S-00-1390-001 Rev 0 (Hot Insulation Specifications For BOP)

Contract No. Document No.
REV
59/2009-EPC S-00-1390-001 0
DATE: 23 AUG 10 SHEET 1 of 20
Prepared N.T.Hiep
PROJECT SPECIFICATION Checked D.T.Vinh
Approved M.Morita
HOT INSULATION
SPECIFICATIONS
FOR BOP
Distribution FOR CONSTRUCTION

PVC
PD
DPD (Site)
Proc M
ALI
Bio-fuel Ethanol Plant in Northern Region Project
PM
JVC
PM
EM
REV DATE PAGE DESCRIPTION PREPD CHKD APPD
PEN
CVL A 23 Aug 10 ALL ISSUED FOR APPROVAL NTH DTV M.M
PIP
0 11 Oct 10 ALL ISSUED FOR CONSTRUCTION NTH DTV M.M
INST
ELC
DHT
Section changed in last revision are identified by a vertical line in the margin
Bio-Fuel Ethanol Plant in Northern Region Project Contract No.: 59/2009-EPC
Specification for Hot Insulation. Doc No.: S-00-1390-001 Rev. 0
SHEET : 2 of 20
CONTENTS
PAGE
1. GENERAL ........................................................................................................... 3
2. APPLICATION RANGE TO BE INSULATED .............................................. 3
3. INSULATION THICKNESS ............................................................................. 4
4. MATERIAL ......................................................................................................... 4
5. APPLICATION ................................................................................................... 5
SHEET : 3 of 20
1. GENERAL
This specification covers the general requirements for hot insulation material application,
inspection procedures Bio-Fuel Ethanol Plant in Northern Region Project. Further detail
requirements shall be applied when required base on the insulation material supplierss
recommend practice.
2. APPLICATION RANGE TO BE INSULATED
Insulation shall be in principle applied for piping, instrument and equipment in accordance with
indicated P&ID and Line Index.
2.1. Insulation type
(1) H : Hot Insulation for Process/ Steam/ Condensate Service
(2) P : Personnel Protection
2.2. Hot Insulation

The temperature range to be insulated shall be from 650C and above under the normal
opening condition except otherwise required by the requirement of the process.
2.3. Personal protection
(1) The personnel protection shall be required at temperature of 650C and above under the
normal opening condition
(2) Lines and equipment in intermittent operation, i.e., cool down, blow down, lines, etc.,
shall only be insulated where required for personnel protection.
(3) Unrecovered steam condensate lines shall only be insulated where required for
personnel protection.
(4) The extent of personnel protection shall generally be confirm to surface that are
otherwise uninsulated, at locations bounded by distances of 2.0m vertically and 0.5 m
horizontally, beyond access ways, ladders, platforms, and normal work area at ground
level of other elevation used by opening and maintenance personnel.
2.4. Extent of Insulation.
(1) Manways under DN600 and nozzle necks less than DN300 shall not be insulated.
Flash all manways and nozzle necks and seal to prevent entry of water.
(2) Exchanger body flanges shall not be insulated, unless otherwise indicated in the
Project Specification.
(3) Valves and flanges on insulation steam supply and recovered steam condensate lines
shall be insulated.
(4) Flange type valves, flanges and pipe fittings such as unions shall not be insulated on
insulated process lines. The insulation shall be beveled and stopped short a sufficient
distance to permit the removal of bolts or breaking down on unions with no damage to
the insulation or weatherproofing, except as given in Project Specification.
(5) Expansion joint bellows, ball joints strainer and steam traps shall not be insulated,
except as given in the Project Specification.
(6) Rotating equipment shall not be insulated except where specification specified.
SHEET : 4 of 20
3. INSULATION THICKNESS
(1) The insulation thickness shall be determined as operation temperature.

(2) Multiple layer shall be provided for thickness above 100m.
(3) The insulation thickness of hot insulation for Process/ Steam/ Condensate service (H) shall be
followed with table 1.
(4) The insulation thickness of personnel protection (P) shall be 30mm, unless otherwise specified.
4. MATERIALS
4.1. Insulation Materials

4.1.1 Fiberglass
The following material shall be applied for the service of temperature up to 6000C.
Fiberglass: Fiberglass Heavy Density, Insulation Class A, B and H. Fiberglass:
ANSI/ASTM C547, class 1 or ASTM C-612-93 or equiv.).
4.1.2 Mineral wool
Mineral wool: rigid pre-molded, minimum compressive strength, linear shrinkage of
0, conforming to ASTM C 612-70.
Minimum density : 160 kg/m3
4.2. Fastening Material
Fastening material shall be as shown below.
These materials shall be adjusted if required based on the detail application procedures or
recommendation to be proposed by the insulation materials supplier.
(1) Stainless steel wire (for insulation material)
1.2 mm minimum : For nominal diameter of DN300 and below.
(2) Stainless steel band
Outside diameter of pipe or equipment
DN600 or smaller : 13mmW x 0.4 mmt.
DN600 above : 13mmW x 0.4 mmt.
(3) Stainless steel self tapping type screw with round head (4-5 mm dia. x 12 mm long).
4.3. Metal Jacketing Sheet
Metal jacketing sheet material and thickness shall be as follows.
4.3.1 Aluminum sheet (color: silver)
(1) Up to DN300 of pipe or vessel : 0.4 mm thickness
(2) Over diameter of pipe or vessel : 0.4 mm thickness
(3) Flange, valve, manholes, equipment : 0.4 mm thickness
4.3.2 Stainless steel sheet
(1) Up to DN300 of pipe or vessel : 0.25 mm thickness
(2) Over diameter of pipe or vessel : 0.25 mm thickness
(3) Flange, valve, manholes, equipment : 0.25 mm thickness
SHEET : 5 of 20
(Note) Stainless steel sheet shall be applied on equipment used in the caustic
service.
4.4. Other material
4.4.1 Flashing compound
The following or equivalent material shall be applied as flashing compound.
Material: Forster 30-45 foam seal or equivalent
4.4.2 Anti-abrasion material Material : Hydrocal B-11 or equivalent
4.4.3 Finish Cement Material : Hard setting Cement (ASTM C449) or
equivalent
4.4.4 Mastic Material: Foster 90-07 HI Mastic or equivalent
4.4.5 Glass Cloth Fabric Material : 10 x 10 threads per inch
4.4.6 Support Ring Carbon steel : For carbon steel pipe
Stainless steel, ASTM A240 Type 304: For stainless steel pipe
4.4.7 Void and joint filler Loose fiberglass same as paragraph 4.1.1
5. APPLICATION
Insulation shall be applied in accordance with the requirements outline below. Further detail
requirements or adjustment, if required, shall be applied based on the insulation materials
suppliers recommend practice.
5.1. General
(1) Insulation materials shall be store so that they are protected from rain and water, even
under insulation work.
(2) Equipment, vessel and piping shall be insulated after specified pressure and leakage
test are completed.
(3) Surface to be insulated shall be free from dust, grease, water, moisture and any other
foreign materials.
(4) All metal protruded through insulation shall be flashed with joint sealer.
(5) Insulation shall be applied to equipment and piping after confirmation of insulation of
support rings, bolt, stubs and nuts specified. Supporting for insulation on vertical
piping shall be located at intervals of 6 meters approx.
(6) Insulation of which thickness is over 100 mm, or other thickness when recommend by
insulation materials supplier from economical view point, shall be of the multi-layer
construction. Butted joints of inner and outer layer shall be staggered at a distance of
minimum 150mm.
(7) Insulation shall be protected from any damages during the insulation work before
installation of metal jacketing.
(8) In the case of piling up the insulation materials for their store, limit the height of
piling so as not to damage the insulation materials.
(9) The opening for manhole or measuring point of wall thickness of equipment, etc. shall
be provided so as to remove the insulation materials partially.
SHEET : 6 of 20
5.2. Piping
Refer to attached figures.
(1) Insulation shall be applied with staggered joints and butted tightly together and
secured with tie wire or band. Twisted ends of wire shall be bent and forced into
insulation.
(2) In case of multi layer construction, all joints shall be staggered and outer layer shall
be applied to fit inner layer closely.
(3) Insulation materials shall be covered with metal jacketing as specified in Item 4.3.
Metal jacketing sheet shall be overlapped minimum 50mm. The longitudinal joint of
jacketing shall be overlapped and fixed by self tapping screw.
(4) Fitting such as elbows, tees, reducers and welded valve shall be insulated with the
same materials and in the same manners as specified for those adjacent pipes.
5.3. Vessel
Refer to attached figures.
(1) Vessels shall be covered with insulation with end joint staggered and edges butted
tightly together. The insulation shall be fastened with stainless steel band or wire at
250 mm intervals.
(2) When multi-layer construction is applied, butted joints of inner and outer layer shall
be staggered.
(3) Vessel heads shall be insulated with insulation blanket.
(4) Insulation materials on the bottom head of vertical vessels shall be mitered-cut to fit
head shape.
Insulation shall be secured with stainless steel band and wire netting fastened with
wire to nuts weld to vessel skirt.
(5) Insulation material shall be cut neatly to expose all nozzles, manholes, nameplate
and other connection. The portion cut shall be seal completely with joint sealer.
(6) Metal jacketing sheet shall be applied on the insulation surface. Joint portions of
jacketing sheet shall be applied with self tapping screw at intervals of 150 mm
approx. The sheet shall be fastened with stainless steel band at interval of approx.
300 mm.
(7) Bottom portion of vertical vessel with skirt shall be applied with hard setting cement
reinforced with galvanized wire netting instead of jacketing sheet.
SHEET : 7 of 20
TABLE1 THICKNESS FOR HOT INSULATION
INSULATION TYPE INSULATION MATERIAL

(1) H : Hot Insulation for Process/ Steam/ Condensate Service (1) Fiber Glass
(2) Mineral wool
Unit: mm
OPERATION TEMPERATURE
NOMINAL OUTSIDE 1010C 1510C 2010C 2510C 3010C 3510C 4010C

UP TO
TO TO TO TO TO TO TO
DIA. DIA. 1000C
1500C 2000C 2500C 3000C 3500C 4000C 4500C
DN15 21.3 25 25 30 40 50 60 70 80
DN20 26.7 25 25 30 40 50 60 70 80
DN25 33.4 25 25 30 40 50 60 70 80
DN40 48.3 25 25 30 40 50 60 70 90
DN50 60.3 25 30 30 40 50 60 80 90
DN80 88.9 25 30 40 50 60 70 80 100
DN100 114.3 25 30 40 50 60 70 90 100
DN150 168.3 25 30 40 50 60 80 90 110
DN200 219.1 25 30 40 50 70 80 100 110
DN250 273.1 25 30 40 50 70 80 100 120
DN300 323.9 25 30 40 50 70 90 100 120
DN350 355.6 25 30 40 50 70 90 100 130
DN400 406.4 25 30 40 60 70 90 110 130
DN450 457.2 25 30 40 60 70 90 110 130
DN500 508.0 25 30 40 60 70 90 110 130
DN600 609.6 25 30 40 60 70 90 110 130
DN650 660.0 25 30 40 60 70 90 110 130
DN700 711.0 25 30 40 60 70 90 110 140
DN750 762.0 25 30 40 60 70 90 110 140
DN1100 1066.8 25 30 40 60 70 90 110 150
FLAT SURFACE 30 30 40 60 80 100 120 150
Single-layer Multi-layer
Note: Instrumentation (pipe and instrument) shall be insulated to a thickness of 30 mm in all cases.
SHEET : 8 of 20
Fig.1 APPLICATION FOR STRAIGTH PIPING

SHEET : 9 of 20
Fig.2 APPLICATION FOR SUPPORT RING

SHEET : 10 of 20
Note: If the pipe cover used for DN350 above, distance ring can be omitted
Fig.3 APPLICATION FOR DISTANCE RING

SHEET : 11 of 20
Fig.4 APPLICATION FOR ELBOW (DN80 and LESS)

SHEET : 12 of 20
Fig.5 APPLICATION FOR ELBOW (DN100 and ABOVE)

SHEET : 13 of 20
Note: Sufficient clearance (bolt length + 20 mm) shall be provided for bolt removal without any
damage of pipe insulation
Fig.6 APPLICATION FOR FLANGE

SHEET : 14 of 20
Note: Sufficient clearance (bolt length + 20 mm) shall be provided for bolt removal without any
damage of pipe insulation
Fig.7 APPLICATION FOR VALVE

SHEET : 15 of 20
Fig.8 APPLICATION FOR TEE

SHEET : 16 of 20
Fig.9 APPLICATION FOR VERTICAL VESSEL

SHEET : 17 of 20
Fig.10 APPLICATION FOR VERTICAL VESSEL (SHELL SIDE)

SHEET : 18 of 20
Fig.11 APPLICATION FOR VERTICAL VESSEL (STIFFENER RING)

SHEET : 19 of 20
Fig.12 APPLICATION FOR VERTICAL VESSEL (IN SKIRT)

SHEET : 20 of 20
Fig.13 APPLICATION FOR HORIZONTAL VESSEL

S-00-1390-001 Rev 0 (Hot Insulation Specifications For BOP)

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Contract No. Document No.

DATE: 23 AUG 10 SHEET 1 of 20

PROJECT SPECIFICATION Checked D.T.Vinh

Distribution FOR CONSTRUCTION

2. APPLICATION RANGE TO BE INSULATED .............................................. 3

3. INSULATION THICKNESS ............................................................................. 4

2. APPLICATION RANGE TO BE INSULATED

2.2. Hot Insulation

(1) The insulation thickness shall be determined as operation temperature.

4.1. Insulation Materials

TABLE1 THICKNESS FOR HOT INSULATION

INSULATION TYPE INSULATION MATERIAL

NOMINAL OUTSIDE 1010C 1510C 2010C 2510C 3010C 3510C 4010C

Fig.1 APPLICATION FOR STRAIGTH PIPING

Fig.2 APPLICATION FOR SUPPORT RING

Fig.3 APPLICATION FOR DISTANCE RING

Fig.4 APPLICATION FOR ELBOW (DN80 and LESS)

Fig.5 APPLICATION FOR ELBOW (DN100 and ABOVE)

Fig.6 APPLICATION FOR FLANGE

Fig.7 APPLICATION FOR VALVE

Fig.8 APPLICATION FOR TEE

Fig.9 APPLICATION FOR VERTICAL VESSEL

Fig.10 APPLICATION FOR VERTICAL VESSEL (SHELL SIDE)

Fig.11 APPLICATION FOR VERTICAL VESSEL (STIFFENER RING)

Fig.12 APPLICATION FOR VERTICAL VESSEL (IN SKIRT)

Fig.13 APPLICATION FOR HORIZONTAL VESSEL

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