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INSULATION OF PIPING AND EQUIPMENT

SCOPE
This procedure covers the requirements for materials and application of thermal
insulation and weather proofing to piping and equipments specified at CUI Programme
release for assessment and mitigation.
SAFETY CONSIDERATIONS
1. Insulators shall meet the safety coordinator for general safety guidelines before
commencing any insulation activity.
2. Insulators shall take appropriate preventive measures and precautions to reduce
personal exposure to mineral fiber dust and crystalline silica. Such measures and
precautions shall include at least the following:

Approved dust musk (8210) or respirator with filter shall be worn.


Goggles or safety glasses shall be worn.
Impervious coveralls, safety shoes and gloves (knitted rubber gloves) shall be
worn.
Saws to cut insulation shall be fine cut type.
All cutting operation shall be in restricted and ventilated area.
In case of dust generation, do not dry sweep the floor. Always wet the floor before
sweeping.

3. Insulators are responsible to train their assistants and helpers in proper material
handling, fabrication and use of insulation materials.
REQUIREMENTS:
1. Insulation Removal or Delagging

Cladding and insulation shall be removed on specified piping and equipment that
was confirmed with Technologist and Operation(with approval via e-mail).
Care must be taken on removal of cladding and insulation for possible re-use (fillup insulation cladding delagged form).
Delagged section of equipment and piping must be reported immediately to
inspection team for inspection and assessment thru inspection request and letter of
transmittal.

Delagging should extend if deemed necessary or if required by inspector, if


insulation was wet from contaminants or the metal surface are visible for
accumulation of corrosion, provided that it is within the acceptable range as
mentioned by Technologist.

2. Reinsulation

Painting works or necessary corrective actions or mitigation is pre-requisite to


reinsulation. Painting Inspection Report must be properly signed-off prior to
reinsulation.
Sections to be reinsulated shall be clean, free form oil, grease, dirt, moisture and
other contaminants.
Insulation shall not be applied if it has been removed from storage wet.
If insulation cannot be dried, it should be replaced.
Preformed mineral wool insulation shall be installed tightly together in a
staggered joint arrangement.

3. Cladding Installation

Metal cladding shall be overlapped 50mm minimum at all seams (see Fig.1),
arranged to completely shed water, and preferably located on the bottom side on
the horizontal pipe (see Fig 2.). Joints shall be staggered 100mm between
sections (see Fig 3.). The edges of the aluminum cladding at the overlapped
should be furrowed or crimped with a 15mm radius bead. (see Fig 4).
50mm Circumferencial
Overlap

Furrowed Edge
50mm Longhitudinal
Overlap

Figure 1

45.00

45.00

50mm Longhitudinal
Overlap
Zones indicating prefered
position of circumferential
overlap

Figure 2

Figure 1.
Metal cladding overlap

50mm Circumferencial
Overlap

Furrowed Edge
50mm Longhitudinal
Overlap

Figure 1

45.00

45.00

50mm Longhitudinal
Overlap
Zones indicating prefered
position of circumferential
overlap

Figure 2

Figure 2.
Zones indicating preferred position of
circumferential overlap

15mm radius bead

50mm Overlap

Figure 4

Staggered Joints

Figure 3

Figure 3.
Staggered Joint Arrangement

15mm radius bead

50mm Overlap

Figure 4

Staggered Joints

Figure 3

Figure 4.

Furrowed or Crimped Edge with 15 mm Radius Bead

Should the insulation and cladding be terminated near flanges on vertical pipes,
end cap should be installed on top termination with sealant on end cap
circumference touching pipe while end flushing should be installed on lower
termination with no sealant at all points. End cap will also be installed on
horizontal pipe termination with sealant on cladding touching pipe (see Fig. 5).

Endcap
Sealant

Sealant

Endcap

Vertical pipe w/ Endcap

Horizontal pipe w/ Endcap

Endcap
Figure 5.

Cladding should be fastened with screws 150mm on centers along the


longitudinal seams. The cladding shall be secured with bands or steel strap
installed at 300mm on centers.
Gaps in cladding shall not be present in the intersection of the branch and header
on tees and stub-ones. Claddings, over-laps and seams shall be arranged in such a
way to avoid moisture penetration into the insulation.
Cladding over vertical pipes shall be supported on by 50mm long S-clip made out
of band or strap. The clips shall be equally spaced with one clip at the overlap.
The minimum number of S-clips shall be 2 for pipe size smaller or equal to NPS 6
and 4 for pipe size greater than NPS 6.
Flashing compound or sealant shall be applied at all source of moisture
penetration.

4. Safety Insulation

After completion of mitigation on pipe with insulation safety, mineral wool


insulation will not be reinstalled but will be replaced with galvanized or stainless
steel wire netting (see Fig. 6).
Distance between pipe surface and wire netting will depend on nominal pipe
diameter and pipe operating temperature (see Table 1).

Gusset Plate 30x3mm


Steel Ring 30x3mm

500 to 1000mm

Galvanized wire or
Stainless steel wire netting

number of gusset plates;


One per 100mm circumference,
but minimum 4 numbers

Figure 6.
Wire Mess Guard Detail
Table 1.
Recommended Distance Between Perforated Metal Sheet/Guards and Bare Surface

And Insulation Thickness for Personnel Protection


Nominal Operating Temperature ( C )
70 to 250

>
250

350

Nominal
Pipe
Diameter

400

450

500

600

Insulation Thickness

( DN )

Distance fr sht / grd to bare metal surface


( mm )

< 25
25
40
50
80
100
150
200
250
300
350
400
450
500

50
50
50
50
50
50
50
50
50
100
100
100
100
100

Equipment Channels/Flat Surfaces

( mm )
25
25
25
25
30
30
30
30
30
30
30
30
30
40

30
30
30
40
40
40
40
40
40
40
40
40
40
40

40
40
40
40
40
50
50
50
50
50
50
50
50
50

40
40
50
50
50
50
60
60
60
60
70
70
70
70

50
50
60
60
60
70
70
80
80
80
80
80
80
80

60
60
70
70
80
80
80
80
100
100
100
100
100
100

40

40

50

70

80

100

QUALITY CONTROL AND INSPECTION


The insulation system shall be inspected during the following stages.

At the time of material receipts.


Before installation of the insulation
During installation of insulation.
Before and during installation of cladding.

1. Quality control activities shall include at least the following activities at the time of
receipt of the materials.

Appropriate checks to verify materials received at the site are same as the
specified or approved materials. Such checks shall include verification of labels,
material safety data sheets, delivery receipts, and thicknesses. If unspecified or
unapproved insulation, weatherproofing, and accessories are located at the site,
such materials must be removed from the site.
Warehousing of materials to assure product dryness and life.

2. Quality control activities shall include at least the following prior to insulation
application:

A determination whether the pipe or equipment to be insulated is heat treated. If it


is heat treated, inform all insulators that welding of insulation supports is strictly
prohibited.
Verify that pressure test on portion of pipe to be insulated has been completed.
Verify that surface cleaning has been performed, as required.
Verify that all Painting and Coating has been completed.
Verify the protective coatings or barriers over stainless steel surfaces to prevent
external stress corrosion cracking have been applied.

3. Quality control activities shall include at least the following during insulation
application:

Appropriate checks to verify materials applied are the same as the specified or
approved materials.
Verify product temperature limit against the operating temperature of the insulated
item, insulation code (applied versus the insulation code on the PEFS), thickness,
and weatherproofing.
Check for insulation supports (location, type, width, and length as applicable)
Verify installation of insulation to ensure that surface is continuous without gaps
or voids.
Verify tightness of joints and fasteners.
Verify location, width, and installation of expansion joints.

4. Quality control activities shall include at least the following prior to and during
weatherproofing:

Verify that insulation is dry, prior to application of weatherproofing.


Check for proper overlaps and flashing in weatherproofing.
Check for proper location of bands, screws, S-clips, J-clips, and breather springs.
Verify that weatherproofing at cut outs, protrusions, and locations where moisture
could enter the insulation has been properly installed.

The insulator is solely responsible for all quality control activities and documentation. If
the insulator is unable to conform to this specification, he shall inform inspector for
resolution.