Board. The
insulation shall be supplied with factor applied class ‘O” foil finish. The
insulation material and thickness shall conform to BS 5422.
 Products should be selected considering the risk of corrosion under insulation
and hence painting should be selected considered as per TAQA painting
specification prior to application of insulation.
 Ceramic and Asbestos products shall not be used in view of Hearth and Safety
requirements.
b. The Vendor / Sub-Contractor may use alternative insulation materials of requisite
thickness, subject to TAQA approval.
c. All insulation material shall be asbestos free, and shall be of low chloride content,
chemically inert, non-sulphurous, rat-proof, vermin proof, impervious to hot water
and steam. Insulation shall be non-corrosive to steel or aluminium.
d. For hot insulated lines operating above 95°C, the insulating material shall not
crack, sag, de-laminate or show any sign of flaming, glowing, smouldering or
smoking when tested as per ASTM C411.
e. All insulation and finishing materials shall be new, free of damage and in
conformity with this specification and the minimum requirements stated in Table 7
(the requirements apply to “ex-factory” quality). Materials shall be protected
against weather and moisture during transport and be delivered at the site in their
original packaging and be stored clear of the ground.
f. All fastening materials such as binding wire, strapping bands, self-tapping screws,
rivets, clips and quick-release toggles applied on metal finishing shall be of

stainless steel (SS316); exception hard aluminium self-tapping screws or rivets
applied on aluminium finishing may be considered.
g. Insulation, fastening and sheeting material to be applied on stainless-steel
surfaces shall not contain zinc or be galvanized. To prevent interchanging of
insulation materials intended for stainless application and intended for
carbon/low/medium alloy steel application, the materials intended for stainless-
steel application and their packing shall be clearly identified. Materials deviating
from this specification shall not be used, unless Supplier has written prior
approval from Contractor.
3.8.2 Polyurethane Insulation
Polyurethane insulation shall be cellular and shall comply with the requirements of
ASTM C591 Type 11. Following additional requirements shall also be met:
a. Thermal Conductivity shall be measured in accordance with ASTM C-177 at 20°C
measured on 25 mm (1") thick foam, cut on both sides and aged at 21°C for 180
days. Thermal conductivity shall not be greater than 0.023 W / mK. The thermal
conductivity for freshly blown foam shall be no greater than 0.020 W / mK.
b. Density shall be a minimum of 45 kg / m3 (2.8 lb / ft3) measured in accordance
with ASTM D1622.
c. Compressive strength shall be a minimum of 200 kPa29 (psi) at 20°C measured
in accordance with ASTM-D1621.
d. Maximum water absorption shall not be more than 4% when measured in
accordance with ASTM D2842.
e. Maximum permissible change in dimensions shall be less than 2%. The Vendor
shall ensure that satisfactory dimensional stability tests have been performed by
the manufacturer. The Vendor shall provide manufacturer's testing
procedure/certificate to TAQA.
f. Minimum percentage of closed cells shall be 90% when measured in accordance
with ASTM D-2856.
3.8.3 Cellular Glass Insulation
Cellular glass insulation shall be supplied in rigid block and preformed pipe form in
accordance with ASTM C552. Following additional requirements shall also be met.
a. Thermal Conductivity, shall not be greater than the following when measured to
ASTM C-177 0.045 W / mK at 20°C, 0.042 W / mK at 0°C and 0.038 W / mK at -
20°C.
b. Density shall be 125 kg / m3 (7.8 lb / ft3) ± 10% when measured in accordance
with ASTM C-303.
c. Minimum compressive strength shall be 490 kPa (71 psi ), when measured in
accordance with ASTM C-165.
d. Water vapour transmission shall be 0 when measured in accordance with
ASTM E-96.
3.8.4 Loose Fill Insulation
a. Unless loose fill insulation is enclosed in a cold box or other airtight container, the
insulation material shall have permeability not more than 5.01 per m-cm (3 per m-

inch) as per the desiccant method, when measured in accordance with ASTM C
355.
b. The moisture content of loose fill type insulation shall not exceed 0.5%, by weight,
on installation.
3.8.5 Vapour Barrier
Acceptable types of vapour barriers and their applications are given below.
a. Metal Vapour Barrier
This type of vapour barrier shall be applied to all polyurethane foam insulation and be
manufactured from corrugated aluminium sheet, Alloy 3003 or 5005, in accordance
with ASTM B-209. Corrugation shall be 5 mm (0.1875"). The sheet shall be heat
laminated with a layer of chemically inert polyethylene and a layer of Kraft paper to
give a total minimum thickness of 0.2 mm (0.008" ).
Tape for sealing joints in the vapour barrier shall be a composite aluminium foil tape,
reinforced with a self bonding layer made of butyl rubber on the back face, minimum
width 75 mm (3"), to allow for sufficient cover of the joints.
b. Non Metallic Vapour Barriers
Non-metallic vapour barriers shall be used on all cellular glass insulation. For
equipment and straight runs of piping a self sealing bituminous sheet membrane
shall be used. For small items, fittings, elbows and irregular shapes, a mastic shall
be applied and reinforced with a suitable synthetic fabric.
The bituminous sheet membrane shall be a minimum of 1 mm (0.04") thick with a
permeability of 0.0018 per m inch (0.003 per m-cm) and a tensile strength of 200 kPa
(30 psi).
Mastic shall have a permeability of less than 0.005 per m-cm (0.003 per m-in ) and
be applied to a thickness of 3 mm.
3.8.6 Materials for Weatherproofing
Finishing materials for piping and equipment insulation shall be as specified below.
a. Aluminium
AlMg 99.5 (IS) alloy 1060, temper H14, in accordance with ASTM B-209M.
b. Stainless Steel Sheet
Austenitic Stainless steel sheet shall be in accordance with ASTM A167 .
c. Perforated plate:
 Perforated plate shall be used for shielding:
 Material: The same as sheeting material.
 Perforated area should be at least 35%
 Hole diameter: Maximum 5 mm in a triangular grid pattern.
 Plate thickness: 1.0mm.
3.8.7 Accessories
a. Auxiliary Materials
 Support ring material for Piping:

Outer ring: Stainless steel 316
Inner ring: Stainless steel 316
 Weather-resistant vapour barrier finishing layer:
Tough, elastic finishing layer onto latex base (Foster Monolar Mastic 60-91
or equivalent).
 Flexible elastomers or silicone Paste:
Metal Sealant (Foster Elastolar 95-44 or equivalent).
 Seam filler:
Joint sealant/adhesive (Foster Adhesive 81-82 or equivalent).
 Glass fabric:
Glass cloth V 10, 600 gm/m2 or equivalent.
 Nonabrasive:
Foster 30-16 or equivalent.
b. Materials for impulse tube
 Hot insulation
SS Chicken Wire mesh, Mesh Opening ¾”, wire dia 1.2mm
SS Wire, 1.0mm Dia.
Self Adhesive Aluminium Tape, 100mm wide x 30 Yard/Roll
 Cold insulation
Rubber Insulation Pipe, Size: ½” Dia x ¾” Thick x 1.8 Mtrs/Tube.
Self Adhesive Aluminium Tape, 100mm wide x 30 Yard/Roll.
3.9 INSTALLATION
3.9.1 General
Application of all thermal insulation shall be in accordance with this specification.
Deviation from this specification is only allowed when Supplier has written approval
from Contractor. Application of insulation materials, if not outlined in this specification,
shall be in line with CINI and manufacturer’s specification/recommendations.
Supplier shall submit the insulation procedure for Contractor’s approval.
Supplier shall confirm, in writing, compatibility of insulation system components
(insulation material, adhesives, additives and vapour barriers). The components shall
be from the same manufacturer.
Insulation for piping / vessels can be applied either with preformed sections or
blanket-type insulation. Performed pipe sections and segments shall be supplied as
factory pre-molded cylindrical parts. Any damages as well as poorly closing joints are
not acceptable.
Instruments requiring insulation shall be insulated with standard prefabricated
insulation boxes with windows for taking the readings. Instrument tubing should be
insulated by instrument tubing.

Prior to the installation of any insulation materials the Vendor shall make the following
checks. Discrepancies shall be brought to the attention of TAQA.
a. Sufficient space is provided between adjacent flanged joints for bolt withdrawal at
flanged joint insulation boxes.
b. Piping is sufficiently elevated above the support level, so that cold supports can
be installed including insulating thermal spacers between the support steel and
the underside of the insulation.
c. Insulation shall not be installed until all testing and inspection has been completed
on equipment and piping to be insulated.
d. All surfaces shall be thoroughly cleaned of all dirt and grease. Paint shall be dry
before installation of insulation.
e. All insulation joints shall be butted together.
f. Each layer of insulation shall be installed with staggered transverse or longitudinal
joints and secured in place by wire or metal bands. Where multiple layer
insulation is used, each layer shall be secured in place and the joints of each
layer offset.
g. All gaps in the insulation shall be filled with insulating cement.
h. The Vendor / Sub-Contractor shall not install insulation that is damp or wet.
Insulation shall be installed during dry weather conditions.
i. The Vendor / Sub-Contractor shall not carry out any welding or drilling on piping
or equipment.
j. The Vendor / Sub-Contractor is responsible for ensuring that all insulation
supports including thermal spacers have been installed.
k. The Vendor / Sub-Contractor shall be responsible for completing the insulation
including closure pieces at termination points.
l. A minimum clearance of 50 mm (2") is required between the outside surface of
any insulation finish and adjacent pipe, structural member or equipment.
3.9.2 Hot Insulation for Piping
a. Single Layer Insulation
 The insulation shall be installed by dry application on pipe surfaces that
have been blasted and painted in accordance with AA0-0000-TAA-00-MC-
SPC-0001 Surface Preparation and Painting.
 The insulation sections and segments shall be secured by stainless steel
wire. The banding shall be spaced every 300 mm (12").
b. Multiple Layer Insulation
 When the thickness of insulation exceeds 80 mm (3"), the insulation shall be
applied in several layers. Each layer shall be a minimum of 40 mm (1.5") thick
and shall be equal in thickness to the other layers where practicable.
 Stainless steel straps shall be used for fixing the insulation. The straps shall
be spaced every 250 mm (10").
c. Pipe Fittings
Insulation of elbows, bends, reducers, T-pieces and other fittings in all pipe sizes

shall be insulated with pre-molded insulation sections or cut segments of the
same insulation material as the connecting pipe. For fastening of sections and
segments, at least three (3) stainless-steel (316) wires (diameter 1mm) per
section shall be used for each layer of insulation. The twisted ends of the wire
shall be pressed into the insulation material to prevent damage to the finishing
layer.
d. Valves and Flanges
 All the flanges, flanged connections and valves on insulated lines and
equipment shall be insulated, except lines which are insulated for personal
protection. Insulation shall be done with removable type enclosures
manufactured from metal plate (same material as sheeting associated pipe).
 The enclosure shall be lined internally with same insulation material in the
same thickness as for the associated pipe. The insulation material shall be
attached to the inside of enclosure with clips. Wire mesh of blankets shall face
the object to be insulated. Clips shall be screwed to the enclosure wall.
 The insulation shall be fitted over the connected pipe insulation. The stuffing
box gland of all insulated valves shall be kept outside the insulation enclosure.
 Heat exchanger flanges shall be insulated with removable enclosures.
 When insulation of valves and flanges is required, the insulation shall consist
of a preformed insulating box providing sufficient room for flange bolt
withdrawal.
 For control valves only the valve body shall be insulated.
 Insulation enclosures for valves and flanges for viscous fluids shall be
provided with drainage outlet, which give visible indication of a possible leak.
 The insulation material on flanges, flanged connections and valves for pipes
having hot oil shall be loose Cellular glass.
 When the following valves and flanges have to be insulated, the enclosures
shall be provided with quick release toggles to allow frequent and/or eassy
removal:
 Control valves.
 Safety/relief valves.
 Remote-operated valves.
 Flanges of strainers.
 Flanges and valves connected to spool pieces around pumps and
Compressors
 Spectacle blinds, spades and spacers.
e. Supports for Piping Insulation
 Vertical Pipe
The Vendor / Sub-Contractor shall install support rings so that the
unsupported insulation height never exceeds 4.0 m. The spacing of vertical
support rings shall be as provided in Table 9 below:

 Piping NPS 6” and below
Table 9. Insulation Support Span
Pipe Size Operating Temperature Insulation Support Spacing
6” or Less Less than 350 0 C 4m
6” or Less More than 350 0 C 2 to 3 m
8” or More Less than 350 0 C 3m
8” or More More than 350 0 C 2 to 3 m
 Horizontal Pipe
For horizontal piping NPS 4” and above, the Vendor / Sub-Contractor shall
install spacer rings for mineral fibre and glass fibre insulation so that the
weather shield may be supported. These rings shall be spaced a minimum of
0.9 m apart.
f. Weatherproofing
 All insulation shall be covered with a metal jacket for weatherproofing.
Aluminium sheet shall be used, except where the jacket is required for
fireproofing of a system. Galvanized steel jacket shall be used if fireproofing of
the system is required. The jacket shall be machine rolled and overlapped by
75 mm (3").
 Preformed metal jackets shall be installed on elbows, valve and flange
insulation boxes. Branches and line reductions shall be provided with flashing.
Flashing seams shall be sealed with a mastic sealer. A moisture barrier shall
be installed between the metal jacket and the insulation.
 Jacketing shall be secured with stainless steel or galvanized steel self-tapping
screws spaced at 150 mm (6") centres on the longitudinal joints and with the
metal bands at the centre and ends on circumferential joints.
3.9.3 Polyurethane Foam Insulation (Foamed-In-Place)
Foamed in place polyurethane insulation may be applied only to straight runs of piping
below NPS 30.
a. Foam Application
Foam may only be applied under following atmospheric conditions:
 The ambient (dry bulb) temperature is not less than 18°C
 The dry bulb temperature is not predicted to fall within 2.8°C of the dew point
temperature
 The wind speed shall not exceed 4.5 m/s, otherwise spraying operations shall be
suitably shielded.
 The metal surface temperature shall be in between 27 and 50°C.

Any deviation from these requirements shall be subject to approval from the TAQA.
b. The minimum thickness of each foam pass shall approximately be 13 mm (0.5").
Total thickness tolerance shall be -0 and +13 mm (0.5").. The spray equipment
used for plastic foam application shall have a demonstrated capability of meeting
the surface roughness criteria.
c. Testing or cleaning out of the spray equipment on the surface to be insulated is
not permitted. The finished surface of the foam shall be dry, free of dust and
foam overspray before application of the vapour barrier and metal jacketing.
3.9.4 Pre-formed Block Insulation for Piping
a. Single Layer Insulation
 The insulation shall be installed by dry application on pipe surfaces that have
been blasted and painted in accordance with AA0-0000-TAA-00-MC-SPC-0001,
without any under layer between the pipe surface and the insulation. All joints for
block insulation shall be butted together. The gaps between sections of
insulation shall not exceed 1.25 mm (0.05”).
 Stainless steel bands shall be used to secure block insulation to piping at
intervals of 250 mm (10"). (See Appendix 1).
 All gaps in the insulation shall be filled with a compatible joint sealer or adhesive.
b. Multiple Layer Insulation
 When the thickness of insulation exceeds 3" (76 mm), the insulation shall be
applied in several layers.
 Each layer shall be a minimum of 38 mm (1.5") thick and shall be equal in
thickness to the other layers where practicable.
 Each layer of insulation shall be installed with staggered transverse or
longitudinal joints and secured in place by stainless steel wire or bands. The wire
or bands shall be spaced every 10" (250 mm). Wire shall not be used to hold
polyurethane foam insulation.
 Side and end joints shall be coated with joint sealer adhesive.
 All gaps in the insulation shall be filled with a compatible joint sealer or adhesive.
c. Pipe Fittings
Where block insulation is specified, insulation of elbows and other fittings shall be in
shaped segments or blocks which shall be secured by stainless steel bands.
d. Valves and Flanges
 Insulation of valves and flanges shall consist of a preformed insulating box
providing sufficient room for flange bolt withdrawal. The required distance for bolt
withdrawal measured from the inside face of flange shall be L + 25 mm (1"),
where L=length of bolt. (See Appendix 1).
 The Vendor shall ensure that all voids in insulation boxes are filled and carefully
packed with the loose fill insulation.
 For cold insulated manual valves, the insulating box material shall be finished
clear of the valve packing gland on extended bonnets in cryogenic service.

 For control valves, only the body shall be insulated.
e. Supports for Piping Insulation on Vertical Pipes
The Vendor / Sub-Contractor shall install support rings, to support the insulation, at
intervals of not more than 3.6 m.
f. Pipe Supports
Piping shall be supported by rigid bands or saddles to match the outside diameter of
the insulation, to permit continuous insulation at support points. Insulation at
supports shall be the load bearing type such as hard wood blocks, or other rigid
thermally resistant material, of the same outside diameter as the insulation and
clamped to the pipe.
3.9.5 Application of Vapour Barrier for Piping
A continuous vapour barrier shall be applied to all cold service insulation installed on
piping. Acceptable types of vapour barrier and specific requirements are given in Section
3.8.5
a. Non Metallic Vapour Barriers for Cellular Glass
Non-metallic vapour barrier shall be in the form of, bituminous sheet membrane for
straight runs of piping and bituminous mastic for small items, fittings, elbows and
irregular shapes. The mastic shall be applied and reinforced with a suitable fabric.
When mastic type vapour barrier is used, a minimum of 3 coats are required for all
surfaces. The application of second coat shall be made after a minimum of 4 hours
of application of the first coat. After 24 hours of drying time, the third coat shall be
applied. The total coating thickness shall be 1.1-1.5 mm (0.045” - 0.060").
Successive coats shall be in a contrasting colour to the preceding coat. The colour
of the final coat shall be specified by TAQA.
The mastic shall be reinforced with a synthetic fibre fabric which shall be applied
after the first coat of mastic. The fabric shall be applied by pressing smoothly, without
distortion, into the coating. Metal fasteners such as staples shall not be used to
secure the fabric.
Double layers of fabric shall be applied at joints of attachments or at insulation box
joints.
Any section of the vapour barrier exposed to temperatures below -45°C shall be
secured with stainless steel bands.
b. Metallic Vapour Barriers for Polyurethane Foam
Corrugated aluminium sheet vapour barriers, as described in Section 3.8.5, shall
be installed over all piping insulated with polyurethane foam. All longitudinal and
circumferential joints shall be sealed with the composite aluminium foil tape.
3.9.6 Equipment, Vessels, Drums and Exchangers
a. General
 Heads of columns, vessels, heat exchangers, manholes, etc. with a diameter up
to 1000 mm, may be insulated with insulated caps of metal plate. Caps shall be
internally lined with mineral wool blankets.
 Heats of columns, vessels, heat exchangers, manholes, etc. with a diameter over
1000 mm shall be insulated with blankets, with wire mesh at the outside.

 Stiffeners, rings, girders, etc. attached to insulated towers, tanks, vessels, heat
exchangers, etc. shall, unless otherwise indicated, be insulated with the same
insulation material in the same thickness as for the equipment concerned
 Equipment shall be insulated with preformed block type insulation. The insulation
shall be applied with transverse or longitudinal joints staggered and secured with
metal bands as specified below.
 Single layer thermal insulation shall be applied dry, without an under layer.
 Hot Insulation
When the insulation thickness exceeds 80 mm (3"), the insulation shall be
supplied in several layers. Each layer shall have a minimum thickness of 40 mm
(1.5"). All layers shall be equal in thickness where practicable.
 Cold Insulation
When the insulation thickness exceeds 2" (50 mm), the insulation shall be
applied in several layers. Each layer shall have a minimum thickness of 2" (50
mm). All layers shall be equal in thickness where practicable.
 Side and end joints shall be coated with joint sealer adhesive.
b. Vertical Equipment
 Shell Insulation
Support rings on vertical vessels and exchangers shall be located at the
bottom of the insulated area and thereafter on 3.7 m and 2.4 m centres toward
the top of the equipment for hot and cold insulation respectively. Support rings
shall be 6 mm (0.25") thick and one half the insulation thicknesses in width,
with a minimum width of 12 mm (0.5") for hot insulation and 25 mm (1”) for
cold insulation.
The preformed insulation blocks or staves shall be secured by horizontal
stainless steel bands 19 mm (0.75") wide x #24 SG thick, placed 300 mm
(12") apart, upward from the support rings. Maximum continuous length of
straps shall not exceed 6.0 m.
Any gap between the top of insulation and the support above, shall be filled
with part compressed mineral fibre.
 Vessel Head Insulation
Insulation on vessel heads shall be held in place with bands radiating from a
floating ring. The bands shall be spaced at the tangent line of the head a
maximum of 300 mm (12") apart. The floating rings shall be made of 6 mm
(0.25") round steel rod.
Where bands are impractical due to an irregular surface, 14 BWG (2 mm)
stainless steel or copper wire shall be used at 230 mm (9") centres.
c. Horizontal Equipment
The preformed insulation blocks or staves shall be secured by stainless steel
bands placed circumferentially around the shell. The bands shall be 19 mm
(0.75") wide x #24 SG (0.6 mm) thick, located 300 mm (12") apart. Vessel heads
on horizontal drums shall be insulated as per paragraph 3.9.6 (b) above.

d. Vessel Supports
Vessel skirts, support legs and support saddles shall be insulated only for the
sections immediately adjacent to the equipment insulation, Vessel supports shall
be fireproofed if required..
e. Manways and Flanged Nozzles
Where man ways and flanged nozzles are to be insulated for system
requirements or personnel protection, they shall be insulated by means of
insulated covers, which shall be removable without damage to the vessel
insulation.
f. Exchanger Insulation
 Hot Insulation
Exchangers, reboilers and condensers shall normally be insulated over the
exchanger bonnet, terminating before the channel flanges, leaving sufficient
space to permit bolt withdrawal from the channel head flanges. Normally the
channel heads shall not be insulated except, when in steam service for
reboilers, or for the purposes of personnel protection.
Fin-tube exchangers shall be insulated with preformed pipe sections, leaving
the nozzles clear of insulation, unless required for steam service or personnel
protection.
 Cold Insulation
Exchangers in cold service shall be completely insulated over the exchanger
bonnet, including the channel flanges, leaving sufficient space to permit bolt
withdrawal from the channel head flanges. Channel heads shall also be
insulated. Cellular glass or polyurethane foam insulation blocks applied in
staggered joint construction shall be used for this insulation. Fin-tube
exchangers shall be completely insulated with preformed sections.
g. Expansion Joints
Expansion joints shall be provided on all columns operating at a temperature of
150°C and above, or with an outside diameter greater than 2 m. Expansion joints
shall be at 3.7 m centres maximum.
3.9.7 Rotating Machinery Insulation
Insulation for pumps and turbines where required, shall be the box type and block
type for hot and cold insulation respectively. The insulation shall be removable type
for ease in maintenance. Design of the covers shall be submitted to TAQA for
approval, prior to the fabrication.
3.9.8 Storage Tank Insulation
a. Hot Insulation
The supporting base for insulation shall be made watertight by applying a
bituminous water proofing emulsion.
The lowest course of insulation shall be of waterproof insulating material such as
cellular glass. Roof insulation shall be carried out only if expressly required by
design and if installed shall be capable of bearing the weight of operating
personnel.
Insulation blankets shall be placed against the supports and horizontally secured
with stainless steel or galvanized steel straps, 25 mm (1") wide x 0.6 mm (#24
SG) thick located on 250 mm (10") centres.
b. Cold Insulation
The insulation shall be supported by rings at 3.7 m (12 ft) centres toward the top of
the tank. Support rings shall be as described in 3.9.6.b
Shaped insulation blocks shall be placed against the supports and horizontally
secured with stainless steel or galvanized / aluminised steel straps located on 250
mm (10") centres.
3.9.9 Cold Boxes
Cold boxes shall be designed and internally insulated by the cold box vendor. Individual
piping and equipment items within a cold box shall be located a minimum of 300 mm
(12") from all other internal items, the cold box framework or internal surface of the cold
box wall.
The exterior of the cold box does not require insulation. Cold boxes shall be of gas-tight
construction and continuously purged with nitrogen to eliminate moisture.
Nozzles passing through the cold box shall be sealed with insulated sleeves. Insulation
of lines entering or leaving the cold box shall be taken up to the insulated sleeve
termination and sealed.
3.9.10 Application of Vapour Barrier to Equipment
A continuous vapour barrier shall be applied to all cold service insulation installed on
vessels, drums exchangers, tanks and other components of equipment. Acceptable
types of vapour barrier and specific requirements shall be as per Section 3.8.5
a. Non Metallic Vapour Barriers for Cellular Glass
Requirements of Section 3.9.5 a shall apply.
b. Metallic Vapour Barriers for Polyurethane Foam
Requirements of Section 3.9.5 b shall apply.
3.9.11 Weatherproofing (Cladding)
a. Hot insulation on equipment, storage tanks and rotating machinery shall be
protected by an aluminium sheeting cover or galvanized steel sheeting if
fireproofing of equipment is an additional requirement.
b. Cold insulation on equipment, storage tanks and rotating machinery shall be
protected by metal jacketing. The types of approved metal jackets are described
in Section 3.8.6.
c. Vessels, Drums and Exchangers
The sheeting shall be suitably shaped, flanged and fixed to anchor rings. Single
metal plates shall overlap by a minimum of 50 mm (2") and 75 mm (3”) on both
longitudinal and circumferential joints for hot and cold insulation respectively.
Overlapping shall allow for the drainage of rainwater. Metal jackets also used for
fireproofing or for electrically traced equipment, shall be sealed by flexible mastic
in the plate seams.

The metal plates shall be secured with self-tapping screws at 150 mm (6") centres
or with stainless steel bands 19 mm (0.75") wide x 0.6 mm (#24 SG) thick.
To allow for thermal expansion and movement of jacket sections, screws shall not
be used in the end laps of jackets. Metal jackets on vessel heads shall be
fabricated and installed using the "orange-peel" method, secured with self-tapping
screws.
Expansion joints for metal jacketing shall be made by overlapping 50 mm (2") and
75 mm (3”) of the sheet for hot and cold insulation respectively.
For vertical equipment the joints shall be located at the support rings. The joints
shall be pitched at 4.6 m, for operating temperatures up to 350°C and shall be
reduced by 450 mm (18") for every increase in operating temperature of 50°C
down to a minimum spacing of 0.9m for temperatures of 700°C and above.
d. Storage Tanks
Storage tank shell insulation shall be protected by corrugated aluminium sheeting.
The protective sheeting shall be shaped, flanged and secured with anchor rings.
The metal sheet shall overlap by at least 150 mm (6") on both the longitudinal and
circumferential joints. The overlapping shall permit drainage of rainwater.
The metal sheets shall be held in place with stainless steel or cadmium plated
self-tapping screws on 6" (150 mm) centres, or with stainless steel bands 25 mm
(1") wide x 24 SG (0.6 mm thick).
Protective sheeting for the tank roof shall be completed in the same manner as
the shell. The outer sheets shall be folded downwards and overlap the whole
circumference of the shell finishing sheet. Protective sheets shall overlap adjacent
lower sheets by 150 mm (6").
3.10 SHIPPING AND STORAGE
3.10.1 General
This section describes the minimum requirement for the presentation and protection
of insulation materials during sea and land transportation and storage, prior to
installation, including the insulation materials installed as a part of a package unit.
3.10.2 Packing
Insulation shall be packaged for shipment by the manufacturer so that the product is
fully protected from penetration of moisture.
Loose supply of insulation shall be packaged into parcels of a size that can be easily
handled without damage to the contents and shall be suitably protected from external
damage.
3.10.3 Shipping
Parcels of loose insulation shall normally be shipped in containers of standard
international size, unless of a small quantity, less than the capacity of a container.
Insulation containers shall be stored on board ship so that the containers have
maximum protection from ingress of moisture from the sea or weather. Shipment by
deck cargo shall not be permitted.

3.10.4 Storage
Upon receipt on-site, insulation containers or insulated packed units shall be stored
inside a warehouse or other weather protected shelter. Containers shall not be
opened until ready for immediate use. Undue movement or agitation of containers
shall be avoided.
4. QUALITY ASSURANCE AND QUALITY CONTROL
4.1 QUALITY ASSURANCE
The Vendor / Sub-Contractor shall maintain an effective quality system that complies with
project requirements as well as those of ISO-9001.
4.2 QUALITY CONTROL
Vendor shall submit the Preliminary Inspection and Test Plan in his offer and the same
shall be firmed up within 2 weeks from replacement of order.
4.3 INSPECTION
The Vendor shall allow the Inspector access to all areas of manufacture, installation
and testing of the insulation, including weatherproofing.
The Vendor always has the responsibility to provide adequate quality control and
inspection of installation equipment and insulation materials.
Any inspection by the Inspector does not relieve the Vendor of these responsibilities
or those under his guarantees.
The inspection of the insulation material shall be in accordance with the relevant
ASTM Specification for the insulation material as listed in section 2.0
The inspection of insulation shall include the quality control of application materials.
Work shall not proceed to the next step of the insulation installation sequence, e.g.
surface preparation, priming, insulation application, weather shield application, until
the previous work has been inspected and approved.
5. DOCUMENT REQUIREMENTS
5.1 GENERAL
This section covers the minimum requirement of documentation required for the
design, fabrication, installation and inspection of insulation to be provided by the
Vendor / Sub-Contractor.
5.2 SCHEDULES AND REPORTS
The Vendor / Sub-Contractor shall supply a schedule showing the documents for
review and approval and detailed schedule for insulation installation.
5.3 DATA AND CALCULATIONS
a. The Vendor / Sub-Contractor shall supply completed Data Sheets containing all
the relevant information necessary for appraisal of the Vendor's design by the
TAQA.

b. Project specific instructions shall be issued to the Vendor with the Purchase
Order / Contract which describes the data and calculations to be submitted and
the methods of submission.
5.4 DRAWINGS
P & IDs, line lists, piping general arrangements and isometrics, that show the type,
extent and thickness of insulation in “Issued For Construction” status shall be
provided to the Vendor / Sub-Contractor for implementation.. Vendor / Sub-
Contractor shall use these drawings for completion of insulation work and shall
submit the As Built drawings to TAQA.
5.5 MATERIALS FABRICATION AND INSTALLATION
a. Documentation of all materials manufacture and quality control, installation and
field inspection activities shall be maintained, and it is the Vendor / Sub-
Contractor's responsibility to collate all documentation and certification relating to
a specific Purchase Order / Contract and to generate and issue data books in
accordance with the contract requirements. As a minimum, these data books
shall include the following:
 Quality Plans,
 Material Certificates of Conformity,
 Shop Test Procedures,
 Field Test Reports,
 Inspection Reports,
 Concession Requests (accepted and rejected),
 Release Dates.
b. Following completion of insulation work, all appropriate documentation and
certification necessary to complete the contract data shall be collated, checked
and authorised by the Inspector prior to handover to TAQA. Two copies of the
complete Data Books shall be dispatched to TAQA.
c. The Vendor / Sub-Contractor shall supply one set of reproducible original

drawings.

1.0 APPENDIX 1 TYPICAL DETAILS OF INSULATION


FIGURE 1 TYPICAL DETAIL FOR COLD INSULATION OF VALVES, EQUIPMENT
NOZZLES & INSTRUMENTS


FIGURE 2 a. APLLICATION OF COLD INSULATION FOR HORIZONTAL VESSELS


PLAN C-C

FIGURE 2 b. APLLICATION OF INSULATION FOR HORIZONTAL COLD VESSELS


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PRODUCTION FACILITY (PHASE 1)

SPECIFICATION FOR INSULATION

Document Owner: TAQA

Document Approver: Project Manager

Revision No: 000 Issue Date: Date 28-06-2013

Amendment Summary: Issued for Design

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Rev Para. Revision Description

Hold No Para. Description of Hold

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ASTM C165 Standard Test Method for Measuring

ASTM C177 Test Method for Steady State Heat Flux

ASTM C355 Water Vapour Transmission of Thick Materials.

ASTM C411 Hot-Surface Performance of High Temperature

ASTM C547 Mineral Fibre Preformed Pipe Insulation

ASTM C 592 Mineral Fibre Blanket Insulation and Blanket -

ASTM E 84 Surface Burning Characteristics of Building

ASTM E 96 Water Vapour Transmission of Materials in

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BS 5608 Preformed Rigid Polyurethane (PUR) and

BS 5970 Code of Practice for Thermal Insulation of Pipe

Commission Industrial Insulation (CINI)

Process Industry Practices (PIP)

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3.1.3 Cold insulation shall be required for the following purpose:

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Personal Protection shall be provided to 2.13 m above grade or platforms and

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°F 300 400 500 600 700 800 900 1000

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Table 2 . Insulation Thickness for Hot Service (Heat Conservation)

Maximum Operating Temperature

°F 300 400 500 600 700 800 900 1000

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Table 3. Insulation Thickness for Cold Conservation

Material: Cellular Glass

°F +40 +20 0 -25 -75 -125 -175 -225 -275

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°F +40 +20 0 -25 -50 -75 -100

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