Davy Process

Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 1 of 39

INDEX

1 GENERAL

2 DESIGN BASIS

3 MATERIAL

4 APPLICATION

5 INSUALTION FINISH

6 CONTRACTOR’S SCOPE OF WORK

7 CONTRACTOR’S OBLIGATION

8 INSPECTION

9 MEASUREMENTS

10 GUARANTEE

ANNEXURES

1. Project Specific Insulation Material & Thickness Chart

2. Insulation Inspection checklist

3. Hot Insulation Installation details

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 2 of 39

1. GENERAL

1.1. This specification covers design, material specification, installation and

inspection requirements for above ground and below ground external hot
insulation of piping, vessels and equipment operating between ambient
temperature and 1425o C for the purpose of heat conservation, process
stabilization, temperature maintenance, personnel protection and fire
protection. Wherever necessary this specification indicates the basis for
selecting type of insulation.

1.2. This specification is suitable for use in outdoor service with normal
process plant atmosphere. Alternative designs and materials shall not be
used, unless approved in writing by client/ AKPG.
1.3. This specification does not cover cold service insulation and dual
temperature services insulation.
1.4. This specification does not cover insulation for boiler or fired heaters and
associated air heaters, economizer, flue gas ducting and air ducting.

1.5. Piping, equipment, storage tanks and vessels requiring insulation are
normally specified on the following project documents.

1.5.1. Process and Instrument Diagrams (P&IDs) and Line Designation

Lists

1.5.2. Piping General Arrangement Drawings & Isometrics or 3D model

1.5.3. Instrument Piping interface Details, Instrument Data Sheets

1.5.4. Vendor Drawings/ Engineering drawings/ Data sheets of vessels

and equipment.

1.5.5. Vendor General Arrangement Drawings for equipment within

Package Plant

1.5.6. Steam tracing/manifolds/lead lines etc as specified in the Steam

Tracing Specification and drawings

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 3 of 39

2. DESIGN BASIS

2.1. GENERAL

2.1.1. In this Standard, Insulation for prevention of heat loss is designed

to provide economic thickness such that surface temperature on the
cladding does not exceed 55 o C.

2.1.2. Insulation comprises a layer of heat resisting fibre material

enclosed within protective metal sheeting, sealed against the
ingress of moisture and designed to allow differential expansion.

2.2. CRITERIA

2.2.1. Insulation Types

2.2.1.1. Heat Conservation Insulation (Code: H)

- The Primary consideration for using heat

conservation insulation shall be economics.
- Design of heat conservation insulation shall be
based on local average ambient climatic condition
and project economics.
- Heat conservation insulation shall be used if normal
operating temperature exceeds 65 0 C, unless loss of
heat is desirable.

2.2.1.2. Process Stability Insulation (Code: H or project specific)

- The primary consideration for using process

stability insulation shall be control of process
temperatures, including impact due to sudden
changes in ambient conditions.
- Design of process stability insulation shall be based
on anticipated extremes in ambient conditions.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 4 of 39

2.2.1.3. Personnel Protection Insulation (Code: P)

- The primary consideration for using personnel

protection insulation shall be to limit the
temperature of exposed surfaces.
- Design of personnel protection insulation shall be
based on summer dry bulb temperature and low
wind velocity to reflect a worst-case condition.
- Personnel protection insulation shall be used if
normal temperature of a surface exceeds 60 0 C. and
if the surface is in an area that are accessible to
personnel. Accessible area defined as an area in
which personnel regularly perform duties other than
maintenance during plant shut down.
- Personnel protection shall be provided to 2.1m
above grade of platform and 900 mm horizontally
from the periphery of platform, walkways or
ladders.
- Personnel protection shall be of insulation, shields,
guards or barriers.
- If corrosion under the insulation is a concern, or if
heat loss is desirable, use of fabricated shields/
guards of wire netting in lieu of insulation should be
considered.

2.2.1.4. Prevention from Freezing Insulation (Code: PF) (Frost

Protection)

- The primary consideration for the use of this

category is protection from freezing.
- Design of prevention from freezing insulation shall
be based on local climatic conditions.
- Prevention from freezing insulation may be
combined with other types of insulation.
- Insulation for frost protection should be applied to
exposed pipes has a temperature below due point.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 5 of 39

2.2.1.5. Insulation Types for Traced and Energy transfer

Jacketed systems (Code: ST, ET, SJ, HT, HJ)

- The primary consideration for using tracing or heat

transfer jacketing and associated insulation shall be
to control process temperatures.
- Design of insulation shall be based on the operating
temperature, heat transfer jacketing temperature, or
the tracer temperature. The same insulation
thickness as that for heat conservation shall be used
unless design optimization dictates a different
thickness.
- Over size insulation shall be considered to
accommodate tracer(s) or heat transfer jacketing.
- Grooving of insulation to accommodate tracing will
not be allowed unless specified by client.

2.2.1.6. Acoustic Control Insulation (Code: AC)

- The primary consideration for use of Acoustic

control insulation shall be control of Noise.
- Normally, acoustic control insulation shall have a
dedicated design for each application.
- Special consideration of insulation materials and
jacketing is normally required.
- Acoustic control insulation may be combined with
other type of insulation.

2.2.1.7. Fire Protection Insulation (Code: FP)

- The primary consideration for use of fire protection

insulation shall be control of the rate of heat gain in
a fire.
- Design of fire protection insulation shall be based
on maximum allowable heat gain, fire case

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 6 of 39

characteristics, allowable time duration, and process

characteristics. Refer to API RP 521 for materials
selection and design criteria.
- Fire protection insulation may be combined with
other types of insulation.

2.2.1.8 Solar Insulation (Code : S)

- Primary consideration for use of Solar insulation is

to avoid increase in temperature by absorption of
solar radiation.
- Solar insulation may be combined with other type
of insulation.

2.2.2. Internally refractory lined piping and equipment and any other
items for which heat loss is essential shall not be insulated.

2.2.3. Insulation is not desired for piping and equipment for which heat
loss is desired - excepting for personnel protection or to avoid
thermal stress problems.

2.2.4. Instruments and associated piping subject to operating flow and/ or

temperature condition prevailing in the connected piping or
equipment shall be insulated to the same requirements as that of
piping or equipment.

2.2.5. Extent of Insulation

Refer to Table - 1 “Datasheet for extent of Insulation”

2.3. THICKNESS BASIS

The insulation thickness specified in this specification are base on the

Indian conditions. In case of different climatic and economic conditions,
they need to be reviewed. The basic criteria are highlighted below which
are used to arrive at thickness. Material properties used in thickness
calculation are highlighted as part of Insulation material specification.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 7 of 39

Average Annual temperature: 40 0 C

Average Annual wind speed: still air

Personnel protection design wind speed still air

Personnel protection design summer dry bulb temperature:

Personnel protection maximum surface temperature: 60 0 C

Emittance of existing surface: 0.8

Emittance of Jacketing: 0.3

(Aluminium)

Design Factor for thermal conductivity: 1

Design factor for piping complexity: 1.2 simple

Refer to Annexure 1 for insulation thicknesses for selected material and

temperatures.

2.4. CODES AND STANDARDS

Refer to Insulation Material specification attached with this specification.
All the codes mentioned shall be the latest issues

3. MATERIALS
3.1. GENERAL
3.1.1. All material shall be of high quality and good appearance.
3.1.2. Insulation and accessory materials shall be formulated without
Asbestos.
3.1.3. Materials shall be new and shall be used prior to expiration date.
Sealants, mastics and adhesives shall be supplied in factory sealed
containers. Multilayer Calcium Silicate pipe insulation shall be
ordered factory tested.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 8 of 39

3.1.4. All material shall be qualified for use on austenitic stainless steel
in accordance with ASTM C 795. The material manufacturer shall
furnish test certificate.
3.1.5. Insulation material shall be low chloride content (Maximum limit
10mg/ kg.), chemically inert, non – sulfurous, rot proof, vermin
proof, impervious to hot water and steam, non – injurious to health
and non corrosive to steel and Aluminum.
3.1.6. Insulation and jacketing material backed with paper or other
flammable material is not acceptable.
3.1.7. All mastics, cements, adhesives, caulks, labels, marking pens and
tapes that come in contact with stainless steel shall have a
maximum leach able chloride content of less than 50 ppm, when
tested in accordance with ASTM C 871
3.1.8. Use curved segments, beveled lags and V – grooved materials
manufactured to specific diameter that assure complete inside and
outside diameter closure.
3.1.9. Special attention is required for fibrous material as its installed
thickness could be reduced due to compaction affecting
performance.
3.1.10. The client shall have right to inspect any or all the tests conducted
on insulation material by manufacturer at his shop or any
laboratory.

3.2. INSULATION MATERIAL

Insulation material shall be as per the Annexure 1 attached with this
specification. This is a project specific insulation material.

3.3. WEATHER PROTECTION JACKET

3.3.1. Aluminum jacketing shall be used as weather protection over

insulation unless otherwise specified and shall be ASTM B209
alloy 3003 H16, ASTM 1209 alloy 5005 for marine atmosphere
environments or IS: 737 designation 31000 (Old NS3) condition
H3 for flat sheets and H4 for corrugated sheets.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 9 of 39

In case fire proofing is required at the same time aluminized steel

plates shall be used.
Incase Galvanized steel need to be used it should be in accordance
with ASTM A 526, hot dip galvanized to A525 coating designation
G90
If stainless steel sheet, it should be in accordance with ASTM A
167, type 304 L or 316 L.

3.3.2. The thickness of the sheets shall be as specified in Table - 2

3.4. ANCILLARY MATERIALS

3.4.1. Securement Bands/Wires

3.4.1.1. If material is aluminum then specification shall be ASTM

B209 Alloy 3003 H16 or IS:737 designation 31000 (Old
NS3) condition H3; if stainless steel it shall be AISI 304.

3.4.1.2. The band material for shaping bands and distance rings
shall be minimum 0.5 mm thick and be 10, 20 or 25 mm
wide aluminum or stainless steel.

3.4.1.3. Binding wire shall be bright-annealed AISI 304 stainless

steel wire thickness min 1.0 mm.

3.4.1.4. Rivets required for metal jacket securement shall be

aluminum "POP" blind eye type. For aluminized steel or
stainless steel, stainless steel rivets shall be used.

Rivets shall be of the expanding type min, 5 mm

diameter.
3.4.2. Self-Tapping Screws:

Screws for aluminum plates shall be aluminum screws in

accordance with DIN7g71 dimensions ½ inch x no. 10.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 10 of 39

For Aluminized steel and stainless steel plates AISI 304 screws ½
inch x no. 8

3.4.3. Sealing Compound for Water Proofing

- Elastomeric sealing compound or
- Fibre based bituminous feltstrips

4. APPLICATION

4.1. GENERAL

4.1.1. The application methods, given in this Standard are general in

nature. The contractor is responsible for applying an insulating
system that will give a satisfactory operational performance and
the requirements given herein shall be regarded as the acceptable
minimum. The contractor shall carry out the work in accordance
with the best practices of insulation application with the minimum
of waste and the final job shall have a neat efficient and
workmanlike appearance.

4.1.2. All hydrostatic/ pneumatic tests on piping and equipment including

steam-tracing system shall be carried out before insulating material
is applied. The insulation contractor shall only insulate these
sections of the plant that has been specifically released for such
work by the engineer-in-charge. If insulation must be installed
before pressure test, then all welds and flanged joints in the pipe
shall be left uncovered till successful completion of pressure test.
Then insulation shall be completed. Client prior to commencement
of insulation shall approve this method of testing.

4.1.3. Where insulation has been specified on piping or equipment

flanges that are to be hot bolted, the insulation shall not be
installed until hot bolting has been accomplished and the flange
determined to be leak free.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 11 of 39

4.1.4. Unless otherwise specified, all insulation materials shall be

installed in a single layer when the total thickness does not exceed
75 mm.

4.1.5. When applying single layer insulation, other then hinged pipe
covering, the circumferential butt joints of each half section shall
be staggered.

4.1.6. Thick nesses 90 mm and greater shall be applied in multi-layers

with staggered joints. Consideration shall be given to multi-layer
insulation for operating temperature over 316 0 C.

4.1.7. When applying double layer or multi-layer insulation, each

succeeding layer shall be staggered to the longitudinal and
circumferential joint of the layer beneath. All joints of all layers
shall be staggered.

4.1.8. Each layer of double layer or multi-layer insulation shall be held in

place separately.

4.1.9. All insulation shall be smooth and free from cracks, voids, gaps,
and depression greater than 3 mm. All cracks, voids, gaps and
depressions greater than 3 mm shall be refitted and not filled.

4.1.10. Insulation Contractor shall not carry out any welding or drilling on
plant equipment and piping. He shall however be responsible for
carrying out a check and confirm that all insulation supports as per
drawings have been fabricated and installed.

4.1.11. Insulation shall be finished beveled and weather proofed at all

terminal points where it is required to remove bolts etc without
damage to the insulation.

4.1.12. Equipment nameplates shall remain visible after beveling back the
insulating material and carefully sealing the exposed edges to

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 12 of 39

prevent ingress of moisture have applied insulation by silicon

rubber compound.

4.1.13. All projections such as lifting lugs, turnings and stiffeners on

piping and equipment (i.e. vacuum rings) shall be insulated with
the same thickness of insulation as specified for the equipment
item or pipeline.

4.1.14. Thermo well bosses, pressure tappings and weep hole nipples shall
not be insulated but left accessible. Flanges for hydrogen service
shall never be insulated.

4.1.15. Wet or damaged insulation shall not be used under any

circumstances.

Insulation material to be applied shall not be kept over bare ground

to avoid water absorption. Installed material awaiting its
protective cover shall be adequately protected from damage, rain
and contamination and shall be covered with cladding within
minimum time.

Insulation materials shall be supplied completely dry suitably

protected from weather and stored in a dry warehouse.

4.1.16. A minimum clearance of 25 mm between outside surface of any

insulation finish and adjacent equipment, pipe or structural
members shall be maintained.

4.1.17. Insulation supports shall not project out of the insulation outer
surface and shall be given sufficient coverage of insulating
material to avoid hot spots on the metallic cover at support position

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 13 of 39

4.2. CORROSION PREVENTION

4.2.1. Carbon steel and low alloy piping and equipment with normal
operating temperatures of 200 o C and below shall be protected
against corrosion by painting as specified in the Standard Painting
Specification. While for equipment (Vessels, Exchangers, Tanks
and Spheres) this coating shall be provided by Painting Contractor.
Note that the drying time for heat resistance aluminum paint at
ambient temperature is about 3-4 weeks. No insulation shall be
applied before paint is completely cured.
4.2.2. Insulation cement shall not be used on stainless steel piping or
equipment.

4.2.3. All insulated austenitic stainless steel piping and equipment shall
be protected against chloride attack as follows:

- Wrap with 0.19mm thick aluminium foil before applying

insulation up to 450o C
- Above 450oC apply two coat of heat resistant silicon
aluminium paint before application of insulation

For operating temperatures from 50 oC upto 120 oC, shall be

painted with silicon aluminum chloride free paint as per painting
specification.

4.3. APPLICATION ON PIPING

4.3.1. Horizontal Pipe

4.3.1.1. General

Insulation material shall be applied to fit snugly against

the contours and shaped only where necessary to achieve
this requirement. The insulation shall be carried out with
the least number of material pieces as possible and all
unavoidable gaps, cavities and voids suitably filled with
compatible loose fill material.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 14 of 39

4.3.1.2. Pipe Section/ Moulded Blocks/Segments

- End joints of adjacent blocks shall be staggered one

half of the length of the block.

- Included angle between segments shall not be less than

30 o for both single and double layer insulation.

- Further minimum arc length of segments should meet

the following staggering requirements

- When double layer is applied both longitudinal and

circumferential joints shall be staggered. There are
between the longitudinal seam lines of the inside
and outside layers of insulation shall have and angle
over 15 o or the longitudinal joints staggered at least
by one layer thickness whichever is more stringent.

- Circumferential seams of the inside and outside layers

shall be at least 100 mm apart.

4.3.1.3. Mattress (Fibrous Insulation Rock or Glass Wool)

Shall be applied over the surface with joints tightly butted

and laced together with binding wire.

4.3.1.4. Insulation Securement (all insulation materials)

Each layer of insulation shall be secured firmly in place

with at least 3 loops of binding wire/band one loop to be
placed not more than 75 mm from each end and at least
one loop to be equally spaced between end loops for each
section. Binding wire shall be drawn about the insulation

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 15 of 39

with ends tightly twisted together bent under and pressed

into the surface of insulation. Bands or wires in no case
are spaced more than 200 mm apart.

For calcium silicate all joints shall be sealed with

insulating cement of same composition as the moulded
block.

Each layer of insulation shall be secured by the same

method as above.

4.3.1.5. Framework for Supporting Cladding: Fibrous Insulation

This is not necessary for rigid materials. This is required

mainly for horizontal pipe runs provided with fibrous
insulation in blanket forms. Piping provided with fibrous
resin bonded pipe sections need not be provided with this
framework.

Spacer rings shall be fabricated out of 25 x 3 MS flats.

The outside diameter of these rings shall be equivalent to
the outside diameter of the insulation. Spacer rings shall
be riveted to "Z" shaped slabs fabricated from the same
sized MS flats "Z" shaped lugs or ceramic studs shall be
provided at intervals of not more than 300 mm along the
circumference of the insulation subject to a minimum of 3
"Z" shaped lugs. Spacer rings shall be provided at every
approx. 900 mm. To minimise direct heat conduction
through the "Z" shaped lugs, a packing of 2 sheets of 3
mm thick millboard shall be provided at the joints of the
"Z" shaped lugs and pipes. Joints between MS spacer
ring and "Z" shaped shall be rivetted by 5 dia MS rivets
with 2 sheets of 3-mm thick millboard interposed.
Horizontal piping less than 1500 mm below grade or
1500 mm above grade, where mechanical damage is
possible, shall be provided with support plates instead of
spacer rings.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 16 of 39

4.3.2. Vertical Pipe (All Insulation Materials)

Insulation on vertical or near vertical piping (i.e. greater than 45 o

angle from horizontal) shall be supported by bolted on metal
collars for pipe sizes above 200 mm and insulation thickness above
120 mm. Metal collars shall be of 6 thick MS or alloy steel bar (to
suit piping material).

Outside diameter of collar shall be around 13 less than OD of

insulation. Where multi-layer insulation is used, support collar
shall be extended to provide for each layer.

Support positions shall be at no greater distance apart than 5 meter.

They shall be spaced so that the compressive strength of the
insulation is not exceeded as a minimum a support ring shall be
installed the start of a vertical rise. In addition also spacer rings
may be required at every meter and before and after elbow and
valve.

4.3.3. Expansion Joints (both Vertical and Horizontal Piping)

Expansion joints for system using rigid insulation shall be

provided at regular intervals taking into account, as an example
expansion joints may be required as follows:

- Expansion of equipment and piping

- Expansion, contraction or shrinkage of insulating

material

- The resilience of the insulation

- Method of supporting of the insulation; design details

and sketches of proposed joints shall be submitted to
consultant for approval

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 17 of 39

Temp oC Spacing (M)

Upto 200 Not required

200 to 300 10
300 to 350 8
350 to 400 6
400 to 550 5
- Sheeting shall be provided with expansion facilities
with an overlap of at least 100 mm.

- Expansion joint shall be formed by a 25 mm space

between the pipe insulation sections and compressed
mineral rock fibres shall fill the space. Expansion joints in
each layer shall be offset at least 150 mm from each other
in case of multi-layer insulation. Expansion joint for first
layer for vertical pipe shall preferably be just below
insulation support collars.

4.3.4. Elbows and Bends (all Insulation Materials)

Insulation material shall be mitred and shall be same as that of

pipe. Insulation securement bands/wires shall be same as that for
equivalent dia pipe. Each mitred section shall be secured with
minimum 2 wires/bands. For bends/elbows of nominal pipe size
4" and below due to lack of space for all insulation materials,
insulation shall be secured by spirally wound. Insulation joints of
block materials shall be suitably sealed with adhesive for
isocyanurate/cellular glass and by insulating cement for calcium
silicate. Fittings below 50 mm nominal dia if insulated with
insulating cement build up in 6 mm layers to the thickness of
insulation of the adjacent piping. Each layer of insulation cement
shall be reinforced with 25 mm No. 20 SWG wire mesh.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 18 of 39

4.3.5. Tee (all Insulation Materials)

Preformed pipe sections or segments shall be carefully cut and

shaped around "Tee" junctions and the insulated material of the
tangential pipe shall be carefully and neatly cut to mate upto the
material applied to the parent pipe without the creation of voids or
gaps at the junction. Insulation shall be adequately secured by
wire/band of same specification as that of same size pipe.

4.3.6. Flanged Joints or Valves (all Insulation Materials)

Flanged joints or valves shall normally not be insulated. If to be

insulated, they shall be insulated with prefabricated removable
aluminum enclosures, lined with pipe sections/lags/slabs.

Welded valves, if insulated shall be insulated with oversized pipe

sections or lags cut and shaped to fit around the body of the valve.
Insulated valves shall be cut and shaped around the valve stem and
kept clear of the stuffing box gland.
4.3.7. Insulation Flashing (all Insulation Materials)

Insulation shall be stopped short of flanged joints and unions by a

sufficient distance to permit easy removal of the flange nuts and
bolts or loosing of the unions to take place without disturbance or
damage to the insulating material. At these positions the insulation
shall be beveled and sealed with a metal closure, which in turn
shall be sealed with waterproof sealing material. (Refer pg. 49 of
73)

4.3.8. Pipe Supports (all Insulation Materials)

Insulation at solid welded or clamped supports shall be cut and

shaped to fit around the support and banded securely to enable the
insulation to be carried with the pipe movement. When the pipe

PC1499011 R2 CONT.
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Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 19 of 39

hangers pass through insulation on piping outdoors, metal hoods

packed with a waterproof sealing material shall be furnished and
installed. Upper bolts of the hanger clamps are not to be covered
with insulation.

4.3.9. Steam Trace Piping (all Insulation Materials) (Except Calcium

Silicate)

Steam traced piping and fittings shall be installed with oversized

sections to allow accommodation of both parent pipe and tracer
without damage or deformation of the insulation. Traced
instrument line and fittings shall be totally enclosed by the
insulation in a similar manner and the designed warm air annulus
maintained throughout the tracer pipe length. Insulation supports
for vertical pipe shall have suitable clearance for tracer pipe.
Suitable putty or cement shall be used to improve the contact
between pipe and tracer throughout length of tracers.

4.3.10. Electrical Traced Piping

Electrical traced piping shall be provided with the same size

insulation as could be provided if the piping were not electrically
traced.

4.4. HORIZONTAL EQUIPMENT

4.4.1. Application : (All Materials)

4.4.1.1. Blanket shall be applied over the surface with joints

tightly butted and laced together with wire.

Other block insulation shall be applied with the longer

dimension parallel to the axis of the vessel or equipment.
When blocks are applied in multiple layer, all joints of
successive layers shall be parallel to the long axis shall be
staggered and sealed with insulating cement for calcium

PC1499011 R2 CONT.
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Page 20 of 39

silicate or suitable adhesive for others. In all cases the

insulation is to fit the contour of the vessel or equipment
so that the use of leveling coat of insulating cement
should not be normally necessary to get an acceptable
smooth exterior.

In case mechanical damage is possible, rigid type of

insulation shall be supplied or alternative measures shall
be proposed to the client such as support plates.

4.4.1.2. Special considerations for insulating high temperature

vessels (Required only if provided with Calcium Silicate
Insulation)

- This provision is required to take care of the effects

of equipment circumferential thermal expansion on
insulation

- This provision is required only for vessels and

exchangers provided with calcium silicate
insulation

- Calcium silicate insulation should be installed in

beveled or curved segments only to avoid voids and
provide an efficient insulation system.

- For equipment upto 3000 mm in diameter and 200

o
C to take care of equipment circumferential
expansion the circumferential block is cut and fitted
to be 13 mm greater in circumference than the
equipment and secured so that tension of the bands
produces compression on the butt edges rather than
on the surfaces towards the vessel the title annular
space and the compressiveness of the blocks would
suffice to take care of circumfernetial expression of
equipment.

PC1499011 R2 CONT.
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- If the vessel is above 3000 mm in diameter or if

temperature is above 200 oC or both, a 25 mm thick
rock wool fibre blanket insulation shall be applied
around the equipment prior to the application of
calcium silicate. This acts as an expansion area
around the equipment to act as mechanical and
sometimes thermal cushions. The calcium silicate
block must be cut and fitted to the outside radius of
the equipment Plus the thickness of the Rockwool
spacer insulation. The insulation when installed
should not come to the fibrous blanket.

- Above provision to take care of circumferential

expansion is required both for shell and head.

4.4.1.3. Insulation Securement

- Each layer of insulation on shells of equipment shall

be secured by bands at every 225-mm centers and
50 mm from the edge of each slab. Each band shall
be machine stretched and tensioned to remove slack
only.

- Each layer of insulation on vessel heads shall be

secured as follows:
Band shall be in radial direction connecting the
head central floating ring and shell girth ring. The
radial bands shall be placed at not more than 150
mm centers for rigid and 300 mm for fibrous
insulation measured at the girth ring. These bands
shall be machine stretched and sealed. Outermost
layer of insulation shall also be supported by wire to
the shell girth ring. Insulation to heads shall be

PC1499011 R2 CONT.
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CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 22 of 39

secured using wire and floating rings or using wire

mesh.

4.5. VERTICAL EQUIPMENT

4.5.1. Application (all Insulation materials)

4.5.1.1. Surfaces to be insulated shall be supplied on support rings

as specified on the Vessel Standard

4.5.1.2. Application details on shell, top and bottom heads shall

be similar to that of horizontal equipment. Insulation
shall be laid on insulation support rings provided by the
fabricator

4.5.2. Insulation Securement (all Insulation Materials)

4.5.2.1. Bottom and top head insulation shall be supported by

wire drawn through holes in the insulation supports
provided by the vessel fabricator.

4.5.2.2. Top head insulation shall be secured by floating

ring/bands or wire mesh provided by insulation fabricator
similar to head of horizontal vessel.

4.5.2.3. Shell insulation shall be supported by bands at every 225

mm on the cylindrical portion and the bands shall be kept
horizontal

4.5.2.4. Insulation securement for bottom head for vessel

supported on legs shall be wire/wiremesh secured to the
welded on nuts provided by the Vessel Manufacturer

4.5.2.5. For insulation on tank roofs, Insulator shall provide his

proposal on the method of protection for approval on
areas where mechanical damage may occur i.e. near the
platform adequate support plates shall be provided.

PC1499011 R2 CONT.
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4.5.3. Expansion joints (all Insulation Materials)

Sufficient expansion points shall be provided as per the straight

lengths involved. The expansion joint shall be provided at the
insulation support rings. The details of the expansion joint
proposed shall be got approved by KPG/ Client.

4.5.4. Flange, nozzle, channel cover, manway and handhole flanged

cover (all insulation materials)

Insulation shall be stopped short of uninsulated flanges and nozzles

etc. A sufficient distance to permit withdrawal of bolts without
damaging the insulation is to be bolt length + 20 mm. Insulation
shall be weather proofed and sealed at these locations.

4.6. IRREGULAR SURFACES SUCH AS PUMPS, COMPRESSORS,

TURBINES ETC.

4.6.1. Application

4.6.1.1. Fibrous Material; Material Application & Insulation

Securement

This shall be prefabricated removable aluminum cover

lined with mineral Rock/Glass wool pipe
sections/legs/slabs/mattresses.

4.6.1.2. Calcium Silicate

- Insulation material shall be insulating cement/block

insulation cut and fitted.

- Insulation shall be applied in maximum 25 mm

thick layer until the scheduled thickness is obtained.

PC1499011 R2 CONT.
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TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

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- Each layer shall be covered with a layer of wire

mesh. The final layers shall be travelled to a
smooth finish with 6-mm thick finish cement.

- Insulation shall be beveled back to 45 o from all

casing flanges, shaft seal caps and bearing boxes.

5. INSULATION FINISH

5.1. GENERAL

Protective coverings or finishes over the insulation are being provided for
the following reasons.

- Protection against Mechanical damage

- Protection against Chemical or atmospheric condition

- Good appearance

- Clean surface

- Retardation of flame from spreading

- Commonly aluminum or Aluminized steel, Galvanized sheets of

suitable thickness are used for this purpose. Refer to Aneexure

- To prevent ingress of water

- Galvanized iron sheets shall be given a suitable protective coat of

anti-corrosive paint on the inner surface. In case there is a chance
of chemical corrosion then aluminum sheets shall also be given an
anti-corrosive protection.

PC1499011 R2 CONT.
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TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

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- The shells of large and tall columns, vessels or tanks of 5 M

diameter and above shall be finished with corrugated sheet metal
for better wind resistance.

5.2. PIPING 1" AND LARGER

Insulation material shall be covered with aluminum sheets or GI sheets

duly painted if required.

Sheets shall be mounted with an overlap of at least 50 mm for both

longitudinal and circumferential seams such that no water can enter the
insulation material.

Sheets shall be formed and edges furrowed. Longitudinal seams for

horizontal lines shall always be mounted in the area and longitudinal
seams of adjacent sheets shall be staggered.

For elbows, Flanges and Tees etc contractor shall cut furrow and form
sections of sheeting

Sheeting sections for bends, elbows, Tees and non-insulated protruding

parts shall be close fitted to prevent ingress of water.
If close fittings of sheeting around non-insulated protruding parts is not
possible, sheeting shall be provided with sealing plates. Sealing plates
shall be cut to the exact dimensions of the protruding part.

Seams where water can enter the insulation material (e.g. Tees, Sealing
Plates etc.) shall be sealed with silicon rubber compound.

Pipe hangers shall be provided with rain caps

Ends of insulated parts such as flanges, flanged valves, instruments etc

shall be provided with end caps so as to allow for the withdrawal of bolts
without disturbing the insulation.

PC1499011 R2 CONT.
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For non-insulated flanges, flanged valves and instruments, seams between

caps, pipe and sheeting shall be sealed with silicon rubber compound.

Aluminum/ GI sheeting shall be fastened with aluminum/ GI self-taping

screws. Contractor shall use at least six screws per meter for piping with a
total insulated diameter below 600 mm and at least ten screws per meter
for piping the total insulated diameter of 600 mm and more.

Sheeting segments for elbows and bends shall be fastened with two screws
per segment.

In addition to the two screws, segments shall also be attached to each other
with four screws equally spaced over the circumference of the sheeting.

Sealing plates and sheeting sections for Tees shall be fastened with
minimum four screws at maximum intervals of 100 mm.

Holes for self-tapping screws shall be drilled next to the longitudinal

furrow and shall have a maximum diameter of 3.3 mm.

Sheeting shall be provided with expansion facilities at the following

locations :

1) Bends or elbows
2) Between hangers or supports in long straight lines
3) All locations where sheeting is fixed to a certain position (e.g. branch
connections)

Expansion seams shall be provided with an overlap of at least 100 mm,

double furrows and fastening with a stainless steel band between the
furrows.

In case fireproofing is required and for aluminum piping, insulations shall

be covered with aluminized steel sheets.

PC1499011 R2 CONT.
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Aluminized steel sheets shall be fastened with stainless steel self-tapping

screws.

Holes in electrical traced piping for electrical cables shall be provided

with rubber sealing rings to prevent damage to the cable and to provide
water tight sealing.

5.3. WEATHERPROOFING OF COLUMNS, VESSELS, HEAT

EXCHANGERS, REACTORS AND TANKS

Insulated surfaces shall be covered with aluminum sheets. Longitudinal

seams shall be staggered.

For heads and stiffeners, sheeting shall be cut in segments and formed to
fit closely to the head or stiffener.

To prevent ingress of water, sheeting shall be mounted with an overlap of

50-mm minimum at all seams. Edges of all sheets shall be furrowed. To
accommodate the overlap of the adjacent top sheets for vertical furrow to
each sheet shall be removed over a length of 50 mm.

Sheeting shall be fastened with aluminum self-tapping screws at intervals

of 100 mm. For the equipment body, contractor may also use aluminum
rivets.

When fastening the sheeting, contractor shall pay special attention to

crossing of longitudinal and circumferential seams.

Holes for self-tapping screws shall have a maximum diameter of 3.3 mm

Holes for rivets shall have a maximum diameter of 4.1 mm.

Caps around reinforcing rings shall be used to compensate expansion of

column, vessel, reactor or tank.

If there is no reinforcing rings applied to the equipment, Contractor shall

provide at least one expansion seam per 10 metres from base. Expansion

PC1499011 R2 CONT.
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TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

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seams shall be provided with two furrows and an overlap of at least 100
mm. Sheeting shall be fastened with stainless steel band mounted next to
the second furrow.

Openings in the sheets for protruding parts shall be provided for. For
inspection purpose, each opening shall be 100 mm larger than the
protruding part. For insulated protruding parts with an insulation
thickness over 50 mm the diameter of the opening shall be equal to the
total insulated diameter of the protruding part.

For uninsulated protruding parts, opening shall be closed with sealing

plates, which fit close around the protruding part. Plates shall be mounted
on top of the equipment sheeting with an overlap of 50, and furrowed
edges.

For insulated protruding parts such as nozzles, opening shall be closed by

connecting the sheeting of the insulated protruding part of the sheeting of
the equipment with an overlap of 50 mm.

All vertical seams between sheets all seams between sheeting on top of
equipment, seems between sealing plates and equipment sheeting, seams
between nozzle and equipment sheeting and seams between sheeting and
end caps for flanges shall be sealed with silicon rubber compound to
prevent ingress of water.

For horizontal equipment, longitudinal seams shall be located in the area

shown in figure A1. In those cases where this is not possible seams shall
be sealed with silicon rubber compound.

In case fire proofing is required and for aluminum equipment Contractor

shall use aluminized steel plate fastened with stainless steel self-tapping
screws or stainless steel rivets. Holes for stainless steel self-tapping
screws and rivets shall have 3.1 mm maximum diameter.

Metal boxes from aluminum or aluminized steel plate with Perspex glasses
shall be inserted in the openings provided for name plates, thermowells,
sight glasses etc. Boxes shall be screwed on top of the vessel sheeting

PC1499011 R2 CONT.
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TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

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with self-tapping screws and all seams shall be sealed with silicon rubber
compound.

5.4. INSULATION CAPS FOR HEAD OF EQUIPMENT, MANHOLES,

HAND HOLES ETC

Heads of columns and vessels with a diameter upto 1000 heads of heat
exchangers, manholes, hand holes etc may be insulated with caps
manufactured from aluminum plate. Seams shall have an overlap of 50
mm and shall be sealed with silicon rubber compound.

Caps shall be internally lined by mineral wool blankets. Blankets shall be

cut to the correct size and pressed against the wall of the cap with wire
mesh facing the object to be insulated. Blankets shall be fastened with
clips. Riveted to the sheeting of the cap. Total insulation thickness shall
be equal to the insulation thickness specified for the equipment.

To prevent mechanical damage due to frequent removal, caps for heat

exchangers shall be supplied with as steel reinforcing frame from angular
steel reinforcing frame from angular steel 25x 3 mm

Caps for heads and heat exchangers with a diameter upto 1000 mm shall
be mounted over the insulation of the equipment body and shall be
attached to the body sheeting by means of 20 mm wide flanged rim.

Caps for exchangers with a diameter over 1000 mm shall extent upto a
distance "A" of the connecting flange. The flange will be insulated as
described for piping flanges with the exception that enclosures for
exchangers flanges shall be provided with an angular steel reinforcing
frame

Caps for manholes, hand holes etc shall be attached to the equipment
sheeting by means of a 20-mm wide flange rim forced to the open end of
the cap.

PC1499011 R2 CONT.
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TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

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Davit for manholes hall also be insulated by the removable cap.

Contractor shall use aluminum self-tapping screws to fabricate the caps

and to mount caps for manholes etc and caps for heads with diameter
below 1000 mm on the equipment sheeting. Holes for screws shall have a
maximum diameter of 3.3 mm. Screws shall be mounted at 100-mm
intervals.

To attach the sheeting of caps for exchangers to the steel reinforcing frame
contractor shall use an aluminum rivets .

Holes for rivets shall have a maximum diameter of 4.1 mm.

In case fire proofing is required and for aluminum equipment, contractor

shall use aluminized steel plate with stainless steel plate with stainless
steel screws and stainless steel rivets. Holes for screws and rivets shall be
maximum 3.1 mm diameter.

Protruding parts in caps shall be insulated and jacketed.

6. CONTRACTOR’S SCOPE OF WORK

6.1. The scope of work of the Contractor shall include the supply and
application of basic insulation materials and all accessories as per
Specifications.

6.2. Supply and application of insulation shall include all items such as but not
limited to all insulating materials, metallic sheet covering, wire netting,
cement plaster, screws, binding wires, scaffolding, aluminum foil for SS
pipes, GI sheets for sheeting material, ribbon, spacer rings, stays, bands,
studs, cleats, flat, support rings, consumable etc as per the specification.
No asbestos material should be used for insulation purpose.

PC1499011 R2 CONT.
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6.3. Supply and application for vapour barrier consisting of bituminous

solution, glass fibre material etc as per specification on Piping &
Equipment, wherever shown as insulated on the drawings, data sheets or
any other documents forming part of this specification.

6.4. Besides the labour and supervision required for insulation, Contractor
shall be responsible for providing :

- Equipment tools and tackles necessary to perform the work in a

workmanlike and efficient manner and to complete the work as per
time schedule

- All scaffolding required for carrying out the work

- Supply of all materials and consumables required for performing

the work

- Storage of insulation, consumables and all other equipment and

materials brought to the site.

- Provision of all safety gear and personal protection gear.

- Special protection required if any, for performing work during

adverse weather conditions as well as for avoiding deterioration /
damage of the insulated surface until ready for use, protection of
surrounding equipment, structures during the course of wash and
any other precautions as may be directed by the Engineer-in-charge.

- Metallic jacketing materials shall be one of the following:

- Aluminium
- Aluminium jacketing shall be half hard quality meeting
ASTM B 209M, Alloy 1060, temper H 14.
- Aluminized steel
- The material shall be Aluminized Steel Type 2, coating
designation T2-100 in accordance with ASTM A 463.
- Stainless Steel

PC1499011 R2 CONT.
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- The sheet shall be in accordance with ASTM A 167, Type

304L or 316L.
- Galvanized steel
- The sheet shall be in accordance with ASTM A 526; hot-dip
galvanized to ASTM A 525 coating designation G90.
- Cleaning up the working area regularly during the course of
work for the purpose of good housekeeping as well as
cleaning up the site on completion of work as directed by
the Engineer-in-charge.

6.5. Bidders to note that the insulation on pipes/equipment located in open area
shall be provided with all necessary protection so that rainwater does not
enter insulation under any circumstances.

7. OBLIGATIONS OF THE CONTRACTOR

7.1. The Contractor shall work in accordance with this specification and the
site rules and regulations of the Owner.

7.2. Special treatment coatings etc shall be applied strictly in accordance with
the procedure lay down herein and with the manufacturer's instructions.
Where the manufacturer's instructions conflict with this specification, the
former shall take precedence.

7.3. The Contractor shall remove all dirt from surfaces to be insulated and shall
ensure that all surfaces requiring insulation are clear and thoroughly dry
before applying any insulation.

7.4. The Contractor shall cover all opening in vessels, towers and any other
equipment to prevent the entry of insulating materials and shall daily
remove from job site all cartons wrappers and other debris.

7.5. Each day's application of insulation has to be weatherproofed overnight by

either the final protective cladding or some form of temporary
weatherproof covering. Contractor will not be allowed to use any water
soaked insulated material and if rain soaks any part of the installed

PC1499011 R2 CONT.
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TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

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insulated material. Then those parts should be removed and reinsulated by

fresh material.

7.6. Before starting the work, the Contractor and Engineer-in-charge shall
agree to detailed program of work. Before the application of insulation,
the Contractor shall check with Engineer-in-charge that the equipment or
pipeline to be insulated is released for insulation (i.e. all testing, picking,
painting etc are complete). The Contractor shall not start insulation job till
he gets clearance from Engineer-in-charge in writing.

7.7. Code inspection plates or stampings, sight glasses, name plates and data
plates on equipment and piping shall be left exposed by the Contractor
without insulation. The opening left for these purposes shall be suitably
sealed to prevent water entering into the insulation.

7.8. Insulation of all flanges, valves etc where required shall be left off until
authorization is given by the Engineer-in-charge to carry out this work. In
general this will be done after lines or equipment joints have been proved
tight by hydrostatic tests and/or have reached operating conditions.

7.9. If additional supports such as supports on vertical piping welded studs on

equipment, floating rings around top of equipment to support the
equipment head insulation etc other than those shown in the drawings are
found necessary the same shall be provided by the Contractor without any
extra cost to the Owner.

7.10. All the equipment, tools, tackles and scaffolding materials, consumables
and all other materials intended for use by the Contractor shall be of prime
quality and offered for inspection to the Engineer-in-charge before being
put up to use. Such inspection shall be carried out at site and only the
approved items shall be employed for performing the work.

7.11. The Contractor shall have to work in co-ordination with other contractor
carrying out works connected with other jobs without causing any
interference to those works. Under the above circumstances the
Contractor will have to abide by the contract and will have to abide by the

PC1499011 R2 CONT.
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instructions of the Engineer-in-charge, who will co-ordinate the various

activities. furrows

7.12. During the course of work as well as during an agreed period after
completion of work Contractor shall provide the requisite man materials,
consumables and supervision required for (a) the touch up repair of any
insulation work already completed (either by Contractor or otherwise) as
may be requested by the Engineer-in-charge. All such work shall also be
performed in accordance with these specifications.

7.13. The Contractor shall guarantee that physical and chemical properties of
the materials used are equivalent to or better than that specified in the
Technical Specifications of work and shall furnish test certificates from an
approved authority or an institution mentioning all the properties and
results of the test carried out for all insulating materials supplied by them
for the subject work.

7.14. The Contractor shall check and confirm that the thickness of insulation
indicated is suitable for the Design Basis covered in technical
specification. If the insulation thickness is not indicated in some cases,
then it shall be furnished by the Contractor and approved by Engineer in
charge.

8. INSPECTION

8.1. All materials supplied and used by the Contractor shall be the best to meet
the requirements of specification and shall be subject to inspection by the
Owner / Engineer-in-charge. Any material not meeting with the specified
requirements shall be rejected and such rejected material shall not be used
and shall be replaced by the Contractor at his own cost.
8.2. The installation workmanship shall also be subject to inspection by the
Owner/Engineer-in-charge at all times. Any work found to have been
damaged or improperly installed should be rectified or reinstalled to the
satisfaction to the Owner at Contractor's expenses.

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8.3. Inspection and approval of materials and workmanship by the Owner /

Engineer-in-charge shall not relieve the insulation contractor or any of his
responsibilities.

8.4. Prior to commencing insulation work on any particular section, the

insulation contractor should be satisfied that all insulation supports on
Vessels, vertical pipelines and shoes on horizontal pipelines have been
correctly installed. Additionally all thermal tracing lines are properly in
place and all metal surfaces are clear and free of foreign or spattered
materials.

8.5. Refer Annexure 2 for Joint Inspection. Contractor should satisfy all the
points mentioned in the format.

9. MEASUREMENTS

9.1. The Contractor in the presence of the Consultant and Owner shall take
measurements.

9.2. The measurement for Hot Insulation/Steam Treated Line shall be as per IS
14164/1994.

Vendor to quote for cost of unit length of insulation for various pipe size
and insulation thickness combination for each type of insulation.
The purpose of quantification of fittings such as elbows, tees, reducers,
flange and valves etc in this Enquiry Spec is for bidder to device the
equivalent length of insulated pipes using the factor as per IS: 14164 for
each inline piping component and to arrive at final quantity & cost at the
stage of enquiry. Since the cladding thickness of valve is one size more
than piping contractor may quote separately.

PC1499011 R2 CONT.
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10. GUARANTEE
The Contractor shall guarantee all insulation work carried out by him against
defective material and workmanship for a period of two years from the date of
completion and handing over and he shall repair or replace promptly without cost
to the client any part or parts of the insulation that fails within the said period.

The Contractor shall also conduct, within 3 months of commissioning of the plant
or at a time mutually agreed between the Contractor and the Purchaser/Owner, a
performance test by measuring the temperature as indicated in the insulation
schedule and other parameters as per Design Basis the temperature on the surface
of the insulation does not exceed values indicated in the Design Basis. Incase of
defects, contractor shall rectify the defects at his own cost.

PC1499011 R2 CONT.
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TABLE - 1

DATA SHEET FOR EXTENT OF INSULATION

INSULATION REQUIREMENTS FOR PIPING & EQUIPMENT

INSULATION CODES:
H - Heat Conservation H - Process Stability
P - Personnel Protection S - Solar
FP - Fire Protection Insulation ST - Steam Traced
P
H (1) P
(As required
ITEMS AMB - AMB - ET & ST
by
649O C 649O C
Purchaser)
Straight or bent pipe, socket weld, threaded
or butt weld pipe fittings (Elbows, Tees etc) YES YES YES
Socket weld, threaded or butt weld valves
Steam traps, related strainers, Pipe unions etc NO (4) NO (4) NO (2)
Flanged pipe fittings, flanged valves
(excluding relief and control valves) flange YES (5) NO (2, 5) YES (5)
orifice sets, piping flanges connected to
equipment nozzles and flanged special items
(i.e. strainers)
Primary piping for instrument connections,
sample piping, vent and drain piping NO NO YES
Expansion or rotation joints, slide valves etc NO (4) NO (4) YES (5)
Instruments and associated tube NO NO YES
Relief valves NO NO NO

PC1499011 R2 CONT.
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Control valves NO (2, 5) NO (2, 5) YES (5)

Tee and inline strainers NO (2, 5) NO (2,5) YES (5)
Vessels, shell and head surfaces YES (4) YES (4) YES
Vessel hand holes NO (2, 5) NO (2, 5) N/A
Vessel manways NO (2, 5) NO (2, 5) N/A
Vessel instrument trim NO NO YES
Shell and tube heat exchangers, excluding YES (5) YES N/A
flanged joints
Heat exchanger flanged joints NO (2, 5) NO (2, 5) N/A
Pump casings NO (2, 5) NO (2, 5) YES (5)
Steam turbines YES (3) (5) N/A
Compressors (5) NO (2) N/A
Blowers, fans (5) YES (4) N/A
Internally insulated items NO (4) NO (4) N/A

1 Economics of insulating these items will vary dependent on climate, fuel cost,
labour and material cost
2 Insulate or guard only where required for personnel protection
3 Insulation shall be furnished by the equipment supplier
4 Provide removable metal guards or suitable personnel barriers where required for
personnel protection
5 Removable/reusable covers should be considered

Personnel Protection (PP) shall be provided to 2.10 meters above grade or platforms and
0.900 meters horizontally from the periphery of platforms, walkways or ladders.

PC1499011 R2 CONT.
 Davy Process
Technology
MUMBAI
PROJECT: MA / DMF PLANT Doc. No.:
CHEMANOL-1499-00-PP-SP-2800-X01
TITLE : SPECIFICATION FOR HOT INSULATION Rev.: 01

Page 39 of 39

TABLE - 2

THICKNESS OF PLATE FOR WEATHER PROTECTION JACKET

ITEMS TO BE INSULATED ALUMINIUM ALUMINIZED STEEL

PLATE PLATE
In mm in mm
PIPING
1-1/2 in 0.8 0.6
2 in through 16 in. 0.8 0.6
> 16 in. 1.0 0.8
FLANGED & VALVE CAPS
< 16 in. 0.8 0.6
> 16 in. 1.0 0.8
REMOVABLE CAPS
@ 200 through 400 mm 0.8 0.6
@ 301 through 600 mm 0.8 0.6
@ > 601 mm 1.0 0.8
SQUARE CAPS OR CABINET 1.0 0.8
CAPS FOR INSTRUMENTS
EQUIPMENT 1.0 0.8
TANK 1.0 0.8
DUCTING 1.0 0.8

Different requirements may be applicable to the package units. (Refer Equipment Data Sheet)

PC1499011 R2 CONT.