Welcome

ICorr
Insulation Inspection Level 2
 OUTLINE OF THE DAY
• FIRE DOOR
• Smoking area
• Coffee break
• Lunch
• Coffee break.
• Coffee break
• Recap/questions and revision/reading.
• Finish.
 Who are ICorr?
• Institute of Corrosion
• Registered charity (UK)
• A learned society that has served the corrosion science needs of
industry since 1959
• To advance understanding of science, technology and engineering
practice in corrosion control
• Local (voluntary) branch committees
 Membership
• Open to anyone
• Links with others with similar
interests
• Corrosion Management journal
• Social and technical events
 Membership

• Membership grades :
• Ordinary
• Technician : TICorr
• Professional : MICorr
• Fellow : FICorr

• Sustaining Company Membership

 Training and Certification
• The ICorr Scheme was introduced in 1996 and is
increasingly becoming internationally recognised.
• Courses available:
• Painting Inspector Levels 1, 2 & 3
• Pipeline Coatings Inspector Level 2
• Insulation Inspector Level 2
• Fireproofing Inspector Level 2
• Cathodic Protection Technician Levels 1&2
• Hot Dip Galvanising Inspector
 Training Course and Exam
• The course consists of the
following: • Complete a minimum of 16
hours, ICorr approved
• Training Notes structured training.
• Visual Presentations • Attempt the examination within
• Hand-Outs 90 days of completion of
• Practical Demonstrations training.
• Interactive Discussion
• Revision Questions
• Candidates own notes
 Examination Format

• General Paper (20 multi-choice + 3 Written questions)

• Specific Paper (15 multi-choice + 2 Written questions)
• (70% Pass mark required on theory papers)

• Practical Paper
• Identification of samples
• (80% Pass mark required)
 Exam Certificate
Certification lasts 5 years
 Exam paper failures

• Need to resit failed paper within 90 days of completing course

• 2 further attempts. Retest fee
• Don’t give up !!!!
 Topics to be covered
• Normative Documents • Design and application
• Inspection, QA of Insulation systems
• Purpose of insulation • CUI
• Insulation materials • Inspection of insulation
• Fixing materials • Reporting
• Protective materials • Practical identification
• Storage of materials • Health and safety
 Definition of Inspection
BS EN 28402
• Activities such as measuring, examining, testing, gauging one or more
characteristics of a product or service and comparing with specified
requirements to determine conformity.
 Inspection

• Gathering information and comparing against

specified requirements.
• Does the work comply with “specified requirements?”
• Part of Quality Control but not “Controlling, Ensuring
or Guaranteeing results”.
• Checking the work: other parties may then act on the
information that the inspector records and provides.
 Quality Control
• Quality Control : Operational
controls used to maintain
quality or conformance of a
product. “Controlling the
quality of the work and making
changes to it if non compliant”
Quality Assurance
• Procedures and systems of
work created to give confidence
in quality or conformance of
product. Needs to be dynamic
to meet changing customer
needs
 Role of the Inspector
Read, understand and follow instructions
• Get to know the Specification. Read it and understand it. Is it up to
date ????
• Check that all aspects are clear
• It is far easier to have revisions made at the pre-project stage than when
the job is in progress/completed. This is when disputes occur
 Units of Measurement
• Not all specifications are country specific.
• Be aware of ISO and American units.
• µm (microns/micrometres), Mils/Thou
• There are 25.4 microns (µm) in 1 Mil/Thou
• There are 1000 microns (µm) in 1 mm
• Metal cladding thickness : mm/SWG (Standard Wire Gauge)/BWG
(Birmingham Wire Gauge)
 “Normative” Documents

• Reference documents which provide Rules, Guidelines, Practices and

Procedures for activities or results.
• What should happen if followed to the letter
• “A Given Result”
 Specification

• BS 4778 part 1 : a document that prescribes the requirements with

which a product or project has to conform.
• Should indicate the means and the criteria whereby “conformity” can be
checked, eg against Standards.
• Amendments are known as “waivers, concessions, variations, revisions,
dispensations”
• Governing and contractual document for any painting or coating project
• Should provide the contractor and inspector all the necessary
information to carry out their duties.
• Lists all technical requirements and methods for testing and acceptance
criteria.
• If the specification does not precisely cover what is required, it is easy
for things to go wrong.
• Wrong thickness of insulation = wasting energy or safety issues.
• Wrong insulation type = corrosion, fire, energy loss.
• Wrong density = compromised performance
 Inspection and Test Plan ITP

• Should tell the inspector ……

• What type of test/checks to perform
• When/how often checks are performed
• What are the acceptance criteria
• What to do with non-conformities
• Hold and witness points to verify conformity
 Standards
• Document established by consensus and approved by a recognised
“Body”
• Rules and guidelines for repeated use.
• ISO, BS, SSPC, ASTM, etc
• Used as a reference
• Eg BS 3533 Glossary of Thermal Insulation terms, ISO 9229 Thermal
Insulation Vocabulary
 Code of Practice

• Document that recommends practices and procedures for the design,

manufacture and maintenance of products or structures
• Eg; BS5970 Code of practice for Thermal Insulation operating from -
100ºC to +870ºC.
• Covers uses, forms and temperature ranges etc
 Material data sheets

• Created by the material manufacturer

• Give details of material characteristics.
• Outline correct manner of usage, storage, tolerances etc.
 Thermal Insulation
BS 3533:1981 Glossary of
thermal insulation terms
• Thermal Insulation: A
material or system that
has the property of
resisting the transfer of
heat.
•
BS EN ISO 9229 Thermal Insulation
Vocabulary
• Thermal Insulation: Process
of reducing heat transfer
through a system or
description of a product,
component or system that
performs this function.
 Purpose of insulation
• The purpose of insulation in the broadest sense is to restrict the flow of energy,
namely heat and sound

• The reason for this include:

• Reduce noise pollution
Inhibit freezing in unheated pipes
Personal protection (safety from heat/cold)
Conserve energy (plant efficiency)
Control process (heat lowers viscosity of oil)
In order to understand insulation we need to know how heat energy travels
through material.
 Transfer of Heat.

• Convection – Transfer through liquids and gases

• Conduction – Transfer through solids
• Radiation – Transfer via electromagnetic waves
 Convection
(Warm air rises)
• Molecules free to move
• Receive energy and knock into
each other
• Transfer heat become less dense
and rise
• Cooler molecules move in to
replace molecules displaced.
• Convection “currents” form
within liquid/gas
 Conduction
• Metals good conductors of heat
and electricity.
• Molecules and atoms not free to
move.
• Heat transmitted to other
areas/objects (eg. through pipe
supports)
• Non-metals generally poor
conductors
Conduction
 Radiation
• No direct contact with heat
source eg light bulb/the sun
• Electromagnetic waves transmit
energy through a space
• Dark/dull objects emit and
absorb more heat that
light/shiny objects
• Surface area is a factor.
 Heat Capacity
• The energy required to raise the
temperature of a substance by
1°C
• Small items may heat up/cool
down quicker than larger items
• Small bore pipe would need
more insulation than a large
bore pipe.
• Heat capacity of product
• Heat capacity of insulation (its
efficiency)
• Heat capacity of pipe/vessel
• Flow rate of product
• Energy flows from high to low
energy ie : from hot to cold
 Heat Capacity
of different materials
 Transfer of Sound

• Sound/noise travel by vibration

• Insulation materials need to be flexible not rigid.
• Fibrous products
• Energy transformed into heat
 Personnel Protection

• Materials used to stop contact between ourselves and a surface that

could cause injury.
• Perforated metal/wire meshing
• Generally used above +55ºC
• below -10ºC
• Governed by specifier.
 Fundamental requirements
for insulating material

• Non conductive
• Traps air or inert gases
• Generally weak (brittle/deformable)
• Require support or protection from deformation/damage
• Absorbant
 Coding for Insulation
• BS5970 2012 : Code of Practice for thermal Insulation operating
between
• -100°C and + 870°C
• No current comparable ISO Standard
• Recommends practices and procedures for products and their uses
• Some products do not conform to a “Standard” and may have variations
to temperature ratings
 Insulation Systems

“Hot insulation” keeps product “hot”

“Cold Insulation” keeps product “cold”
“Acoustic Insulation” keeps process “quiet”
“Personnel Protection” keeps workers “safe”
 Abbreviations from BS 5970
HC : Heat Conservation > +60°C
CC : Cold Conservation > -10°C
PP : Personnel Protection > +55°C > -10°C
A : Acoustic
AC : Anti Condensation or Acoustic Cold
FP : Frost Protection
> Value is greater than/higher than
< Value is less than/lower than
 Insulation Material Types
• Mineral fibre/wool • Phenolic foam
(Rock, Glass, Slag) • Polyurethane foam
• Aerogels (flexible or rigid)
• Perlite • Polyisocyanurate
• Calcium silicate • Baked cork
• Vermiculite • Synthetic Rubber/Nitrile
• Cellular/Foamed Glass rubber/EPDM
• Polyethylene
• Polystyrene
 Hot Insulation Systems
• Vermiculite up to +1100°C
• Calcium Silicate up to +1000°C
• Mineral Wool up to +850°C
• Perlite up to +650°C
• Cellular Glass up to +430°C
• Phenolic foam up to +180ºC
• Polyisocyanurate (PIR) up to +140°C
• Pyrogel up to +650ºC
• These temperatures are only a guide
 Cold Insulation Systems
• Cellular Glass down to -270°C
• Perlite loosefill down to -200°C
• Mineral wool down to -200°C
• Phenolic Foam down to -180°C
• Polyisocyanurate down to -145°C
• Polyurethane down to -100°C
• Cryogel down to -270ºC
• These temperatures are only a guide
 Condensation Protection

• Insulation may stop condensation at the vessel/pipe surface but

moisture may be drawn into the insulation.
• Insulation may become saturated and affect performance and
strength
• May freeze and rupture
• Use of pre formed sections and bends with vapour barrier
 Acoustic Insulation
• H.V.A.C. Heating ventilation air conditioning
• Reduce noise pollution from fluids or gases transported at high
velocities.
• Fibrous mineral wool with heavyweight barium loaded, lead vinyl
sheeting or polyethylene sheeting
• Thicker than normal metal cladding to reduce vibration.
 Categorising Insulation Materials
• Either by fundamental material basis – Organic or Inorganic
• Or by material form
• Or by physical application – Pre-formed slabs/lags/sections, flexible mattresses
and blankets, loose fill, paste/plastic composition, foams, metallic foil, sprayed
(fibrous, foamed/cellular, granular)
 Organic Insulation
• Based on Carbon, “once living” ….”Poly”
• Polyurethane, PolyVinylChloride, Polyethylene, Polyisocyanurate, Cork,
Rubber, Elastomerics
• Degrade at temperatures over 200°C , some at far lower temperatures
• Degradation by UV (sunlight)
• Weak bonds between the Carbon atoms
 Inorganic Insulation

• Not from Carbon (organisms)….mineral based, usually silicon.

• Mineral fibre/wools, Cellular glass, Vermiculite, Perlite, Calcium
Silicate
• More temperature resistant
• Strong bonds between silicon atoms.
 Insulation by
Generic Material Class
• Granular (small grains that contain voids or hollow spaces between
which allow transfer of gases/moisture)
• Cellular (small individual walled cells separated from each other and
containing air/inert gas)
• Fibrous
• Reflective
 Insulation by Physical Form
• Pre-formed pipe sections, slabs, blocks, and lags (pre-formed rigid
insulation in more than 2 pieces for pipes/vessels)
• Flexible mattresses/blankets,
• Loose fill
• Paste/plastic composition, cements
• Metallic foil
• Sprayed (foamed/cellular, fibrous, granular)
BS 5970
 Comparison of Insulation Materials
INSULATION TYPE TO BS 5970 MATERIAL CATEGORY
ORGANIC. LOWER EXTREMES
OF HEAT RESISTANCE AND UV
STABILITY
INORGANIC. RESISTANT TO
HIGHER TEMPERATURES AND
MORE UV STABLE
INSULATION MATERIAL PHYSICAL FORMS AVAILABLE APPROXIMATE WORKING TEMPERATURE RANGE
RIGID PREFORMED PIPE
POLYURETHANE SECTIONS. SLABS. SPRAYED. -180 TO +110°C
RIGID PREFORMED SECTIONS.
POLYISOCYANURATE (PIR) SLABS -200 TO +200°C
FLEXIBLE PREFORMED PIPE
POLYETHYLENE SECTIONS -45 TO +100°C
CELLULAR PREFORMED PIPE
POLYSTYRENE SECTIONS.SLABS. LOOSEFILL -60 TO +75°C
RIGID PREFORMED PIPE
PHENOLIC FOAM SECTIONS. SLABS -180 TO +120°C
FLEXIBLE PREFORMED PIPE
SECTIONS. ROLLS. FLEXIBLE
SYNTHETIC RUBBER SLABS -200 TO +150°C
RIGID PREFORMED PIPE -268 TO +430°C (+480°c WITH OUTER COATING
CELLULAR
CELLULAR GLASS SECTIONS, SLABS, LAGS, BLOCKS OF BITUSEAL)
RIGID PREFORMED PIPE
SECTIONS, BLOCKS, SLABS, LAGS,
CALCIUM SILICATE PLASTIC COMPOSITION. AMBIENT TO +800/1000°c
GRANULAR RIGID PREFORMED SECTIONS,
PERLITE BLOCKS, SLABS, LOOSEFILL -200 TO +870°C
RIGID PREFORMED SECTIONS,
VERMICULITE BLOCKS, SLABS, LOOSEFILL AMBIENT TO +1100°C
PREFORMED PIPE SECTIONS, VARIOUS GRADES. '-200 TO +650/850°C
SLABS, LAGS, ROLLS, BLANKETS, GENERALLY ABOVE AMBIENT. ALSO HVAC AND
FIBROUS MINERAL WOOLS MATS/MATTRESSES ACOUSTIC
CRYOGEL -200 TO +125°C
AEROGELS ROLLS AND BLANKETS
PYROGEL AMBIENT TO +650°C
 Fibrous Insulation

• Mineral Fibre/Mineral Wool/Glass Wool/Rock Wool

• Aerogels
 Mineral Wool,
blanket with chicken wire support
 Mineral Wool

• Fibrous
• Excellent thermal and acoustic insulation.
• Non-combustible
• Resistant to high temperatures.
• Cost effective and easy to handle.
• Maintenance free/rot proof
• Various densities
• Temperature range generally above 0°C to +650°C. Glass wool
• Denser versions to +850°C. Rockwool
• Some versions used down to -200ºC
• Can absorb moisture on “cold work” and become saturated so maybe
foil wrapped
• Chemically inert but leaches chlorine when wet
• Lags, slabs, pre-formed sections, mattresses, blankets
 Aerogels

Cryogel (White) with vapour barrier -

270ºC to +125ºC Pyrogel (Pink) ambient to +650ºC
• Fibrous.
• Expanded silica 3% and air 97%
• Currently the most insulative material commercially available
• Hydrophobic; water hating.
• Porous but non-absorbant, water beads on surface.
 Granular Insulation

• Calcium Silicate
• Perlite
• Vermiculite
 Calcium Silicate
Slabs, blocks and preformed segments
• Made from silica and lime with glass or cotton reinforcing fibres
• Operates up to 1000°C
• Preformed sections/slabs usually 25-75mm thick
• High compressive strength
• Porous, will absorb moisture
• Multi layer systems
• Can lose integrity once heated and requires cladding for support
• Displays permanent shrinkage after exposure to high temperatures
• Segments oversize to allow shrinkage of inner layer
• Often coated with hard setting compound or self setting cement for foot
traffic on vessel tops which gives support to metal cladding
• Widely used in power industry as durable over long maintenance
periods
Multi layer system, hotwork
• Joint sealers not applied on inner layer
• Generally only used over 300°C
• Often coated with :
• Hard setting composition
• Self setting cement
• Repairs and sealing outer joints using “Maggie” powder with mineral
fibres Plastic Composition.
• Stainless steel metal cladding
 Perlite

Slabs and blocks Loosefill

• Operates at temperatures up to +870°C
• WR1200 system contains >50% Sodium Silicate binder as corrosion
protection
• Granular.
• Loose fill or pre-formed
• Looks similar to calcium silicate, but rough/lumpy
 Vermiculite
Pipe shell halves and loosefill
• Granular
• Pre-formed sections and loose fill
• Flaky mineral exfoliated at high temperatures to improve thermal
properties
• Petrochemical high fire risk areas
• Can withstand up to 1100°C
• Clad with Austenitic Stainless Steel. Aluminium melts at 660°C
 Cellular Insulation
• Cellular glass
• Rigid Phenolic foams
• Polyurethane foams
• Polyisocyanurate (PIR)
• Polyethylene
• Polystyrene
• Synthetic rubbers
• Cork
Cellular Glass
Fabricated blocks
• Probably one of the most versatile commercially available insulation
materials
• Non-absorbant
• Can operate at temperatures between -260°C to +430°C (480°C with
external bituseal)
• Widely used offshore
• Foamglas, Kaimann, Anglitemp
• Glass composition “foamed” under molten conditions to form sealed
cells.
• Cellular, brittle, friable and rough feel
• Vulnerable to abrasion, needs anti abrasion compound on inside as
vibration/expansion of pipe will damage it
• Several grades governed by compressive strength and density
• Can be cut by saw, has a sulphurous smell
 Forms of Cellular Glass
PSG : Pipe Segments
Sometimes termed “Lags” with bevelled
PSH : Pipe shell halves. Flush edged edges
 TSG : Tank pre-curved segments with
PSQ : Pipe Shell Quarters with bevelled edges
bevelled edges
Pre-fabricated elbows Tee Pieces
 Rigid Phenolic Foams
Pipe shell halves with condensation barrier
• Fine cellular structure
• “Velvety texture”
• Preformed sections, lags and slabs
• Temperature range -180°C to +120°C
• Degrades rapidly under UV to a buff colour (Organic)
• All “foams” can emit toxic smoke
Polyisocyanurate Foams (PIR)
Rigid preformed segments
• Temperature range of -200°C to 200°C
• Coarse cellular nature
• Denser than rigid urethane and better properties
• Rigid, not spongy.
• Low density versions deformable
• Organic
• Several densities: Higher compressive strength for around pipe hangers
Polyurethane Foam
• Temperature range -180°C up
to +110°C
• Cellular, Organic
• Similar “velvety” feel to phenolic
foams
• Image has a “kraft paper” backing
• Lower operating temperature
than Phenolics and PIR
Polyethylene
• Cellular, Organic
• Flexible
• Greasy feel
• Difficult to seal/glue
• Operating temperature -45 to
+100°C
• Generally used in
domestic/commercial markets
• Frost protection
Polystyrene
• Loose fill
• Slabs and pre-formed sections
• Cellular, Organic
• Frost protection
• -60 to +75°C
• Residential and commercial
Synthetic Rubber
• Typically for frost protection
• -100°C to +100°C
• Some types down to -200°C
• Cellular
• Either nitrile rubber, EPDM,
armaflex
• Seam at 6 o clock to stop water
ingress
• Elastomeric/flexible
 Insulation “K” Values
• High “K” value materials are less insulative
• Sometimes stronger with higher compressive strength
• Eg for pipe hangers, tank floors etc
• Low “K” value materials are more insulative.
• May be lower density, weaker or more compressible
Thermal Characteristics
 Protective coverings

• Metal cladding various metal types.

• Hard setting compositions and self setting cements. Alternative to metal
cladding.
• Synthetic sheet materials such as: EPDM, UV cured GRP (Fibaroll),
Chloro-sulphonated PE
• Liquid solutions for cellular glass.
• Vapour barriers/seals
 Vapour seals/barriers
• Cold work/CRYOGENIC applications operating below dew point
• Condensation protection
• Prevent passage of moisture from exterior into the insulation system
• Where systems may undergo temperature cycling
 Wide range of types

• Acrylic latex
• Solvent based vinyl polymer
• Polyvinyl acetate
• Hypalon
• Elastomeric polymers
• Alibutyl laminate foils
• Mastic solutions
 Terostat for cellular glass
• Silane modified polymer, self extinguishing
• High elasticity/flexibility/bond strength
• Mainly factory applied
• Glossy and tacky
• Can hold damaged areas together
• UV and moisture resistant
• Solvent free and odourless
• Joints sealed with Terostat PC Mastic
Terostat Primary Vapour Barrier

Back
Alibutyl Laminate Vapour Barrier
(requires protective cladding)
 Reinforced Aluminium Foil
Light duty anti condensation barrier
 Hand applied vapour barriers

• Applied by gloved hand, trowel or float and smoothed off

• Generally toxic/irritant
• Hand applied barriers usually in 2 x 1mm layers so are similar in
thickness to single coat factory applied vapour barriers
• Wet film thickness can be checked with wet film thickness comb
 Two layer vapour barrier

• Eg. Fosters 6075. Blue 1st layer then 10x10 scrim cloth with 2nd outer
layer of contrasting Grey

Back
 Protective Polyethylene
Sheet (PE)
• Chloro-suphonated PE
• Replaces metal cladding
• Overlapped using
adhesive and joints
sealed with sealant
• Can melt in fire
• Can deform at folds and
perforate
• Ulvashield
Hard setting composition
for Calcium silicate
• Red/Brown PD40 Bulldog
• Dry powder based on clay and mineral fibres and mixed with potable
water
• Usually applied in 2 x 5mm layers = 10mm. Wire mesh reinforcement
• 1st layer rough to aid adhesion of next coat
• Cures via heat. Can be painted
• Slow mixing speed 5-20 revs per minute so as not to entrap air
Self Setting Cement
• Grey
• Based on Portland cement. Alkaline
• Usually applied in 1 x 5mm layer
• Undergoes hydraulic set by water evaporation
• Can be painted
• Both are not waterproof and need weather protection
• Paint
• Metal cladding
• Fiba clad
• Both products can be used over granular and cellular products
 Scrim Cloth
• 10x10 ……10 squares per linear
inch (2.5mm)
• Glass fibre cloth
• Gives strength to hard setting
compositions and hand applied
vapour barriers
• Normally 75mm overlaps
 Glass Reinforced Polyester
• Alternative to metal cladding
• Glass reinforced polyester resin
• Fiba Clad pre-cured material in pre-formed sections
• Fiba Roll (cures by uv light) or cured using catalyst (cold cure)
• Mechanically strong, seamless, waterproof, flexible
• Used over a wide range of insulation
• Maximum +100°C with peaks to +160°C
• Can be overpainted
• Rolls 600-1000mm wide and 1 to 2 mm thick
• Store at +25°C maximum
• Detailed “working procedures manual”
• Several types including self adhesive versions
 Applying Fiba Clad
(pre cured rigid sections)
Adhesive applied to
Fibaclad overlap
UV Cured Fibaroll layers
 Fiba Roll

• Cured by UV light or halide lamps.

• Does not cure under fluorescent tubes or house lights
• Supplied in black UV blocking bag
• Extended roll core prevent edge damage
• Check the lighting is adequate
• Apply the correct way round !!
• Supplied between 2 barrier films,
• Yellow film is bottom, Clear film is top.
• Bottom surface tacky to apply to substrate
• Keep the external Clear PE sheet in place until fully cured
• Don’t apply in wet weather
• Seams must watershed
• Check overlap requirements
Overlaps
 Cure test for Fibaroll
• 2 pieces of fibaclad applied over
each other
• Placed in an area of suspect
poor light
• Allow to “cure”
• Check degree of cure by
scratching with fingernail.
 Whitening

• Causes :
• Outer film removed too soon
• Condensation formed on surface
• Not enough light
 Metal Cladding
• Used to protect insulation form damage, snow, rain, UV, spillages etc
• Arranged so as to shed water, sloped/pent
• Can be painted to give extra protection or for identification purposes
• Overlapping seam not less than 50mm
• 75mm overlaps for pipes over 600mm diameter
• Secured by metal banding, screws or rivets in accordance with
Specification.
• Overlaps at either 8,9,10 or 2,3,4 o’clock positions preferred.
WATERSHEDS
• 12 o’clock and 6 0’clock positions to be avoided
• All joints sealed with 5mm bead of suitable sealant to stop moisture
ingress
 Cladding thicknesses
• Thicknesses of cladding :
• 0.5mm = 24 gauge
• 0.7mm = 22 gauge
• 0.9mm = 20 gauge
• Generally:
• Up to 150mm diameter 0.5mm/24g
• >150mm <450mm diameter 0.7mm/22g
• >450mm diameter 0.9mm/20g
 Metal Cladding

Available in:
• Aluminium
• Stucco aluminium
• Aluzinc
• Galvanized steel
• Austenitic Stainless steel
 Aluminium Cladding
• Easy to work with, easily damaged
• Light weight
• Forms a passive oxide under dry conditions
• Can look poor/mottled in humid locations or in presence of alkalis
• Stucco type increases strength, hides scratches and abrasions.
• Melts at 660°C and can start other fires
Mill Finish Aluminium
Stucco Aluminium (Embossed)
Ventureclad Stucco
self adhesive roll
 Aluzinc
• Steel sheet coated with an alloy of 55% aluminium/43% zinc/2% silicon
• Heat resistant to 315°C
• Harder and more rigid than aluminium
• More abrasion resistant/Anti fingerprint
• Excellent corrosion resistance
• No protection on cut edges of sheets
• Smaller spangle effect compared to galvanizing
Aluzinc coated Steel
small spangle effect
Corrugated Aluzinc
 Galvanized Steel

• Zinc coated steel by hot dip process

• More rigid than aluminium
• Spangle effect forms dull grey protective “patina” when oxidised
• Service temperature 230ºC
• Zinc melts above 460°C
• No protection on cut edges of sheets
Galvanized Steel,
larger spangle effect
 Austenitic Stainless Steel

• Many different grades, 304, 316 etc

• Contains Chromium and Nickel
• Good corrosion resistance and strength
• Forms a passive oxide layer when oxygen present
• Affected by chloride salts (offshore, estuaries, etc) can lead to pitting
• Carbon steel grindings – rust staining
• Easily worked, cut/formed/welded
• High melting point, used in areas of fire risk often in conjunction with
Vermiculite
 Stainless steels

304 food grade onshore 316 polished petrochemical/offshore

 Identification of metal cladding

• So how do we know we have the correct type and thickness of metal

cladding ???
By appearance/finish??
 By Thickness
(Standard Wire Gauge)
 Gaps/Finishing details
• Heat loss can occur at gaps.
• Water ingress and saturation of materials.
• Corrosion
• Expansion and ice formation
• Heat loss from bare surface can be up to 20 times greater than an
insulated one
 Vertical Metal Cladding
• Vertical runs supported
by S clips same material
as cladding
• tile fashion watershed
• 4 clips per seam evenly
spaced on circular
overlaps
• 5mm bead of sealant
applied to joints
S clips
 Finishing details
(Fixings and alignment)
Sealing of joints,
5mm bead of sealant
Pre-formed Bends and Tees
(Correct aspect!)
Check Correct Aspect

Water flows over seam

Incorrect Aspect

Water ingress
Slippage
Slippage support
Watershedding For Bends
 Drain Holes/Drain Plugs
• In metal cladding
• Drilled from inside to outside.
• Put in before installation so as not to perforate Primary Vapour Barrier
• Check they are there. Not taped up.
• Check diameter usually 5-15mm and spacing usually 3 metre intervals
• At lowest point.
Terminations
 Removable flange and valve boxes
• Ready made or custom
made. Flange, valve
boxes etc
• Typical clearance for
bolts on flanges is Stud
length +25mm unless
nuts are larger
• Specification should be
consulted
 Bolt clearance

Acceptable Better
Flanges : Stud length + 25mm/spec
Flange Boxes
Removable Valve Box
Removable Blankets
Pipe Hangers
Hanger Rod Rain Shield
External Pipe Support
and support sleeve
 External Support
(Higher density insulation to resist compression)
Roller pipe support
 Fixing Materials

• Wire netting • Adhesives

• Binding wire • Anti-abrasion compound
• Binding tape • Joint sealant
• Fixing bands • Pop rivets
• Self-tapping screws • Support rings
• Nuts and bolts • Self adhesive pins
• Metal banding • Scrim cloth
• S Clips • Velcro straps
• Toggles and clips
 Anti Abrasion Compound (Cellular Glass)

Mastic and scrim cloth, high operating Factory spray applied, lower operating
temperature range temperature range
Exterior Reinforcement
• FoamGlass
• Bituseal and mastic stops freeze
thaw damage to outer cell walls.
• High temperature stresses and
thermal cycling stresses
 Metal banding

Tensioning tool for metal banding Metal banding and clips

• Stainless steel, aluminium or aluzinc
• “Pitch” of bands: how many/spacing and location….check spec or obtain
agreement
• Good guide is 25mm back from joints, and 300mm centres
• Check tension : loose/too tight
• Can be spring loaded for use around large tanks/vessels to allow
expansion
Banding spacing/pitch
Check correct use
 Securing of banding clips

Correct Incorrect
 Stainless Steel
Self Tapping Screws
• Tex screws/self drilling screws
• Easily removed for maintenance
• Neoprene washers to stop water
ingress and working loose due to
vibration
 Pop Rivets
• Need to be removed by drilling
• Can shake loose under vibration
 Support rings
Generally 6m apart on 100mm-400mm pipes
and 4m apart on 450mm-600mm pipes
Support ring and
thermal break
 Support ring

• Support ring used to prevent

insulation slipping to the flange.
• Usually at least half the
width/diameter of the insulation
material
Self Adhesive Pins
• Self adhesive “sticky
pins” and washers for
mineral wool slabs
• Check correct length,
type and spacing
• Galvanized steel or
Aluzinc
• HVAC, maybe friction
welded
Rockwool slab and self adhesive
pins in a diamond pattern
 Wire Netting,
added strength to mineral wool
 Binding Wire
1-1.2mm galvanized, not used on Cellular Materials
 Binding wire cuts
cellular and foam insulation
Aluminium tape and bands
Reinforced Glass Binding
Tape (Cellular glass)
 Joint sealant/mastic
Check correct type and application conditions
Continuous 5mm bead of sealant no gaps !!
• Suitability for use/operating temperature
• Check storage temperature
• Check application temperatures
• Wide range of types check compatibility with insulation/material
• Expiry date/shelf life
• Mix ratio/pot life
• Is it correct/specified??
 Adhesives
• Bitumen:
• Low cost thermoplastic.
• Adheres to many types of substrate : concrete, glass, metal.
• Used where low stress is encountered.
• Oils and solvents can soften.
• Epoxy:
• 2 part adhesive will have a “pot life”.
• Poor flexibility and brittle below -25°C.
• Excellent resistance to oils/mould
• Resistant to water and alkalis.
• Can cause dermatitis.
• Can be used for gap filling.
• Natural rubber:
• Rubber based, some vulcanised or cured with second component to
improve properties
• Vulcanised rubber ok to 100°C
• Un-vulcanised rubber ok to 50°C.
• Brittle below -35°C.
• Good resistance to water
• Poor resistance to oils and solvents.
• Other adhesives include:
• Neoprene-phenolics
• Nitrile-phenolics
• PVA
• Styrene-butadiene cements (SBR)
• Silanes
• Polyurethanes
• Silicones
Adhesives for pre-formed section and slabs.
 Bleeding through vapour
barrier from use of incorrect adhesive
 Storage of Materials
• In order for insulation to perform properly it must be stored correctly
• Weather proof buildings and off ground
• Rigid sections and segments should be stored end up in crates/boxes
• Flexible mattresses and slabs laid flat
• Temperature should not drop below 5°C for jointing compounds and
mastics
• Check min/max storage temperatures.
• Fixing wire, banding, screws etc. should be stored in clean containers
• Metal cladding stored outside should be protected from water ingress
and staining
• Thickness, type and grade
• Do not store materials too high – prevent crushing
• Check conditions, stock rotation and shelf lives.
 Design and Specifying
Insulation systems
• Production of a specification
• BS 4778 Pt 1
• “The document that prescribes the requirements with which the
product or service has to conform.”
 Specification Requirements
• Insulation type
• Thickness
• Density
• Fixing methods
• Vapour barriers
• Cladding
• Expansion/contraction joints
• Access
 Useful References
• Process Industry Practices (PIP)
• https://www.pip.org/
• Committee Industrial Insulation (CINI)
• https://www.cini.nl/en/
• TICA : Thermal Insulating Contractors Association http://tica-acad.co.uk
• FESI : Federation of European Insulation Companies http://www.fesi.eu/
 Design and Specifying
Insulation systems
• What will be insulated? Vessel, piping system, machinery? Size and
complexity
• Temperature limits of insulated items.
• Fluids to be insulated.
• Why is insulation needed ? HC, CC, PP
• What type of insulation ? Flexible/rigid ?
• What is the substrate type? Steel ? Stainless ?
• Calculate appropriate thickness. Computer programme based on
acceptable heat loss/gain
 Geographical and
Environmental considerations
• Temperature extremes
• Wind direction : airborne contamination
• Rain : amount and severity
• Snow : weight and duration
• Relative humidity
• Seismic readings : opening of joints
• Indoors/outdoors
• Availability of skilled manpower/trades
 External Forces to which
Weather-Barrier are subjected
 Differential expansion and
contraction of insulation materials.
Effect of Expansion Movement on
Weather-barrier or Covering
 Expansion and Contraction in HC
• Design needs to account for expansion and contraction.
• Hot service – requires provision for Expansion Joints.
• In a steam system designed at 538°C.
• Steel pipe may expand 8mm per 1m length. Calcium silicate shrinks up
to 2mm per 1m length.
• Need to account for 10mm/1metre
• Therefore a total of 152mm needs to be accounted for in a 15m pipe
length.
 Expansion and Contraction HC

• Cellular Glass very akin to steel/stainless steel

• PU Foam can undergo irreversible expansion of 3% above 70°C and
Phenolic Foams can shrink by 2% at the same temperature
• Calcium Silicate and Perlite can undergo even greater permanent
shrinkage
 Heat conservation (HC)

• Not specifically defined in BS 3533, but as a general guide:

When the product is at higher than ambient temperature and the
requirement is to prevent heat loss, then the insulation is described
as Hot Insulation.
Generally when the operating temperature is above +60ºC
 Trace Heating
• External heat source common in process industries to maintain process
parameters
• Steam or electric.
• Leaks in system can lead to steam boiling under insulation and bursting
of insulation seals such as glass rope/silicone beads
• Mineral wool blankets and foams can become saturated
• Sections oversize: air gap heat circulation
Steam Single Trace Heating
Recess cut into Cellular Glass
Electric Trace Heating
Electric Trace heating
Electric Trace Heating System
 Sealing to step water ingress
Hard setting composition Self setting cement
Silicone sealant Silicone tubing and seaant
Ali foil, silicone sealant and fibaclad Fibaclad and silicone sealant
Gland plate for weather resistance
Sealant damaged….CUI
(Use glands/entry caps)
Gaps in cladding leading to CUI, no
staggered joints or drain holes
 Application for HC

Pre-check that pipe coating is satisfactory

and that the surface is dry.
• Check the item has been released for
insulation and correct item is identified
• Check that no fouling can take place, all
hangers, brackets and trace heating
checked so no “hot paths”
• Protect insulation from damage
 Application of HC insulation

Insulation plus fixing

• Single layer, check joints are staggered (generally 150mm).
• Joints should be tightly butted.
• Insulation is correct thickness
• Secured correctly. Bands, wire, tapes are correct and spaced properly.
• Aluminium foil is correctly wrapped on Stainless Steel pipework
Staggered Joints
 Application of insulation
• Where total thickness is >100mm for hot apply in multiple
layers.
• Longitudinal joints staggered by at least 45° preferably 90°
Staggered joints
 Application of insulation

Metal Cladding
• Overlapping seams should be at least 50mm.
• Overlaps should generally be at the 2 o’clock or 10 o’clock positions
• Check if joints are to be weather proofed.
• Secured correctly using banding, rivets or screws
• Continuous 5mm bead of sealant along joint
Expansion Joint
Expansion “Slip” Joint
 Cold conservation (CC)

• As a general guide: When the product is at a lower temperature than the

ambient conditions and the requirement is to prevent heat gain, then
the insulation is called Cold Insulation.
• Generally below -10ºC
Cryogenic usually below -80ºC (LNG etc)
Systems with vapour barriers to stop condensation
 Expansion and Contraction CC
• Cold conservation – Contraction joints are required.
• Pipes may contract at a different rate to insulation
Stainless pipe will contract 1.7 mm per metre at -38°C.
At -38°C PIR will contract 8mm per metre and cellular glass 0.8mm per
metre
Expansion and Contraction Joint
(Different material densities)
Vapour barrier expansion joint over
mineral wool held in place by bands
Single layer CC to -50°C (Cold Service)
Shiplap Joints
TEROSTAT PC pre-applied coating

Backing film peeled back to create neat edge.

Apply bead of TEROSTAT PC to joints…
TEROSTAT PC pre-applied coating

…bead of TEROSTAT PC applied to joints…

 TEROSTAT PC pre-applied coating

…offer up sections…then remove rest of backing film to

create neat edge
TEROSTAT PC pre-applied coating

…fit temporary or permanent banding…

…simply smooth excess to seal joint.

Job completed quicker

Quality consistent
TEROSTAT PC pre-applied coating

TEROSTAT PC for tanks/vessels

TEROSTAT PC pre-applied coating

FOAMGLAS® STRATAFAB (200°C) with TEROSTAT PC

12”/100mm Centrica Barrow Gas Plant, May 2005
Double layer CC below -50°C
No direct paths for water penetration
 Double layer insulation for service below -
50°C
• Ensure correct pipe is identified
• Ensure pipe is released for insulation
• Check for obstructions to insulation application
• Inspect for damage/coating defects
• Free from oil/moisture
• Test for contaminants if required by specification eg salts
Check for obstructions !!
• Check all insulation materials in suitable condition for application and
can be protected from the weather
• Install 1st layer of cellular glass dry without sealant
• Anti abrasion compound to inside if cellular glass
• Circumferential joints staggered 150mm, horizontal joints at 9 o clock
and 3 o clock,
• Held in place with glass tape at specified intervals
• Apply secondary vapour barrier (if specified) unless it is already factory
applied and seal joints (usually an aluminium foil and taped seams)
• Install 2nd layer of cellular glass, circumferential joints staggered 150mm
and vertical joints at 12 o clock and 6 o clock/different pitch to inner
layer
• This layer may have a factory applied primary vapour barrier eg. Terostat
•
• Sealed at all joints with specified sealant and pressed together until
sealant oozes out.
• Fit stainless steel bands at specified distances over the top
• Banding clips may require foil tape applied to prevent damage to
cellular glass and overlying vapour barrier .
• Tighten bands until joint sealer oozes out and smooth off with spatula
• Do not over tighten
• If there is no factory applied primary vapour barrier, apply specified
“primary vapour barrier” eg Fosters 6075 in 2 layers of 1mm each. Grey
as 1st layer with 10x10 scrim cloth and followed by 2nd coat of contrasting
blue shade. 75mm overlap
• Zero permeability foil may be used
• Apply cladding system over insulation for protection with longitudinal
joints facing downwards at 10 or 2 o’clock positions at a common side
to ease scaffold access
• Secured with metal bands at specified intervals
• No screws or other fixings which may damage vapour barrier to be
used
• Joints sealed with 5mm bead of sealant
• Complete report and submit for sign off
Coldwork/Cryogenic 2 layers
 Joint detail CC
(1st layer applied no sealant)
Staggered overlaps
Staggered joints
Banding and edge detail
Vapour barrier and bands
Terostat Vapour barrier
 Vapour Barrier

• If vapour barrier sheeting is used:

• Check correct material is being used
• Longitudinal overlap is correct distance
• Any butt joints also get an overlapping strip applied.
• Free from wrinkles, blisters and open joints
 Vapour Stop

• To be applied at every Termination.

• Isolates small sections rather than full pipe, usually either side of flanges
or at a specified distance.
• Check overlap distances on existing insulation or pipe.
• If using scrim check it gets fully covered and is free from wrinkles.
• If multi component check mix ratio
 Vapour Stop, stepped and
sealed under cladding/wrap
 Sealing Termination FOAMGLAS ®
Terostat & specified sealant

© Pittsburgh Corning (UK) Ltd August 2013

 Application of insulation

CC – Metal cladding
• Absolutely NO screws!
• Joints all sealed as with heat conservation
• All cladding secured by banding not wires.
• If rivets are used then holes in metal must be pre-drilled and a piece of
Aluminium tape place on vapour barrier to prevent rivet wearing away
vapour barrier.
 Inspection stages
(dependent upon number of layers)

• Should be before work commences

• After first fixing
• After first vapour barrier
• After second fixing
• After primary vapour barrier
• Inspection of final system after cladding
 Freezing after water
ingress into cold system
Any Problems?
Any Problems?
Hope its not for cryogenic
Damage leads to water ingress
Damage (Cellular Glass)
 Acoustic Insulation

• HVAC; Heating, Ventilation and Air Conditioning

• Useful Normative Document ISO 15665, acoustic insulation for pipes
and flanges.
• Noise/sound travels by vibration.
• Octave band frequency; high/low
• Acoustic insulation will NOT BE RIGID/INFLEXIBLE
Fibrous (mineral wool)
acoustic insulation
 Acoustic Insulation “A”

System maybe:
Surface preparation
Aluminium foil
Insulation
Heavyweight sheeting
Metal cladding
 Application Acoustic
• Thickness as laid down in specification
• Nearly always Mineral Wool sections, blankets, lags or mattresses
• Nitrile Rubber, Lead vinyl, heavy weight Polyethylene sheet or barium loaded
sheeting used in addition overlapping onto itself by 75mm.
• Acoustic specifications may call for a gap to be created between the
vessel and the insulation usually mineral wool on the top
Acoustic Insulation
 Acoustic Insulation
Nitrile Rubber sheeting
• Overlaps sealed with adhesive
• Overlapping segments cut from templates used on bends. Screws may be
permitted for cladding on bends.
• Metal cladding (usually of thicker gauge) secured with bands as vibration may
shake rivets/screws loose.
Application of Insulation for Acoustic Cold
(AC)

Metal cladding
• Normally the same as for Cold Conservation i.e. no screws/rivets
• Screws could be permitted for bends and tees etc. see spec.
• Usually foil vapour barriers
 Offshore Material Considerations

• Non-combustible
• No release of toxic or corrosive gases during a fire
• Water repellent
• Mineral wool should not be used where sprinkler or deluge systems exist
 Liquid absorption
calcium silicate 400%
Liquid absorption
mineral wool 600%
 Consequences

• Considerable increase in weight and effects on load bearing

structure/ craneage during refit work/maintenance
• Reduced thermal efficiency
• Corrosion under insulation
• Potential for “Oxidative Self Heating” with hydrocarbons
(Spontaneous Combustion)
 Insulation of flammable liquids

• Insulation materials that absorb fluids can reduce the flashpoint and
present a fire hazard.
• Non absorbent material may be chosen for toxic substances to
prevent potential build up under insulation.
 Oxidative Self Heating

• Many insulation materials can wick and absorb organic fluids into their
matrix
• Fluid is then heated by the vessel/pipe
• Fluid oxidises and produces heat which is retained within insulation !!
• Can lead to spontaneous combustion
• Cellular glass is non absorbant
• No wicking
Cellular glass non wicking
 Iron (and Steel)

• Iron and steel are extracted from Iron Ore

• This exists in the Earths crust in an oxidised form known as Iron “Oxide”
• Iron oxide is stable and inert
• In balance with the environment.
• Little tendency to change or combine with other materials.
Iron Ore (Iron Oxide)
• Iron oxide has very strong bonds between the Iron (Fe) and Oxygen (O)
atoms
• Separating the iron from the oxygen requires an enormous amount of
energy
• Iron Ore (Fe2O3) is smelted in a furnace with Coke/Carbon (C) at 1500-
1600ºC
Iron/Steel Manufacture
• Input of heat energy breaks bonds between Iron(Fe) and Oxygen (O)
atoms
• Oxygen (O) bonds with the Carbon (C) to form Carbon Dioxide gas (CO 2)
• Iron (Fe) is extracted from its metal ore
• Tremendous energy from the heat input in the furnace is absorbed by
the metal
• The extracted Iron contains energy and is unstable !!!!
 Metal Extraction and Refining
Unstable

Stable
 Corrosion

• Corrosion is often described as :

• “A degradation of a material, usually a metal, due to an
electrochemical reaction with its environment”
• “A reversion of a metal back into its stable ore-like state”
• It occurs at the microscopic level
• Results in metal loss and loss of strength
 Key Words

• Metal
• Environment
• Electro-Chemical Reaction
• Degradation
• Iron and Steel created by heat removing oxygen from the iron ore
• A useful metal is created.
• The metal is now “active” and in a high energy state .
• Metal seeks to return to its “stable low energy state”…………Iron Oxide
• Metal does this by seeking to rebond with oxygen as this is one of the
most abundant elements in the environment.
• Rebonding with Oxygen creates “Iron Oxide”….Rust……!!
• However a “medium” is required for this reaction to take place.
• This medium is Water (Electrolyte)
• KEEP THINGS DRY
The Corrosion Cycle
 Corrosion Products (Rust)

• Corrosion products are less dense

and hence larger in volume than
the original metal as they are
some form of compound….metal
+ oxygen (Oxide)
• Rusting leads to coating failures
due to expansion under coatings :
cracking/adhesion loss of the
coating
 C.U.I.

• Corrosion under insulation. (C.U.I.)

• What is it.
• How it is caused.
• Effects of C.U.I.
• How it can be prevented.
 Corrosion under Insulation (CUI)

• Caused by aerated water at the metal surface where dissolved oxygen in

water increases corrosion rates
• Where does water come from?
• Rain, wash down, Fog, Steam discharge, condensation, deluge systems.
• How does water get there ?
 Ingress of water
• Mechanical damage to cladding or vapour barrier
• Poor design eg: incorrect overlaps and watersheds
• Poor practice, breakdown or missing sealant, gaps in cladding, etc
• Lack of maintenance
• Severe environment
 Why is CUI such an
aggressive form of corrosion?
• Not visible : “Closed system”, will remain undetected for longer.
• Increased period of wetness by electrolyte
• Collection and increase of high concentrations of contaminants such
as chlorides and sulphates.
• Moisture can reduce thermal insulation properties by up to 20x
• Potential for catastrophic failure
• Critical temperature for CUI approximately +30 to +120°C with steel
• Can occur outside of these temperatures
• High temperature moisture may evaporate
• At very low temperatures moisture may freeze or corrosion may be
suppressed
• Corrosion rate under wet insulation may be 20x greater than in ambient
conditions
• Moisture ingress can track along, within or under insulation by capillary
action
• Can create corrosion some distance from ingress point.
• External cladding can lock in moisture
• Drainage points at base of vertical runs and 6 o’clock position on
horizontal runs.
• Moisture may form ice, expand and open up joints and let in more water
!!
Drain plugs or holes (size and spacing)
Good water shedding design
• Mineral Wool, Perlite and Calcium Silicate are porous and will hold
moisture
• Not all solutions are neutral pH 7
• Some solutions form acids pH 0 – 7
• Some solutions form alkalis pH 7-14 (Caustic)
 Salt contamination

• Chloride salts marine/offshore

• Sulphate salts downwind of refineries, chemical plants etc (acid rain)
• Nitrate salts : contaminated run off from “industrial farms” to river
waters that are then used for cooling waters/washing down.
Combustion products from engines/vehicles
• Salts (chlorides) from local pollution or coastal/marine environments.
• They dissolve in water to form conductive “ions” which allow a greater
corrosion current to flow.
• Solutions are typically alkaline.
• Salt solutions concentrate within the insulation
CUI, saturated mineral wool
Saturated mineral wool
• PU foam and PIR may have fire retardants or contain halogens, acids are
used in the manufacture of Phenolic foams.
• These chemicals can leach out and form acidic solutions if moisture
enters the insulation
Saturated P.I.R.
Examples of situations
that may lead to CUI
Cladding has not been cut and sealed properly around a gantry
Pipe cladding is short and therefore cannot be sealed
Pipe coatings have not been suitably applied prior to the application of the
insulation
Hanging pipe support buckles when the pipe moves due to expansion from
trace heating
Footpath/cut through
 Stress Corrosion Cracking (Stainless steel and
alloys)
• Tension cracks
• Stainless steel reacts with salt ions dissolved in moisture (electrolyte)
• Pipes and vessels under pressure (tension)
• Pulling apart at grain boundaries
• Intergranular cracks form
• Intensified at welds, defects, impurities.
 Coating Systems for use under Insulation
Carbon steel
• High Build Epoxy systems,
• Thermally Sprayed Aluminium

Stainless steel
• High Build Epoxy
• Phenolics and epoxy phenolics.
• Siloxanes and silicon alkyds
• Aluminium foils.
 Coating Inspection checks

• Has the surface been prepared correctly.

• Reports ?? Can these be inspected ?
• Degreasing, surface profile, surface cleanliness ?? Specified
requirements
• Coating type, minimum and maximum dfts
• Overcoating limits. Minimum/maximum
• Air and substrate temperatures, relative humidity and dew point for
application.
 How to prevent CUI

• Best practice
• Eliminate funnelling of water to insulation.
• Select insulation that is non-wicking or does not hold a lot of water eg (Cellular
Glass)
• Avoid breaks in cladding, more breaks = more CUI!
• Use of anti-corrosion coating on the substrate
• Periodic inspection : NDT or Removal ?

KEEP THE INSULATION DRY

 Inspection for CUI
• Profile Radiography
• Ultrasonic thickness measurement
• Infrared thermography
• Neutron backscatter
• Strip and search
• Inspection plugs

• No current technique capable of economically determining extent of CUI

 Personal Protection (PP)
• Mesh usually 50mm from pipe
surface.
• Perforated metal sheet
• Generally used if above > +55°C
and below > -10°C
Perforated steel and support rings
 Application of PP
• Common distances :
• 2.2m vertically on walk ways
• 1.2m each side
• 0.3m below
• There may be project specific
requirements, check
specification !!
Damage to PP
 Inspection Checklist General
• Principal • Remarks
• Project
• Location
• Description
• Contractor
• Date
• Report number
• Inspector
 Inspection Checklist
Condition of substrate
• System released for insulation • No obstructions
• Surfaces are clean and dry • Any technical deviations are
• Heat tracing is installed and observed and documents.
released for insulation • Containment is in place
• Coating system is correct • Supports are correctly installed
• Comments
 Inspection Checklist
Materials
• Materials received in approved • Comments
condition • Temporary protection available
• Materials are correct to for uncompleted work
specification
• Stored in correct manner in dry
weatherproof buildings and off
the ground
• Samples obtained for
verification/testing
 Inspection Checklist
Installation
• Insulation is correct thickness • Insulation securement is correct
and number of layers • Vapour barrier is installed
• Securement bands, tape, wires correctly and undamaged
are correct and at correct pitch. • Expansion/contraction joints are
• Joints are staggered and sealed installed as specified
• Bends and fittings are • Extent of insulation is correct.
prefabricated • Comments
 Inspection Checklist
Jacketing and Finishing
• Correct type thickness and finish • S-clips are used as specified
of materials have been used • Expansion/contraction overlaps
• Overlap, amount and placement correctly installed
are correct • All terminations have been
• Securement correct sealed correctly
• Joints correctly positioned • Correct type and installation of
• Flashing is approved and vapour barrier
correctly installed
 Inspection Checklist
Flanges, Valves, Equipment
• Correct allowance for bolt • Comments
removal
• Removable box covers are
correct
• Correct watershed installation
on jacketing
• Valve extension handles are
installed
• Protrusions are watertight
sealed
 Inspection Checklist
After “Start-Up”/Maintenence
• Insulation finishing/jacketing is • Surface temperatures are
damaged checked
• Poor joint sealing • Infra red scan carried out
• Insulation is missing • Comments
• Materials are left behind/untidy
jobsite
 Difficulties for Contractors

• Ambiguous Specifications
• Delays by client in giving clarifications
• Optimistic supplier data sheets
• Supply problems of specific materials
• Weather conditions
• Insulation clashes with other objects
• Delays out of his control/conflicting trades
 Contractor Malpractices

• Incorrectly staggered joints

• Badly sealed joints in cladding
• Missing cladding
• Incorrect cladding type/thickness
• Use of screws on cladding used for Cryogenic insulation
• Cellular glass without anti-abrasion compound on inner layers
• Insulation applied over paint defects
• Insulation damaged due to poor storage
• Incorrect diameter insulation leaving gaps between pipe and insulation
• Inadequate strapping and wrong pitch
• Overtightening banding
• Loose banding on cladding
• Applying wet material
• Applying material to wet surface
• Faulty application of vapour seal
• Inadequate surface preparation prior to primer application
• Wrong system installed eg. PU foam and vapour seal for -200°C use
• No expansion/contraction joints in calcium silicate system operating at
up to 900°C
• Cladding joints collecting not shedding
• Incorrect mesh in use as reinforcement
• Double layered system with joints incorrectly spaced,
• Fixings at wrong pitch,
• Poorly fitting to pipe as a whole,
• Liquid vapour seal not being dry before cladding being fitted.
 Risk Based Inspection
(Inspection locations and intervals)
• Risk = Probability of failure x
consequence of failure
Probability : operating temperature, location,
length of time in service
Consequence : Likelihood of loss of life,
environmental impact, cost of loss of product
etc
 Question ?

• As an inspector what would you do on your visit to a site where you

“suspected” the insulation work was incorrect and the materials used
were also incorrect ??
• Consult project specification to ascertain if work is correct…there may
have been revisions to the specification due to external factors you are
not aware of!!
• Obtain technical data sheets and/or certificates of conformity for
insulation products being used
• If the above are not to the agreed specification discuss the issue with
contracts manager, supervisor, sub-contractor, etc always respecting the
correct chain of command
• Report findings to supervisor/manager and whether remedial action has
been carried out
• Document with details of parties concerned, products used, areas,
locations and extent and back up with photographs if possible.
• If necessary raise non-conformance report (NCR) or issue the correction
report so it can be raised on your /clients behalf.
 Acknowledgements
• Altrad NSG/Centrica Barrow in Furness
• Interserve/Syngenta Huddersfield
• PPG Foamglas
• Cape Ltd
• Deborah Services Ltd
• IBSL Ltd.
• Elcometer Ltd
• Defelsko Corporation
• Sheffield Insulation Ltd (SIG)