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: QPS-PI-HI-101
PROCESSSOLUTIONSPVT.LTD.
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0
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21.11.10
DATE
Issued As Standard
DESCRIPTION
S R Patil
PREPARED BY
PID
REVIEWED BY
BKD
APPROVED BY
DOC NO . : QPS-PI-HI-101
PROCESSSOLUTIONSPVT.LTD.
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INDEX
SECTION NO.
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 GENERAL DESIGN BASIS EXTENT OF INSULATION ON PIPING SYSTEM EXTENT OF INSULATION OF EQUIPMENT MATERIALS GENERAL INSULATION MATERIAL FIBROUS MATERIAL (ROCK & GLASS WOOL) INSULATION MATERIAL (CELLULAR GLASS ) WEATHER PROTECTION JACKET 8.1 FIBROUS MATERIAL (ROCK & GLASS WOOL) 8.2 REGID MATERIAL (CELLUAR GLASS) 8.3 ANCILLIAR MATERIALS 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 APPLICATION METHODS (GENERAL) PIPING HORIZONTAL EQUIPMENT VERTICAL EQUIPMENT FLANGE, NOZZLE, CHANNEL, COVER, MANWAY AND HANDHOLE FLANGED COVER. IRREGULAR SURFACES SUCH AS PUMP, COMPRESSOR, TURBINE ETC. VERTICAL STORAGE TANK INSULATION FINISH (CARBON SETEEL) 16.1 PIPING 16.2 EQUIPMENT 16.3 VERTICAL STORAGE TANK 17.0 ANNEXURE I 17.1 OWNERS OBLIGATIONS 17.2 CONTRACTORS CONDITIONS 18.0 ANNEXURE II INSULATION THICKNESS FOR HOT INSULATION (IH) 19.0 ANNEXURE III INSULATION THICKNESS FOR PERSONAL INSULATION (IS) 33 32 31 13 15 20 22 23 24 25 27
TITLE
PAGE NO.
1 2 3 4 5 6 9 11
DOC NO . : QPS-PI-HI-101
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STANDARD SKETCHES FOR HOT INSULATION STANDARD OF VESSELS, PIPING AND EQUIPMENT
FIG. NO. 01 FIBROUS AND APPLICATION REGID DESCRIPTION INSULATION DETAILS FOR HORIZONTAL PIPE SHEET 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59
02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
METHOD OF STAGGERING OF SECTION FOR PIPE INSULATION FIBROUS MATTRESS INSULATION - DETAILS SPACER RINGS FOR CLADDING SUPPORT (FOR HORIZONTAL PIPE) DETAIL OF SPACER RING FOR FIBROUS INSULATION (MATTRESS) BOLTED-ON INSULATION SUPPORT FOR VERTICAL PIPE INSULATION DETAILS FOR PIPES, BENDS & ELBOWS INSULATION DETAILS FOR BENDS & ELBOWS INSULATION DETAILS FOR PIPE BRANCHES AND REDUCERS INSULATED REMOVABLE COVERS FOR VALVES INSULATED REMOVABLE COVERS FOR FLANGED JOINTS INSULATED DETAILS FOR LINES ON SHOE INSULATION OF STEAM TRACED PIPING INSULATION FOR HORIZONTAL EQUIPMENT INSULATION FOR EQUIPMENT HORIZONTAL HEADS USE OF FLEXIBLE INSULATION IN COMBINATION WITH RIGID INSULATION TO COMPENSATE FOR VESSEL EXPANSION INSULATION DETAILS FOR VERTICAL VESSELS INSULATION DETAILS FOR VERTICAL VESSEL HEADS INSULATION DETAILS FOR VERTICAL VESSEL (`J & `S CLIPS) INSULATION DETAILS FOR VERTICAL STORAGE TANKS INSULATION SUPPORTS FOR STORAGE TANKS INSULATION SUPPORTS FOR STORAGE TANKS (DETAILS FOR ROOF) FIRE PROOFING AND INSULATION SUPPORT FOR VERTICAL VESSEL MACHINERY INSULATION INSULATION ENCLOUSERS FOR CONTROL VALVES & OTHER IN-LINE INSTRUMENTS INSULATIN FOR LEVEL GAUGES INSULATION SUPPORTS FOR HORIZONTAL VESSEL
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1.0 GENERAL:
SCOPE
1.1 This specification covers design and material requirements for above ground, external insulation of piping and equipment operating between ambient temperature and 550 C for the purpose of heat conservation, process stabilization, temperature maintenance, personnel protection and fire protection. Wherever necessary this specification indicates the basis for selecting a criterion. 1.2 This specification is suitable for use in out door service with normal process plant atmospheres. Alternative designs and materials would be specified if necessary for corrosive atmosphere of potential leaks and spills of chemicals. 1.3 This specification does not cover cold service insulation. For cold services QPS Specification QPS-PI-CI-101 is applicable. 1.4 This specification does not cover insulation for boiler or fired heaters and associated air heaters, economizers, fuel ducting and air ducting. 1.5 Piping, equipment, storage tanks and vessels requiring insulation shall normally be specified on the following project documents. a) Process and Instrument Diagrams (P&IDs) and Line List. b) Piping General Arrangement Drawings & Isometrics. c) Instrument Piping Details and Schedules. d) Vessel, Exchanger, Storage Tank & sphere documents and Insulation Schedules e) Equipment suppliers General Arrangement Drawing for equipment items in package plant.
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g) Steam jacketing. h) Hot water or liquid jacketing. i) j) Hot Oil jacketing. Fire hazard protection to prevent fast boil off of liquid.
k) Personnel protection. Applicable where exposed surface temperature exceeds 65C in normal or short-term operating conditions. Over internally insulated piping and equipment, provide open mesh metal guards and for surfaces which are not internally insulated provide insulation on that part of surfaces with which operating and maintenance personnel may come in contact while performing routine duties. The intent of P&IDs, Line classification lists and engineering drawings etc. which designate insulation for personnel protection is to call attention only to the eligibility of such service. The actual extent of insulation shall be determined by Field Construction Personnel and/or operating personnel using the following criteria: Exposed surfaces operating above 65 C and
located within 600 mm horizontally or 2100mm vertically of a normal access, walkway of work area. 2.5 Instruments and associated piping subject to operating flow and/or temperature conditions prevailing in the connected piping or equipment shall be insulated to the same requirements as that of piping or equipment.
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g) Expansion joints, hinged joints and hose. h) Sight flow indicators. 3.8 Insulation shall be designed to provide an absolute minimum clearance of 25mm between the outside surface of any insulation finishing material and adjacent surfaces. 3.9 Where insulated horizontal piping is supported on steel shoes, the height of the shoe shall be such that the underside of the insulation finishing material is clear of the supporting structures upon which the shoe rests by 25mm minimum.
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g) Turbine casings to be insulated shall exclude shaft seal caps, shaft bearing housings, throttle valves, governors and supports. h) Exchanger channel and covers; shell and channel flanges & Exp. Joints. i) j) Nozzles, manholes and hand holes and flanges of equipment. Surfaces of coolers and condensers.
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* Mean Temperature is Hot Face Temp. + Cold face Temperature. 2 - Not more then 0.6 percent. Sulphur Content (IS : 3144) Liner Shrinkage (IS : 3144) Heat Resistance (IS : 3144) Compressive Strength (Average) min. at 10 % deformation Recovery after compression (IS : 8183Appendix A IS : 9842Appendix A) Alkalinity (IS : 8183 Appendix B / IS : 9842 Appendix B) Chloride Content ( IS : 3144 ) Dimension - PIPE SECTION : Hollow cylinder, split length wise on one or both sides of the cylindrical axis. Thickness Length : 25, 40, 50, 60 & 75mm Tolerance in : 3 mm Tolerance in - Not to exceed 20 ppm - pH of the solution of the material shall be between 7.0 and 10.0 - After compression to 75 % of the original thickness, recovery shall not be less than 90% of thickness. - Not more then 2 percent when subjected to soaking conditions of soaking heat at the stated max. temp. of use (550 C) for 24 hours. - When heated to max. temp. (550 C), sample shall maintain its general form and shall not suffer visible deformation of the fibrous structure. - 120 kg/m2
Thickness : 3 mm When installed on the pipe of the specified size, sections shall
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fit snugly and shall have tight longitudinal and circumferential joint. - BLANKET : Unless otherwise specifically required, standard width shall be 600mm to 1200mm, standard length 1500mm to 2400mm Thickness : 25, 30, 40, 50, 60 & 75 mm
- BLOCK AND BOARDS ( IS : 8183 ) : Lengths widths : 1000mm to 1400mm : 500mm to 1000mm
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Test thermal conductivity as per ASTM C240, C177 and C518. Test shall be at least for 3 specimens. Compressive Strength : 517 kPa (average min.) Test method as per ASTM C240 and Recommended Practice ASTM C165. Test shall be at least for 4 specimens. Flexural strength average min. 414 kPa. Test method as per ASTM C240 and clause ASTM 3.4 C203. Determine the method of test specimens as per method given in ASTM C390. Water absorption, volume % (average max.) 0.5. Test method as per ASTM C240. Test shall be at least for 3 specimens. Water vapour transmission (average max.) metric perm-cm of grains/24 h.m2 mm Hg. cm of thickness at 26.7 C : 0.0084. Test method as per ASTM E96. Test shall be at least for 2 specimens.
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Dimensions: Flat Blocks: Shall be rectangular sections and shall be true to form and dimensions, the corners square and the sides parallel. Size and thickness shall be as follows: Width (mm) 300 450 Length (mm) 450 600
Pipe Sections : Shall be supplied as hollow cylindrical shapes split in half lengthwise (in a plane including the cylindrical axis) or as curved segments. Upto 350mm size, only pipe sections split in half lengthwise shall be used. The insulation shall be supplied in sections of segments in lengths of 450mm or 600mm to fit standard of pipe. Insulation for pipes upto 150mm size shall be furnished in 600mm length, and for pipe above 150mm nom. size in 450mm length. Thickness for both pipe sections and flat blocks shall be 25, 30, 40, 50, 60 & 75mm. Dimensional Tolerance shall be as follows: Block Length Width Thickness GENERAL: Periodical checks for density, thickness, shape and size as per above requirements shall be repeated at site, as per norms and frequency decided at site as per the directions of PROJECT Site-in-Charge. Special attention is required for fibrous material as its installed thickness could be reduced due to compression affecting performance. a) All the codes mentioned shall be the latest issue. b) PURCHASER shall have right to inspect any or all the test conducted on insulation material by manufacturer at his shop or at any laboratory. 1.6 mm 1.6 mm 1.6 mm Pipe 3 mm - 3 mm
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e) On Vertical Storage Tanks. f) 8.9 Band, glavanised steel, 40mm wide X 3mm thk. galvanising per IS : 277 class-2.
For Securing Rigid Insulation: a) On Piping upto 16 OD. Wire, annealed galvanised steel, 16 SWG, galvanised per class 2 (heavy coating of zinc, nominal 600 g/m2) per IS : 227. b) On Piping 18 OD and Larger. Band, galvanised steel, 20 wide X 24 SWG thk., galvanising per above (same as for piping upto 16 OD). c) On Vertical & Horizontal Vessels. Band, galvanised steel, 20 wide X 24 SWG thk, galvanising per above (same as for piping upto 16 OD).
8.10 For Securing Cladding On Insulation (Both Fibrous And Rigid): a) For Piping: Band, Aluminium 12 mm (min.) wide X 24 SWG thk. b) On Equipment: Band, Aluminium, 20 mm wide X 24 SWG thk. c) On Vertical Storage Tanks: Band, Stainless Steel, 25 mm wide X 24 SWG thk. 8.11 Rivets: Rivets required for metal jacket securement shall be the expanding Aluminium POP blind eye type, 9.5mm long X 5mm . 8.12 Screws: Screws required for metal jacket securement shall be cadmium plated steel, self tapping type A No. 8mm X 12mm long to BS 4176 complete with neoprene washers under the head. 8.13 S and J clips - Formed from 25mm wide stainless steel banding. 8.14 To ensure prefect water proofing, all the cladding joints shall be packed with sealing materials which may either be in the from of a elastomeric sealing compound or fiber based bituminous felt strips.
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: Single : Silicon resin based with Aluminium flakes as pigment : 20 microns/coat (min.) : It should be suitable to withstand temperature upto 600 C; when the paint becomes dry, the painted surfaces shall show no discontinuity.
9.7
The insulation contractor shall not carryout any welding or drilling on plant equipment and piping.
9.8
Insulation shall be finished, beveled and weatherproofed at all terminal points where it is required to remove bolts etc. without damage to the insulation.
9.9
Equipment name plates shall remain visible after insulation has been applied by beveling back the insulating material and carefully sealing the exposed edges to prevent ingress of moisture.
9.10 All projections, such as lifting lugs, trunnions and stiffeners on piping and equipment (i.e. vacuum rings) shall be insulated with the same thickness of insulation as specified for the equipment item or pipeline. 9.11 Thermowell bosses, pressure tappings and weep-hole nipples shall not be insulated in but left accessible. 9.12 Double layer insulation shall be required when the insulation thickness is greater than 75mm. Insulation installed in two or more layers shall be staggered joint construction and each layer shall be secured in place and details of securement shall be the same for each layer. 9.13 Wet or Damage Insulation shall not be used under any Circumstances. Insulation material to be applied shall not be kept over bare ground to avoid water absorption. Installed material awaiting its protective cover shall be adequately protected from damage, rain and contamination, and shall be covered with cladding at a minimum loss of time. 9.14 A minimum clearance of 25mm between outside surface of any insulation finish and adjacent equipment, pipe or structural members shall be maintained. 9.15 Insulation supports shall not project out of the insulation outer surface and shall be given sufficient coverage of insulating material to avoid hot spots on the metallic cover at support positions.
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10.0 PIPING:
10.1 10.2 MATERIAL: FIBROUS MATERIAL (ROCK OR GLASS WOOL):
a) Can be used for all piping other than electrical traced pipes upto 125 C. b) Can be used for all temperatures. c) Shall be in performed pipe section in 2 halves for sizes upto which manufactured and at least for all pipes with outside diameter over insulation of 500mm. In bigger sizes, multisegments are preferable if manufactured, otherwise, blankets are acceptable. d) Pieces of insulation with crushed and damaged ends shall not be used.
10.3
CELLULAR GLASS: a) Can be used for all piping including electrically traced piping for service temperatures
below 125 C (with electrical and steam tracing the maximum metal temperature reached by tracer in order to conduct the requisite heat into the pipe shall be the deciding factor).
b) In-situ foaming may be allowed by engineering-charge after discussions with client and
head-office.
10.4
10.5
10.6
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d) When double layer is applied, both longitudinal and circumferential joints shall be staggered. The arc between the longitudinal seam lines of the inside and outside layers of insulation shall have an angle of over 15 or the longitudinal joints staggered at least by one layer thickness, whichever is more stringent. Circumferential seams of the inside and outside layers shall be at least 100mm apart.
10.7
10.8
10.9
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d) Expansion Joints (Both vertical and horizontal piping. All insulation materials) (See Fig. 3) e) Expansion joint shall be provided at regular intervals as below : Temp. C Upto 200 200 to 300 300 to 350 350 to 400 400 to 450 f) Spacing (Meter) Not required 10 8 6 5
Expansion joint shall be formed by a 25mm space between the pipe insulation sections and the space shall be filled by compressed mineral rock fibers. Expansion joints in each layer shall be offset at least 150 from each other in case of multilayer insulation. Expansion joint for first layer for vertical pipe shall preferably be just below insulation support collars.
10.11 ELBOWS AND BENDS (All insulation materials) (See Fig. 6 and Fig. 7):
Insulation material shall be mitered and shall be same as that of pipe. Insulation securement band / wire shall be same as that for equivalent dia pipe. Each mitered section
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shall be secured with minimum 2 wires / bands. For bends/ elbows of nom. pipe size 6 & below, due to lack of space, for all insulation materials, insulation shall be secured by spiral wound 16 SWG galvanised steel wire for hard materials & 10 SWG galvanised steel wire for soft materials. Insulation joints of block material shall be suitably sealed with adhesive for isocyanurate/ callular glass. 10.12 TEE (All insulation materials) (See Fig. 8): Preformed pipe sections or segments shall be carefully cut and shaped around Tee junctions and the insulation material of the tangential pipe shall be carefully and neatly cut to mate upto the material applied to the parent pipe without the creation of voids or gaps, at the junction insulation shall be adequately secured by wire/ band of same specification as that of same size pipe. 10.13 FLANGED JOINTS OR VALVES (All insulation materials) (See Fig. 9 and Fig. 10): a) Flanged Joints or valves, if to be insulated, shall be insulated with prefabricated removable Aluminium covers, lined with pipe sections/ lags/ slabs. b) Welded valves, if insulated, shall be insulated with oversized pipe sections or lags, cut and shaped to fit around the body of the valve. Insulated valves shall be cut and shaped around the valve stem and kept clear of the stuffing box gland. 10.14 INSULATION FLASHING (All insulation materials): Insulation shall be stopped short of flanged joints and unions by a sufficient distance to permit easy removal of the flange nuts and bolts or breaking of the unions to take place without disturbance or damage to the insulating material. At these positions the insulation shall be bevelled and sealed with a metal closure which inturn shall be sealed with waterproof sealing material. 10.15 PIPE SUPPORTS (All insulation materials) (See Fig. 11): Insulation at solid welded or clamped supports shall be cut and shaped to fit around the support and banded securely to enable the insulation to be carried with the pipe movement. When the pipe hangers pass through insulation on piping outdoor, metal hoods packed with a waterproof sealing material shall be furnished and installed. Upper bolts of the hanger clamps are not to be covered with insulation.
10.16 STEAM TRACED PIPING (All insulation materials) (See Fig. 12): Steam traced piping and fittings shall be installed with oversized sections to allow accommodation of both parent pipe and tracer without damage or deformation of the insulation. Traced instrument line and fittings shall be totally enclosed by the insulation in a
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similar manner and the designed warm air annulus maintained throughout the tracer pipe length. Insulation supports for vertical pipe shall have suitable clearance for tracer pipe. Suitable pulley or cement shall be used to improve the contact between pipe and tracers, throughout length of tracers. 10.17 ELECTRICAL TRACED PIPING (Polyisocyanurate / Cellular Glass): Electrical traced piping shall be provided with the same size insulation as would be provided if the piping were not electrically traced.
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11.3
CELLULAR GLASS:
a) Can be used on all surfaces. b) Temperature limitation for each shall be as per 7.0 c) Curved segments/ blacks, miter cut and shaped to fit.
11.4
11.5 11.6
11.7
Blanket shall be applied over the surface with joints tightly butted and laced together with 1mm galvanised lacing wire. Other block insulation shall be applied with the longer dimension parallel to the axis of the vessel or equipment. When blocks are applied in multiple layers, all joints in successive layers shall be parallel to the long axis, shall be staggered and sealed with insulating
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cement for calcium silicate or suitable adhesive for others. In all cases, the insulation is to fit the contour of the vessel or equipment, so that the use of a leveling coat of insulating cement should not be normally necessary to get an acceptable smooth exterior.
11.8
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MATERIAL:
Fibrous material shall be same as specified for horizontal equipment. Calcium silicate, Polyisocyanurate and cellular glass shall be same as for horizontal equipment.
12.4
Corrosion protection shall be applied before applying insulation (All insulation materials) Corrosion prevention before applying insulation for stainless steel surfaces shall be same as specified for horizontal equipment.
12.5
Application (All insulation materials) (Fig. 13 & 14): Application details on shell, top and bottom heads shall be similar to that of horizontal equipment. Insulation shall be laid on insulation support rings provided by the fabricator. See enclosed sketch (Fig. No. 22).
12.6
INSULATION SECUREMENT (All insulation materials) (Fig. 13, 14 & 15): a) Bottom and top head insulation shall be supported by 16 SWG annealed galvanised
steel wire drawn through holes in the insulation supports provided by the fabricator.
b) Top head insulation shall be secured by floating ring/ bands provided by vessel
fabricator similar to head or horizontal vessel.
c) Shell insulation shall be supported by bands at every 225mm centres on the cylindrical
portion and the bands shall be kept horizontal.
d) Insulation Securement for Bottom head for vessel supported on legs shall be identical to
that of Top head.
e) For insulation securement of bottom heads inside skirt no floating rings/ bands need be
provided; Firm securement should be ensured just by 16 SWG annealed wire drawn over insulation tightly and through the holes on support rings provided by the fabricator.
12.7
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13.0 FLANGE, NOZZLE, CHANNEL COVER, MAN-WAY AND HANDHOLE FLANGED COVER (All insulation materials):
a) Where insulation is required, these shall be insulated with lined removable prefabricated
covers secured with bands or quick release toggle clips.
b) Otherwise, insulation shall be stopped short of uninsulated flanges and nozzle etc., a
sufficient distance to permit withdrawal of bolts without disturbing the rem inder of the insulation. Insulation shall be weather proofed and sealed at these locations.
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14.2 14.3
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15.5
SHELL:
Refer Fig.No. 20 & 21 This Standard indicates the extent of insulation/cladding supporting/ sacrament details provided by tank fabricator. Insulation contractor shall check for its presence before insulation application work. Following is provided by tank fabricator. a) Water Shed At the junction of shell and roof, water shed is provided to act as top covering for the shell insulation as shown in Fig. No.-20 & 21. b) Insulation Support will consist of 5mm steel rods provided at 400mm diamond pitch. Length of these lugs is 3mm less than insulation thickness. c) Cladding Support form tank top, horizontal rings shall be provided at every 1175mm on tank shell.
TANK ROOF:
Tank roof shall be provided as per Fig. No. 21.
15.9
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16.1
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j)
The practice of locating all joints in the top portion of elevated horizontal pipes for the sake-of-good-appearance when looking up from grade shall be strongly discouraged. The joints shall be located to shed water.
16.2
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encircle the equipment. Vertical overlaps shall not be screwed for horizontal equipment. j) The metal finish shall be banded and sealed at 450mm centers.
k) The insulated heads of vertical and horizontal equipment shall be fabricated from flat metal, in an Orange peel construction with all radial seams overlapping a minimum of 50 mm and secured with self-tapping screws at 150mm centers. All overlaps shall be ball swaged and be rendered water tight per 8.14. l) Projections from the heads shall be sealed using metal flashings, neatly cut to fit around the projections and extending above the jacket for a minimum of 80mm. The seal between flashing and jacket shall be weatherproofed with self-tapping screws and mastics. m) Insulation at bottom heads of fully skirted equipment does not require weatherproofing. n) Heads of equipment's 24 OD and smaller shall be finished and waterproofed with square ended fabricated covers.
16.3
16.4 16.5
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16.6
ROOF:
a) All cladding joints shall be sealed by electrometric metal sealants. b) Min. 75mm overlap shall be ensured at all joints. c) At all joints, cladding-to-cladding securement shall be provided by self-tapping screws and proprivets alternately, every 150mm centers. d) Cladding shall be secured by bolting at every 300mm provided by tank fabricator. For details of cladding arrangement and bolting, see Fig.No. 20 & 21.
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17.0 ANNEXURE I:
17.1 OWNERS OBLIGATIONS:
Following free facilities shall be provided near the work site. a) Open space for storing contractors materials shall be provided. b) Water and Electricity supply. c) Supply of cement.
17.2
CONTRACTORS CONDITIONS:
a) Mode of measurement will be as per IS : 7413-1981 & IS:7240-1981.
b) Contractor should submit the copy of the contract labour license to the personnel Dept. before starting up the work. c) Contractor has to maintain certain registers under the contract & the same shall be shown to the personnel department as and when asked for. d) Contractor has to maintain certain register under contract labour act. e) Contractors should comply with ESIS rules and challan of ESI payment should be submitted regularly during the tenure of the contract. f) Transportation for contractors crew and their accommodation, food etc. will be arranged by the contractors. g) The rates quoted by the contractors must be inclusive of the following : Handing and transportation of all items at site. Consumable materials.
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