Duqm Refinery Project EPC Package 2 - Utilities and Offsites

Duqm Refinery Project
EPC Package 2 –
Utilities and Offsites
Contract No. CNT-1100-1000-007
HOT SERVICE INSULATION
B1 14-Aug-2018 Class 1 IFD (Issued for Design) I.Ghosh S.Meguid V.Ciccotosto

A1 01-Jul-2018 Class 1 ICCI (Issued Client Comments Incorporated) I.Ghosh S.Meguid V.Ciccotosto
O1 25-Jan-2018 Class 1 IFCR (Issued for Client Review) FK MR VC
Rev. Date Document Class Issue Purpose Author Checked Approved
Number Origin Document Number Rev.
Client’s Number DRP001-OUF-SPE-W-000-010

B1
Contractor’s Number DRP001-EY2S-SPC-000-030-010
Duqm Refinery Project – EPC Package 2 Hot Service Insulation
Revision History
Amendment Revision Amender

Amendment
Date Number Initials
INCORPORATION OF FEED AMENDMENT NOTES, EPC2

25-01-2018 O1 MR
DESIGN NOTES AND DESIGN DEVELOPEMENT
01-Jul-2018 A1 IG Incorporated Company Comments
14-Aug-2018 B1 IG Issued for Design
Related Documents
Document Number Document Name Description of Content
Holds
Section Number Short Description of Hold
Definitions and Abbreviations
Term Comment
DRP001-OUF-SPE-W-000-010 Page 2 of 52 Rev: B1

CONTENTS
1. SCOPE ......................................................................................................................................4
2. REFERENCES ..........................................................................................................................5
3. DEFINITIONS ............................................................................................................................6
4. DESIGN - GENERAL .................................................................................................................7
5. DESIGN - PIPING INSULATION ...............................................................................................8
6. DESIGN - EQUIPMENT .............................................................................................................9
7. DESIGN – HFSO PIPELINE .................................................................................................... 10
8. MATERIALS - GENERAL ........................................................................................................ 17
9. MATERIAL - THERMAL INSULATION .................................................................................... 18
10. MATERIAL - WEATHERPROOF JACKET ............................................................................... 19
11. MATERIALS - ANCILLARIES .................................................................................................. 20
12. APPLICATION - GENERAL ..................................................................................................... 21
13. APPLICATION - PIPING .......................................................................................................... 22
14. APPLICATION - EQUIPMENT ................................................................................................. 26
15. APPLICATION - TANKS .......................................................................................................... 29
16. INSPECTION AND TESTING .................................................................................................. 29
17. HANDLING, PRESERVATION AND STORAGE ...................................................................... 30
18. FIGURES................................................................................................................................. 32

1. SCOPE
1.1 This specification covers the use of thermal insulation for above ground, external
insulation of piping and equipment operating between Ambient Temperature and 540°C,
for the purpose of Heat Conservation, Process Stabilisation, Temperature Maintenance,
and Personnel Protection for the Duqm Refinery in Duqm, Sultanate of Oman. For
services operating in excess of 540°C, process licensor shall recommend a suitable
insulation system and advise required insulation thickness.
1.2 The insulation requirements of this specification are suitable for use in both indoor and
outdoor service with normal process plant atmospheres. Alternative designs and
materials shall be considered if necessary for highly corrosive atmospheres or potential
leaks and spills of chemicals.
1.3 This specification is intended to cover piping, pressure vessels and circular ducting, heat
exchangers and mechanical equipment.
1.4 This specification does not cover cold service insulation. Cold service insulation is
covered by specification DRP001- OUF-SPE-W-000-011.
1.5 This specification does not cover acoustic attenuation insulation. Acoustic Insulation is
covered by specification DRP001- OUF-SPE-W-000-012.
1.6 This specification does not cover Vendor designed insulation for Boiler or Fired Heater
packages including Airheaters, Economisers, Gas Flues and Air Ducting. The
specification is intended to cover Contractor supplied insulation for parts of such
packages except for rectangular ducting.
1.7 This specification does not cover Daily Service Tanks, Process or Large Product
Storage Tankage nor insulated underground lines. For any tanks which require
insulation for the prevention of heat loss, the Vendor shall submit a suitable insulation
system and required insulation thickness complete with detail of heat preservation
calculations to Contractor for review and approval.
1.8 Piping and equipment requiring insulation shall be specified on the following project
documents:
1. Piping and Instrumentation Diagrams and Line Lists.
2. Piping General Arrangements and Isometrics.
3. Instrument Piping Details and Schedules.
4. Vessel and Exchanger Datasheets and/or Drawings and Insulation

Schedules.
5. Equipment Vendor’s General Arrangement Drawings for equipment items

and package plant.

2. REFERENCES
2.1 Project Specifications

DRP001-OUF-DCR-Z-000-018 Environmental Design Basis
DRP001-OUF-SPE-U-000-002 Project Design Data
DRP001-OUF-SPE-V-000-003 Pressure Vessel Standard Detail

Drawings
DRP001- OUF-SPE-W-000-008 Painting of New Equipment and Piping
DRP001- OUF-SPE-W-000-011 Cold Service Insulation
DRP001- OUF-SPE-W-000-012 Acoustic Insulation
DRP001-OUF-SPE-Y-650-011 Pipeline Mechanical Basis of Design
DRP001-OUF-PRO-Q-000-003 Vendor Quality and Environmental

Requirements
2.2 Codes & Standards

ASTM A240 Specification for Chromium and Chromium-Nickel Stainless
Steel Plate, Sheet and Strip for Pressure Vessels and for
General Applications.
ASTM B209 Standard Specification for Aluminum and Aluminum-Alloy

Sheet and Plate
ASTM C168 Standard Terminology Relating to Thermal Insulation
ASTM C390 Standard Practice for Sampling and Acceptance of Thermal

Insulation Lots
ASTM C450 Standard Practice for Fabrication of Thermal Insulating Fitting

Covers for NPS Piping, and Vessel Lagging
ASTM C547 Standard Specification for Mineral Fiber Pipe Insulation
ASTM C552 Standard Specification for Cellular Glass Thermal Insulation
ASTM C553 Standard Specification for Mineral Fiber Blanket Thermal

Insulation for Commercial and Industrial Applications
ASTM C585 Standard Practice for Inner and Outer Diameters of Thermal
Insulation for Nominal Sizes of Pipe and Tubing
ASTM C592 Standard Specification for Mineral Fiber Blanket Insulation and
Blanket-Type Pipe Insulation
ASTM C612 Standard Specification for Mineral Fiber Block and Board
Thermal Insulation
ASTM C795 Standard Specification for Thermal Insulation for Use in

Contact with Austenitic Stainless Steel

ASTM C929 Standard Practice for Handling, Transporting, Shipping,

Storage, Receiving, and Application of Thermal Insulation
Materials For Use in Contact with Austenitic Stainless Steel
BS 476 Fire Tests on Building Materials and Structures
BS EN 485 Aluminium and aluminium alloys – Sheet, strip and plate
BS EN 10025 Hot Rolled Products of structural steels
BS EN 10088-2 Stainless steels Part 2: Technical delivery conditions for

sheet/plate and strip of corrosion resisting steels for
construction purposes
BS 2972 Methods of Test for Inorganic Thermal Insulating Materials
BS 3958 – 4 & 5 Specifications for Thermal Insulation Materials
BS 4174 Specification for Self-tapping screws and metallic drive screws
ISO 9001 Quality Management Systems
3. DEFINITIONS
Company Duqm Refinery & Petrochemical Industries Company
Contractor Joint venture of Petrofac International LTD & Samsung

Engineering Co. LTD. Contractor includes its approved
Manufacturers, Suppliers and Sub-Contractors.
Vendor Supplier of equipment and support services for a particular

piece of equipment/package
Applicator Entity that undertakes the insulation application in accordance

with this specification

4. DESIGN - GENERAL
4.1 In this specification, insulation for the prevention of heat loss is designed for the
following conditions:
 Ambient Temperature (winter monthly minimum mean): 12.3°C
 Wind Speed (average annual): 6.48 m/s
 Insulation finish emissivity: 0.1
 Minimum Insulation Thickness: 25mm
 Heat Flow Limit: 300 W/m2
4.2 In this specification, insulation for personnel protection is designed for the following
conditions:
 Ambient Temperature (summer monthly maximum mean): 43.8°C
 Maximum cold face surface temperature: 65°C
 Wind Speed (minimum monthly average): 2.97 m/s
 Insulation finish emissivity: 0.1
 Minimum Insulation Thickness: 25mm
4.3 Insulation comprises a layer (or layers) of heat resisting fibre material enclosed within
protective metal sheeting sealed against the ingress of moisture and designed to allow
differential expansion.
4.4 Internally refractory lined piping and equipment shall not be insulated. Over these areas
personnel protection shall be achieved by the use of stood-off metal guards.
4.5 Insulation is not necessary for piping and equipment for which heat loss is desired -
other than for acoustic attenuation, personnel protection or to avoid thermal stress
problems.
4.6 The purpose for which insulation is required is identified by the applicable symbols in
Table 1. Piping and Equipment to be insulated shall be identified by these symbols on
Piping and Instrumentation Diagrams and Line Lists.
4.7 Instruments and associated piping subject to operating flow and/or temperature
conditions approximating those in the piping or equipment to which they are connected,
shall be insulated to the same requirements as that piping or equipment. The insulation
requirements shall be classified by symbols in accordance with Table 1.
4.8 All insulated austenitic stainless steel, Carbon steel and low alloy piping and equipment
shall be protected against corrosion by painting in accordance with Painting of New
Equipment and Piping Doc. No. DRP001- OUF-SPE-W-000-008.
4.9 All insulated austenitic stainless steel piping and equipment shall be protected against
chloride attack with a 0.15 mm thick, sacrificial aluminium foil system. The foil shall be

applied with 50 mm overlaps and secured with stainless steel wire or bands.
The aluminium foil shall have a chemical composition of 98% minimum aluminium and
shall not have an adhesive backing.
Stainless steel foil shall be used for operating temperatures in excess of 500°C.
4.10 To assist corrosion prevention insulation materials shall be of the correct chemical
nature and shall include the following requirements
1. Carbon Steels - Insulation to be chemically neutral or slightly alkaline.
2. Aluminium - Insulation to be chemically neutral or slightly acidic.
3. Stainless Steels - Insulation shall be as free as possible of soluble chlorides

(20 ppm maximum).
4.11 Personnel protection shall be applied in accordance with Table 4 to all exposed surfaces
operating above 65°C and located within 600mm horizontally or 2100mm vertically of a
normal access walkway or work area.
Pipe and Equipment designated for personnel protection (“PP” or “PG”) shall be fully
painted in accordance with specification DRP001- OUF-SPE-W-000-008.
4.12 The Material for stand off metal guards used in personnel protection shall be as follows:
 BS EN 485-NS3-H6
 ASTM B209 Alloy 3003 – H14 of H16
 316 stainless steel in fire hazard areas or in case personnel protection is applied
on 300 series stainless steels or Ni-Based Alloys. The material shall comply with
BS 10088-2 or ASTM A240.
The minimum standoff distance shall be in accordance with Figure 7 to prevent
deliberate or accidental contact.
5. DESIGN - PIPING INSULATION
5.1 Insulated piping systems shall have straight pipe, bends, tees and non-flanged pipe
fittings completely insulated.
5.2 All valves and flanged joints shall be insulated only in the following services:
1. Steam services
2. Trace heated or jacketed services
3. Closed Condensate services.
4. Other special services when agreed with Company
5.3 Bucket and Float type steam traps shall be traced and insulated together with the inlet
piping.
5.4 Insulation on inlet piping to Thermostatic and Thermodynamic steam traps shall
terminate a minimum of 450mm from the trap leaving the remainder of piping and the
trap uninsulated.
5.5 Steam trap outlet piping shall not be insulated except for Personnel Protection
considerations.

5.6 Insulation shall not be applied to the following unless otherwise specified for Acoustic
Attenuation, Personnel Protection or other special reasons.
1. Piping which becomes hot intermittently, such as relief valves, vents, steam-
out and snuffing steam systems, flare and blowdown systems and by-
passes at control valves.
2. Supports for piping.
3. Steam Traps. (except as noted in paragraph 5.3).
4. Valves, including control valves and flanges in process piping systems

(except as noted in paragraph 5.2).
5. Pipe union fittings.
6. Thermowell bosses and pressure tappings.
7. Expansion joints, hinged joints and hose assemblies.
8. Sight flow indicators.
5.7 Piping shall be designed to provide an absolute minimum clearance of 25mm between
the outside surface of any insulation finishing material and adjacent surfaces.
5.8 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 structure upon which the shoe rests by 25mm minimum.
5.9 Vertical piping insulation shall be supported by bolted collars at intervals (see figure 6,
together with figure 1, section18). Collars shall be supplied, fabricated, and fitted by the
Insulation Applicator.
6. DESIGN - EQUIPMENT
6.1 Support skirts of insulated vertical vessels greater than 1200mm diameter shall be
insulated both internally and externally for a minimum distance of 600mm below the
bottom tangent line. On skirts which do not require fireproofing the insulation shall
terminate not less than 300mm above the support concrete or steelwork. Where
support skirts are to be fireproofed the insulation shall extend to the top of the
fireproofed areas and stainless steel finishing material shall be used to protect the area
of skirt insulation below the bottom tangent line.
6.2 Support skirts of insulated vertical vessels of 1200mm diameter and less shall be
insulated externally only, as described in paragraph 6.1 above.
6.3 Bottom heads of insulated vertical vessels fully enclosed by a support skirt shall be
insulated without weatherproof jacket finishing material and shall be insulated only when
the vessel outside diameter is greater than 1200mm.
6.4 Liquid ends of positive displacement pumps and casings of centrifugal pumps shall be
insulated only when heat traced or jacketed.

6.5 Insulation shall not be applied to the following unless otherwise specified for Acoustic
Attenuation, and Personnel Protection or other special reasons.
1. Pumps with operating temperatures below 200oC unless pumped fluid has a
pour point above minimum design ambient temperatures.
2. Fans, compressors, blowers or other rotating or reciprocating equipment.
3. Internally insulated or refractory lined equipment unless specially designed

for metal temperature control.
4. Heads of vessels fully enclosed by support skirts with vessel diameters

1200mm and less.
5. Internal surfaces of fully enclosing support skirts of insulated vessels with

vessel diameter 1200mm and less.
6. Exchanger channel covers.
7. Nozzles, manholes and handholes, and flanges of equipment.
8. Surfaces of coolers and condensers.
9. Nameplates on all equipment items.
10. Thermowell bosses and pressure tappings.
6.6 Insulation for vessels and similar equipment shall be adequately supported or
suspended, dependent on insulation material form, with clips and support lugs, welded
on at intervals around the equipment item and positioned by the Equipment fabricator in
accordance with Standard Detail Drawings specification DRP001-OUF-SPE-V-000-003.
6.7 External vacuum stiffening rings on equipment shall be fully and independently
insulated. The insulation finishing metal sheeting shall be sealed and allow for
differential expansion. The sheeting shall be shaped to shed water.
7. DESIGN – HFSO PIPELINE
7.1 The HFSO Pipeline from refinery to jetty complete with Skin Effect Heat tracing shall be
insulated. See Pipeline Mechanical Basis of Design (DRP001-OUF-SPE-Y-650-011) for
design conditions of the Pipeline. The insulation type shall be either shop-applied,
sprayed PIR insulation or a traditional shop or field applied insulation system, based on
the final design of the skin effect tracing. Contractor will confirm insulation requirements
with heat tracing manufacturer and verify the most cost-effective method of insulation
installation. A high density foam insulation with a high-strength cladding material such
as FRP shall be used local to the pipeline clamp supports.

DESIGN - TABLE 1
INSULATION AND PROTECTION SYMBOL, CLASSIFICATION AND
GENERAL CONDITIONS OF USE
SYMBOL CLASSIFICATION INSULATION INSULATION THK NOTES

THICKNESS SELECTION
TABLE NO. CONSIDERATION
REF.
HC Heat Conservation Normal Operating Each section of the Equipment
(Process Lines) temp. of process having defined sections
where normal Operating Table No. 3 fluid and nominal operating at differing
Temps exceed 93oC pipe size. temperatures may be insulated
(200oF) to suit its individual
temperature. For Shell and
Tube Exchanger Shells and
Channels use the higher of the
inlet and outlet temperatures.
PS Process Stabilisation to Special Special Piping and equipment subject
assist process control. Consideration Consideration to special specific
considerations to determine
insulation thickness and design
which shall be clearly indicated
on the P&ID’s and Line Lists.
ST Steam Tracing Table No. 3 Normal Operating Insulation where operating
SJ Steam Jacketing temp. of process plant requires a protective
fluid and one pipe heating system to protect
ET Electric Tracing
size greater than piping, equipment, and
parent pipe. instruments against the effects
of ambient temperatures
(including hydrate formation,
condensation, viscosity change
and pour point suppression).

DESIGN - Table 1 (Continued)
INSULATION AND PROTECTION SYMBOL, CLASSIFICATION AND

GENERAL CONDITIONS OF USE
SYMBOL CLASSIFICATION INSULATION INSULATION THK NOTES

THICKNESS SELECTION
TABLE NO. CONSIDERATION
REF.
PP Personnel Protection Table No. 4 Nominal pipe size and Over unlined piping and
(Insulation) normal operating equipment insulate or provide
temp. open mesh metal guards on
operating plant which would
normally be left uninsulated and
PG Personnel Protection
which may be accessible during
(Stood-off metal- guard)
the performance of routine duties
-- --
by operating (not maintenance
only) personnel. SEE NOTE *
AC Acoustic attenuation for See Acoustic Category The acoustic insulation symbol
noise control at various specification attenuation subject to shall be added to any other
levels of requirement. for Acoustic calculated insertion thermal insulation symbol which
Insulation loss requirements. applies. contractor shall specify
doc.no. in detailed engineering which
DRP001- class of acoustic insulation is
OUF-SPE-W- required (A, B or C) and update
000-012. accordingly.
NI Not insulated -- -- If no other symbol applies NI
shall be indicated for definition
and clarity and is required for
computer MTO purposes.
NOTE* The intent of Piping and Instrumentation Diagrams, Line Classification lists, Insulation
Summaries etc. which designate insulation for types PP and PG is to call attention only to
the eligibility of such service. The actual extent of such insulation shall be determined
using the criteria defined in paragraph 4.11.

DESIGN - Table 2
INSULATION AND METAL COVER, FORM AND SECUREMENT METHOD
ITEM NOMINAL SIZE OF INSULATION MATERIAL

ITEM FORM
Straight pipe Up to 200m (8") Preformed Pipe Sections
Straight pipe 250 mm (10") to Preformed pipe section or
500mm (20") multi-segments.
Straight pipe Above 500mm (20") Multi-segments
Welded valves and All sizes As per straight pipe cut and
butt-weld tees, and shaped to fit.
reducers.
Flanged Valves, All sizes Suitable
Flanged Joints Preformed
Bends and Elbows All sizes As for straight pipe cut and
shaped to fit.
Equipment Heads All sizes Preformed Blocks & Slabs cut
(except bottom and shaped to fit.
heads of Vertical
Equipment)
Equipment Shells All sizes Preformed pipe or Multi-pipe
segments or slabs cut and
shaped to fit.
Vertical Equipment All sizes Flexible wire-backed mattress.
Bottom Heads
without Skirt
Vertical Equipment All sizes over 1200mm Flexible wire-backed mattress.
Bottom Heads with (4ft)
Skirt
Casings of Pumps, All sizes Preformed slabs cut to suit
Turbines, removable cover.
Compressor etc.
Manholes and
Handholes, and
where required
Exchanger Channels

DESIGN Table 2 (Continued)
INSULATION AND METAL COVER, FORM AND SECUREMENT METHOD
ITEM INSULATION OD OF COVER THICKNESS

METAL THICKNESS
COVERING OVER
INSULATION
Straight Pipe Flat Metal * Up to 150mm 0.8mm thick

Straight Pipe Flat Metal * 150mm up to 1.0mm thick
450mm
Straight Pipe Flat Metal * 450mm and 1.2mm thick
above
Welded Valves and Butt- Flat Metal * All sizes As per straight pipe
Weld Tees and
Reducers
Flanged Valves Flat Metal * All sizes 1.2mm thick
Flanged Joints Removable
Covers
Bends and Elbows Flat Metal * Up to 80mm As for straight pipe.
Stove pipe or
pressed elbows
Flat Metal * 80mm and larger As for straight pipe.
fabricated mitred
elbows
Equipment Heads Flat Metal * All sizes 1.2mm thick
(Except Bottom Heads of 'Orange Peel'
Vertical Equipment) Fabrication
Equipment Shells Flat Metal * All sizes 1.2mm thick
Vertical Equipment Flat Metal * All sizes 1.2mm thick
Bottom Heads without Fabricated to suit
skirt
Vertical Equipment Not required - -
Bottom Heads with Skirt
Casings of Pumps, Flat Metal * All sizes 1.2mm thick
Compressors, etc, sheet fabricated
Manholes, Hand holes, removable
and where required, covers.
Exchanger Channels
* Note: FOR INSULATION IN FIRE HAZARD ZONES STAINLESS STEEL SHEETING SHALL BE
USED.

DESIGN - Table 3
INSULATION THICKNESS FOR HEAT CONSERVATION
NORMAL OPERATING TEMPERATURE (oC) AND THICKNESS (MM)

NOMINAL Up 151 201 251 301 351 401 451 501 541
PIPE to to to to to to to to to and
SIZE 150 200 250 300 350 400 450 500 540 Over
MM INS THK THK THK THK THK THK THK THK THK
15 1/2 25 25 25 50 50 50 50 80 80 Insulation thickness
at Operating
20 3/4 25 25 25 50 50 50 80 80 80
Temps over 540oC
25 1 25 25 25 50 50 50 80 80 80 shall be the subject
40 1 1/2 25 25 25 50 50 80 80 80 100 of calculation and
50 2 25 25 50 50 50 80 80 80 100 special
65 2 1/2 25 25 50 50 50 80 80 100 100 consideration.
80 3 25 25 50 50 50 80 80 100 100
100 4 25 25 50 50 50 80 80 100 100
150 6 25 25 50 50 80 80 100 100 130
200 8 25 25 50 50 80 80 100 100 130
250 10 25 50 50 50 80 80 100 100 130
300 12 25 50 50 50 80 80 100 130 130
350 14 50 50 50 50 80 80 100 130 130
400 16 50 50 50 50 80 100 100 130 150
450 18 50 50 50 50 80 100 100 130 150
500 20 50 50 50 50 80 100 100 130 150
OVER OVER
500 & 20 & 50 50 50 75 75 100 130 130 150
FLAT FLAT
SINGLE LAYER DOUBLE LAYER
Double Layer shall be constructed

with layer thickness as follows:-
Thk 1st Layer 2nd Layer

50 25 25
80 40 40
100 50 50
130 50 80
150 70 80

DESIGN - Table 4
INSULATION THICKNESS OVER PROCESS PIPING

AND EQUIPMENT FOR PERSONNEL PROTECTION PURPOSES
NORMAL OPERATING TEMPERATURE (oC) AND THICKNESS (MM)

NOMINAL Up 151 201 251 301 401 501 541
PIPE to to to to to to to and
SIZE 150 200 250 300 400 500 540 Over
mm Ins Thk Thk Thk Thk Thk Thk Thk Personnel
15 1/2 Guard 25 25 25 50 50 80 protection at
elevated
20 3/4 Guard 25 25 25 50 50 80
temperatures
25 1 Guard 25 25 25 50 80 100 shall be
40 1/2 Guard 25 25 25 50 80 100 subject to
50 2 Guard 25 25 50 50 80 130 calculation
and special
65 2 1/2 Guard 25 25 50 50 100 130
consideration.
80 3 Guard 25 25 50 50 100 130
100 4 Guard 25 50 50 80 100 150
150 6 Guard 25 50 50 80 130 180
200 8 Guard 25 50 50 100 130 180
250 10 Guard 50 50 50 100 150 200
300 12 Guard 50 50 80 100 150 200
350 14 Guard 50 50 80 100 150 230
400 16 Guard 50 50 80 100 180 230
450 18 Guard 50 50 80 130 180 230
500 20 Guard 50 50 80 130 180 250
OVER OVER
500 & 20 & Guard 50 75 100 150 230 300
FLAT FLAT
SINGLE LAYER DOUBLE/TRIPLE LAYER
Double/Triple Layer shall be constructed with

layer thickness as follows:-
Thk 1st Layer 2nd Layer 3rd Layer

50 25 25 -
80 40 40 -
100 50 50 -
130 50 80 -
150 70 80 -
180 80 100 -
200 100 100 -
230 50 80 100
250 70 80 100
300 100 100 100

8. MATERIALS - GENERAL
8.1 All material shall be as described in the following paragraphs, and shall be of high
quality and good appearance.
8.2 Insulation materials shall be of low chloride content, chemically inert, non-sulphurous,
rot proof, vermin proof, impervious to hot water and steam, non-injurious to health and
non-corrosive to steel or aluminium, (even if soaked with water at ambient temperatures
for extended periods). Insulation material must be CFC free, designed with the
guidelines of Montreal Protocol,1987, for protection of Ozone layer as per Environmental
Design Basis DRP001-OUF-DCR-Z-000-018.
8.3 Insulation materials shall be water repellent.
8.4 Insulation materials containing ASBESTOS in any form are not permitted.
8.5 Insulation and jacketing materials backed with paper or other flammable material are not
acceptable.
8.6 Zinc bearing materials shall not be used on stainless steel pipe and/or equipment.
8.7 Material shall have low smoke emission and shall not melt or drip in fire as per BS 476
and relevant ASTM standard.

9. MATERIAL - THERMAL INSULATION
9.1 Rigid insulating material shall be Fibrous Preformed (Mineral Fibre with resin binder)
Insulation and shall be of long fibred rock material processed from a molten state into
fibrous form and bonded with a binder suitable for the intended operational temperature
range.
9.1.1 Preformed materials shall satisfy the minimum requirements of quality standard in
accordance with BS 3958 (Parts 4 and 5), ASTM C547 and ASTM C612.
9.1.2 The insulation material shall be supplied plain faced in Manufacturer's Standard sizes
and the average measured length, width and thickness shall not differ from the standard
dimensions specified by more than plus or minus 3mm.
9.1.3 Insulation shall conform to the following physical requirements:-
Density - nominal 110-145 kg/m3

Alkalinity (approx) PH Between 6 and 10
Combustibility Non-combustible
Compression strength (av.) minimum at 160-320 kg/m2
10% deformation
Hygroscopicity % volume 0.20 maximum
Linear shrinkage (av. max) Below 2%
Chloride content not to exceed 20 ppm See Fig. 1 ASTM C795 wicking type
Insulation over Stainless Steel
Sodium plus Silicate content minimum 40ppm
*Mean Temperature Average maximum 'k'

oC W/M oC
50 0.043
100 0.052
150 0.064
200 0.078
250 0.093
300 0.110
* Mean temperature is Hot face temp + Cold face temp

2
9.2 Flexible insulation shall be layers of a long fibred mineral material, made from rock
processed from a molten state into fibrous form, and be without binder. It shall be
stitched through with heat resistant ties (galvanised wire) to galvanised wire netting on
one side (ties and netting shall be stainless for stainless steel surfaces).
9.2.1 Flexible materials shall satisfy the minimum requirements of quality standard in
accordance with ASTM C592 or ASTM C553.
9.2.2 The insulation material shall be supplied as flexible mattresses in manufacturer’s

standard sizes.

9.2.3 In addition the insulation shall have the following physical properties:-
Density - nominal 120-135 kg/m3

Alkalinity (approx) PH Between 6 and 8
Combustibility Non-combustible
Chloride content not to exceed 20 ppm
*Mean Temperature Average maximum 'k'

oC W/M oC
38 0.043
93 0.052
149 0.061
* Mean temperature is Hot face temp + Cold face temp

2
10. MATERIAL - WEATHERPROOF JACKET
10.1 The selection of Aluminium material in both coil and flat sheeting form for use as the
thermal insulation protective metal cover shall take precedent over other metallic
coverings with the exception of insulation in fire hazard zones where stainless steel
covering shall be used.
10.2 Aluminium jacketing shall be flat mill finished commercial grade of alloy ALMn which
shall comply with BS EN 485 or ASTM B209 under the following material designations:
 BS EN 485 - NS 3 - H6
 ASTM B209 Alloy 3003 - H14 or H16
 Stainless steel jacketing required in case of fire hazard areas shall be flat mill
finished grade 2B of steel to comply with BS 10088-2 or ASTM A240. Stainless
Steels Grade shall be SS 304 or SS 316.
10.3 Aluminium metal jacketing shall be supplied with factory applied protective barrier
coating of polysurlyn applied to one side which shall comply with BS 476 Class 1
(Surface Spread of Flame). The backing shall be directly laminated to the aluminium
without use of adhesives or glue.
10.4 Alternative jacketing such as coated mild steels/ Aluminized steel can also be used for
weather proofing after approval of COMPANY and CONTRACTOR.

11. MATERIALS - ANCILLARIES
11.1 Binding and tie wire used where indicated to secure insulation materials and sacrificial
foil over stainless steel surfaces shall be 18% Cr - 8% Ni stainless steel wire having a
minimum diameter of 1.22mm. The wire shall be fully annealed.
11.2 Banding for use over insulation and over metallic finishing jacket shall be in handable
coils ready to be cut to required lengths at site. Bands shall be as shown in Table 2 of
this specification 20mm or 12mm wide x 0.5mm thick - fully annealed 18% Cr – 8% Ni
stainless steel.
Expansion sections of banding where required to cater for differential expansion shall be
of the same size and material as the flat bands and shall be of the 'Expand-R-Strap' type
or 'Techalloy' Breather spring type or an approved equivalent.
11.3 Banding clips for use with securing bands shall be of the same stainless steel material
as the banding and shall be of the 'Butterfly' type similar to 'Band-it-Valstrap Clips'.
11.4 Rivets required for metal jacket fabrication shall be the expanding Monel 'pop' blind eye
type, 9.5mm long x 5mm diameter.
11.5 Screws required for metal jacket fabrication shall be stainless steel slotted pan head
self-tapping type A No. 8 dia. x 12mm long to BS 4174 complete with neoprene washers
under the head.
11.6 The material requirements of normal insulation accessories shall be as follows:
1. 'S' and 'J' clips - Formed from 20mm wide stainless steel banding.
2. Removable cover fastenings - Shall be of the quick release, spring shackle

lock type, material similar to the removable metal cover.
3. Metal cleats - Used as supporting angles on weatherproofing jackets shall

be of similar material as described for the jacketing material in paragraphs
10.2, 10.3 and 10.4. The size shall be 65mm high x 50mm wide with the
returned angle toe 13mm less than the insulation thickness. The cleats
shall be 6mm thick.
4. Floating rings - Shall be 10mm dia. carbon steel rod conforming to BS EN

10025 Grade S275.
5. Sacrificial foil - Use as a barrier material between stainless steel piping and
equipment surfaces and insulation material shall be 0.06mm thick
aluminium foil for operating temperatures of 500oC and below, and
stainless steel foil at operating temperatures in excess of 500oC.
11.7 Sealing compound for use as metal sealant, sealing overlaps of metal jacketing shall be
a suitable flexible non-setting compound having properties which render materials
waterproof, weatherproof, chemically resistant and fire resistant.

12. APPLICATION - GENERAL
12.1 The requirements of application, given in this Specification in no way absolve the
Applicator from responsibilities of applying an insulating system that will give a
satisfactory operational performance and the requirements given herein shall be
regarded as directives and guidelines for the acceptable minimum. The Applicator shall
carry out the work in accordance with the best practices of insulation application with the
minimum of waste and debris and the final job shall present a neat, efficient, and
workmanlike appearance.
12.2 All hydrostatic tests on piping and equipment, including steam tracing systems, shall be
carried out before insulating material is applied. The Insulation Applicator shall only
insulate those sections of the plant that have been specifically released by an authorised
agent of the Contractor for such work. If however, it has been planned and decided to
insulate prior to other trades work and before tests have been completed, insulation
shall terminate a suitable distance before and after welded and flanged joints, and
sealed against water ingress and also protected from mechanical damage which may be
caused by other trades and during subsequent testing.
12.3 Surfaces to be insulated shall be clean, dry and free from loose rust scale. It shall be
the Insulation Applicator's responsibility to remove the loosely adhering scale and dirt by
an appropriate method which does not scar, scour or damage the metal surface.
12.4 Insulated stainless steel, carbon and low alloy steel piping and equipment require
protective coatings as specified in specification of Painting of New Equipment and
Piping Doc. No. DRP001- OUF-SPE-W-000-008.
Where coatings are applied, repairs if necessary, shall be carried out by the appointed
Painting Contractor and the coatings shall be the subject of inspection by an authorised
agent of the Contractor prior to the commencement of insulation application.
12.5 Insulated stainless steel piping and equipment shall be wrapped with sacrificial foil prior
to insulation application. The foil shall be secured with stainless steel tie-wires at
sufficient intervals to ensure the foil remains in place throughout the service life of the
insulation. The supply and application of foil shall be the responsibility of the Insulation
Applicator.
12.6 The Insulation Applicator shall NOT carry out any welding or drilling on piping or
equipment, Applicator shall however be responsible to carry out a check and confirm
that all insulation supports, as indicated on fabrication drawings, have been installed and
welded into position. The Insulation Applicator shall also confirm that a sufficient and
satisfactory number of supports have been provided.
12.7 Insulation shall be finished, sealed and weatherproofed at all terminal points including
either side of temporary shop supports, lifting lugs, testing points etc. At these positions
on shop insulated items closure pieces shall be designed and fabricated, to fit exactly at
a later date on site, without impairing the weatherproofing. The Insulation Applicator
shall remain totally responsible for the finished insulation.
12.8 Equipment nameplates shall remain visible after insulation has been applied. The
surrounding edges shall be efficiently sealed against water ingress.
12.9 The application of the insulation shall take into account expansion movements of piping,
and equipment at normal operating temperatures and include provision within the
insulating system for any differential expansion anticipated. Shop applied insulation

shall take into account not only thermal expansion and contraction movements but also
movements of flexing and vibration created by on-off loading and transportation. The
anticipated scope of these movements shall be outlined to the Insulation Applicator by
the item Shop Fabricator.
12.10 Thermowell bosses, pressure tappings and weep hole nipples shall not be insulated but
left accessible, the surrounding edges of insulation shall be positively sealed against
water ingress.
12.11 Double layer construction shall be required when operating temperatures are over
300°C and/or the insulation thickness is greater than 100mm. Insulation installed in two
or more layers shall be staggered joint construction and each layer shall be adequately
secured in place.
12.12 Insulation shall be applied in large regular pieces cut to size where necessary and firmly
butted together to minimise voids, and to keep edges of material under compression.
Circumferential joints shall be staggered by one half sections.
12.13 Wet or damaged insulation shall not be used under any circumstances. Installed
material awaiting its protective cover shall be adequately protected from damage, rain,
and contamination by other trades such as oils, spent welding rods, paint etc.
12.14 A minimum clearance of 25mm between the outside surface of any insulation finish and
adjacent equipment, pipe or structural members shall be maintained. Care shall be
taken where insulation is shop applied to ensure this minimum clearance.
12.15 Where voids occur in the insulation they shall be filled with suitable fibrous loose fill
material. Loose fill used for shop applications shall be protected from possible damage
during subsequent lifting and transporting.
12.16 Where installed, expansion joints shall comprise of compressible mineral fibre of
sufficient density and composition to operate efficiently as both insulant and expansion
facility at the given operating temperatures.
12.17 Insulation supports shall not project proud of the insulation outer surface and shall be
given sufficient coverage of insulating material to avoid hot spots on the insulation
metallic weatherproof cover at support positions.
12.18 Weatherproof jacket shall be designed and installed to shed water at ALL times. Flat
horizontal surfaces are not acceptable. It shall be borne in mind throughout shop
application that sloping planes in shop conditions may possibly become flat surfaces
when finally positioned at site and continuous care shall be taken to ensure that final
orientation is known by the Insulation Applicator.
13. APPLICATION - PIPING
13.1 Preformed insulation shall be applied, supported and secured to straight length single
pipe runs using two half sections up to the maximum manufactured sizes, above this
size piping shall be insulated with the minimum number of cut segments.
13.2 Insulating material shall be applied to fit snugly against the contours presented to the
applicator and neatly cut and shaped only where necessary to achieve this requirement.
The insulation shall be carried out with the least number of material pieces as possible
and all unavoidable gaps, cavities, and voids shall be suitably filled with compatible

loose fill material.
13.3 Shop fabricated piping shall be amply supported and positioned in such a manner that
allows complete all-round uninterrupted access to the work piece. At temporary support
points during shop fabrication, insulation shall be terminated and sealed and closure
pieces fabricated for later installation at site.
13.4 The insulation materials shall be secured to the pipes by means of circumferential tie
wires or bands in accordance with the following:
 Pipe up to 200mm (8”) NB – 1.22mm minimum diameter stainless steel wire
 Pipe 250mm (10”) to 500mm (20”) NB – 12mm wide diameter stainless steel
bands
 Pipe above 500mm (20”) NB and Equipment Shells – 20mm wide diameter
stainless steel bands
Tie wires or bands shall be positioned sufficient to provide three ties or securing
positions for each length of pipe insulation section. Ends of tie wires shall be turned into
the insulation material.
13.5 Each layer of insulation on piping requiring two or more layers shall be secured in
exactly the same method as required by paragraph 13.4 above. Joints of each layer
shall be offset by staggering.
13.6 Where necessary the insulation on vertical or near vertical piping (i.e. greater than 45o
angle from horizontal) shall be supported by bolted-on metal clips provided and installed
by the Insulation Applicator who shall assume responsibility of adequate pipe insulation
support. Support positions shall be at no greater distance apart than the following:
Pipe Operating Temps. Support Spacing
oC mm
Up to 370 4500
From 371 to 480 3500
From 481 to 650 2500
Where multilayer insulation is used, supports shall be extended to provide for each
layer. If support positions are used to create expansion joints, care shall be taken to
ensure that expansion joints in each layer shall be offset at least 150mm from each
other.
13.7 Over pipe bends and elbows the insulation shall be correctly sized mitre cut pipe
sections or segments to suit the contour of the bends without gaps and ill-fitting pieces.
The mitred pieces shall be secured in place with at least two ties per complete mitred
collar of insulation.
13.8 Preformed pipe sections or segments of insulation shall be carefully cut and shaped
around 'tee' junctions and the insulating material of the tangential pipe shall be carefully
and neatly cut to mate up to the material applied to the parent pipe without the creation
of voids or gaps at the junction.

13.9 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 to and damage of the insulating material. At these positions the
insulation shall be straight edged and sealed against water ingress with a metal closure.
13.10 Insulation at solid welded or clamped pipe supports shall be cut and shaped to fit around
the support and tied securely to enable the insulation to be carried with the pipe
movement. Pipe supports designed to allow the pipe to move independently shall be
insulated to allow movement to take place without damage to the insulating material.
13.11 Traced pipe and fittings shall be insulated with oversized insulating sections to allow
accommodation of both parent pipe and tracer without damage or deformation of the
insulation. Traced instrument lines and fittings shall be totally enclosed by the insulation
in a similar manner and the designed warm air annulus shall be maintained throughout
the traced pipe length.
13.12 Where specified, valves and flanged joints shall be insulated with lined removable
covers held into position with 12mm wide stainless steel bands or quick release toggle
clips. Designs of these covers shall be submitted to Contractor for approval prior to
fabrication. Insulated valves shall be completely covered, but the insulation shall be cut
and shaped around the valve stem and kept clear of the stuffing-box gland. Insulation
covers shall overlap and totally enclose the sealed ends of piping insulation.
13.13 The piping insulation protective metal sheeting finish shall provide a weatherproofed and
mechanical damage resistant covering over the whole of the insulated areas and be
applied and fitted in such a manner as to provide a close fitting assembly without gaps.

13.14 Straight pipe shall have metal jacketing cut and machine rolled (approx. 1-metre-long)
wrapped around, with 50mm minimum overlaps on both longitudinal and circumferential
overlaps. All laps shall be arranged to shed water.
13.15 A single ball swage shall be made on all circumferential overlaps. Longitudinal overlaps
shall be 'cracked' with a 45° angle inward turn of the overlapping edge to ensure a tight
metal to metal contact.
13.16 At all operating temperatures the seams at overlap positions shall be rendered
watertight by the use of a metal seam sealer which shall be applied between
overlapping metal edges in sufficient quantity and care to ensure that insulation remains
dry and unwetted whether the possible water impingement is from rain, hose, or fire
sprinklers.
13.17 The metal covering shall be secured tightly around the insulated pipe and held in place
with 12mm wide stainless steel bands on a maximum of 300mm centres. One band
shall be located on each circumferential lap and the distance between laps divided at
equal band spacings. The band securing seals shall be kept neatly in line and
positioned away from viewing angles as much as is possible.
13.18 Vertical overlaps on vertical or near vertical piping shall be staggered to provide
overlaps at 'North' and 'South' positions in alternate sections of covering.
13.19 Each section of metal covering on vertical piping with insulation OD's larger than 250mm
shall be supported from the next lower section with two 'S' clips fabricated from banding
material. The 'S' clips shall be of sufficient length to allow the minimum overlap of
50mm.
13.20 On vertical piping with insulation OD's of 600mm and larger, the securing bands shall be
supported by 'J' clips fabricated from banding material. The 'J' clip spacing shall be a
minimum of two per band. All 'J' clips shall be screwed into position and secured.
13.21 Insulated bends and elbows in piping 80mm and larger, shall be metalled with 'lobster
back' segments using 10mm minimum ball swage to assist shaping. The metal bands
shall be screwed with self-tapping screws and include metal sealants to provide a
completely waterproofed arrangement.
13.22 Insulated bends and elbows in piping smaller than 80 mm may use complete pressed
humped back flat metal elbows or fabricated 'stove pipe' elbows but these fitments shall
be completely and positively waterproofed.

14. APPLICATION - EQUIPMENT
14.1 The insulation over equipment shall be supported by rings, bars, clips etc., welded and
fitted to the metal surfaces by the equipment fabricators. Maximum use shall be made
of these provisions by the Insulation Applicator.
14.2 Sections and slabs shall be cut and shaped to fit the equipment contours using the
minimum number of insulating pieces.
14.3 With the exception of vertical vessel bottom heads as specified in section 6.3, the heads
of equipment shall be insulated with preformed material of a form best suited to the
curvature of the equipment.
14.4 Insulating material shall be secured to equipment items by means of 20mm wide
stainless steel bands at 300mm maximum centres. Bands shall be machine stretched
and tensioned to take out slack only.
14.5 The bottom heads of vertical vessels shall be insulated with flexible wire-backed
mattress. These shall be fixed by wires to the support clips provided on the vessel head
and radial bands.
14.6 Insulation securing bands on equipment larger than 2135mm outside diameter shall be
provided with expansion sections at 7620mm maximum spacing.
14.7 On vertical equipment an expansion gap of approximately 25mm shall be allowed

beneath each support or stiffener ring. Expansion gaps shall be filled with an even
distribution of compressed mineral rock fibres.
14.8 Expansion gaps shall be provided on horizontal equipment with mineral fibre as
described in paragraph 14.7 above being compressed between joints of the equipment
insulation at 3660mm maximum intervals.
14.9 Where specified; pump casing, turbines, compressors, equipment flanges, nozzles,
channel covers, manway and handhole flanged covers shall be insulated with lined
removable prefabricated covers secured with 20mm wide stainless steel bands or quick
release toggle clips. Design to be approved by Contractor as in 14.12 below.
14.10 Insulation shall be stopped short of uninsulated flanges and nozzles etc., a sufficient
distance to permit withdrawal of bolts without disturbing the remainder of the insulation.
Insulation shall be weatherproofed and sealed at these positions.
14.11 Insulated bottom heads of shop insulated vertical equipment with fully enclosed support
skirt, shall be provided with temporary weather resistant protection which shall efficiently
prevent the ingress of water and weather during transportation, storage and lifting.
14.12 The insulation over pumps, compressors and turbines shall be in the form of lined
removable metal covers. Design of the covers shall be submitted and approved by
Contractor prior to fabrication. Removable covers shall be fabricated by the Insulation
Applicator and be made up in sizeable pieces designed to be quickly and easily taken
apart and reassembled. In the fully assembled state lined covers shall represent an
efficient, weatherproof, waterproof and sound resistant covering.
14.13 The protective metal weatherproof jacket over vertical vessel shells shall be constructed
of rectangular sheet metal panels applied in a "wallpaper" pattern with the short width of

panel in a circumferential direction parallel to the equipment insulation support rings and
the longer length of panel in a parallel direction to the vessel centre line. The weight of
the panel shall be taken on the equipment insulation support rings, via angle brackets
bolted to the panel in accordance with Fig 3. There shall be a minimum of two brackets
per panel. Shop applied insulation shall ensure that angle brackets remain in contact
with support rings. The short width of panel shall be rolled to suit the outside curvature
of the vessel insulation. The long side of panel shall be cut to suit the distance between
insulation support rings.
14.14 The panels shall be applied commencing at the bottom of the vessel. Each
circumferential ring of panels shall be tensioned by means of temporary tensioning
bands until the final joint is screwed tight. 'S' clips shall be used as sheeting support at
unscrewed circumferential overlaps. 'S' clips shall be riveted into position on shop
applied systems, to prevent slippage during transportation.
14.15 The panels shall be held tight over the vessel insulation by means of circumferential
20mm wide stainless steel bands and seals. The bands shall be positioned on all
horizontal overlaps and at 450mm centres. Bands shall be held in their relative
positions with 'J' clips and be machine stretched and sealed to remove slack only.
14.16 The panels shall have a minimum overlap of 80mm on both horizontal and vertical
edges. The overlaps shall be arranged to shed water at all times.
14.17 The vertical overlaps shall be secured with self tapping screws at 75mm pitch, these
shall be constructed with a 150mm overlap. All overlaps shall be rendered watertight by
use of a metal sealant positioned between overlapping metal edges.
14.18 All equipment projections such as nozzles, shall have the metal jacketing sealed using a
metal flashing cut to fit the projection and extend over the jacket by at least 75mm. The
seal between the flashing and jacket shall be made water tight by use of self tapping
screws and metal sealing mastic.
14.19 Horizontal cylindrical equipment shall be finished with flat metal jacket arranged in
circumferential bands with the edge of the sheets with the longer dimension applied
around the circumference of the equipment insulation.
14.20 The panels shall have a minimum of 75mm overlap on both longitudinal and
circumferential edges, both overlaps being finished with a simple ball swage and
rendered water tight with a metal seam sealer applied between overlapping metal
edges.
14.21 Horizontal overlaps shall be secured with No. 8 x 15mm long, self tapping screws set in
the overlap at 75mm intervals, and shall be so arranged that staggered bands of
panelling encircle the equipment. Vertical overlaps shall not be screwed.
14.22 The metal protective finish shall be banded and sealed at 450mm centres ensuring that
one band is set over each vertical overlap.
14.23 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
50mm and secured with self tapping screws at 75mm centres. All overlaps shall be ball
swaged and be rendered water tight by the use of metal seam sealer between metal
overlaps.
14.24 Projections from the heads shall be sealed using metal flashings neatly cut to fit around

the projections and extending over the jacket for a minimum of 75mm. The seal
between flashing and jacket shall be weatherproofed with self tapping screws and seam
sealing mastics.
14.25 Insulation on bottom heads of fully skirted equipment does not require weatherproofing.
(See para. 14.11 re-temporary shop insulated covering).
14.26 Heads of equipment 550mm OD and smaller shall be finished and waterproofed with
square ended fabricated covers.
14.27 On shop insulated items at temporary shop supports, the insulating system shall be
terminated and sealed, and closure pieces shall be designed and fabricated to fit the
open positions. Designs of closure pieces shall take into account the insulating
requirements together with support and securement and the necessity of maintaining
waterproofing and weatherproofing after closures are in place. Design proposals shall
be approved by Contractor before fabrication of closures commences. Closure pieces
shall be fitted at site by the site appointed Insulation Applicator.

15. APPLICATION - TANKS
15.1 Method of installing insulation of tanks shall be similar to the vertical equipment
insulation with the following exceptions:
15.2 The lower 300mm (minimum) of the shell from foundation to top shall be insulated with
cellular glass and the remainder of the shell shall be insulated with mineral fibre blanket
or board type insulation. Cellular glass material shall in accordance with ASTM C552.
15.3 Vertical (pencil) rods used to secure the insulation and jacketing material shall be
installed by the tank fabricator. Bands used to secure insulation and weatherproofing
jacket shall be secure to vertical rods.
15.4 The insulation gaps over the pencil rods shall be completely filled with blanket type
insulation and a strip of weatherproofing jacket shall be installed over the insulation and
held in place with the screws spaced on 150mm centres on the adjacent insulation
weatherproofing. The minimum overlap of the strip on the adjacent jacket shall be
150mm on both vertical sides. Strips shall overlap each other a minimum of 150mm and
shall be arranged to shed water.
15.5 Only closed (crimp type) seals shall be used for bands. Wing type seals are not
allowed. The maximum distance between bands shall not exceed 300mm. Expansion
(breather) springs shall be provided with angle cleats bolted to the stainless steel bands
to allow for the thermal movements of the tank. The expansion spring spacing shall be
calculated based on operating conditions of each tank, but shall be a minimum of 2 per
band and/or every 9m maximum.
15.6 Shop fabricated tank insulation panels may be used subject to the Contractor/Company
approval. Details of the panels shall be submitted for Contractor and Company’s
approval prior to sue. If roof insulation is required the Applicator shall submit proposals
based on the size, shape and flex, operating temperature and roof stiffeners of each
tank requiring insulation to be agreed upon by Contractor.
16. INSPECTION AND TESTING
16.1 Quality Control

The Applicator shall have in place and maintain a Quality Assurance and Quality Control
system that meets the requirements of ISO9001 and is in accordance with Specification
DRP001- OUF-PRO-Q-000-003.
The Applicator shall submit to Contractor for approval, his proposed quality control and
testing procedures for all factory and/or field manufactured insulation
materials/components.
Tests to be undertaken shall include physical properties of all insulation materials.
The Inspection and Test Plan shall reference all test procedures, witness points,
acceptance/rejection criteria, frequency of testing and how control of quality is measured
and maintained.
Criteria for establishing the acceptability of lots or shipments of preformed insulation

shall be based on those for sampling and inspection within the framework of ASTM
C390 or an alternative test procedure approved by Contractor. Certification for other
tests shall be to the requirements of BS 2972.

Where appropriate, results shall be plotted on statistical control charts showing upper
and lower limits of acceptance.
Manufacturers of all materials shall supply test certificates indicating all test results of
the applicable tests required by this specification.
Certification of Ancillary and weather proof jacketing shall be EN 10204/10474 – 3.1 or

2.2 with Company approval.
16.2 Inspection
The Applicator shall advise Contractor and allow ample notice before commencing
specific insulation applications.
The Contractor’s Inspector shall be afforded all reasonable facilities for carrying out his
duties in verifying that the insulation is executed in accordance with the specified
requirements.
The Contractor’s Inspector shall have the right to inspect and test the insulation and
cladding at all stages, including any subsequent repairs; and to reject any and all tools,
instruments, materials, staging, equipment or work which does not conform to the
specification.
The acceptance or rejection of completed or partially completed insulation work is the

sole right of the Contractor or his authorised representative.
The Applicator shall be responsible for the repair of any minor defects or localised
replacement of insulation and cladding, where this becomes necessary in the course of
inspection by the Contractor.
Any defective or rejected insulation as identified by markings made by the Contractor’s

Inspector, shall be repaired or replaced by the Applicator in accordance with the repair
procedure given in Section 16.3.
Prior to final acceptance of completed work, a joint inspection shall be made by the
Applicator and Contractor and an agreed inspection report signed by both parties.
16.3 Repair of Defects or Damages

The proposed method and conditions under which repairs are carried out shall be
approved by Contractor’s Inspector before commencement.
In the case of minor defects, rectification shall generally be of a localised nature.
In the case of major defects, rectification shall involve more extensive removal and
replacement of the insulation system, at the discretion of Contractor’s Inspector.
Where the insulation and/or cladding has sustained damage attributable to the
Applicator, the affected areas shall be removed and replaced.
17. HANDLING, PRESERVATION AND STORAGE
17.1 Handling and Packaging

Insulation materials should be packed in properly constructed waterproof cartons or
crates to minimize mechanical damage and provide weather protection. Insulating

materials should not be unpacked from their containers until required for use at the job-
site. Packaging should be marked with type of material, size, thickness, quality and
quantity.
Packaging should allow for materials to be handled such that the risk of mechanical
damage is minimized. Stacking heights of material shall be limited to avoid crushing of
lower layers.
17.2 Storage
All forms of insulation must be kept dry and protected from damage and shall be stored
in dry weatherproof stores. Manufacture and storage methods used shall be adequate
to protect the insulation materials and accessories from degradation for at least 12
months.

18. FIGURES
Figure 1: PIPING (1 OF 4)




Figure 2: REMOVABLE COVERS (1 OF 3)



Figure 3: VERTICAL EQUIPMENT (1 OF 3)



Figure 4: HORIZONTAL EQUIPMENT (1 OF 3)



Figure 5: STIFFENER RINGS AND CONICAL SHAPES (1 OF 3)



Figure 6: BOLTED ON INSULATION SUPPORT COLLARS

Figure 7: PERSONNEL PROTECTION
Table : Stand-off Distance for Hot Surface
Pipe Size/Vessel Dia Minimum Standoff Distance (mm)
up to 8 inch 50
> 8 inch or flat surfaces 100
Figure 8: STEAM TRACING


Figure 9: PIPING SUPPORT DETAILS (1 OF 2)

Figure 9: PIPING SUPPORT DETAILS (2 OF 2)

Duqm Refinery Project EPC Package 2 - Utilities and Offsites

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Duqm Refinery Project

HOT SERVICE INSULATION

B1 14-Aug-2018 Class 1 IFD (Issued for Design) I.Ghosh S.Meguid V.Ciccotosto

O1 25-Jan-2018 Class 1 IFCR (Issued for Client Review) FK MR VC

Rev. Date Document Class Issue Purpose Author Checked Approved

Number Origin Document Number Rev.

Client’s Number DRP001-OUF-SPE-W-000-010

Amendment Revision Amender

INCORPORATION OF FEED AMENDMENT NOTES, EPC2

01-Jul-2018 A1 IG Incorporated Company Comments

14-Aug-2018 B1 IG Issued for Design

Document Number Document Name Description of Content

Section Number Short Description of Hold

Definitions and Abbreviations

DRP001-OUF-SPE-W-000-010 Page 2 of 52 Rev: B1

DRP001-OUF-SPE-W-000-010 Page 3 of 52 Rev: B1

1. Piping and Instrumentation Diagrams and Line Lists.

2. Piping General Arrangements and Isometrics.

3. Instrument Piping Details and Schedules.

4. Vessel and Exchanger Datasheets and/or Drawings and Insulation

5. Equipment Vendor’s General Arrangement Drawings for equipment items

DRP001-OUF-SPE-W-000-010 Page 4 of 52 Rev: B1

2.1 Project Specifications

DRP001-OUF-SPE-U-000-002 Project Design Data

DRP001-OUF-SPE-V-000-003 Pressure Vessel Standard Detail

DRP001- OUF-SPE-W-000-008 Painting of New Equipment and Piping

DRP001- OUF-SPE-W-000-011 Cold Service Insulation

DRP001- OUF-SPE-W-000-012 Acoustic Insulation

DRP001-OUF-SPE-Y-650-011 Pipeline Mechanical Basis of Design

DRP001-OUF-PRO-Q-000-003 Vendor Quality and Environmental

2.2 Codes & Standards

ASTM B209 Standard Specification for Aluminum and Aluminum-Alloy

ASTM C168 Standard Terminology Relating to Thermal Insulation

ASTM C390 Standard Practice for Sampling and Acceptance of Thermal

ASTM C450 Standard Practice for Fabrication of Thermal Insulating Fitting

ASTM C547 Standard Specification for Mineral Fiber Pipe Insulation

ASTM C552 Standard Specification for Cellular Glass Thermal Insulation

ASTM C553 Standard Specification for Mineral Fiber Blanket Thermal

ASTM C795 Standard Specification for Thermal Insulation for Use in

DRP001-OUF-SPE-W-000-010 Page 5 of 52 Rev: B1

ASTM C929 Standard Practice for Handling, Transporting, Shipping,

BS 476 Fire Tests on Building Materials and Structures

BS EN 485 Aluminium and aluminium alloys – Sheet, strip and plate

BS EN 10025 Hot Rolled Products of structural steels

BS EN 10088-2 Stainless steels Part 2: Technical delivery conditions for

BS 2972 Methods of Test for Inorganic Thermal Insulating Materials

BS 3958 – 4 & 5 Specifications for Thermal Insulation Materials

BS 4174 Specification for Self-tapping screws and metallic drive screws

ISO 9001 Quality Management Systems

Contractor Joint venture of Petrofac International LTD & Samsung

Vendor Supplier of equipment and support services for a particular

Applicator Entity that undertakes the insulation application in accordance

DRP001-OUF-SPE-W-000-010 Page 6 of 52 Rev: B1

 Ambient Temperature (winter monthly minimum mean): 12.3°C

 Wind Speed (average annual): 6.48 m/s

 Insulation finish emissivity: 0.1

 Minimum Insulation Thickness: 25mm

 Heat Flow Limit: 300 W/m2

 Ambient Temperature (summer monthly maximum mean): 43.8°C

 Maximum cold face surface temperature: 65°C

 Wind Speed (minimum monthly average): 2.97 m/s

 Insulation finish emissivity: 0.1

 Minimum Insulation Thickness: 25mm