Insulation - RPMS ENGG SPC PP 012

Reliance Project Management System
Standard Specification
for
Hot and Acoustic Insulation
RPMS-ENGG-SPC-PP-012
0 25.08.2020 Issued for Implementation MD RS AS/VKM
Rev Date Revision Details Prepared Checked Approved

By By By
Reliance Project Management System RPMS-ENGG-SPC-PP-012
Standard Specification for Hot and Acoustic Insulation Date: 25/08/2020, Rev. 0
STANDARDS SUB-COMMITTEE ENDORSEMENTS
Sr. No. Name Signature Date
Ajay Shrivastava
1 (Sub-Committee Chairman)
_____________________________ _________________ ___________
Anand Umakanthan
_____________________________ _________________ ___________
2
A. Srinagesh
_____________________________ _________________ ___________
3
S. Sammadar
_____________________________ _________________ ___________
4
Kuddallur Seshadri
_____________________________ _________________ ___________
5
_____________________________ _________________ ___________

6
_____________________________ _________________ ___________

7
_____________________________ _________________ ___________

8
_____________________________ _________________ ___________

9
_____________________________ _________________ ___________

10
RECORD OF REVISIONS
Date Revision Details Revision

Number
25.08.2020 First Issue-Based on Bechtel Review 0
Contents
1. Purpose...................................................................................................................... 5
2. References ................................................................................................................. 5
3. Conflicts and Deviations ............................................................................................ 7
4. Abbreviations and Definitions................................................................................... 7
5. Technical and Design Requirements ......................................................................... 9
6. Basic Properties of insulation material ................................................................... 18
7. Application procedure............................................................................................. 22
8. Inspection and Testing ............................................................................................ 43
9. Vendor Data ............................................................................................................ 43
10. Packing, Preservation, shipment and Storage ........................................................ 44
11. Measurement Wastages Norms. ............................................................................ 44
12. Attachment.............................................................................................................. 46
1. Purpose
This Standard Specification is to ensure uniform and sound approach to the hot &
acoustic Insulation for Piping, Equipment and Storage Tanks etc. for all projects of
Reliance.
All tanks, vessels, columns, equipment and piping containing hot fluids or vapours
are to be insulated to meet one of the below requirements.
a) Conserve heat energy/Minimize heat loss.
b) Maintain temperature for process control or product
c) Provide personnel protection.
d) Maintain noise level within specified limit <85 db.
e) Fire protection
This Standard Specification covers minimum requirement for the manufacturing,
supply, application & quality control of thermal insulation for Tanks, Vessels,
Columns, Equipment and Piping operating in the temperature range from ambient
to 600 °C.
This specification is not applicable for cold service insulation. Refer RPMS-ENGG-
SPC-PP-013 for cold insulation.
2. References
The latest edition of following Codes and Standards are referenced in this standard
specification and all relevant provisions of these reference codes and standards
shall be applicable. Any deviation with respect to below mentioned codes and
standards shall be brought to the notice of Buyer for approval.
Standard Standard Description
ASTM B209 Standard Specification for Aluminum and Aluminum-Alloy
Sheet and Plate
ASTM C165 Test Method for Measuring Compressive Properties of
Thermal Insulations.
ASTMC168 Terminology Relating to Thermal Insulating Materials
ASTMC177 Test Method for Steady-State Heat Flux Measurements
and Thermal Transmission Properties by means of the
Guarded Hot-Plate Apparatus
ASTMC303 Test Method for Density and Dimensions of Preformed
Block-Type Thermal Insulation
ASTMC356 Test Method for Linear Shrinkage of Preformed High-
Temperature Thermal Insulation subjected to Soaking
Heat
RIL Confidential Page 5 of 48


ASTMC411 Test Method for Hot-Surface Performance of High-
Temperature Thermal Insulation
ASTMC447 Practice for Estimating the Maximum Use Temperature of
Thermal Insulations
ASTMC585 Practice for Inner and Outer Diameters of Rigid Thermal
Insulation for Nominal Sizes of Pipe and Tubing (NPS
System)
ASTMC680 Practice for Determination of Heat Gain or Loss and the
Surface Temperatures of Insulated Pipe and Equipment
Systems by the Use of a Computer Program
ASTMC692 Test Method for Evaluating the Influence of Thermal
Insulations on the External Stress Corrosion Cracking
Tendency of Austenitic Stainless Steel
ASTMC795 Standard Specification for Thermal Insulation for Use in
Contact with Austenitic Stainless Steel
ASTMC871 Test Methods for Chemical Analysis of Thermal Insulation
Materials for Leachable Chloride, Fluoride, Silicate, and
Sodium Ions
ASTMC930 Materials and Accessories Classification of Potential
Health and Safety Concerns Associated with Thermal
Insulation
ASTMC1338 Test Method for Determining Fungi Resistance of
Insulation Materials and Facings
ASTMC1728 Standard Specification for Flexible Aerogel Insulation
ASTMC1729 Standard Specification for Aluminium Jacketing for
Insulation
EN 13472 Thermal insulating products for building equipment and
industrial installations. Determination of short-term water
absorption by partial immersion of preformed pipe
insulation
AGI Q- 132 Specification for test methods of classification
temperature for mineral wool insulation for industrial use.
IS 8183 Bonded mineral wool specification
IS3144 Mineral wool thermal insulations –method of test
IS9842 Preformed Fibrous pipe insulation- specification


ISO 15665 Acoustics – Acoustic Insulation for Pipes, Valves and
Flanges
RPMS-ENGG-SPC-PP- Standard Specification for Protective Coatings (Shop &
014 Field)
RPMS-ENGG-SPC-PP- Standard Specification for Cold Service Insulation
013
RPMS-ENGG-PRA-PP- Engineering and Procurement strategy for Hot, Cold and
040 Acoustic Insulation
3. Conflicts and Deviations

In the event of conflict or deviation from requirements stipulated in this
specification and other applicable documents, the following order of precedence
shall govern:
1. Line designation Table (LDT) & Equipment GA Drawings
2. The Material Requisition
3. This Standard Specification
4. Codes and Standards Specifically Referred
5. Other National and International Standards as Referenced
Latest revisions of codes and other statutory requirements as applicable at the time
of enquiry, shall be applicable. In case of any conflict, the decision of owners
engineer in charge shall be final and seller shall implement that without any
commercial implications. All “local and statutory requirements as applicable shall
be complied to without any deviation”.
1. “Data Sheets and Drawings” represent those attached to the Material
Requisition – Equipment Datasheets, Stock Code Item Description, Piping &
Instrumentation Diagram.
2. “Material Requisition” represents Material Requisition for Quotation,
superseded by Material Requisition for Purchase on execution of a Purchase
Order
4. Abbreviations and Definitions

Abbreviations
AHA : Acoustic Hot Insulation Class A
AHB : Acoustic Hot insulation class B
AHC : Acoustic Hot Insulation Class C
AIA : Acoustic Insulation Class A

AIB : Acoustic Insulation Class B

AIC : Acoustic Insulation Class C
ASTM : American society for testing and materials
BIS : Bureau of Indian standard
BS : British Standard
C/C : Centre to Centre
CUI : Corrosion Under Insulation
DEC : Design Engineering Contractor
ET : Electric Traced
FI : Fire safe insulation
FSI : Flame Spread Index
HC : Heat Conservation
HCET : Heat Conservation with Electric tracer
HCHT : Heat Conservation with High pressure steam tracer
HCLT : Heat Conservation with Low pressure steam tracer
HCMT : Heat Conservation with Medium pressure steam tracer
HCWT : Heat Conservation with warm water tracer
ISO : International Organization for Standardization
LDT : Line Designation Table
LRB : Lightly Resin bonded
MW : Mineral Wool
NI : No Insulation
O&M Operations and Maintenance
PG : Personnel guards
PP : Personnel Protection
PS : Pipe Section
SDI : Smoke Development Index
SP : Solar Protection
SS : Stainless Steel
ST : Steam Traced
WFT : Wet Film Thickness

Definitions
Parties responsible for complying with an Engineering Standard
Supplier/Vendor: Party which manufactures or supplies materials and services to
perform the function as specified by Buyer
Buyer: Owner (Reliance or Owner-appointed licensor, DEC or EPC who specifies
equipment and services for purchase from Supplier
Parties referred within body of Engineering Standard
Owner: Reliance Industries Limited or specified Reliance Group Company
DEC: Detailed Engineering Contractor
EPC: Engineering, Procurement and Construction Contractor
Contractor: DEC or EPC
Insulation Contractor: Supplier of insulation services
Applicator: The party contracted to install the insulation systems
Insulation Material Supplier: Supplier / Manufacturer of insulation materials
Standard Terminology Relating to Thermal Insulating Materials is defined in ASTM
C168.
5. Technical and Design Requirements
5.1. Basic Design and Engineering of an insulation system shall be governed by
following parameters.
▪ Heat conservation with economical thickness
▪ Avoiding of corrosion under Insulation (CUI).
▪ Compliance with safety requirements for personnel protection
(PP/PG).
▪ Compliance with process conditions / requirements.
▪ Acoustic requirements
▪ Fire safe requirements (FI)
5.2. Based on above criteria following are the type of insulation covered in this
standard specification.
• These Insulation codes to be used by all stake holder, DEC or Process licensors
for P&ID, ISO and PDS CAD modelling.

Insulation type Insulation material

HC Heat conservation
HCLT Heat Conservation with Low pressure steam tracer
Heat Conservation with Medium pressure steam
HCMT
tracer
HCHT Heat Conservation with High pressure steam trace
HCWT Heat Conservation with warm water tracer
HCET Heat Conservation with Electric tracer
SP Solar protection (potable water ,Breathing air etc.)
AIA/AIB/AIC Acoustic insulation Class A/ Class B/ Class C
Heat conservation + Acoustic insulation Class A/Class
AHA/AHB/AHC
B/ Class C
PP Personnel protection
PG Perforated guard
NI No insulation
DC Dual Condition (hot and cold service)
Note:1: For all other details of "DC" type insulation refer RPMS-ENGG-SPC-PP-013.
Note:2:Details of Insulation and material required against each type of insulation
shall be as per Table 1.
Note:3:Inside and outside diameters of pipe insulation shall comply with ASTM
C585.

Table 1: Insulation and materials requirements

Type of insulation & Applicable insulation and Cladding material
Insulation type Insulation material Cladding material
0.9 mm aluminium cladding with
polysurlyn moisture barrier ,
Silica aerogel +Mineral wool
HC 0.8 mm thick corrugated
Slab or Pipe section
cladding for Equipment and
tanks >900 mm diameter
Silica aerogel +Mineral wool
HCLT, HCMT, polysurlyn moisture barrier
Slab or Pipe section
HCHT, HCWT & 0.8 mm thick corrugated
HCET (Insulation thickness as for
HC. Type insulation).
polysurlyn moisture barrier
Mineral wool Slab or Pipe
SP 0.8 mm thick corrugated
section
Mineral wool slab or pipe 0.7/0.8/1.2 mm thick Aluzinc
AIA/AIB/AIC
section. cladding as per acoustic class
Silica aerogel +Mineral wool 0.7/0.8/1.2 mm thick Aluzinc
AHA/AHB/AHC
Slab or Pipe section cladding as per acoustic class
0.9 mm AL. cladding with
polysurlyn moisture barrier
Mineral wool slab or pipe
PP 0.8 mm thick corrugated
section.
1.2 mm Aluminum perforated
PG NA
guard
NI No insulation
As per Table 5-2 of As per Table 5-2 of
DC
RPMS-ENGG-SPC-PP-013 RPMS-ENGG-SPC-PP-013

5.3. Extent of insulation

5.3.1. Extent of insulation for Vessel, equipment and exchanger
5.3.1.1. All Equipments, Exchangers and Vessel within the scope of this specification shall
be completely insulated including all hand hold covers, Manholes, support ring
stiffeners, lifting lug, etc.
5.3.1.2. For tank insulation, anchor chairs shall be insulated fully by insulation contractor.
5.3.1.3. All instrument assemblies requiring insulation and attached to insulated equipment
shall be insulated for the operating temperature of equipment.
5.3.1.4. All the protrusion shall be insulated minimum 300 mm or 4 times the insulation
thickness, whichever is the more stringent.
5.3.1.5. Bottom dish ends of insulated vessel secured in skirt, shall be cladded with hard set
cement and Reinforcement glass cloth in lieu of Cladding material.
5.3.1.6. Vessel trims of insulated vessel or equipments, shall be insulated as per vessel
insulation thickness up the extent to 300 mm or 4 times the insulation thickness.
5.3.2. Extent of insulation for piping
5.3.2.1. Straight Pipes, elbows, tees and all other welded fittings shall be insulated as
defined in LDT.
5.3.2.2. Lines with Tracers and Jacketing shall be completely insulated, valves and flanges
shall be insulated as per guidelines provided in section 5.3.3.
5.3.2.3. All protrusions, Vent, Drains, by pass & support attached to parent piping shall be
insulated with the same insulation thickness as of parent pipe and extent of
insulation shall be 4 times the thickness of insulation or 300 mm, whichever is
greater.
5.3.2.4. For steam trap insulation, steam trap manufactures guidelines shall be followed
5.3.2.5. For closed recovery system, outlet piping of steam trap shall be insulated.
5.3.2.6. Condensate lines down stream of steam trap, discharging to drainage system, shall
not be insulated unless otherwise specified. If insulation is required for safety
purpose, perforated guard shall be provided.
5.3.2.7. Relief valves, flare and blow down piping system shall not be insulated unless
otherwise specified.
5.3.3. Extent of insulation for valves and flanges
5.3.3.1. Unless otherwise specified, all valves & flanges shall be insulated in steam and
condensate lines.
5.3.3.2. Flanges and valves shall not be insulated in system containing
 Hydrogen service.
 Hydrocarbon /Process lines.

 Hydrocarbons above their auto-ignition temperature.

 Flange joints where 80% rule for bolting has been applied as per ASME B
31.3.
5.3.3.3. Valves and flanges for the lines categorized in clause 5.3.3.2, shall be insulated if
specifically required by Process Licensors. In addition to Process Licensor’s
requirement, below guidelines shall be strictly followed.
5.3.3.4. All such valves and flanges shall be clearly identified/ defined in LDT and Marked in
Isometrics.
5.3.3.5. Valve body only to be insulated excluding bonnet and valve flanges, leaving the
flange joint open for inspection.
5.3.3.6. Bolts of flange joints shall not be covered with insulation.
5.3.3.7. Wherever conventional lagging and cladding is not feasible for valve size up to 6”,
same shall be insulated with removable box type Pad Insulation with suitable silicon
impregnated fiber glass cloth or high silica cloth for higher temperature.
5.3.3.8. Where ever Fire safe insulation is specified, valve and flanges shall be insulated with
boxes using cellular glass material with thickness as per Process Licensors /DEC
specification. In case of non-availability of Process licensors /DEC guidelines,
insulation shall be carried out as per “Attachment No 8” of this specification.
5.4. Insulation Thickness Table
5.4.1. Thickness of insulation for Heat Conservation (HC)
• Heat conservation thicknesses calculated using NAIMA (North American
Insulation Manufacturers Association) 3E PLUS surface temperature computer
analysis.
Table 2:Thickness calculation Basis
Inner Wrap Silica Aerogel
Outer Layer Mineral wool
Bare Surface Emittance 0.8
Cladding Emittance 0.3
Average Ambient Temperature 35 °C
Maximum Outer Temperature 55 °C
Wind Speed 0 m/s

Table 3- Thickness Table for Heat conservation (HC)

Silica Aerogel /Mineral wool combination thickness Table (mm / mm)
NPS
(IN) Operating Temperature (°C)
151- 201- 251- 301- 351- 401- 451- 501- 551-
55-150 200 250 300 350 400 450 500 550 600
0.5 0 / 40 0 / 40 0 / 50 0 / 65 0 / 65 0 / 80 0 / 100 0 / 115 0 / 125 0 / 165
0.75 0 / 40 0 / 40 0 / 50 0 / 65 0 / 80 0 / 90 0 / 100 0 / 125 0 / 150 0 / 175
1 0 / 40 0 / 40 0 / 50 0 / 65 0 / 80 0 / 90 0 / 115 0 / 125 0 / 165 0 / 175
1.5 0 / 40 0 / 40 0 / 50 0 / 80 0 / 80 0 / 100 0 / 115 0 / 150 0 / 175 0 / 200
2 10 / 40 20 / 25 25 / 25 20 / 65 25 / 65 25 / 90 30 / 75 35 / 75 35 / 75 45 / 75
3 10 / 40 20 / 40 15 / 50 15 / 65 25 / 75 15 /115 30 /115 35 /140 50 / 75 50 / 75
4 10 / 40 20 / 40 25 / 40 25 / 65 25 / 75 25 /100 25 /125 35 /140 60 / 75 60 / 75
6 10 / 40 20 / 40 20 / 65 25 / 65 25 / 90 25 /115 35 / 75 50 / 75 60 / 75 70 / 75
8 10 / 40 20 / 50 20 / 65 25 / 65 25 / 90 25 /125 40 / 75 60 / 75 60 / 75 70 / 75
10 10 / 40 20 / 50 20 / 65 25 / 75 25 /100 30 /125 50 / 75 60 / 75 60 / 75 70 / 75
12 10 / 40 20 / 50 15 / 65 25 / 75 30 /100 40 /125 50 / 75 70 / 75 70 / 75 70 / 75
14 10 / 40 20 / 50 20 / 75 25 / 75 25 /115 25 /140 50 / 75 70 / 75 70 / 75 80 / 75
16 10 / 40 20 / 50 20 / 75 25 / 75 25 /115 25 /140 50 / 75 70 / 75 70 / 75 80 / 75
18 15 / 50 10 / 65 20 / 75 25 / 90 25 /115 25 /150 50 / 75 70 / 75 70 / 75 80 / 75
20 15 / 50 10 / 65 20 / 75 25 / 90 25 /115 25 /150 60 / 75 70 / 75 70 / 75 80 / 75
24 15 / 50 10 / 65 20 / 75 25 / 90 25 /125 25 /150 60 / 75 70 / 75 70 / 75 80 / 75
30 15 / 50 10 / 65 20 / 75 20 /105 20 /140 50 / 75 60 / 75 70 / 75 70 / 75 80 / 75
36 15 / 50 10 / 65 20 / 75 20 /105 20 /140 50 / 75 60 / 75 70 / 75 80 / 75 80 / 75
Pipe>36”
and all
equipments 15 / 50 10 / 65 20 / 75 20 /105 20 /150 40 /125 70 / 75 80 / 75 80 / 75 90 / 75
Insulation thickness for piping and equipment shall be selected from above Table 3
and same shall be specified in equipment data sheet and piping isometric.
Thickness shown in Table 3, 10/40 means, combination of
• 10 mm Silica Aerogel
• 40 mm mineral wool
When operating temperature exceed 600°C, additional layer of ceramic fibre
blanket shall be provided on the hot face (Inner most layer) of piping or equipment
as per thickness mentioned below,

• Operating temperature between 601°C and 700°C - 13 mm

• Operating temperature between 701°C and 800°C - 38 mm
• DEC to calculate the temperature at outer most layer of ceramic fiber blanket
and shall specify the thickness of “HC” insulation as per Table 3 provided above.
5.4.1.1. Thickness Break up for Mineral wool insulation (Pipe section /Slab)
• Mineral wool insulation shall be applied in single layer for all piping and
equipments up to thickness 75mm.
• When mineral wool insulation thickness is more than 75 mm, required
thickness shall be build up in multiple layer as per Table 4.
Table 4: Thickness Break-up for multilayer mineral wool insulation
Sr no Total thickness of mineral wool material Thickness break up
1 80 40+40
2 90 40+50
3 100 50+50
4 105 40+65
5 115 40+75
6 125 50+75
7 140 65+75
8 150 75+75
9 165 40+50+75
10 175 50+50+75
11 180 40+65+75
12 190 40+75+75
13 200 50+75+75
5.4.1.2. Provision of foil at interface of Silica aerogel and Mineral wool material.
• Foil shall be provided at Silica aerogel and Mineral wool Interface as per table
below.
Sr No Operating Temperature Type of Foil
1 300°C to 400 °C 0.19 mm Aluminum foil
2 Above 400 °C 0.1 mm SS foil

• Securement of foils for piping & equipments,
Pipe diameter 8” & below 1 mm diameter wire (SS304) @200 CC

Pipe diameter above 8” and all 0.2 mm thick X 10 mm wide SS304
equipment bands @200 CC
• All insulation penetrations and terminations (valve bonnets, supports,
trunnion’s, instrument tubing, etc.), the foil shall be folded over the exposed
end of the Silica aerogel and compressed around the penetration to form a
tight fit cover.
• To improve air sealing at pipe supports, wrap foil over the Silica aerogel such
that the foil drapes onto the web of the support by 50mm.
5.4.2. Thickness of insulation for Personnel Protection (PG/PP)
5.4.2.1. Thickness of insulation for PP & PG for piping and equipment shall be as per Table
5.
Table 5- Thickness Table for Personnel Protection (PP)
Operating
Insulation Type Remarks
Temperature
Refer “Attachment No.9
& 11” for piping &
Perforated Guard 1.2 mm all along
equipment respectively
56°C to 200°C the line / equipment for
(refer clause 7.2.5 for
approachable area. (refer 7.2).
S=distance of Perforated
guard)
201 °C to 400 °C 65 mm thick mineral wool Slab or pipe section
401 °C to 600 °C 90 mm thick mineral wool Slab or pipe section
5.4.3. Thickness of insulation for Solar Protection (SP)

5.4.3.1. Thickness of insulation for solar protection shall be calculated by DEC. If not
specified, 40 mm mineral wool thickness shall be used.
5.4.4. Thickness of insulation for Impulse line
5.4.4.1. Impulse line shall be insulated sing fiber glass braided ceramic rope. Thickness &
layers of fiber glass braided ceramic rope shall be as per below Table 6.
Table 6- Thickness Table for impulse lines
Size of No. of insulation
impulse Operating Temperature. Thickness of each layer
Layer
line
½” Up to 150 °C 2 13 mm
¾” Up to 150 °C 2 19 mm
½” 151°C to 250 °C 2 19 mm
Size of No. of insulation

impulse Operating Temperature. Thickness of each layer
Layer
line
¾” 151°C to 250 °C 2 19 mm
5.4.4.2. For lines operating above 250 °C, thickness of insulation shall be calculated by DEC.
5.5. Acoustic Insulation Engineering Requirement
5.5.1. General requirement
5.5.1.1. The performance of Acoustic Insulation is defined as Class A, Class B or Class C.
Minimum insertion loss shall be as specified in ISO 15665 for the defined Class of
Acoustic Insulation, for piping equipment and tanks
5.5.1.2. Acoustic Insulation shall be provided to all piping operating with sound pressure
level greater than 85 dB (A) at 1.0-meter distance.
5.5.1.3. Class A provides the lowest level of acoustical benefit. Where a section of pipe is
designated with class A insulation, the associated flanges and valves need not be
insulated.
5.5.1.4. Class B &C insulation shall be applied in 2 x 50mm layers of mineral wool with
staggered joints. All flanges and valves shall be insulated to the same class as the
pipe except where insulation of such devices is not allowed for safety reasons (for
example in hydrogen service). Pipe supports when necessary shall be insulated
down to the concrete or steel base, or alternatively to the vibration isolator. (Refer
“Attachment No. 26”)
5.5.1.5. Process Licenser’s / Manufacturer’s requirements of Acoustic Insulation for
Equipment and /or piping shall be in accordance with the relevant specifications
furnished by them.
5.5.2. Acoustic Insulation Thickness Requirements
5.5.2.1. Wherever the Hot and Acoustic (AHA, AHB, AHC) Insulation is required for piping /
Equipments, silica aerogel + mineral wool insulation material shall be used.
5.5.2.2. Thickness of insulation system shall be as per Table 3 (Clause 5.4.1). The thickness
of Insulation shall be more stringent of the two requirements.
5.5.2.3. Wherever insulation is required for Acoustic reasons only the insulation material
shall be Mineral wool material and thickness of insulation shall be as per Table 7
(Insulation type AIA, AIB, AIC).
Table 7- Insulation requirements for acoustic insulation
Acoustic class Insulation thickness with only mineral
wool
AIA 50 mm
AIB 100 mm (50 mm + 50 mm)

AIC 100 mm (50 mm + 50 mm)
5.5.3. Cladding for Acoustic Insulation

5.5.3.1. The Table below shows the recommended thickness of the cladding materials.
Table 8- Cladding requirement based on acoustic insulation type
CLASS Min. mass of cladding. (kg/m²) Cladding Type & Thickness. (mm).
A 4.5 0.7 Aluzinc
B 6.0 0.8 Aluzinc
C 7.8. 1.2 Aluzinc
5.5.3.2. In case correct gauge of Aluzinc cladding is not available to achieve the required
mass as per Table 8, then the cladding may be composed of an outer layer of metal
for weather jacketing and an inner damping layer. The inner layer may be made of
PVC foil weighted with barium oxide to provide the additional mass or a high mass-
per-unit-area limp rubber or plastic sheet.
5.5.3.3. The total weight for the vinyl sheet and cladding shall comply with Table 8. The
material should be suitable for service between -29°C and 82°C and have the ability
to self-extinguish. Adhesive for laps shall be phenolic-based nitrile material,
compatible with the sheet and approved by the loaded vinyl manufacturer. The
loaded vinyl may be bonded to the insulation-facing side of the cladding.
6. Basic Properties of insulation material
Unless otherwise specified, materials shall be selected from those described in
Table 9. All materials shall comply with the relevant BS / ASTM or Indian standards.
Insulation materials can affect personal health. Guidance on the classification of
health and safety concerns associated with insulation materials and accessories is
defined in ASTM C930.
6.1.1. Properties of mineral wool material
Table 9- Insulation materials
Sr.
Properties Standard Acceptable values
no
1 Density
1.1 Mineral wool IS 8183 / IS-
144 kg/m³ ±10% Tolerance
mattress 3144
1.2 Mineral wool pipe IS 9842/ IS- 160 kg/m³ ±10% Tolerance
section 3144

Sr.
Properties Standard Acceptable values
no
1.3 IS 8183 / IS- 150 kg/m³ ±10% Tolerance
Mineral wool slab 3144
2 Dimensions
2.1 Length 1.5 meter +/-0.5%, width 0.6
Mineral wool meter +/-0.5%, Thickness -2/+5mm
mattress
2.2 Mineral wool pipe Length 1 meter (+/-0.5%), ID(+/-1.6mm),

section Thickness -2/+5 mm, OD(+/-1 mm)
2.3 Length 1-meter (+/-0.5%) X Width 0.6
Mineral wool slab (+/-0.5%), Thickness-2/+3mm
3 pH Content & IS 8183 / IS- 7 to 8

Chloride content 3144 14 mg/Kg Max
4 Fire resistance ASTM E 84 FSI<5, SDI<10
5 No flammable material attached to insulation
6 Insulation material shall be asbestos free
For approved supplier for Mineral wool material refer RPMS-ENGG-PRA-PP-040,

No other equivalent material Shall be used without prior approval from Core
Engineering.
6.1.2. Properties required for Silica Aerogel insulation material
6.1.2.1. Silica aerogel material shall confirmed to ASTM C1728 Type III, Grade 1, Category
A. The material going to be used shall be Pyrogel XTE from Aspen Aerogel. No other
equivalent material may be used without prior approval from Core Engineering.
Sr no Properties Standard Acceptable value

1 ASTM C
Density 176 kg/m3 (-0/+5% Tolerance)
1728
6.1.2.2. Higher version of Silica aerogel -Pyrogel HPS from Aspen Aerogel may be used for
high temperature lines operating above 350°C, however higher version of silica
aerogel may be used on stand-alone basis (i.e. without Mineral wool combination)
with Core Engineering approval.

6.1.3. Properties for Cellular Glass material

6.1.3.1. Cellular Glass material shall confirm to requirement of ASTMC 552 Grade 6, with
additional requirement as Table 10.
Table 10- Cellular glass insulation materials
1 Density ASTM C 303 115 kg/m³ ± 10% Tolerance
2 Water vapour ASTM E 96 0.00 ng/pa.s.m
permeance
3 FSI/SDI ASTM E 84 0/0
6.1.3.2. Gypsum Cement (Hydrocal B 11) shall be used as a bore coating. Thickness of
gypsum cement shall be ≥ 1.2 mm.
For approved supplier for Cellular glass & Ancillaries material refer RPMS-ENGG-
PRA-PP-040, No other equivalent material Shall be used without prior approval
from Core Engineering.
6.1.4. Properties for Aluminum Cladding material
• Insulation shall be protected from weather, oil spillage, mechanical wear or
other damage by Aluminum cladding with factory applied 75 microns thick
Polysurlyn moisture barrier heat laminated to inner surface of cladding.
Properties as Table 11.
Table 11- Aluminium cladding materials
1 Plain Aluminium ASTM C Thickness 0.9 mm/ 1.2mm, Aluminum
Cladding 1729 shall be 5005, 3105, 3103 or 1100 alloys
with H14 tempered in accordance with
ASTM B209 or 19000 H2 as IS 737.
2 Corrugated ASTM C Thickness 0.8 mm, Pitch of corrugation

Aluminium 1729 30 mm, Corrugation depth shall be 6 mm
Cladding
3 Polysurlyn ASTM C 75µm thick (over and above cladding
1729 thickness)
For approved supplier for Aluminum Cladding material refer RPMS-ENGG-PRA-PP-

040, No other equivalent material Shall be used without prior approval from Core
Engineering.

6.1.5. Properties of Aluminized steel cladding.

6.1.5.1. Aluminized Steel shall be type T2-100 as designated in ASTM A463 or approved
equal.
6.1.6. Properties of Aluzinc Cladding
6.1.6.1. Aluzinc cladding shall be as Table 12.
Table 12- Aluzinc cladding materials
Sr no Material Standard Requirement
1 0.7/0.8/1.2mm Properties shall be Material shall be CS
Aluzinc as per ASTM type B, with
A792/792M minimum coating
weight as per Table
2 of ASTM A792 and
coating grade
AZM210
For approved supplier for Aluzinc Cladding material refer RPMS-ENGG-PRA-PP-040,

No other equivalent material Shall be used without prior approval from Core
Engineering.
6.1.7. Ceramic Fiber Blanket properties.
6.1.7.1. Ceramic fiber blanket shall be used for Insulation where surface temperature is
above 600 °C. Ceramic fiber shall confirm to ASTM C 892 Grade III, Type 8. Materials
shall be as Table 13.
Table 13- Ceramic Fibre Blanket
Density 128kg/m³ ± 10%
Maximum Service Temperature 1260°C
Thermal Conductivity @ 800°C 0.15 W/m K
For approved supplier for Ceramic fiber blanket material refer RPMS-ENGG-PRA-
PP-040, No other equivalent material Shall be used without prior approval from
Core Engineering.
6.1.8. Ceramic Fiber rope properties
6.1.8.1. Ceramic fiber rope shall be used for impulse piping insulation purpose. Properties
shall be as Table 14

Table 14-Ceramic fibre rope

Density 250 kg/m³± 10% with fibre glass braiding
Maximum Service Temperature 500°C for Impulse lines
6.1.8.2. All other properties shall be as per ASTM C 892 Grade III, Type 8.
For approved supplier for Ceramic fiber rope material refer RPMS-ENGG-PRA-PP-
040, No other equivalent material Shall be used without prior approval from Core
Engineering.
6.1.9. Cladding for Fire Safe Services
6.1.9.1. For fire safe services the cladding shall be as specified by DEC/Process Licensors.
6.1.9.2. Generally, for Fire safe requirement Polysurlyn moisture barrier sheet is not
recommended as per standard practice.
6.1.10. Anti-Vibration Seal for Acoustic Insulation
The following materials are suitable for use in anti-vibration seals: -
1. Synthetic rubber.
2. Natural rubber.
3. Non-flammable felt.
4. Strip and Stick AR 300
5. Silica Aerogel material Strip
Where these materials are not compatible with the operating temperature, the seal
shall be made from suitable compressed porous-layer material.
6.1.11. Cladding Sealing Strip for Acoustic Insulation
6.1.11.1. All cladding joints shall be sealed with an elastomeric sealant. The material shall be
fiberglass reinforced sponge silicone tape such as “STRIP-N-STICK AR 300”
manufactured by Saint Gobain Performance Plastics or an approved equivalent.
Each strip shall be 13mm wide x 1.5mm thick minimum.
7. Application procedure
7.1. Surface Preparation prior to Insulation of tanks, equipment and piping.
7.1.1. All surface preparation, materials, and other work shall comply with all applicable
environmental and safety provisions, laws, regulations, ordinances, etc., of the
city, county, state, province, or nation pertaining to the work being performed
and the materials being used.

7.1.2. The surface to be insulated shall be cleaned free of oil, grease and all other
foreign matter and moisture prior to the application of any insulation. No
insulation shall be installed until completion of any stress-relieving, chemical
cleaning, coating application, pressure testing, tracer installation, and release of
the surfaces in writing by RMPG’s site representative.
7.1.3. Painting shall be as per RPMS-ENGG-SPC-PP-014 prior to the start of insulation.
7.1.4. Damaged painting, rusted surface shall be immediately reported to concern Buyer
representative for rectification.
7.1.5. Selection of foil over the hot surface (over pipe/Equipments) prior to insulation.
MOC Operating Temperature Foil Description
CS Above 400°C 0.19 mm Aluminum Foil
SS & Alloy Steel 201°C to 400°C 0.19 mm Aluminum Foil
SS & Alloy Steel Above 400°C 0.1 mm SS foil
• Securement of foils for Piping & equipments,
Pipe diameter 8” & below 1 mm diameter wire (SS304) @200 CC
Pipe diameter above 8” and all 0.2 mm thick X 10 mm wide SS304 bands @200
equipment CC
7.2. Application procedure for Personnel Protection (PP)/Standoff guard (PG)
7.2.1. Personnel Guards or “PG” insulation shall be applied for protection of O&M
personnel. Protection shall be provided for all exposed surfaces with operating
temperatures 56°C to 200℃ that are located.
▪ within 600 mm horizontally or 2000 mm vertically of normal access
areas
▪ around operating platforms, along the grade & walkway
7.2.2. Perforated guard shall be installed all along the pipeline / Equipment for all
normal accessible areas.
7.2.3. 5 mm thick Silica aerogel material strip shall be provided at each support location
for perforated guard beneath the support clip, to avoid galvanic corrosion. (Refer
Attachment No 9 & 11)
7.2.4. Flanges shall not be insulated. Perforated plate or expanded metal of 1.2 mm
thick shall be used for insulation of flanges. The perforated area shall be at least
35%, with a hole diameter max. 5mm in triangular pattern.
7.2.5. Distance between Hot surface and Perforated plate shall be as per Table 15.

Table 15- Distance between Hot surface and perforated guard

Nominal Pipe Diameter Distance between uninsulated flanges or equipment
(inches) and perforated plate (mm)
1” – 8” 50
10” – 16” 100
18”-24” 150
Equipment and piping > 24” DEC to calculate the distance of perforated plate to
maintain the temperature maximum 55 °C at the
surface of perforated plate .
7.2.6. Application procedure for “PP” type insulation is similar as mentioned in Section
7.3 for Piping and Section 7.5 for equipment. Thickness for mineral wool shall be
according to 5.4.2.1.
7.3. Application of Insulation to Piping in Hot Service (HC type insulation)
7.3.1. General Requirements
7.3.1.1. Wet, oil soaked, and damaged insulation shall not be used. Due Care shall be taken
that no flammable material is attached to the insulation material. All insulation and
necessary materials shall be protected from moisture during Storage & installation.
Suitable protection shall protect insulation in wet weather conditions until the final
application of the permanent cladding or weather barrier. Wet insulation is
unacceptable and must be replaced with dry materials. foil
7.3.1.2. Expanded perlite and cellular glass which has been exposed to the rain or other
moisture shall be dried to the Buyer's satisfaction. Mineral wool and calcium silicate
that becomes wet shall be removed from the site and not used.
7.3.1.3. All piping in hot service (HC) shall be insulated with Silica aerogel blanket as inner
wrap, with all longitudinal and circumferential joints butted tightly. Outer layer
shall be rigid slabs or preformed mineral wool half sections. (Refer “Attachment No.
15”)
7.3.1.4. Insulation adjacent to flanges in piping and equipment shall be terminated to allow
removal of bolts without damage to insulation. Bolt clearance from the flange to
the insulation cladding shall be at least the bolt length +25 mm. For certain flange
bolts, hydraulic bolt tension or torqueing equipment may be used which requires
greater bolt clearance. Mechanical/piping specifications should be consulted for
these clearances. (Refer “Attachment No. 7”).
7.3.1.5. Insulation contractor to prepare detailed sketch and submit for approvals from
buyer prior to application.
7.3.1.6. For supply of bolted type insulation support, insulation contractor shall prepare and
submit sketch showing the support details and obtain approval from Buyer prior to
the supply. The same shall be installed by Insulation Applicator. If welded types of
insulation supports are used, these shall be installed by the Piping contractor.

7.3.1.7. All pipe insulation shall be provided with an aluminum metal cladding with a factory
applied Polysurlyn Moisture barrier, unless otherwise specified.
7.3.1.8. For hydrocarbon & process lines, ends of pipe runs at flanges shall be sealed with
Hard Set Cements (BD6 or CAT 9 Cement or approved equivalent) to prevent the
product from entering in to the insulations in case of leakages. (“Refer Attachment
No. 7”)
7.3.1.9. For utility lines which are insulated except for valves and flanges, ends of pipe runs
at flanges shall be sealed as above. (Refer “Attachment No. 7”)
7.3.1.10. Small bore Insulated utility lines (Except Hydrocarbon /process lines less than 2”),
end of pipe runs shall be sealed as per “Attachment No 27 A”.
7.3.1.11. Insulation contractor shall be aware of the health and safety issues associated with
insulation materials and shall follow the guidance provided in ASTM C930.
7.3.2. Installation of silica aerogel and mineral wool
7.3.2.1. Inner wrap shall be Silica aerogel blanket over hot face. The outer layer over silica
aerogel shall be mineral wool pipe section up to 24” OD of insulation and above 24”
OD of insulation, mineral wool slab shall be used.
7.3.2.2. Silica aerogel insulation shall be applied by “cigarette wrapping” around the pipe,
as illustrated in “Attachment No.15”. Insulation shall be applied square to the
longitudinal axis of the pipe / equipment and pulled tight around the
circumference.
7.3.2.3. For pipe sizes <4”, 5 mm thick Silica aerogel material shall be used, while for pipe
sizes ≥4” both 5 mm and 10 mm thick Silica aerogel can be used.
7.3.2.4. Where ever combination of 5 mm and 10 mm thick silica aerogel is specified, 5 mm
thick layer shall be installed first.
7.3.2.5. Circumferential & longitudinal joints of silica aerogel shall be tightly butted with no
visible gaps. For multi-layer installations, circumferential and longitudinal joints
shall be staggered by a minimum of 75 mm (3”) with respect to previous layer.
7.3.2.6. The Mineral wool insulation over silica aerogel shall be snugly fitted, with all joints
tightly butted with no visible gaps. All circumferential and longitudinal joints shall
be staggered as per “Attachment No. 15”. Before Application of Mineral wool
applicability of foil shall be check as per clause 5.4.1.2.
7.3.2.7. The insulation shall be secured firmly with tie-wire or band as mentioned in this
specification. Twisted ends of the wire shall be bent flush with the surface of the
insulation. When bands are used, it shall be secured with conventional wing seals.
7.3.2.8. For bends up to 24” OD of insulation, miter segments for insulation shall be cut
from mineral wool pipe section. Above 24” OD of insulation, elbows shall be
insulated with Mineral wool mattresses as shown on “Attachment No. 14”.
7.3.3. Securement for basic insulation will be as follows

7.3.3.1. Silica aerogel layer shall be secured layer wise. Initial and subsequent layers of silica
aerogel shall be secured with 1 mm SS 304 wire at C/C 225 mm . Final silica aerogel
layer shall be secured with 0.6 X20 mm SS bands at C/C 225 mm C/C.
7.3.3.2. Securement method for mineral wool over silica aerogel.
OD of insulated surface Securement method for mineral wool
up to 900 mm. 0.6 mm x 20 mm aluminium bands at C/C 225 mm.
> 900 mm. 0.6 mm x 20 mm SS 304 bands at C/C 225 mm.
7.3.4. Application of Metal Cladding

7.3.4.1. The final weather cover for the insulation shall be 0.9 mm Aluminum cladding with
factory bonded Polysurlyn moisture barrier as specified for HC insulation.
7.3.4.2. Cladding shall be provided with minimum 75 mm overlap at the longitudinal seam
and circumferential seam, with double groove on both ends.
7.3.4.3. The cladding shall be applied to ensure a tight fit over the insulation and to prevent
any lifting of the lapping edge at the longitudinal seam. All longitudinal seams shall
be staggered on alternative sides (4 o’clock and 8 o’clock) of the pipe and laps shall
be located to give maximum protection from wind and rain. A bead of Metal Sealant
shall be sandwiched between overlap to prevent rain water penetration, bead
thickness shall be 3.2 mm.
7.3.4.4. Securement of cladding shall be by means of SS self-tapping pan head screws 12
mm long (No. 10) with maximum gap of 100 mm C/C at the longitudinal seam.
7.3.4.5. Screws are not required at the circumferential seam, except for vertical piping,
where a maximum of 4 screws per lap are required for line with OD of insulation up
to 200 mm. Beyond 200 mm OD of insulation screws shall be provided at 45 degrees
along the circumference at equal spacing around the pipe.
7.3.4.6. Any penetrations of the metal cladding by pipe supports, nipples etc., shall be
weatherproofed by a tight fit metal flashing, with minimum overlap 75 mm. Any
voids between the cladding and weatherproofed flashing shall be filled with Metal
Sealant to prevent the ingress of moisture, water and foreign contaminants.
7.3.4.7. The metal cladding at the elbow shall be of lobster back construction or two piece
formed covers secured at seams by SS self-tapped pan head screws 12 mm long
(No. 10). Screws shall be placed at maximum 75 mm C/C.
7.4. Insulation of Valves and Flanges
7.4.1. Application of insulation of valves and flanges for Steam and condensate lines
(HC)

7.4.1.1. Wherever insulation is specified in steam & condensate lines the insulation material
shall be silica aerogel + mineral wool mattress material.
7.4.1.2. Thickness of silica aerogel and mineral wool material shall be same as specified on
Piping as per Table 3.
7.4.1.3. The inner wrap shall be silica aerogel blanket over valves & flanges with 50 mm
overlap.
7.4.1.4. After application of Silica aerogel material, Mineral wool mattress application to be
completed as mentioned above with basic securement procedure as per clause
7.3.3. Application of foil shall be ensure as per Clause 5.4.1.2.
7.4.1.5. The insulation of valves and flanges where specified for steam and condensate
services shall be carried out by means of flexible, reusable, weather proofed covers
or insulation lined boxes in accordance with the valve and flange box details refer
“Attachment No. 8”.
7.4.2. Insulation of valves and flanges in Hydrocarbon / Process lines. (HC)
7.4.2.1. Process Licensors/DEC shall identify valves and flanges to be insulated for
hydrocarbon and process lines. The same shall be marked in LDT and Isometrics by
DECs.
7.4.2.2. For valve size ≥ 8” valve body shall be insulated with silica aerogel and mineral wool
mattress as per 7.4. Valve and bonnet flanges shall not be insulated, bolts shall be
left un insulated. (Refer “Attachment 19 Sheet 4 of 4”). Application of foil shall be
ensure as per Clause 5.4.1.2.
7.4.2.3. For valve size <8”, valve shall be insulated with removable pad type insulation as
per section 7.6. (Refer “Attachment 19 Sheet 3 of 4”)
7.4.2.4. Flanges of all sizes in hydrocarbon and process lines shall be insulated with
removable pad type insulation as per section 7.6.
7.4.3. Expansion Joints (HC)
7.4.3.1. Due to the difference in expansion coefficients of metals and insulating materials,
necessary allowance should be provided for differential movements between the
hot surface, the insulation material and the cladding. DEC to calculate the
differential expansion and provide the distance at which expansion joint shall be
provided.
7.4.3.2. If no guideline is provided by DEC, expansion joints shall be provided on insulated
lines operating at ≥400°C, at every 6 meters centers on horizontal lines and at each
insulation support ring on vertical lines/Equipments as per attachment No. 22.
7.4.3.3. Expansion joints shall be formed by 25 mm space between pipe insulation sections,
this space shall be filled with loose mineral rock fibers. Expansion joints in each
layer shall be offset at least 150 mm from each other in case of multilayer
insulation.

7.4.4. Traced Piping (HC)

7.4.4.1. The inner wrap shall be silica aerogel blanket over traced pipe (electric traced or
steam traced) and outer layer shall be mineral wool.
7.4.4.2. Insulation of steam traced lines shall be in accordance with the requirements for
untraced piping as per section 7.3 with the following exceptions:
7.4.4.3. Where the insulation can be carried out with preformed half sections, they shall be
of sufficient bore size (One size Higher Pipe section shall be specified by DEC to
accommodate the tracers). (Refer “Attachment No.12”). The pipe and tracer shall
be wrapped in 0.19 mm thick Aluminum foil and heat transfer cement shall be
applied at contact point of tracer and core pipe.
7.4.4.4. If the mineral wool pipe section is of equal or smaller diameter as compared to the
required size of pipe section, then the gap formed between the two halves of pipe
sections shall be filled up with makeup piece as shown in “Attachment No. 12”.
7.4.4.5. Weather protection with metal cladding shall be as per clause no 7.3.4.
7.4.5. Impulse Lines
7.4.5.1. Wrap the impulse lines tightly with Ceramic rope braided with fiberglass threads of
250 kg/m³ density. A 3 mm thick coating of mastic (Foster 60-38 or approved
Equivalent) shall be applied to ceramic fiber rope insulation. While this coat is still
wet, glass cloth shall be laid over the surface and embedded in the mastic. Care
shall be taken to ensure that the 10X10 glass cloth is laid smooth and free from
wrinkles and that no air pockets are trapped beneath the surface. At junctions in
the glass cloth, the overlap shall not be less than 75 mm. A second layer of 3 mm
thick mastic coat shall be applied after approximately 12 hours. When dry, this
coating shall be a minimum of 6 mm thick. Apply a coat of aluminum paint (Type 3
refer RPMS-ENGG-SPC-PP-014) of DFT 25 microns over the mastic, after it has dried
completely. A suitable sealant (BD 6 / CAT 9 / Equivalent) shall be applied to stop
the water ingress at the termination points of insulation.
7.4.5.2. Impulse line insulation details shall be as Table 16
Table 16:Table Details of insulation thickness for impulse Line
Size of impulse Operating No. of insulation Thickness of each

line(Ø) Temperature. Layer layer
½” 150 °C 2 13 mm
¾” 150 °C 2 19 mm
½” 250 °C 2 19 mm
¾” 250 °C 2 19 mm
7.4.5.3. Beyond 250 °C operating temperature, impulse lines insulation thickness shall be
specified by DEC, considering touch temperature requirement as per this standard
specification.

7.5. Application of Insulation to Equipment / Vessels (HC)

7.5.1. General Requirements (HC type insulation)
7.5.1.1. Wet and damaged insulation shall not be used.
7.5.1.2. All equipments and vessel in hot service (HC) shall be insulated with Silica aerogel
blanket as inner wrap, with all longitudinal and circumferential joints butted tightly.
Outer layer shall be mineral wool rigid slabs for shell and mineral wool mattress for
dished ends.
7.5.1.3. Supplier to prepare detailed procedure along with sketches and submit for
approvals from Buyer, prior to application.
7.5.1.4. Protected heads of vessels within a skirt shall be insulated with LRB Mattresses and
shall be weatherproofed with hard setting cement (BD6/CAT9), & with
reinforcement of wire mesh.
7.5.1.5. All horizontal equipments & exchangers etc. irrespective of dimensions, shall be
weatherproofed with 0.9 mm flat Aluminum cladding.
7.5.1.6. All vertical equipments, of diameter ≤ 900 mm, shall be cladded with 0.9 mm flat
Aluminum cladding .
7.5.1.7. All vertical equipments > 900 mm in diameter shall be cladded with 0.8mm
corrugated Aluminum cladding . Conical /Tapered portion of vertical vessel shall be
cladded with 0.9 mm flat Aluminum cladding .
7.5.1.8. Insulation supports for equipment shall be as per “Attachment No. 23 & 24”. The
parts of the insulation support to be welded on the equipment shall be welded by
equipment supplier.
7.5.1.9. Where “standoff guards” or shields are used for personnel protection insulation
they shall be fabricated from perforated aluminized plates or aluminum plate,
1.2mm thick. The perforated area shall be at least 35%, with a hole diameter max.
5mm in triangular pattern.
7.5.2. Application of Insulation & cladding to all Horizontal Vessels (All sizes) & Vertical
Vessels (up to 900 mm Diameter)
7.5.2.1. Inner wrap shall be silica aerogel blanket & outer layers shall be of mineral wool
rigid slabs. Thickness of insulation system shall be as per operating temperature of
the equipment.
7.5.2.2. Application procedure for applying insulation on part of equipment between vessel
tangent line shall be same as that of piping (Section 7.3.2).
7.5.2.3. The insulation material securement of silica aerogel & mineral wool shall be with
SS 304 bands 0.6 mm x 20 mm at 300 mm C/C.
7.5.2.4. Stainless steel “Childers” type flat expansion springs shall be provided at every
3mtr C/C.
1. Up to 1800 mm dia. – No spring required

2. >1800 mm to 6000 mm dia. – 2” long expansion springs.

3. > 6000 mm dia. – 4” long expansion springs.
7.5.2.5. Heads of vessels shall be insulated with silica aerogel & mineral wool wired
mattress, cut to conform to the contours of the vessel’s heads. (Refer “Attachment
17”)
7.5.2.6. The segments shall be snugly fitted by stitching with S.S. wires.
7.5.2.7. Securement for the head insulation shall be with 0.6 mm x 20 mm stainless steel
bands fastened to the tangent line support ring at maximum 300 mm C/C and
secured at the support ring at the center of the head. The bands shall be passed
across the head and secured at the opposite point of the tangent line support ring.
7.5.2.8. Metal cladding application requirements between tangent lines on horizontal
vessels for all diameter and on vertical vessels up to 900 mm diameter shall be the
same as for straight pipe (Clause 7.3.4) with the additional requirement of one 0.6
mm x 20 mm S.S. band at each circumferential seam.
7.5.2.9. Horizontal vessels exceeding 1800mm in diameter shall have the tangent to
tangent cladding secured by 0.6mm x 20mm stainless steel bands fitted with
breather springs which shall be tensioned to allow a maximum compression of 1-
1/2” for each 6000mm of the insulation circumference. The bands shall be placed
on maximum 450mm centers. Screws shall not be used. Bands shall be secured with
conventional closed seals.
7.5.2.10. All laps shall be of minimum 75mm; longitudinal laps shall be staggered to give the
maximum spacing between laps while still providing protection from wind and rain.
7.5.2.11. Paragraph 7.3.4 shall apply to all Vessel weatherproofing of cladding penetrations
& for the sealing of all overlaps.
7.5.2.12. Exposed heads of vessel shall be clad with petal construction segmental cladding,
which shall be overlapped to prevent moisture& water penetration. Self-tapping
screws shall be used for fastening cladding. (Refer “Attachment 17”)
7.5.2.13. Heads of vertical vessels contained within a skirt shall be weatherproofed as
follows:
• After application of insulation hairpins made up of 20 SWG. SS. tie wire shall
be attached to the banding.
• This shall be followed by a 3 mm thick skim coat of hydraulic cement armouring
compound with the hairpins being allowed to protrude.
• A layer of 20 SWG. X 25mm mesh SS wire netting shall then be applied over the
entire head and secured to the insulation support ring and to the insulation
support wires by means of the 20 SWG SS hairpins. All butting edges of the
mesh shall be laced using 20 SWG SS tie wire to form a tight cover.
• A final layer with 9 mm WFT hydraulic cement shall be applied and shall be
trowelled smooth and true.
7.5.3. Application of Insulation to Columns and Vertical Vessels > 900 mm Dia.
• For surface preparation refer clause 7.1.
7.5.3.1. The insulation shall be mineral wool beveled slabs applied over an inner wrap of
silica aerogel blanket. Applicability of foil at interface of Silica Aerogel and Mineral
wool Shall be according to Clause 5.4.1.2.
7.5.3.2. The slabs shall be snugly fitted with all joints firmly butted and circumferential
joints staggered.
7.5.3.3. Securement shall be provided by 0.6 x 20 mm SS bands at 300 mm C/C.
7.5.3.4. Exposed heads of vessels shall be insulated with mineral wool blanket faced with
expanded metal cut and shaped to conform to the contours of the head. All butting
edges of the expanded metal shall be tightly laced with 20 SWG SS wire. (Refer
“Attachment 16”)
7.5.3.5. The metal cladding to protect the shell insulation shall be of 0.8 mm corrugated
Aluminum cladding . Overlap at the longitudinal seam shall be one corrugation;
overlap at the circumferential seam shall be 75 mm. (Refer “Attachment 16”)
7.5.3.6. The sheets shall be supported at the circumferential lap by 0.6 mm x 25 mm S.S. ‘S’
clips spaced at 2 per sheet, to allow for vertical expansion. Screws are not required
on circumferential seams. (Refer “Attachment No. 10 Sheet 1& 2”).
7.5.3.7. The cladding shall be secured by 0.6 mm x 25 mm S.S. bands. On vessels exceeding
1800mm diameter the bands shall be fitted with compression springs to allow for
circumferential tensioning of cladding . The bands shall be spaced on maximum 450
mm centers. All bands will be supported on joggle clips at 1800mm centers. Bands
shall be secured with conventional wing seals.
7.5.3.8. Stainless steel “Childers” type flat expansion springs at 3mtr. C/C shall be provided
as mentioned below for securement of insulation.
1. <1800 mm dia. – No springs required
3. Above to 6000 mm dia. – 4” long expansion springs.
7.5.3.9. Vertical seams shall be secured by self-tapping pan head SS screws 12 mm long
(No.10) at 100 mm C/C. All screws on corrugated sheets shall be located at the
crown of the corrugation. Care shall be taken not to locate screws at any place
where they may pierce the circumferential lap.
7.5.3.10. Exposed heads of vessel shall be clad with petal construction segmental cladding,
which shall be overlapped to prevent moisture & water penetration. Self-tapping
screws shall be used for fastening cladding. Overlaps shall be sealed as noted in
clause 7.3.4.
7.5.3.11. Protected heads within a skirt shall be insulated in accordance with paragraphs
7.5.2.13.

7.5.3.12. For vessels operating at a temperature over 400°C, air space shall be provided at
the junction of the skirt to vessel head, where the following criteria are satisfied.
7.5.3.13. Distance of Air Space “Z” Shall ne as per Table 17.

Table 17:Air space distance for vessel shell to skirt connection
Vessel Diameter (mm) Z (mm)
Up to 1800 150
1801 to 3000 200
3001 to 4250 250
4251 & above 300
NOTE:
“Z”- Air space shall under no circumstances be less than Z = Rt.
7.5.3.14. Paragraphs 7.3.4 shall be applied to for weather proofing of all penetration from
cladding.
7.5.4. Man way, Exchanger Shell Cover and Flange Boxes
7.5.4.1. The Insulation system and thickness shall be as that of equipment, with exception
that outer layer over silica aerogel insulation with mineral wool mattress in place
of MW slab.
7.5.4.2. Vessel Manways and their associated flanges, exchanger shell covers shall be
fabricated from minimum 0.9mm thick flat Aluminum cladding with factory bonded
polysurlyn moisture barrier and shall be made in sections (removable) of suitable
size to permit inspection.
7.5.4.3. All box construction seams shall be lock-formed, and individual erection joints shall
be located and arranged to give maximum protection from wind and rain.
7.5.4.4. The boxes shall be positioned on the vessel in conjunction with the vessel cladding
to prevent any ingress of moisture at the location of the box/cladding joint.

7.6. Insulation of Irregular surfaces (Pad Type insulation)

7.6.1. General requirement for Equipment
7.6.1.1. Wherever pumps, turbines and other similar irregular shaped equipment are
required to be insulated, use weatherproof flexible, easily removable, insulated
“tea cozy” type cover made up of silicon impregnated fiber glass cloth and high
silica a cloth.
7.6.1.2. Insulation shall not be applied on pumps handling Hydrocarbon products.
7.6.1.3. Thickness of insulation shall be designed by DEC or Process licensors for all
equipments.
7.6.1.4. The manufacturer shall field measure the irregular surface to ensure that the
fabricated cover conforms to the configuration being insulated, including all
openings and protrusions, etc.
7.6.1.5. Supplier to prepare and submit the pad insulation procedure with all the details to
core engineering for review and approval before proceeding with the job.
7.6.1.6. No force folding or bending of the cover will be acceptable, and no “one size fits
all” cover design will be allowed.
7.6.1.7. The tailor-made cover will be pre-fabricated with a minimum number of joint to
minimize ingress of water.
7.6.1.8. Supplier shall use Buyer approved product for these types of insulation.
7.6.2. Procedure of pad fabrication for equipments
7.6.2.1. At upward facing terminal points the design shall allow for S.S. bands to be passed
through “belt type loops” to positively secure the cover to the assembly. (Refer
“Attachment 19 Sheet 1 & 2”)
7.6.2.2. At horizontal and downward facing penetrations, drawstrings shall be inserted in a
double stitched “tunnel” to effect positive securement.
7.6.2.3. All cover outer jacketing fabric seams shall be machine stitched. No gaps or holidays
will be allowed in any seam. All cover fabric seams shall be turned in or under and
stitched to prevent any raw edges from being exposed on any surface. No pinched
seams shall be allowed.
7.6.2.4. Cover parting faces, terminal ends or splits in covers shall utilize flaps closed off
with Velcro to seal against entrance by wind or water.
7.6.2.5. The cover shall have a waterproof fabric tag (3" x 2") sewn on its outer surface. The
tag shall identify the equipment name and its identification number.
7.6.2.6. The hot and cold face encapsulating cover material shall be silicon impregnated
fiberglass cloth for operating temperature up to 200°C.
7.6.2.7. For operating temperature above 200°C, the inner cover in contact with hot face
shall be high silica cloth and outer cover shall be made up of silicon impregnated
fiber glass cloth.
7.6.3. Procedure of pad fabrication for Valves size up to 6” and Flanges in Hydrocarbon
/Process lines
7.6.3.1. Inner cloth in contact with hot surface shall be High temperature silica cloth.
7.6.3.2. Outer cloth for weather protection shall be Silicon impregnated fiber glass cloth.
7.6.3.3. Thickness of ceramic wool/Silica aerogel shall be as per parent line insulation
thickness. Ceramic wool to be filled in bag prepared with above mentioned two
cloths’ and stitched properly with High temperature fiber glass thread to protect
ceramic wool. Density of loose ceramic wool shall be 128kg/m3.
7.6.3.4. Pad shall be fabricated in two parts with Box type construction and finally covered
with one more layer of Silicon impregnated fiber glass cloth to make it water tight.
7.6.3.5. All the mating surfaces with Pad shall be sealed with High temperature silicon
sealant up to 200°C to avoid any water ingress. Above 200°C no sealant shall be
applied.
7.6.3.6. These pads shall be fixed over valve body with fiber glass bands or any other
suitable removable type attachment. SS band shall not be used for fixation of pad
insulation.
7.6.3.7. Separate set of pads shall be prepared for insulating flanges in such a manner that
the bolts are not covered in insulation.
7.7. Application of Insulation for Tanks (HC, SP)
7.7.1. General requirement
7.7.1.1. Before application of insulation, bottom 400 mm of the external surface of tank
shell shall be painted as per RPMS-ENGG-SPC-PP-014.
7.7.1.2. Bottom 400 mm height from tank base plate shall be insulated with cellular glass.
Thickness of cellular glass material shall be calculated by DEC or Process Licensors
to maintain heat loss equivalent to silica aerogel +mineral wool combination.
7.7.1.3. The tank roofs will be insulated with cellular glass in two-layer construction. The
first layer thickness shall be such that the interface temperature does not exceed
80°C.Thicknes shall be provided by DEC.
7.7.1.4. Material used for insulation work shall be from the approved vendor Insulation
Material Supplier.
7.7.1.5. Thickness of insulation shall be as per thickness table provided in this specification
for heat conservation. The thickness of insulation shall be detailed in Project Tanks
Schedule.
7.7.1.6. Wet insulation shall not be used in any case. Installed Insulation materials over
tanks shall be protected from rain and any contaminants by suitable covering till
permanent cladding is provided.

7.7.1.7. Insulation Contractors are invited to propose either proprietary system such as
“Kitsons Kalzip”, Tyco – “Trac-Loc”, or Conventional Systems, such as detailed
herein. Regardless of system, the insulation contractor shall submit a full design
and detailed drawings for review and approval prior to application. Application of
Insulation with Tyco – “Trac Loc” system do not require any supports on the Tank
shell. Whereas for conventional application, support arrangements to the shell to
be provided (as shown in “Attachment No. 2 and 3”) by Tank Manufacturing
Contractor prior to release the tank for Insulation work.
7.7.1.8. Due regard shall be paid to the effects of wind loading. Calculations for strength of
banding and cladding shall be in accordance with BSI CP3 Chapter V, Part 2.
7.7.1.9. Roof insulation is not designed to support pedestrians. Access to all fittings shall be
via designated walkways only.
7.7.1.10. The insulation contractor shall keep his working locations in a tidy condition.
7.7.2. Surface preparation
• Refer clause number 7.1 for surface preparation.
• Any non-conformities found in painting application shall be reported by
insulation contractor to concern Buyer representative prior to start insulation
work.
7.7.3. Application of insulation over shell portion of tank
7.7.3.1. Inner wrap shall be of Silica aerogel blanket with 50 mm overlap for longitudinal
joints and outer layers shall be of mineral wool slabs.
7.7.3.2. Bottom 400 mm height from tank base plate shall be insulated with cellular glass in
two layers.
7.7.3.3. Insulation material shall be secured over the shell with 0.6 mm x 40 mm SS 304
bands. The bands shall be installed in such a way, that there is a minimum of 2
bands per slab, positioned 150 mm from each slab joint. (Refer attachment No.1).
7.7.3.4. Maximum band length shall be 15 meters. Stainless steel “Childers” type flat
expansion springs at 3mtr. C/C shall be provided on each 15-meter length of band
as mentioned below.
2. Above 6000 mm dia. – 4” long expansion springs.
7.7.3.5. This is to ensure equal tensioning and expansion over the entire tank. Ends of the
bands shall be anchored with 12 mm Ø vertical rod. (Refer “Attachment No.2”).
7.7.3.6. The cladding shall be secured to the vessel by means of 1.2 mm x 50 mm SS 304
bands, with minimum of 4 number of bands per 2-meter sheet. The top outer band
of each lift shall coincide with the horizontal sheet lap.

7.7.3.7. The bands will be supported by joggle clips riveted to the cladding. Material and
width of the clips shall be same as that of bands. Distance between two adjacent
clips shall be 1.8 meters.
7.7.3.8. The thermal movements of the tank will be transmitted through the bands to
suitable breather spring units (Mity spring).
7.7.3.9. The maximum circumferential pitch of the breather springs (Compression Spring)
will be 4.5 meters for cladding securement.
7.7.3.10. Horizontal end laps shall be arranged weather-wise and each sheet shall overlap
the lower sheet by 75 mm. Each lift will be supported by minimum three numbers
0.6 mm x 20 mm SS ‘S’ clips to allow vertical expansion. Screws are not required on
circumferential seams. (Refer “Attachment No.10”).
7.7.3.11. The vertical overlap per sheet shall be one corrugation, and each joint shall be
sealed with approved adhesive/sealer and secured with self-tapping screws or
rivets at 100 mm pitch.
Note: Each “lift” of cladding shall be independent of the one above and one below.
7.7.3.12. Each lift of cladding shall span a maximum circumferential distance of 15 meters.
At the junction of each span the cladding will be secured to the vertical support
anchor plates by “Cromp Arc” studs and nuts (supplied and fitted by the Insulation
Contractor) (Refer “Attachment No.3 and 4”).
7.7.3.13. A molded profile filler strip shall be used to seal the roof to shell junction.
7.7.3.14. All projections shall be cut around locally with close fit to protrusion, maximum gap
around protrusion shall be 3mm, all protrusion shall be neatly finished with flashing
overlapping 75 mm minimum to adjacent surface and sealed with metal sealant to
avoid any moisture or water ingress (Refer “Attachment No.6”).
7.7.4. Roof
7.7.4.1. The tank roofs will be insulated with cellular glass in two-layer construction.
7.7.4.2. If any undulation observed over tank roof, the same shall be filled with Hydrocal
B11 and Cellular glass dust to make the surface smooth.
7.7.4.3. The first layer shall be laid on to the dry and smooth roof plates. The second layer
shall be bonded to the first with PC 88 adhesive. All joints and edges in the second
layer shall be staggered relative to the first and shall be fully sealed with adhesive.
7.7.4.4. At the junction of roof to shell, loose mineral wool shall be used to tightly packed
the space between kerb plate and Cellular glass.
7.7.4.5. The whole system will be secured by means of 0.6 mm x 20 mm SS 304 bands tied
to a floating ring at the center of the tank and an outer ring at the kerb junction.
The bands shall be pitched at 300 mm C/C.

7.7.4.6. The insulation shall be finished with two coats of PC 404 acrylic coating reinforced
with PC 79 polyester cloth, applied in accordance with Pittsburgh Corning’s data
sheets (Refer “Attachment No.5”).
7.8. Application for Solar protection insulation (SP)
7.8.1. Wherever solar protection type insulation is required for Piping or equipments,
insulation material shall be mineral wool pipe section or slab material only.
7.8.2. Thickness of insulation material shall be calculated by DEC.
7.8.3. If no details are available 40 mm insulation thickness shall be considered for solar
protection insulation.
7.8.4. Application procedure is similar as mentioned in Section 7.3 for Piping and Section
7.5 for equipment.
7.9. Inspection Windows / Pockets
A. Piping
Plug type inspection windows of ellipsoidal shape shall be provided on all of the
insulated pipelines having diameter 2” and above. One inspection window shall be
provided at a distance of every 20 meters of straight length of pipe. It should be
provided at the bottom i.e. at 4-6-8 clock position whichever is convenient. There
must be at least one inspection window between two bends which are minimum
10 meters apart. At least alternate bends shall be provided with inspection
windows. The size of the inspection windows shall be as Table 18.
Table 18: Inspection window details for Pipelines
Pipe diameter 2” 35mm x 120mm
Pipe diameter 6” 100mm x120mm
Pipe diameter 8” 100mm x120mm
Pipe diameter >8” 120mm x120mm
B. Exchangers
All the heads shall be provided with four (4) inspection windows one in each
quadrant. Minimum four (4) inspection windows shall be provided on the shell side.
(Refer “Attachment No. 21” for Inspection window details).
C. Columns & Vessels
Heads shall be provided with four (4) inspection windows one in each quadrant.
Four (4) inspection windows shall be provided at 1.5m above every platform.
Minimum two inspection windows shall be provided on shell portion on either side

of the ladder wherever platforms are not available. (Refer “Attachment No. 21” for
Inspection window details).
D. Tanks
One inspection window shall be provided at each course of the tank and at the top.
(Refer “Attachment No. 21” for Inspection window details).
7.10. Application procedure of Acoustic Insulation
7.10.1. Surface preparation shall be as per Clause no 7.1 for Piping and equipment in
conjunction with RPMS-ENGG-SPC-PP-014.
7.10.2. Any non-conformities found in painting, insulation contractor to consult concern
Buyer representative.
7.10.3. Wherever insulation for only acoustic reason is specified (AIA/AIB/AIC) shall be
provided with only mineral wool material, basic application procedure for
insulation shall be same as per clause 7.3.
7.10.4. Insulation for AHA/AHB/AHC shall be provided with silica aerogel and mineral
wool material, basic application procedure for insulation shall be same as per
clause 7.3.
7.10.5. Voids and cracks in mineral wool insulation, which are larger than 2.3 mm, shall
be corrected by re-fitting the insulation unless filling with loose mineral wool has
been accepted in writing by Buyer.
7.10.6. In case correct gauge of cladding is not available to achieve the required mass for
particular acoustic class then alternatively Loaded vinyl sheet shall be applied
between the insulation and metal cladding. Circumferential and longitudinal
joints shall be overlapped a minimum of 50 mm. The loaded vinyl sheet shall be
cemented on both surfaces of the area overlapped.
7.10.7. All longitudinal seams shall be staggered on alternative sides (4 o’clock and 8
o’clock) of the pipe and laps shall be located to give maximum protection from
wind and rain. (Attachment no 15).
7.10.8. On vertical pipe insulation, metal cladding shall overlap 50 mm for circumferential
seams and 75 mm for longitudinal seams. Cladding shall be supported from
insulation support rings or from cladding below using 3 or more stainless steel "S"
clips. Circumferential joints shall be lapped to shed water. The longitudinal seam
shall be located on the leeward side from the prevailing storm wind direction if
possible. In any case, the joints shall be located so they are easily accessible for
caulking.
7.10.9. Cladding shall be held in place using banding placed on the circumferential
overlaps and by screws on 75mm centers along the longitudinal over-laps.
Longitudinal seams of vertical pipe cladding shall be caulked with Fiberglass
reinforced sponge silicone tape as clause 7.11.2.2.

7.10.10. Fiberglass reinforced sponge silicone tape as clause 7.11.2.2. shall be used to
caulk around all protrusions through the cladding. Protrusions with metal
temperatures above 360°C must rely on flashing to keep water out. Other
cladding to cladding seams not waterproof by virtue of their design shall be
caulked with silicone rubber sealant.
7.10.11. Expansion springs shall be fitted to bands that secure cladding on piping larger
than 710 mm. Bands shall not be located adjacent to cladding laps. Springs shall
be extended 1.3 times their original length when tensioned.
7.10.12. Joints in preformed Aluzinc covers shall be fastened with screws on 100 mm
maximum centers. Joints shall include an overlap of at least 50 mm. Bands shall
secure each end of the cover to the pipe cladding.
7.10.13. The acoustic insulation cladding shall not be in direct or indirect metal to metal
contact with the pipe or equipment surface. Any such contact will allow a
transmission of vibrations to the cladding which will reduce or nullify the noise
reduction by the insulation. It may even enhance the noise radiation because of
the greater surface area of the cladding. It is also important that there should be
no gaps in the insulation. Joints in the porous layer shall therefore be staggered at
least 200mm and the cladding shall overlap at all joint (Refer “Attachment No.27
&29”).
7.10.14. The length of pipe to be insulated and the class of insulation shall be as specified
by the Noise Control Engineer / Consultant/ Manufacturer responsible for the
acoustic design. The requirements shall be identified on the P&ID’s, LDT’s and
Isometric drawings. With vertical pipes, any supports which carry the weight of
the cladding shall contain resilient elements to reduce the transmission of
vibrations from the pipe. (Refer “Attachment No. 28”). Where necessary, these
resilient elements should contain mechanical stops to limit excess movement.
Resilient elements shall not be loaded to such an extent that their operational
range of deflection is exceeded.
7.10.15. Insulation of pipe supports; flanges and valves shall be in accordance with the
requirements of the noted class. (Ref. section 5.5.3). Otherwise, the specified
length of pipe or equipment shall be insulated to cover the whole of the noise
radiating area without gaps or voids.
7.10.16. At locations where metal to metal contact would normally occur, anti-vibration
seals shall be applied (Refer “Attachment No. 29, 30 and 31”). They shall have a
minimum thickness of 3mm and a minimum width of 50mm.
7.10.17. At all exposed flanges the acoustic insulation shall be terminated with an end cap.
(Refer “Attachment No. 27 & 29”). This shall be located as close to the flange as
possible and shall not interfere with the requirements for bolt removal. The end
cap shall be isolated from the pipe by means of an anti-vibration seal.

7.10.18. When the noise radiated from a valve has to be reduced, the equipment shall be
surrounded by an acoustic enclosure. Flanges may be surrounded by an acoustic
enclosure or by removable insulation. Acoustic enclosures shall be easily
demountable to provide access to the flange or valve. Joints shall be sealed to
prevent noise leakage (Refer “Attachment No. 25”). If it is required that a flange
should be ventilated for safety reasons, a special construction such as that shown
in “Attachment No. 25" sht. 2 of 2 shall be used. Demountable parts of acoustic
enclosures heavier than 25kg shall have lifting lugs.
7.10.19. The acoustic enclosure shall have an outer surface of metal sheet with a mass per
unit area at least equal to that of the cladding.
7.10.20. The porous layer shall be similar in material to that used on the piping cladding
and shall be retained by an inner surface layer with an open area of about 30 %,
For example, perforated metal sheet. The inner surface layer shall be at least
10mm away from the flange or valve.
7.10.21. Where acoustic enclosures are installed around flanged joints, they shall be of
sufficient length to overlap the end caps on the pipe cladding by at least 100mm
for class B and 200mm for class C.
7.10.22. Cladding shall be continuously bonded and earthed to prevent electrostatic
charging. Where the earth connection is made via pipe it shall be made with
braided wire and not rigid bar.
7.10.23. Special provisions shall be made to protect the acoustic insulation at locations
where it could be susceptible to mechanical damages. For example, separate
supported steps should be provided where insulation may be stepped on. Where
mechanical load cannot be avoided, the cladding should be reinforced by using
stiffer plate and additional distance rings.
7.11. Ancillaries
• There are several ancillary materials, which shall be used to ensure that the
insulation system forms an effective seal to prevent ingress of fluids, or for
other special applications. Approved Ancillaries are listed in Table 19.

Table 19: Ancillaries Items for insulation
Adhesive - PC 88 / Pitt seal 444N or Pittsburgh Corning or approved equivalent

approved equivalent
Sealer Coat - PC 404 or approved Pittsburgh Corning or equivalent
equivalent
Anti-vibration seal- Silica aerogel /Strip Aspen Aerogel /Saint Gobain /Mahavir Corporation
and stick AR 300/MC SRF 400 or approved equivalent
Adhesive sealer strip for cladding in Saint Gobain /Mahavir Corporation or approved
acoustic insulation - Strip and stick AR equivalent
300/ MCSRF 400
Expansion / Compression springs Stainless Steel “Childers” type flat expansion/
compression springs to suit banding width.
Reinforcing cloth PC 79 Owens Corning or equivalent
High Silica cloth Ch-84 AVX Corporation/Urja Industries /Harsh deep
industries/Mahavir Corporation or approved
equivalent
Silicon impregnated cloth Alpha Maritex / Urja Industries /Harsh deep
industries/Mahavir Corporation or approved
equivalent
Profile filler strip B.S.R. Type. Grade S.E. (Internal and External) to suit cladding profile
Metal sealant 95-44/TIC 7030/ Loid Seal Fosters / TIC/ Capricorn Coating and Colours or
94A Approved equivalent.
Hard Set cement - BD6/CAT9 Limpet/ Newkem or approved equivalent
7.11.1. Hard Set Cements, (BD6 or CAT 9 Cement or Approved Equivalent).
7.11.1.1. An asbestos free composition consisting of Approved Portland Cement reinforced
with long, graded, glass silk fibers.
7.11.1.2. It provides a low cost protective coating with a hydraulic set and gives a high degree
of mechanical protection. It should be used for sealing ends of pipe runs at flanges
in hydrocarbon service even where the flanges are being insulated. It can also be
used over mattresses on heat exchanger end covers, pumps etc.
7.11.2. Sheeting Sealants.
7.11.2.1. For sealing joints in metal sheeting, mastic sealants such as Foster Elastomeric 95-
44, TIC 7030, Loidseal 94A or approved equivalent shall be used.
7.11.2.2. Fiberglass reinforced sponge silicone tape 13mm wide x 1.5mm thick minimum
manufactured by from Saint Gobain/Mahavir Corporation or approved equivalent.

7.11.3. Silicon impregnated fiber glass cloth and High silica cloth.
7.11.3.1. This material shall be particularly used for Pad type removable insulation.
Minimum properties requirements for Silicon impregnated glass cloth

Sr no Properties Acceptable value
1 Maximum temperature resistance 210 °C
2 Water vapor permeance 0.00perms
3 Fire resistivity criteria FSI/SDI<25
Minimum properties required for High silica cloth

Sr no Properties Acceptable value
1 Maximum temperature resistance 750 °C
2 Fire resistivity criteria FSI/SDI<25
7.12. Fastening Materials
Fastening material.
Wire 1 mm and 1.6 mm austenitic stainless steel, Type 304.

SS 304 wire shall be soft annealed as per ASTM A 580 /
A 580M.
Banding (over Insulation 0.2 mm x 10 mm stainless steel bands, type SS 304.(for
materials) Securement of foil only )
0.6 mm x 20 mm stainless steel bands, type SS 304.
0.6 mm x 25 mm S.S. bands, type SS 304.
0.6 mm x 40 mm S.S. bands, type SS 304
Banding (over cladding) 0.6 mm x 20 mm,0.6 mm x 25 mm &

1.2 mm x 50 mm S.S. bands type SS 304 as applicable.
Sheet metal screws shall be No. 10 x 12 mm 18-8 SS

self-tapping screws with elastomeric gaskets. Self-
tapping screws for covers and boxes shall be No. 14 x
Self-Tapping Screws 20 mm. with elastomeric gaskets

8. Inspection and Testing

8.1. Insulation Material Supplier
8.1.1. Insulation Material Supplier shall be responsible for the quality of the finished
product regardless of any inspection activity carried out by the Buyer or it’s
appointed representative. TPI shall put their stamp and signed on any box of
batch, material of that box is checked by them. This is to arrest rejection of TPIA
cleared material received at site.
8.1.2. Insulation Material Supplier shall have their own quality control and inspection
staff who are independent of the production departments and who report directly
to the head of the quality control department.
8.1.3. Insulation Material Supplier shall have their own quality plans and procedures for
Inspection and Testing. These procedures shall refer to the relevant sections in
the project specification. The quality plan / ITP shall include the parameters for
acceptance / rejection, the levels of inspection required, and the hold points.
8.1.4. The Inspection and Testing Procedure (ITP) shall be available to the Buyer or it’s
representative for approval prior to commencement of the production. Where
the order has a requirement for a prequalification test, a separate prequalification
Testing and Inspection Procedure shall be required.
8.1.5. Insulation Material Supplier shall have available all inspection instruments and
calibration equipment required to comply with the relevant project specification
inspection requirements and shall ensure the competence of the inspection staff
in the use of such equipment.
8.1.6. Insulation Material Supplier shall investigate process and sign off Non-
conformance Reports (NCR) produced by Buyer or it’s representative.
8.1.7. Insulation Material Supplier shall complete daily inspection report sheets
referenced in the relevant specifications. These reports shall be reviewed and
approved by the Buyer or it’s representative.
8.2. Inspection & Testing criteria during application
8.2.1. Inspection and Testing checkpoint with Frequency shall be as per attachment 36
& 37.
8.2.2. Applicator to prepare detailed ITP and submit to owner for approval before
starting the work.
9. Vendor Data
9.1. The supplier data requirement shall cover the documents to be submitted by a
supplier during the following stages:
• Along with the bid :- Material Catalogues.
• With the supplied material :- Test Certificates & Storage Instructions.

• During training and site services-procedure & supervision.

9.2. Insulation applicator to prepare detailed application procedure with sketches &
ITP and submit to Buyer for review and approval.
10. Packing, Preservation, shipment and Storage
10.1. All hot insulation & related materials shall be packed in damage free containers
suitably marked with the following minimum information for identification:
Marking requirement for dispatch
a. Name of the manufacturer.
b. Type of material and product designation.
c. Batch Number
d. Date of Manufacture
e. Shelf Life / Expiry Date
f. Storage Conditions
g. Material stock code & sap code / material code as mentioned in purchase
10.2. Any materials
order. found without above identification markings shall be rejected by
Buyer. Rejected materials shall be promptly removed and replaced by the
Insulation contractor. Batch number shall segregate insulation materials during
shipment, storage and handling.
10.3. Insulation materials shall be stored, handled and transported in accordance with
the Insulation Materials Manufacturer’s recommendations. Storage time of
materials shall not exceed the shelf life recommended by the insulation materials
manufacturer.
11. Measurement Wastages Norms.
11.1. Mode of Measurement
11.1.1. Measurement of work will be made on UOM (Unit of Measurement) mentioned in
the SOR (Schedule of Rates) and as per specification.
11.2. Mode of Measurement for Piping
11.2.1. All measurements will be as per IS 14164:2008; however, the following will be the
deviations from IS codes.
11.2.2. All measurements for piping shall be taken along the center line of piping as
shown in piping isometrics & GA drawings, through all fittings, such as valves,
flanges, elbows, bends, tees & reducers (Valves and flanges shall be included in
the measurement only for small bore lines up to and incl.2 Inch NB size).
• Other than valves and flanges, fittings like elbows, bends, tees & reducers etc.
will not be measured separately for payment.
• If the valves, flanges, venturi, steam traps/ strainers including flanges and body
and pair of flanges including orifice plate needs to be insulated, all such valves
/ flanges shall be measured in linear measurement in addition to below
measurement.

• For each insulated valve/venturi /steam traps/ strainers including flanges and
body, up to 300 mm line size 1.5 linear meter of piping of the connected parent
line and 2.00 linear meters for Line size above 300 mm shall be taken in to
account.
• For each pair of insulated flanges including orifice plate & flanges, 0.80 linear
meters of parent piping shall be considered.
11.3. Mode of measurement for Equipment
11.3.1. For insulation of equipment, measurement shall be taken in square meter over
the insulated equipment surface. The surface area for the nozzles, manholes,
projections will be derived as per relevant code of IS 14164:2008.
11.3.2. Surface area for ancillaries if indicated separately for payment viz., SS foil
wrapping shall be measured over the actual surface of application.
11.4. Wastage norms for hot insulation
SR No Insulation Commodity Wastage
1 MW pipe section, MW slab, MW 3%
Mattresses
2 Cladding material + Overlap 75 MM 2.5%
3 Silica Aerogel material 5 MM thick and 10 2.5 %
MM thick
4 Cladding Metal sealant 5% over actual
consumption

12. Attachment
Typical Tank shell Bottom insulation with
Attachment 1
Cellular glass
Attachment 2 Typical Tank Shell insulation Installation
Attachment 3 Typical Tank Shell, insulation vertical support

and anchor plate details
Attachment 4 Typical Tank Shell attachment
Attachment 5 Typical Tank shell and roof connection
Attachment 6 Typical Tank shell flash plate detail
Attachment 7 Typical Pipe insulation end closure for

hydrocarbon and process lines
Attachment 8 Sheet 1 Typical Flange box insulation arrangement
Attachment 8 Sheet 2 Typical Valve box insulation arrangement
Typical arrangement for Personnel protection of
Attachment 9 valves, flanges and equipment with perforated
guard
Attachment 10 Sheet 1 Typical vessel insulation arrangement
Attachment 10 Sheet 2 Typical vessel insulation arrangement
Attachment 11 Typical stand off guard/Perforated guard for

personnel protection for piping
Attachment 12 Sheet 1 Typical arrangement for traced line insulation

with pipe section
Attachment 12 Sheet 2 Typical arrangement for traced line insulation

with mineral wool slab
Attachment 13 Typical arrangement for beveled lag slab

configuration
Attachment 14 Typical Pipe elbow insulation
Attachment 15 Sheet 1 Typical pipe insulation method
Attachment 15 Sheet 2 Typical pipe cladding method
Attachment 16 Typical vessel head insulation vertical
Attachment 17 Typical vessel head insulation horizontal
Attachment 18 Typical pipe support insulation
Attachment 19 Sheet 1 Typical arrangement of pad type insulation for

irregular surface
Attachment 19 Sheet 2 Typical arrangement of pad type insulation for

irregular surface
Typical arrangement for insulation of
Attachment 19 Sheet 3 Hydrocarbon process line valves with removable
pad
Typical arrangement for Insulation of
Attachment 19 Sheet 4 Hydrocarbon process line valves>6” with
conventional method
Attachment 20 Typical arrangement of insulation support (Site)

for vessel bottom
Attachment 21 Typical inspection window details
Attachment 22 Typical expansion joint detail
Attachment 23 Typical insulations support detail for vertical

vessel
Attachment 24 Typical insulations support detail for Horizontal

vessel
Attachment 25 Sheet 1 Typical acoustic insulation for flanges and valves
Attachment 25 sheet 2 Typical acoustic insulation for flanges and valves

for venting requirement
Attachment 26 Typical acoustic insulation of support for vertical

pipes
Attachment 27 Typical arrangement of acoustic insulation

cladding end cap
Attachment 27 A Typical arrangement for 2” and below insulation

ends cap for utility lines
Attachment 28 Typical arrangement for cladding support for

vibration isolated
Attachment 29 Typical arrangement for cladding end caps
Attachment 30 Typical arrangement for tees and branches for

acoustic insulation
Attachment 31 Sheet 1 Typical arrangement of cladding support for

acoustic insulation where welding
Attachment 31 Sheet 2 Typical arrangement for cladding support where

welding allowed
Attachment 32 Inspection test plan for Silica aerogel[i]

Attachment 33 Inspection test plan for Mineral wool pipe

section [*]
Attachment 34 Inspection test plan for Mineral wool Slabs [*]
Attachment 35 Inspection test plan for Mineral wool Mattress

[*]
Attachment 36 Check list for Hot & acoustic insulation

application for Piping [*]
Attachment 37 Check list for Hot & Acoustic insulation

application for Equipment [*]
[*] ITP / Check List defines minimum requirements to be included in Supplier's ITP.
Supplier shall develop ITP specific to manufacturing/Application process

Insulation - RPMS ENGG SPC PP 012

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Reliance Project Management System

0 25.08.2020 Issued for Implementation MD RS AS/VKM

Rev Date Revision Details Prepared Checked Approved

STANDARDS SUB-COMMITTEE ENDORSEMENTS

Sr. No. Name Signature Date

_____________________________ _________________ ___________

_____________________________ _________________ ___________

_____________________________ _________________ ___________

_____________________________ _________________ ___________

_____________________________ _________________ ___________

Date Revision Details Revision

RIL Confidential Page 5 of 48

Standard Standard Description

RIL Confidential Page 6 of 48

Standard Standard Description

3. Conflicts and Deviations

4. Abbreviations and Definitions

RIL Confidential Page 7 of 48

AIB : Acoustic Insulation Class B

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Insulation type Insulation material

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Table 1: Insulation and materials requirements

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5.3. Extent of insulation

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 Hydrocarbons above their auto-ignition temperature.

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Table 3- Thickness Table for Heat conservation (HC)

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• Operating temperature between 601°C and 700°C - 13 mm

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• Securement of foils for piping & equipments,

Pipe diameter 8” & below 1 mm diameter wire (SS304) @200 CC

5.4.3. Thickness of insulation for Solar Protection (SP)

Size of No. of insulation

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AIC 100 mm (50 mm + 50 mm)

5.5.3. Cladding for Acoustic Insulation

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2.2 Mineral wool pipe Length 1 meter (+/-0.5%), ID(+/-1.6mm),

3 pH Content & IS 8183 / IS- 7 to 8

For approved supplier for Mineral wool material refer RPMS-ENGG-PRA-PP-040,

Sr no Properties Standard Acceptable value

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6.1.3. Properties for Cellular Glass material

2 Corrugated ASTM C Thickness 0.8 mm, Pitch of corrugation

For approved supplier for Aluminum Cladding material refer RPMS-ENGG-PRA-PP-

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6.1.5. Properties of Aluminized steel cladding.

For approved supplier for Aluzinc Cladding material refer RPMS-ENGG-PRA-PP-040,

Maximum Service Temperature 1260°C

Thermal Conductivity @ 800°C 0.15 W/m K

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Table 14-Ceramic fibre rope

Maximum Service Temperature 500°C for Impulse lines

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Table 15- Distance between Hot surface and perforated guard

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