IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.

IRM-SU-1381-16.1

Thermal Insulation for Hot Lines, Vessels, and

Exchangers

CTC-IRM-SU1381

This document is the confidential property of Chevron U.S.A. Inc. and its affiliates. When made available to any
contractor providing services to Chevron U.S.A. Inc. or its affiliates, the contractor’s use of this document shall be
governed by the confidentiality provisions of the applicable contract or bid package. Without limiting the foregoing,
neither the whole nor any part of this document may be disclosed by the contractor to any third party, other than an
affiliate of the contractor that requires this information for purposes of the contract with the Chevron entity, without the
prior written consent of the Chevron entity that has disclosed this document to the contractor. When requested by
Chevron U.S.A. Inc. or its disclosing affiliate, the contractor must return all copies of this document to the Chevron
entity requesting such return and delete any electronic copies from the contractor’s systems.

Any and all modifications (changes, amendments, etc.) to this document must follow approved Chevron Engineering
Standards governance processes.

Rev Date Description Author Technology Leader

M 05/2008 General revision. K. R. Young —
N 11/2011 General revision. K. R. Young —
O 10/2016 General revision. Replaces IRM-SU-1403 K. R. Young B. Chaloner-Gill
16.0 08/2021 General revision. Adoption of IOGP S-738 (NORSOK J. Harris C. Laughlin
M-004)
16.1 06/2022 Technical Modification. Revised item 7.12-3 J. Harris —

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1

Summary of Changes
The Author denotes the following technical changes to this revision as detailed below:

Author notations regarding this revision

16.0 Updates to adopt IOGP S-738
16.1 Section 7.12 - Piping and Piping Accessories, revised item 7.12-3.

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1

Contents

1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Owner Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Industry Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4 Insulation Type Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.1 Heat Conservation Insulation (HC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.2 Process Stability Insulation (PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.3 Acoustic Control Insulation (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.4 Personnel Protection Insulation (PP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.5 Fire Protection Insulation (FP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.6 Extent of Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 Insulation Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.1 Calcium Silicate Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.2 Cellular Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.3 Expanded Perlite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.4 Mineral Wool Board and Mandrel Wound Pipe Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.5 Flexible Aerogel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.6 Preformed, Closed-Cell, Flexible, Elastomeric Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.7 Microporous Thermal Insulation Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.8 Polymer Impregnated Fiberglass Blanket (PTFE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.9 Jacketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.10 Aluminum Jacketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

5.11 Aluminum Fitting Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.12 Stainless Steel Jacketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.13 Stainless Steel Fitting Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.14 Polymeric Jacketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.15 Fasteners for Metallic Jacketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.16 Mastic (Polyvinyl Acetate or Acrylic) Weatherproofing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6 Design of Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.1 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.3 Piping, Equipment, and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.4 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.5 Heat-Tracing Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1
7.1 Storage and Handling of Insulation Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

7.2 General Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

7.3 Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7.4 Block Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7.5 Securement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7.6 Expansion Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.7 Insulation Expansion Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7.8 Insulation Supports on Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.9 Fitting, Flange, and Valve Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.10 Metal Jacketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.11 Attachments and Projections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.12 Piping and Piping Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.13 Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.14 Vessel Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7.15 Protection of Installed Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

8 Documentation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

9 Quality Assurance Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

10 Appendix—Standoff Distance for Hot Service Expanded Metal Burn Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

11 Appendix—CES Revision Work Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1

1 Scope

1. This document specifies minimum requirements for the design, materials, installation, and inspection of
externally applied insulation systems in hot service for temperatures from ambient to 1200°F (650°C).
2. In addition to requirements within this specification, International Association of Oil & Gas Producers JIP33
S-738 titled "Supplementary Specification to NORSOK M-004 Insulation for Piping and Equipment" shall be
applicable to all material purchases and installation practices.

1.1 Conflict Resolution

1. Conflicts between Purchaser specifications and the applicable codes, standards, laws, and statutes shall be
submitted in writing to Purchaser for resolution.
2. Exceptions to Purchaser specifications shall be submitted in writing for Purchaser review and acceptance

2 References

2.1 Owner Documents

COM-SU-4743 External Coatings

COM-SU-5191 Coating Systems

FPM-DU-5091 Onshore Passive Fire Protection Materials and Application

NCM-DU-2301 Design for Offshore Noise Control

PIM-SU-5209 Flange Gaskets and Bolting

2.2 Industry Codes and Standards

Unless otherwise specified herein, use the latest edition of the referenced documents.

American Petroleum Institute (API)

API Std 521 Pressure-relieving and Depressuring Systems

ASTM International (ASTM)

ASTM C335 Standard Test Method for Steady-State Heat Transfer Properties of Pipe Insulation

ASTM C447 Standard Practice for Estimating the Maximum Use Temperature of Thermal Insulations

ASTM C450 Standard Practice for Fabrication of Thermal Insulating Fitting Covers for NPS Piping, and Vessel
Lagging

ASTM ADJ C0450 Adjunct to C450 Standard Practice for Fabrication of Thermal Insulating Fitting Covers for

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1
NPS Piping, and Vessel Lagging

ASTM C533 Standard Specification for Calcium Silicate Block and Pipe

ASTM C534/C534M Standard Specification for Preformed Flexible Elastomeric Cellular Thermal Insulation in
Sheet and Tubular Form

ASTM C547 Standard Specification for Mineral Fiber Pipe Insulation

ASTM C552 Standard Specification for Cellular Glass Thermal Insulation

ASTM C553 Standard Specification for Mineral Fiber Blanket Thermal Insulation for Commercial and Industrial
Applications

ASTM C610 Standard Specification for Expanded Perlite Block and Pipe Thermal Insulation

ASTM C612 Standard Specification for Mineral Fiber Block and Board Thermal Insulation

ASTM C680 Standard 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

ASTM C692 Standard Test Method for Evaluating the Influence of Thermal Insulations on External Stress
Corrosion Cracking Tendency of Austenitic Stainless Steel

ASTM C795 Standard Specification for Thermal Insulation for Use in Contact with Austenitic Stainless Steel

ASTM C871 Standard Test Methods for Chemical Analysis of Thermal Insulation Materials for Leachable
Chloride, Fluoride, Silicate and Sodium Ions

ASTM C1055 Standard Guide for Heated System Surface Conditions that Produce Contact Burn Injuries

ASTM C1423 Standard Guide for Selecting Jacketing Materials for Thermal Insulation

ASTM C1511 Standard Test Method for Determining the Water Retention (Repellency) Characteristics of Fibrous
Glass Insulation (Aircraft Type)

ASTM C1676/C1676M Standard Specification for Microporous Thermal Insulation

ASTM C1710 Standard Guide for Installation of Flexible Closed Cell Preformed Insulation in Tube and Sheet
Form

ASTM C1728 Standard Specification for Flexible Aerogel Insulation

ASTM C1729 Standard Specification for Aluminum Jacketing for Insulation

ASTM C1763 Standard Test Method for Water Absorption by Immersion of Thermal Insulation Materials

ASTM C1767 Standard Specification for Stainless Steel Jacketing for Insulation

ASTM E84 Standard Test Method for Surface Burning Characteristics of Building Materials

British Standards Institution (BSI)

BSI BS EN 13472 Thermal Insulating Products for Building Equipment and Industrial Installations - Determination

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1
of Short Term Water Absorption by Partial Immersion of Preformed Pipe Insulation
BS EN ISO 29767 Thermal insulating products for building applications — Determination of short-term water
absorption by partial immersion

International Association of Oil & Gas Producers (IOGP)

IOGP S-738 Supplementary Specification to NORSOK M-004 Insulation for Piping and Equipment

IOGP S-738D Data Sheet for Insulation for Piping and Equipment

IOGP S-738L Information Requirements for Insulation for Piping and Equipment

IOGP S-738Q Quality Requirements for Insulation for Piping and Equipment

International Organization for Standardization (ISO)

ISO 1716 Reaction to fire tests for products - Determination of the gross heat of combustion (calorific value)

Norsk Sokkels Konkurranseposisjon, Norwegian Standards Organization (NORSOK)

NORSOK M-004 Piping and equipment insulation

Process Industry Practices (PIP)

PIP INIH1000 Hot Insulation Installation Details

PIP INSH1000 Hot Service Insulation Materials and Installation Specification

PIP INSR1000 Installation of Flexible Removable/Reusable Insulation Covers for Hot Insulation Service

3 General
3-1 - Insulation systems shall satisfy the laws and statutes of the prevailing governing authority.

3-2 - Insulation and accessory materials shall be as follows:

1. Formulated without asbestos.

2. New and installed prior to the expiration date.
3. Qualified for use on austenitic stainless steel in accordance with ASTM C795.

3-3 - Multi-layer rigid insulation including calcium silicate, cellular glass, mineral wool, and expanded perlite pipe
insulation shall be ordered factory nested.

3-4 - Chemical analyses of insulation and accessory materials in accordance with ASTM C871 shall be furnished by
manufacturer to Purchaser.

3-5 - Adhesives, caulks, cements, mastics, sealers, labels, marking pens, and tapes shall have a maximum leachable
chloride content of less than 50 ppm when tested in accordance with ASTM C871.

3-6 - Joint sealer and vapor stop materials shall remain flexible throughout the service temperature range.

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1
3-7 - Fabricated insulation segments shall conform to ASTM C450, including ASTM ADJC0450.

3-8 - Insulated substrates shall be coated in accordance with COM-SU-5191.

3-9 - Insulation thickness shall be designed with 3E Plus® (by North American Insulation Manufacturers Association
[NAIMA]) or comparable commercially available software that was written in accordance with ASTM C680.

3-10 - The minimum insulation design thickness for calcium silicate, cellular glass, expanded perlite, and mineral wool
insulations shall be 1-1/2 inches (38 mm), unless otherwise noted in IRM-SU-1381.

3-11 - Insulation shall be installed in accordance with the details in PIP INIH1000.

3-12 - Maximum use temperature shall be determined per ASTM C447.

3-13 - For cylindrical applications, thermal conductivity values shall be per ASTM C335.

3-14 - Insulation materials operating at temperatures below 500°F (260°C) shall be hydrophobic qualified using ASTM
C1763 Procedures A, B, or C, depending on material type after heat soaking for 24 hours at 600°F (315°C). Criteria
shall be <5 percent absorption/retention.

3-15 - Refractory ceramic fiber shall not be used as an externally insulation material due to its water absorbency.

4 Insulation Type Codes

4.1 Heat Conservation Insulation (HC)

4.1-1 - Heat conservation insulation shall be designated with the code HC.

4.1-2 - The primary consideration for using heat conservation insulation shall be economics.

4.1-3 - Design of heat conservation insulation shall be based on the highest process operating temperature, average
annual ambient climatic conditions, and project economics.

4.2 Process Stability Insulation (PS)

4.2-1 - Process stability insulation shall be designated with the code PS.

4.2-2 - The primary consideration for using process stability insulation shall be to limit heat loss of process
temperature.

4.2-3 - Design of process stability insulation shall be based on required process temperature and annual extremes in
ambient conditions.

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4.3 Acoustic Control Insulation (AC)

4.3-1 - Acoustic control insulation shall be designated with the code AC.

4.3-2 - The primary consideration for use of acoustic control insulation shall be to limit noise in accordance with NCM-
DU-2301 (offshore) or NCM-DU-5096 (onshore).

4.3-3 - Acoustic control insulation shall have a dedicated design for each application.

4.4 Personnel Protection Insulation (PP)

4.4-1 - Personnel protection insulation shall be designated with the code PP.

4.4-2 - Personnel protection shall consist of insulation, shields, guards, or barriers.

4.4-3 - The primary consideration for using personnel protection shall be to limit the surface temperature to 140°F
(60°C) in accordance with ASTM C1055, Figure 1, Threshold B for a 5 second exposure.

4.4-4 - Design of personnel protection shall be based on the highest process operating temperature, highest average
annual summer temperature, and 2 mph (3 km/hr) wind velocity.

4.4-5 - Personnel protection shall be used if the surface is in an area that is accessible to personnel. (“Accessible area”
is defined as an area in which personnel regularly perform duties other than maintenance during plant operation.)

4.4-6 - Personnel protection shall be provided to 7 feet (2.13 m) above grade or platforms, and 3 feet (0.91 m)
horizontally from the periphery of platforms, walkways, or ladders.

4.5 Fire Protection Insulation (FP)

4.5-1 - Fire protection insulation shall be designated with the code FP.

4.5-2 - The primary consideration for use of fire protection insulation shall be sizing over-pressure protection devices in
a fire event.

4.5-3 - Design of fire protection insulation shall satisfy the requirements of API 521.

4.5-4 - Weather jacketing for fire protection insulation shall be stainless steel.

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4.6 Extent of Insulation

4.6-1 - Lines and equipment to be insulated shall be specified by Purchaser.

4.6-2 - Size, normal operating temperature, and thickness of insulation for lines and equipment to be insulated shall be
specified by Purchaser.

4.6-3 - Flow diagrams, line schedule, vessel and equipment lists, dimensional details, and piping drawings shall be
furnished by Purchaser.

4.6-4 - Extent of insulation on vessels and equipment shall be specified by designer on the data sheets in PIP
INSH1000, as applicable, subject to Purchaser agreement. See IRM-SU-1381 Table 1.

IRM-SU-1381 Table 1: Extent of Hot Insulation

Items Heat Conservation [1] Process Stability

Amb to 1200°F (649°C) Amb to 1200°F (649°C)
Straight or bent pipe; socket weld, threaded, or butt weld pipe fittings; Yes Yes
socket weld, threaded, or butt weld valves
Pipe unions No [4] No [4]
Steam traps, related strainers No [4] No [4]
Flanged pipe fittings, flanged valves (excluding relief and control Yes [5] No [2],[5]
valves), flange orifice sets, piping flanges connected to equipment
nozzles, and flanged special items (i.e., strainers)
Primary piping for instrument connections, sample piping, vent and No No
drain piping
Expansion or rotation joints, slide valves, etc. No [4] No [4]
Instruments and associated tube No No
Relief valves No No
Control valves No [2],[5] No [2],[5]
Tee and inline strainers No [2],[5] No [2],[5]
Vessels, shell, and head surfaces Yes [4] Yes [4]
Vessel hand holes No [2],[5] No [2],[5]
Vessel manways No [2],[5] No [2],[5]
Vessel instrument trim No No
Shell and tube heat exchangers, excluding flanged joints Yes Yes
Heat exchanger flanged joints No [2],[5] No [2],[5]
Pump casings No [2],[5] No [2],[5]
Steam turbines Yes [3] Yes [5]
Compressors Yes [5] No [2]
Blowers, fans Yes [5] Yes [4]
Internally insulated items No [4] No [4]
Notes:
1. Economics of insulating these items will vary dependent on climate, fuel cost, labor and material cost, and cost of money.
2. Insulate or guard only where required for personnel protection.
3. Insulation shall be furnished by the equipment Supplier.

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4. Provide removable metal guards or suitable personnel barriers where required for personnel protection.
5. Removable/reusable covers shall be used.

4.6-5 - A list of lines, instruments, vessels, and operating equipment (e.g., pumps and instrument piping) to be heat
traced shall be furnished by Purchaser. The list shall include nominal sizes and thicknesses of insulation.

4.6-6 - Thickness of basic insulation on vessel heads shall be same as thickness of adjacent cylindrical section of
vessel.

4.6-7 - Thickness of basic insulation on pipe fittings shall be same as thickness of adjoining pipe.

4.6-8 - Insulation thickness of heat exchangers shall be determined from average of inlet and outlet temperatures of
particular section being insulated.

4.6-9 - If heater or exhaust stacks are to be externally insulated, thickness of insulation shall be computed to maintain
flue gas temperature above dew point.

4.6-10 - In general, flange joints shall not be insulated. If flange joints must be insulated, the procedure shall be in
accordance with PIM-SU-5209.

4.6-11 - Manual drains and vents for vessels, mechanical equipment, and piping, including threaded and socket welded
valves shall not be insulated unless heat traced.

4.6-12 - Equipment and piping containing heat transfer fluids shall be insulated with cellular glass or removable covers
in accordance with PIP INSR1000.

5 Insulation Materials

5.1 Calcium Silicate Block

5.1-1 - Calcium silicate based materials shall not be used for topsides or offshore applications.

5.1-2 - Calcium silicate pre-molded pipe sections, curved segments, and flat block shall be suitable for hot face
temperatures to 1200°F (649°C) in accordance with ASTM C533, Type I.

5.1-3 - Calcium silicate based materials shall only be used for installations in continuous operation above 300°F
(149°C).

5.1-4 - If curved segments are not commercially available, beveled lags shall be used.

5.1-5 - Scored or v-grooved block shall not be used.

5.1-6 - The insulation shall be infiltrated with an anti-wetting compound.

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5.2 Cellular Glass

5.2-1 - Cellular glass prefabricated pipe sections, curved segments, and flat block shall be suitable for hot face
temperatures to 800°F (427°C) in accordance with ASTM C552, Grade 1.

5.3 Expanded Perlite

5.3-1 - Expanded perlite pre-molded pipe sections, curved segments, and flat block shall be suitable for hot face
temperatures from ambient to 1200°F (649°C) in accordance with ASTM C610.

5.3-2 - The nominal density shall be 12 lb/ft3 (192 kg/m3).

5.3-3 - Expanded perlite insulation shall be infiltrated with an anti-wetting compound.

5.3-4 - If curved segments are not commercially available, beveled lags shall be used.

5.3-5 - Scored or v-grooved block shall not be used.

5.4 Mineral Wool Board and Mandrel Wound Pipe Insulation

5.4-1 - Mineral wool pre-molded pipe segments shall be suitable for hot face temperatures from ambient to 1200°F
(649°C) in accordance with ASTM C547, Type II.

5.4-2 - Mineral wool mandrel wound pipe insulation shall not be cut from board stock.

5.4-3 - Mineral wool pipe insulation shall not be fabricated in wraparound style with fibers oriented perpendicular to
the heated surface.

5.4-4 - Mineral wool board shall be suitable for hot face temperatures from ambient to 1200°F (649°C) in accordance
with ASTM C612, Type 4B, Category 2.

5.4-5 - Mineral wool shall be limited to maximum allowable shot content of 25 percent, calculated per ASTM C612,
Annex A1.

5.4-5.1 - Regardless of actual shot content, delivered density of material shall not be less than 7 lb/ft 3 (112 kg/m3).

5.4-5.2 - If shot content is less than 25 percent, as indicated in ASTM C612, material manufacturer shall not adjust
delivered density.

5.4-6 - Mineral wool shall be infiltrated with an anti-wetting compound and demonstrate hydrophobicity per BSI BS
EN ISO 29767 for board and BSI BS EN13472 for pipe when used at temperatures below its compound degradation
temperature.

5.4-7 - Water retention shall be defined per IOGP S-738.

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5.5 Flexible Aerogel

5.5-1 - Aerogel high-temperature blankets shall be suitable for hot face temperatures from 75°F (24°C) up to 1200°F
(650°C) in accordance ASTM C1728, Type III, Grade 1A.

5.5-2 - The installation of high-temperature aerogel blanket shall conform to manufacturer’s specifications.

5.5-3 - The insulation shall be infiltrated with an anti-wetting compound and demonstrate hydrophobicity per ASTM
C1763 when used at temperature below its compound degradation temperature.

5.5-4 - The water retention after heating to 600°F (315°C) and soaking in water for 24 hours (ASTM C1511) shall be
less than 5 percent.

5.5-5 - The material shall have a heat of combustion (HOC) no greater than 717 cal/g when tested per ISO 1716.

5.5-6 - Each lot of material shall be accompanied by a certificate of analysis showing, at minimum, the test results for
that lot’s thermal conductivity and heat of combustion. A lot shall consist of no more than 10 cubic meters of insulation
material.

5.6 Preformed, Closed-Cell, Flexible, Elastomeric Insulation

5.6-1 - Closed-cell, flexible, elastomeric insulation shall meet the following requirements:

1. Be suitable for hot applications within the temperature range defined by the manufacturer in accordance with
ASTM C534/C534M.
2. Be supplied in preformed pipe segments.
3. Be composed of a thermoset material.
4. Have a flame spread index of less than 25 and a smoke developed index ≤50, in accordance with ASTM E84.
5. Not be used within 25 feet (7.6 m) of fired equipment.

5.6-2 - Installation of preformed, flexible elastomeric insulation shall conform to ASTM C1710 and the manufacturer’s
specifications.

5.7 Microporous Thermal Insulation Blanket

5.7-1 - Microporous thermal insulation blanket shall be suitable for hot face temperatures up to 1200°F (650°C).

5.7-2 - Microporous thermal insulation blankets shall conform to ASTM C1676.

5.7-3 - The water retention after heating to 600°F (315°C) and soaking in water for 24 hours (ASTM C1511) shall be
less than 5 percent.

5.7-4 - The insulation shall be infiltrated with an anti-wetting compound and demonstrate hydrophobicity per ASTM
C1763 when used at temperature below its compound degradation temperature.

5.7-5 - The installation of microporous blanket shall conform to manufacturer’s specifications

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5.8 Polymer Impregnated Fiberglass Blanket (PTFE)

5.8-1 - PTFE impregnated fiberglass needled felted flexible blankets shall be as follows:

1. Be manufactured with non-respirable Type E fiberglass suitable for 75°F to 1200°F (24°C to 650°C)
to continuous use temperatures.
2. Be manufactured with non-respirable Type E fiberglass needled blanket per ASTM C553.
3. Conform to ASTM C553, Type VII thermal conductivity.
4. Demonstrate hydrophobicity by exposure to a 24 hour heat soak, cooling to room temperature, then testing per
ASTM C1511 or ASTM C1763, Procedure B, with a maximum 5 percent water uptake by weight.
5. Be qualified per ASTM C795 regarding influence on external stress corrosion cracking tendency via test results
of ASTM C871 and ASTM C692

5.9 Jacketing

5.9-1 - Insulation shall be protected from weather, spillage, mechanical wear, or other damage by jacketing.

5.9-2 - Jacketing shall be chosen in accordance with ASTM C1423.

5.10 Aluminum Jacketing

5.10-1 - Aluminum jacketing shall not be used for topsides applications.

5.10-2 - Aluminum jackets shall conform to ASTM C1729, Grade 1 Class A.

5.10-3 - Jacket shall have integral, continuously heat laminated moisture barrier of 3 mil co-extrusion of Surlyn and
polyethylene.

5.10-4 - Aluminum jacketing shall be as follows:

1. For vessels and piping ≤ 36 inches (900 mm) in diameter: 0.016 inch (0.41 mm) thick.
2. For vessels and piping > 36 inches (900 mm) in diameter: 0.024 inch (0.61 mm) thick.

5.10-5 - Except as noted, aluminum jacketing for straight pipe sections and fitting, flange, and valve covers shall be flat
with smooth finish or flat with stucco embossed.

5.10-6 - Except as noted, aluminum jacketing for equipment shall be 0.020 inch (0.5 mm) thick, with smooth finish for
straight shell sections and head, transition, flange, and stiffener covers.

5.10-7 - Aluminum jacketing for horizontal shell sections; vertical shell sections 36 inches (900 mm) in diameter and
smaller; and head, transition, flange, and stiffener covers shall be flat.

5.10-8 - Aluminum jacketing for vertical shell sections larger than 36 inches (900 mm) in diameter shall be deep
corrugated, 2-1/2 inch pitch × 5/8 inch depth (64 mm pitch × 16 mm depth).

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5.11 Aluminum Fitting Covers

5.11-1 - Aluminum fitting covers shall not be used for topsides applications.

5.11-2 - Die-formed aluminum elbow covers shall be formed from 0.024-inch (0.6-mm) thick 1100-0 alloy and temper.

5.11-3 - Covers shall be formed to follow both the inside and outside curvature of the elbows.

5.11-4 - Covers shall have a factory-applied 3-mil, 3-layer poly film moisture barrier coating.

5.11-5 - Coating shall be applied pinhole-free and shall be tinted for identification purposes.

5.11-6 - Covers shall be marked on the inside surface with the specific size/thickness combination(s) for which the
covers were designed to fit.

5.11-7 - Covers for larger sizes, for which two-piece aluminum elbow covers are not available, shall be one piece.
Cover shall be pre-molded glass fiber laminate consisting of long high strength glass fibers uniformly embedded in an
organic resin molded to a uniform thickness with a smooth, hard pigmented surface.

5.11-8 - Prefabricated tee covers shall be fabricated from 0.020-inch (0.51-mm) thick aluminum.

5.12 Stainless Steel Jacketing

5.12-1 - Stainless steel shall be ASTM C1767, Grade 1 or 2, Type I, Class A, with 2B mill finish.

5.12-2 - Stainless steel jacketing shall have integral, continuously heat laminated moisture barrier of 3 mil co-extrusion
of Surlyn and polyethylene.

5.12-3 - Stainless steel shall be 0.010 inch (0.25 mm) thick for piping and equipment installations.

5.12-4 - Stainless steel jackets shall be installed such that all seams shed water. Jackets shall be flashed a minimum of 2
inches (50 mm).

5.12-5 - Jacketing shall be flat for all installations except for vertical vessel shells larger than 36 inches (900 mm) in
diameter.

5.12-6 - Jacketing for vertical vessel shells larger than 36 inches (900 mm) in diameter shall be deep-corrugated, 2-1/2-
inch pitch × 5/8-inch depth (64-mm pitch × 16-mm depth).

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5.13 Stainless Steel Fitting Covers

5.13-1 - Die-formed stainless steel elbow covers shall be formed from 0.010-inch (0.25-mm) thick Type 304 or Type
316 stainless steel.

5.13-2 - Covers shall be formed to follow both the inside and outside curvature of the elbows.

5.13-3 - Covers shall be marked on the inside surface with the specific size/thickness combination(s) for which the
covers are designed to fit.

5.14 Polymeric Jacketing

5.14-1 - Rigid and non-rigid polymeric jacketing shall meet the requirements of IOGP S-738, Annex D.

5.14-2 - Polymeric jacketing shall not be used within 25 feet (7.62 m) of fired equipment.

5.15 Fasteners for Metallic Jacketing

5.15-1 - Tie wire, banding, and rivets shall be fully annealed Type 304 stainless steel.

5.15-2 - Breather springs shall be 4 inches (100 mm) long by 1.1875 inches (30 mm) wide by 0.375 inch (10 mm) thick
Type 302 stainless steel.

5.15-3 - Jacket compression springs shall meet the following requirements:

1. Provide 80 lb/inch (1.4 kg/mm) of compression.

2. Be sized for use with 0.75 inch (19 mm) wide banding.

5.15-4 - Crimp-type closed seals shall be used for band securement with compression springs.

5.15-5 - Wire for securing insulation shall be 16-gauge stainless steel. If required, vessel head floating rings shall be
fabricated from stainless steel wire or cable heavier than 16-gauge.

5.15-6 - Stainless steel fasteners for insulation and jacketing shall comply with IRM-SU-1381 Table 2.

IRM-SU-1381 Table 2: Fastener Sizes

Fasteners Size
Inches Millimeters
Bands for piping and machinery 0.50 inch wide × 0.020 inch thick 13 mm wide × 0.5 mm thick
Bands for vessels 0.75 inch wide × 0.020 inch thick 19 mm wide × 0.5 mm thick
S- and J-clips 0.040 inch thick 1 mm thick
Rivets for joining stainless steel As required As required

5.15-7 - Screws shall not be used to attach weatherproofing jackets.

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5.15-8 - Rivets shall be of the type where the mandrel is retained after setting.

5.15-9 - Tape shall be 0.75-inch (19-mm) wide glass-fiber reinforced.

5.16 Mastic (Polyvinyl Acetate or Acrylic) Weatherproofing

5.16-1 - Mastic weatherproofing shall not be used.

6 Design of Insulation

6.1 Performance

6.1-1 - Thermal insulation material and installation shall provide a service life of at least 20 years. Any damage or
defects identified during routine inspection of the insulation system during its service life shall be repaired.

6.2 General

6.2-1 - Insulation shall be installed so that the valves, instrumentation, drains, vents, flange bolting, and other
equipment are easily accessible for maintenance.

6.2-1.1 - To allow for bolt removal at flanged connections, the insulation shall have a minimum bevel back at the
flanges equal to the bolt length plus 1 inch (25 mm).

6.2-1.2 - Mechanical equipment insulation shall not interfere with the normal operation or maintenance of the
equipment.

6.2-2 - Insulation thickness shall be based on normal operating temperatures and, if necessary, temperatures for special
conditions such as steam out.

6.2-3 - Expansion joints in insulation shall be provided to compensate for the differences in the coefficient of
thermal expansion (or contraction) between the insulating material and the piping or equipment material, or
both per manufactures calculations.

6.2-4 - Insulation design shall be submitted to Owner representative for review and acceptance prior to procurement.

6.2-5 - Stainless steel jacketing shall be used on equipment and piping when fire protection is required to comply with
API 521.

6.2-6 - Insulation shall comply with the requirements of FPM-DU-5091 when used for fire protection.

6.2-7 - The thickness of the insulation to be installed shall be determined using commercially available software (such
as 3E Plus®) or comparable commercially available software written in accordance with ASTM C680.

6.2-8 - Designer shall complete the data sheets in PIP INSH1000 as applicable for Purchaser acceptance.

6.2-9 - Insulation for hot service on flanges and flanged valves shall be shop fabricated in accordance with PIP
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INSR1000.

6.2-10 - If insulation thickness exceeds 3 inches (76 mm), the insulation shall be installed in two or more layers.

Note: Until all insulation materials, including mastic, have been removed from working parts such as valve stems
and governor linkages, the installation of insulation is not complete.

6.2-11 - Mechanical equipment such as mufflers shall be insulated for heat conservation, condensation prevention,
process control, and personnel protection.

6.3 Piping, Equipment, and Fittings

6.3-1 - Insulation adjacent to piping or equipment flanges shall allow for removal of the flange bolts without damage to
the insulation. Cutback shall be equal to the bolt length plus 1 inch (25 mm).

6.3-2 - Insulation ends adjacent to piping or equipment flanges shall be beveled to a 45-degree angle and sealed with
mastic.

6.3-3 - Pipe supports shall allow the piping to be insulated to the full thickness specified.

6.4 Heat Exchanger

6.4-1 - The insulation thickness required for the shell portion of the heat exchanger may differ from the insulation
thickness on the channel portion of the exchanger.

6.5 Heat-Tracing Insulation

6.5-1 - Piping and equipment that are heat-traced shall be insulated.

6.5-2 - Expansion loops and crossovers shall be wrapped with fiberglass cloth tape and weatherproofed.

6.5-3 - The insulation thickness for expansion loops and crossovers in the heat-tracing tubing shall be a minimum of
1/4 inch (6 mm) thick.

6.5-4 - Insulation for heat traced piping shall be oversized to accommodate the tracer without gouging or routing the
internal surface to the insulation.

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7 Installation

7.1 Storage and Handling of Insulation Materials

7.1-1 - From delivery to installed finished product, insulation materials shall be protected from the elements and shall
have adequate drainage.

7.1-2 - Insulation materials shall be handled and stored per manufacturer’s printed recommendations.

7.1-3 - Mastics, adhesives, and sealers that are exposed to temperatures outside the recommended temperature ranges
during storage shall be removed from the site and replaced with new material.

7.1-4 - Materials that have exceeded their shelf life shall be removed from the site and replaced with new material.

7.2 General Installation

7.2-1 - Materials shall be stored, mixed, thinned, and applied in accordance with manufacturer’s printed instructions
and IOGP S-738. Conflicts between IRM-SU-1381 and manufacturer’s instructions shall be brought to the attention of
Purchaser for resolution.

7.2-2 - Authorization to proceed with installation of insulation shall be obtained in writing from Purchaser.

7.2-3 - Unless otherwise specified, insulation shall not be installed until completion of the following has been verified:

1. Required hydrostatic or pneumatic pressure testing, or both.

2. Installation of required substrate protective coating systems, including touch-up of previously applied coatings.
3. Installation and testing of required tracing systems.
4. Cleaning of surfaces that are to receive insulation.

7.2-4 - If required by Purchaser, installation of insulation may proceed before pressure testing is complete, provided the
following conditions are met:

1. All welds and flanged and threaded connections are left exposed until the pressure testing is complete.
2. Temporary terminations of installed insulation are adequately protected at all times.

7.2-5 - Vertical lines longer than 20 feet (6100 mm) shall have welded insulation support rings at approximately 18 foot
(5400 mm) intervals. Insulation support rings are not required for flexible aerogel insulation, however, a jacket support
shall be located just above the bottom elbow or tangent line. Additional jacket supports may be required in accordance
with manufacturer's printed instructions.

7.2-6 - A 1-inch (25-mm) expansion joint packed with resilient mineral fiber blanket material shall be provided under
the insulation support ring.

7.2-7 - Insulation material shall be installed after painting has been completed in accordance with COM-SU-4743.

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7.2-8 - Insulated surfaces shall be clean and dry.

7.2-8.1 - Coated surfaces shall be insulated only after paint has reached its full cure per the coating
manufactures application data sheet.

7.2-8.2 - If weather conditions could impair the quality of the insulation materials and impair the application,
insulation shall not be installed until conditions are favorable.

7.2-9 - Insulation material shall be protected from moisture during installation. If insulation material becomes wet
during installation, the insulation material shall be removed and replaced.

7.2-10 - Insulation shall not cover vessel and machinery nameplates and code-inspection plates. The insulation shall be
beveled away from the plates and sealed against water entry.

7.2-11 - Moving parts of mechanical equipment shall be protected when insulation is installed.

7.2-12 - Insulation work shall be incomplete until insulation materials, including mastic, have been removed from the
moving parts.

7.2-13 - Rigid block insulation for hot applications shall be installed in accordance with PIP INIH1000.

7.2-14 - The installation of preformed, flexible, elastomeric insulation shall conform to ASTM C1710 and
manufacturer’s specifications.

7.2-15 - The installation of flexible aerogel insulation shall conform to manufacturer’s specifications.

7.3 Joints

7.3-1 - Longitudinal and circumferential joints for single-layer insulation shall be staggered.

7.3-2 - Where insulation is installed in multiple layers, joints of adjacent layers shall be staggered.

7.3-3 - Insulation shall be installed with tight joints except at contraction or expansion joints.

7.4 Block Insulation

7.4-1 - Where multilayer rigid insulation systems are used, the inner layer shall be a minimum of 1.5-inch (38-mm)
thickness and the subsequent layers shall be a minimum of 1.5 inch (38 mm) and maximum of 3 inch (76 mm) each,
unless accepted by Owner.

7.4-2 - When installing insulation, the circumferential butt joints of each section shall be staggered.

7.4-3 - When installing multi-layer insulation, each succeeding layer shall be staggered to the longitudinal and
circumferential joint of the layer beneath.

7.4-4 - Each layer of multi-layer insulation shall be held in place separately.

7.4-5 - Insulation shall be smooth and free from cracks, voids, and depressions greater than 1/8 inch (3 mm). Cracks,
voids, and depressions in the insulation greater than 1/8 inch (3.2 mm) shall be refitted, not filled.
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7.4-6 - Purchaser shall identify areas that require bore coating of cellular glass, such as the following:

1. The surface being insulated cycles or swings through an operating temperature range greater than 400°F (204°C).
2. The surface being insulated experiences high vibrations.
3. The insulation is carrying the load of the pipe such as at a pipe hanger or supports.

7.4-7 - Protrusions, other than nozzles, through the insulation on equipment and piping shall be insulated for a
minimum distance equal to 4 times the adjacent insulation thickness measured from the surfaces of the equipment or
pipe.

7.4-8 - The insulation thickness for protrusions shall be one-half the insulation thickness of the adjacent insulated
surface but not less than 1 1/2 inches (38 mm).

7.5 Securement

7.5-1 - Insulation shall be secured as shown in IRM-SU-1381 Table 3.

IRM-SU-1381 Table 3: Means of Insulation Block Securement

Size of Insulation Means of Securement

Insulation < 12 inches
(305 mm) outside diameter
(OD)
Insulation 12 to 24 inches
(305 to 610 mm) OD
Insulation > 24 inches
(610 mm) OD
Held in place with 16-gauge Type 316 stainless steel tie wire, except cellular glass
foam insulation that may be held in place with fiberglass-reinforced pressure-
sensitive tape or stainless steel tie wires applied over the tape.
Held in place with 0.50 inch wide × 0.02 inch thick (12 mm wide × 0.50 mm thick)
Type 316 stainless steel bands and wing seals.
Use 0.75 inch wide × 0.02 inch thick (19 mm wide × 0.50 mm thick) Type 316
stainless steel bands and wing seals.

7.5-2 - Metal jacketing shall be secured as shown in IRM-SU-1381 Table 4.

IRM-SU-1381 Table 4: Means of Metal Jacketing Securement

Size of Metal Jacketing Means of Securement

Metal jacketing < 24 inches Held in place with 0.50 inch wide × 0.020 inch thick (12 mm wide × 0.50 mm thick)
(610 mm) OD Type 316 stainless steel bands and wing seals.
Metal jacketing ≥ 24 inches Held in place with 0.75 inch wide × 0.020 inch thick (19 mm wide × 0.50 mm thick)
(610 mm) OD Type 316 stainless steel bands and wing seals.

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1

7.6 Expansion Bands

7.6-1 - Jacket banding on vessels larger than 8 feet (2400 mm) in diameter shall have 4 inch (102 mm) stainless steel
compression springs.

7.6-2 - Springs shall be located every 30 feet (9100 mm) of band length.

7.6-3 - Each spring shall be installed and loaded in accordance with manufacturer’s printed instructions.

7.7 Insulation Expansion Joints

7.7-1 - Insulation expansion joints shall be installed with maximum distance between joints as specified in IRM-
SU-1382 Table 5.

IRM-SU-1381 Table 5: Maximum Distance between Expansion Joints

Pipe Maximum Operating Insulation Expansion Joint

Temperature Spacing, Maximum
°F °C Feet Meters
200 93 60 18.2
400 204 30 9.1
500 260 12 3.6
700 370 9 2.7
Above 700 > 370 6 1.8

7.7-2 - Expansion joints shall also be provided in uninterrupted straight pipe insulation when the run length is equal to
or greater than one-half the maximum allowed distance.

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1

7.8 Insulation Supports on Piping

7.8-1 - Vertical pipe insulation shall be supported by a pipe insulation support located directly above elbows, flanges,
or flanged valves.

7.8-2 - Additional supports shall be required at a maximum spacing of 18 feet of uninterrupted length, but not less than
spacing required for expansion joints.

7.9 Fitting, Flange, and Valve Insulation

7.9-1 - Flanged joints shall not be insulated. If flange joints must be insulated, the procedure shall be in accordance
with PIM-SU-5209. Also see IRM-SU-1381 Section 4.6.

7.9-2 - Insulation for fittings, flanges, and valves shall be fabricated in accordance with ASTM C450.

7.9-3 - Prefabricated, molded, or routed insulation fittings shall be used when commercially available.

7.9-4 - Insulation for fittings shall be fitted and assembled with tight joints. Joining prefabricated assemblies shall be
done with adhesives designed for this use.

7.10 Metal Jacketing

7.10-1 - Jacketing on piping shall be banded at all overlapping joints. The maximum band intermediate spacing shall be
12 inches (300 mm).

7.10-2 - Jacketing on vessels and equipment shall be banded at overlapping joints and at maximum intermediate
spacing of 18 inches (460 mm). One stirrup loop shall be installed on every third sheet to support the metal jacket
bands.

7.10-3 - The metal jacket shall be rolled to fit the circumference of the pipe covering.

7.10-4 - The metal jacket shall be lapped at least 2 inches (50 mm) on all side and end seams.

7.10-5 - The metal jacket for piping for all horizontal vessels and exchanger shells, and for vertical vessel shells, shall
have exposed heads, transitions, and boxed-in stiffener rings, and shall receive flat jacketing

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1

7.11 Attachments and Projections

7.11-1 - Attachments and projections such as angle stiffeners that extend beyond the normal insulation line on piping
and equipment shall be insulated to the same thickness and finished in the same manner as the piping and equipment.

7.12 Piping and Piping Accessories

7.12-1 - Fittings, for purposes of IRM-SU-1381, shall include ells, tees, reducers, stub-ins, and screwed valves.

7.12-2 - Fittings shall be insulated and weatherproofed with the same material and in the same manner as the adjacent
pipe.

7.12-3 - A cutback of bolt length (equal to bolt length plus 1 inch [25 mm]) shall be left uninsulated to permit removing
bolts without damaging the insulation.

7.12-4 - Insulation adjacent to the bolt openings shall be attached with high-temperature metal adhesive.

7.12-5 - Openings between the weatherproofing and piping shall be flashed with a sealant material suitable for the
operating temperature.

7.13 Vessels

7.13-1 - Insulation on vessels operating at temperatures exceeding 400°F (204°C) and larger than 48 inches (1220 mm)
in diameter shall be secured with bands with one breather spring, and then on 30-foot (9000-mm) centers.

7.13-2 - Insulation at vessel connections shall be neatly beveled back to the vessel surface and sealed.

7.14 Vessel Heads

7.14-1 - Vessel heads shall be insulated with block or flexible aerogel insulation or microporous.

7.14-2 - Block insulation shall be either curved or flat. Flat blocks shall be cut into segmented beveled lags to fit the
head contours.

7.14-3 - Insulation on bottom heads of vertical vessels shall be cut and mitered to fit the shape of the head.

7.14-4 - Insulation shall be held in place with stainless steel wire.

7.14-5 - Wire shall be laced through nuts.

7.14-6 - Nuts shall be welded to the inner diameter of the vessel skirt.

7.14-7 - The insulation on the inside of vessel skirt shall be secured with adhesive cement.

7.14-8 - The vessel skirt insulation shall be thoroughly sealed to the bottom head insulation.

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1

7.15 Protection of Installed Insulation

7.15-1 - Installed insulation shall have the required permanent protection or temporary protection applied before the
conclusion of each days work to prevent damaged by rain or other forms of atmospheric moisture.

8 Documentation Requirements
8-1 - Documentation requirements shall be in accordance with project technical requirements.

8-2 - Supplier shall submit the material specification, installation methods, and other pertinent data concerning the
insulation in writing to Purchaser for acceptance.

9 Quality Assurance Provisions

9-1 - Quality assurance provisions shall comply with the requirements of IRM-SU-1381 and the following additional
requirements:

9-1.1 - Prior to the installation of thermal insulation, the surface coating shall be inspected and accepted by the
Purchaser’s representative.

9-1.2 - The insulation contractor shall give written notice to Purchaser at least 48 hours before the installation of
insulating materials, weatherproof jacketing, and completion of work.

9-1.3 - Insulation shall be inspected by Purchaser representative as follows:

1. Before the weatherproofing jacket has been installed.

2. After the weatherproofing jacket has been installed.

9-1.4 - Deficiencies found as a result of inspections shall be repaired by the contractor at no extra cost to Purchaser.

9-1.5 - Rework shall be inspected and accepted by Purchaser representative.

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IRM1381 Thermal Insulation for Hot Lines Vessels and Exchangers IRM-SU-1381-16.1

10 Appendix—Standoff Distance for Hot Service Expanded Metal Burn Guards

10-1 - Use of Expanded Aluminum Mesh Wrap in Lieu of Insulation for Personnel Protection

1. Expanded aluminum mesh may be used for personnel protection for surfaces that operate at temperatures 140°F
– 930°F (60°C – 498°C).
2. Material Spec: Expamet REF. 450A 0.076 mm uncorrugated 4 in. wide × 328 ft. long.
3. Wrapping procedure shall be performed with 50 percent overlap and then return with another 50 percent overlap
to provide a 4-layer wrap. Ends shall be tied up with an 18-gauge stainless steel wire and the rest of the wrapping
shall be spiral wind with binding wire to hold it in place. Sharp ends shall be tucked in to prevent personnel
getting caught or cut on them.
4. Fittings shall be wrapped with single or multiple layers (bolts, flanges, etc.), depending on the operating
temperature.

IRM-SU-1381 Table 6: Standoff Distance for Hot Service Expanded Metal Burn Guards
Operating Temperature Minimum Standoff Distance from Hot Surface
°F °C Inches Millimeters
Above 140 to 300 Above 60 to 149 3.0 76
301 to 400 150 to 204 4.5 114
401 to 500 205 to 260 6.5 165
Above 500 Above 260 Use conventional insulation or barriers with warning
signs.
Notes:

1. The standoff distances shown in this table are based on hot surfaces that are located where the minimum wind
velocity is 5 mph (8 kph), and the metal burn guards constructed of 1/2 inch (12 mm) × #18 316 SS expanded
metal with 316 SS supports that are not directly attached to the hot surface.
2. If clearance problems occur, conventional insulation material or barriers such as light chain or handrails with
warning signs may be used when agreed upon by Owner.
3. Expanded metal burn guards shall be used only where heat dissipation is desired on hot surfaces, and when
agreed upon by Owner.

11 Appendix—CES Revision Work Items

** END OF TECHNICAL CONTENT ** CES Admin Use Only.

CESR: IRM-SU-1381 -AWP : Author Task

CESR: IRM-SU-1381 -AWP: Tech Lead Task

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