Wasit Gas Plant Package #1

SK Engineering & Construction Co. Ltd.

Client : Saudi Aramco Document No. : HOTC-DOC-0031

.

METHOD STATEMENT FOR HOT INSULATION

OF
PIPING AND EQUIPMENT

(REV.2)

HSEM ------------- QCM -------

Sanjeev
2 30-Dec-13 For Approval B. Landicho SKEC CM SKEC PM
Kumar
1 21-AUG- 2013 For Approval D. SINGH NICHOLAS.J SKEC CM SKEC PM

0 12-JULY- 2013 For Reference D. SINGH VIJAYAN.P SKEC CM SKEC PM

REV. DATE STATUS Prepared by Checked by Reviewed by Approved by

 WASIT GAS
PROGRAM, INLET &
Method Statement for Hot Insulation Doc. No. : HOTC-DOC-0031

GAS PROCESSING
REV.NO 2
FACILITIES PROJECT
(WGC) for Package #1
(Piping and Equipment)
PAGE
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INDEX

No. Title Page

1.0 GENERAL 3
1.1 Scope
1.2 Requirements
1.3 Reference specification
1.4 Priority 4
2.0 MATERIALS 4
2.1 Insulation
2.2 Weather proofing
2.3 Storage
2.4 Material Data 5
3.0 SURFACE PREPARATION 6
4.0 HOT INSULATION 7
4.1 Identification of Insulation requirements
4.2 Hot Insulation for Equipment
4.2.1 Insulation Thickness
4.2.2 Application 7
4.3 Hot Insulation for Piping 9
4.3.1 Insulation Thickness
4.3.2 Application

5.0 Weather proofing (Metal Jacketing) 11

5.1.1 Hot Vessels and Equipment
5.2 Hot Piping
6.0 QUALITY CONTROL 13
6.1 Quality Control of Materials
6.2 Quality Control Before Applying Insulation
6.3 Quality Control During Insulation Application
6.4 Quality Control Before & During Weatherproofing
6.5 Quality Control Records
6.6 Repair Procedure 14
6.7 Quality Control Manager
6.8 Duties and Responsibilities of QC Supervisor/Inspector 15

7.0 SAFETY 15
7.1 Material Safety Data Sheets
7.2 Personal Protective Equipment
7.3 Working at Height

8.0 Attachment 15
A). JSA for Insulation activitiesB).
B) MSDS for Rockwool

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PROGRAM, INLET &
Method Statement for Hot Insulation Doc. No. : HOTC-DOC-0031

GAS PROCESSING
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(WGC) for Package #1
(Piping and Equipment)
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1 GENERAL

1.1 Scope:
This method statement covers the general requirements for materials and
application of external thermal insulation on the hot surfaces of piping and
equipment, for the Wasit cogeneration & Steam generation Project.

1.2 Requirements:
1. The external surface of equipment, piping and machinery shall be insulated to
conserve energy by reducing heat loss and to facilitate temperature and sound
control of process system.
2. Equipment and piping shall be insulated under the following conditions:
(a) Hot insulation: A surface temperature above 60oC.
(b) Personal Protection Insulation
3. Personnel protection shall be provided for operating equipment, piping and
machinery when the surface temperature is more than 60oC. On the condition
that the items to be protected are located in the area not exceeding 2.13 meters
above operating floor and not more than 0.91 meters away from the access
side and as instructed by site in-charge. For personnel protection at vertical
pipe, a watertight metallic termination cover shall be provided with tapered to
shed water.
4. Removable type insulation shall be used in areas where access for frequent
maintenance is necessary. The insulation shall be bonded to the removable
cover.
5. Insulation supports for straight vertical pipes shall be fixed above the bottom
elbow and for flanges/valves clearance at a distance of bolt length +25mm.
6. Contact with dissimilar material, which might cause galvanic corrosion, shall be
avoided.
7. Finished insulation and weatherproofing work shall be installed watertight and
shall remain watertight during operation.
8. Flange and manhole flanges shall not be insulated for equipments and lines in
Hydrocarbons Services.
9. Insulation thickness shall be made from thickness Tables in specified for job.

1.3 Reference Specification:

The following Specifications apply for the project with latest revision,

SAES-N-001 Basic Criteria Industrial Insulation.

PIP INIH1000 Hot Insulation Installation Details.
PIP INSH1000 Hot Service Insulation materials & Installation specification.
PIP INSH2000 Installation of Hot Service Insulation system
PIP INSR1000 Installation of Flexible, Removable / Reusable Insulation
covers for Hot Insulation Service.
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Method Statement for Hot Insulation Doc. No. : HOTC-DOC-0031

GAS PROCESSING
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(Piping and Equipment)
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Standard Drawing:-
SAES-N-0012 Insulation Details for Hot piping.
1.4 Priority:
Any conflict exist between the requirements of the listed specifications and related
codes, data sheets, drawings, requisitions, etc., it should immediately be brought to
the attention of the SKEC/ Saudi Aramco and an acceptable solution must be
reached.

Wherever a difference exists between the method statement & specification the
specification shall govern. However, no deviations shall be made from the
specification without written authorisation from the Saudi Aramco.

2 MATERIALS
1. All materials to be used in this project shall be approved by Saudi Aramco. Pre
qualification documents shall be submitted to Saudi Aramco for approval prior to use.
2. All materials to be used in this project should be in accordance with the project
specifications. Hertel-OTC’s Quality Inspector, SKEC and Saudi Aramco nominated
representative should carry out an inspection and approve all materials before any job is
carried out for the project.
3. All insulation materials and accessories used for this project shall be delivered to site
and Hertel shall ensure that all materials are protected from being damaged prior to
installation.
4. Only the materials that shall be used in a given workday shall be stored in the
immediate work area. All materials shall be stored at locations designated by SKEC.
5. Insulation that becomes wet shall be removed and replaced with dry insulation.
6. Wet insulation shall be discarded.

2.1 Insulation:
All Insulation materials for Hot Insulation shall be in accordance with section 2.4 of this
method statement.
.
2.2 Weatherproofing:
1. All Weatherproofing materials for “Hot Insulation” shall be in accordance with section 2.4
of this method statement.
2. All ancillary materials shall be in accordance with section 2.4 of this method statement.
3. All materials to be used in this project shall be approved by the client prior to start of
application.

2.3 Storage and Handling of Insulation Materials:

1. Storage of material shall be in accordance with the requirements of the project
specification. All materials shall be stored in a way that it is protected from exposure to
weather e.g. rain, dust, etc. All material shall also be protected from getting wet and
getting in contact with chemicals and other flammable substances during storage.

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GAS PROCESSING
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(Piping and Equipment)
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2. From delivery to the installed finished product, insulation materials shall at all times
be protected from the elements and have adequate drainage.

3. Insulation materials shall be handled and stored in accordance with the

manufacturer’s printed recommendations.

4. Mastics, adhesives, and sealers that are exposed to temperatures outside the
recommended temperature ranges during storage shall be removed from the site and
replaced with new material.

5. Materials that have exceeded shelf life shall be removed from the site and replaced
with new material.

2.4 MATERIAL DATA

Hot Insulation Material Minimum Requirements:

No: Material Specs. Material Type

1. Pipe Insulation (up to 3” Dia) Rock wool pipe section
ASTM - C547 Nominal Density 100 kg/m3

2. Pipe and Equipment Insulation Rock wool Blankets or Slabs/ Boards

ASTM –C592/C612 Nominal Density 100 kg/m3

3. A). Metal Jacketing Flat aluminium jacketing with moisture barrier

(0.5mm thick <= 6”NPS Alloy 3003 with H14 temper ASTM B209
0.6mm thick >6” up to 20” NPS
0.8mm thick >20” NPS)

B). Stainless steel jacketing shall be used for Fire hazardous areas.

Note: Materials to complete the above specifications will be from one of the following locations:
1. Mineral wool – GCC / Asia /UK
2. Aluminum Sheet – GCC / Asia
3. Ancillaries – USA / Europe / Asia

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Method Statement for Hot Insulation Doc. No. : HOTC-DOC-0031

GAS PROCESSING
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(Piping and Equipment)
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FASTENER & ACCESSORY SCHEDULE FOR HOT INSULATION

Insulatio Insulation Weatherproofing
n
Insulated items Max Max
Outside Fasteners/seals Springs Fasteners Springs
Diameter Spacing Spacing

All
13X0.5 mm
sizes
≤ 300 mm 1.29 mm dia Band and
300 mm N/A 300 mm None
NPS O.D SS304 Wire Wing Seal
(SS304)

13X0.5 mm
>300 mm 13X0.5 mm Band and
≤600 mm All
Band and Wing 300 mm N/A Wing Seal 300 mm None
NPS/Equipment sizes
O.D Seal (SS304) (SS304)

19X0.5 mm
>600 mm 19 x 0.5 mm
All Band and As
NPS/Equipment Bands / wing 300 mm N/A 300 mm Applicable
O.D sizes Wing Seal
type seal
(SS304)
SS 304 Screws
8X13 MM
with Neoprene All size N/A N/A N/A 150 mm N/A
Washers (SS304)

All Pin / speed fix

Duct 300mm -- -- -- --
sizes washers
SS304304
Flanges / All As
- - - Pop Rivet / N/A
Valves sizes Applicable
Toggle

 Silicon Sealant:
S.No Joint Sealant Purpose
1 Foster 95-44 (Silicone Weatherproofing sealant for cladding joints
Sealant)

3 SURFACE PREPARATION
1. All equipment, vessels, and piping shall have been tested and inspected as required by
the relevant specification prior to the installation of insulation.
2. Prior to starting any task a release document will be issued by SKEC to Hertelotc. Hertel
Quality Controls Inspector together with the SKEC and Saudi Aramco nominated
representative will check the area or surfaces where Insulation is to be applied and
appropriate inspection document will be signed.
3. SKEC will identify the areas to be insulated by issuing work release document with
applicable drawings.
4. Insulation materials and application shall be in accordance with the project specification.
All surfaces to be released for insulation shall be dry, clean and free from rust, loose mill
scale, grease and dirt.
5. Insulation material shall be dry on installation and shall be kept free from moisture
during and after installation.

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Method Statement for Hot Insulation Doc. No. : HOTC-DOC-0031

GAS PROCESSING
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(WGC) for Package #1
(Piping and Equipment)
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4. HOT INSULATION
4.1 Identification of Insulation Requirements:
1. All application of insulation system shall be in accordance with the Saudi Aramco’s
specification and recommendation.
2. The type and extent of insulation requirements shall be identified in the applicable
equipment and isometric drawings.
3. Personnel protection insulation is specified for surfaces which normally operates
continuously at temperature in excess of 60C but don’t require that heat loss be
limited. Unless otherwise specified, insulation shall be applied only to that portion of
the surface subject to contact by an operator in the normal performance of his duties
– up to 2.13 Meter above finished grade or platforms and within 0.91 meter
horizontally of normal operating locations.
4. Mineral Wool Pipe Cover shall be used for piping size up to 3”, for pipe sizes over 3”
and for equipment Mineral Wool Blanket shall be used unless otherwise specified.
5. On manholes and hand holes, extent of insulation shall be as follows:-
For Hot Equipment, manholes and hand holes shall be thoroughly insulated with
removable covers.

4.2 Hot Insulation for Equipment

4.2.1 Equipment Insulation Thickness:

Insulation thickness shall be as indicated on 4.1 site insulation work list for
equipment/isometric drawing.

4.2.2 Application
1. The following shall not be insulated for Hot insulation unless otherwise specified:
 Pipe supports and guides
 Inside of skirts on skirt supported towers and vessels 750mm and
less in diameter
 Channel covers operating below 93 0C
 Shell and tube heat exchanger flanges
 Steam traps and the outlet side of steam trap piping
 Spectacle blinds
 Drain and vent piping on insulated equipment down stream of the
first block valve
 Nameplates
 Untraced branches from traced lines downstream of the first block
valve
2. Insulation on the inside and the outside of support skirt for vertical vessels shall
be equal to the shell insulation thickness.
3. For equipment operating below 400 0C, insulation of the skirt shall extend at least
a minimum of four times the shell’s insulation thickness.

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(Piping and Equipment)
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4. On equipment operating above 400 0C, the insulation of skirt shall be 600 mm
below tangent line, and to the top of the fireproofing if the skirt is fireproofed.
5. Insulation material for hot equipment shall be mineral fibre blanket. All materials
approval will be obtained from client prior to the start of the project and the same
materials shall be used. However, if any change is required, then the appropriate
approval will be obtained as necessary.
6. The insulation on the shell of equipment below 24 inches shall be secured in
place with 13 mm wide 0.5mm thick stainless steel band and seals at a maximum
spacing of 300 mm centres unless otherwise noted in the drawings.
7. The insulation on the equipment 24 inches and over shall be secured in place
with 19mm wide 0.5mm thick stainless steel band and seals at a maximum
spacing of 300 mm unless otherwise noted in the drawings.
8. When metal band exceeds 9.1 m between securement points, one breather
spring should be provided to accommodate expansion and contraction of the
shell.
9. The mineral wool with density 100 kg/m3 shall be used blanket for shell of Vertical
equipment and block for top head of vertical equipment/.
10. Banding of insulation over the heads of equipment shall be as follows: A floating
ring, large enough to clear the centre nozzle, if there is any, shall be made from 6
mm diameter carbon steel round bar or from 6 pieces of inter twisted gage #16
SS wire. This ring shall be placed on the centre of the head. A girth ring, made
from 2 bands shall be installed on the shell at approximately 150 mm from the
tangent line of the head. Bands shall run radially from the floating ring to the girth
ring. The radial bands shall be spaced 300 mm maximum centres on the girth
ring.
11. On vertical vessels, which are, skirt supported, the bands on the bottom head
shall be attached to the inside skirt support angle or blank nuts.
12. Stiffener rings shall be insulated with the 50 mm thickness as the same shell
insulation materials from the outer exposed surface of the stiffener ring.
13. Installed insulation shall have the required permanent protection or temporary
protection applied before the conclusion of work on that day.
14. Installed insulation shall have temporary protection applied if rain or other forms
of atmospheric moisture can damage the insulation during each work shift.
15. Insulation thicknesses 3-1/2 inch (90mm) and greater shall be applied in
multilayers with staggered joints. Consideration shall be given to multilayer
insulation for operation temperatures over 600oF (316oC)
16. Each layer of double layer or multi-layer insulation shall be held in place
separately, i.e., all layers should be separately secured by using stainless steel
wires or bands.
17. All insulation shall be smooth and free from cracks, voids, gaps and depressions
greater than 1/8in. (3mm). All cracks, voids, gaps and depressions in the
insulation greater than 1/8in. (3mm) shall be refitted not filled.
18. Removable insulation plugs shall be provided to permit on-stream ultrasonic
inspection when required by the operating proponent. Plugs shall be vapour
tight, ultra violet resistant and be such that they can be opened and reclosed
without disturbing the adjacent insulation.
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Method Statement for Hot Insulation Doc. No. : HOTC-DOC-0031

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(Piping and Equipment)
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19. Wicking or fibrous type insulation shall not be used on tanks and vessels
handling hydrocarbon liquids with the operating temperature above 93 oC where
spillage or leakage onto the insulation is likely to occur. Cellular glass insulation
shall be used on Tanks and vessels which is impermeable material accordance
with ASTM E-96.

4.3 Hot Insulation for Piping:

4.3.1 Piping Insulation Thickness:

1. Insulation thickness shall be as indicated on the Piping isometric drawing and
Lines list.
2. For hot and personnel protection insulation thickness shall be determined by
using the 4.1 Site Insulation work list
3. Insulation materials and accessories shall be in accordance with section 2.4 of
this method statement.

4.3.2 Application:

1. Pipe shall be insulated with mineral wool pipe section a cover for less than and
equal to 3” NPS and mineral wool blanket a cover for greater than 3” NPS Dia.
2. Pipe Insulation having outside diameter of less than 12” (300 mm) shall be
secured with stainless Steel wire, pipe insulation having outside diameter of 12”
(300 mm) up to 600 mm insulation O.D. shall be secured with 13 mm stainless
steel bands and seals and pipe insulation over 600 mm O.D. shall be secured
with 19 mm stainless steel bands and seals. The maximum spacing between
bands or wires shall not exceed 300 mm.
3. The circumferential joints on straight piping shall be staggered by a minimum of
approximately 150 mm
4. The circumferential and longitudinal joints in the second and succeeding layer of
multiple layered piping shall be staggered by approximately 150 mm from the
joints of the preceding layer.
5. On long vertical piping runs, clamped insulation supports shall be furnished and
installed in accordance with the requirements.
6. Expansion joint spacing shall be in accordance with specification. Expansion
joints shall be packed tightly with fibreglass loose fill insulation.
7. Insulation adjoining insulated pipe, flanges and valves shall be bevelled down
and terminated at a suitable distance from the flange to allow easy removal of
nuts and stud bolts. The minimum distance shall be equal to the length of the bolt
plus 25mm.
8. Insulation termination shall be provided with a metal flashing collar (end cap).
9. All exposed insulation shall be weather proofed metal with mastic.
10. Flanges and valves shall be insulated only in a piping system insulated to
conserve energy. Where there is a need for access for frequent maintenance, the
insulation shall be of the removable types. Allowance must be made for the
removal of flange bolts without disturbing the fixed insulation and permanent
vapour barrier. Packing glands shall be left exposed.
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(Piping and Equipment)
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11. For hydrogen service or where heat conservation insulation is not required for
flanges, a sheet metal shroud should be installed over flanges for personnel
protection. Spectacle blinds shall be left visible for easy accessibility and not
totally enclosed by insulation boxes.
12. If insulation is to be applied over certain austenitic alloy steel (300-series
stainless steel) where the operating temperature is between 40oC to maximum
services temperature, it is recommended to apply a stress corrosion barrier or
specially formulated paint before the application of insulation to prevent stress
corrosion cracking and pitting as per SAES-L-133 Para 7.2.5.

All Materials are qualified for use on austenitic stainless steel in accordance with
ASTM C795. Test reports to be provided for following tests.

a) ASTM C692 Standard test method evaluate the influence of thermal

insulations on external stress corrosion cracking tendency of austenitic. This
chemical analysis shall not vary by more than 50% from the chemical
analysis of the production lot tested.

b) ASTM C871, Standard test methods for chemical analysis of thermal

insulation material for leachable chloride, fluoride, silicate and sodium ions.
This chemical analysis shall not vary by more than 50% from the chemical
analysis of the production lot tested in accordance with ASTM C692.

13. If aluminium jacketing is provided on lines with an operating temperature

exceeding 400oC (750oF) stainless steel jacketing shall be used at points of
contact with insulated surface.

PIPE ELBOWS
1. Pipe elbows shall be insulated with mineral wool pipe sections cut at job site into
shape to fit the elbow.
2. Insulation elbows whose outside diameter is less than 300 mm shall be secured
with 1.3mm (#16) stainless steel wires. Elbows whose outside diameter is equal
to or greater than 300mm to 600mm shall be secured in place with at least 13mm
wide stainless steel bands and seals and insulation outside diameter greater than
610mm shall be secured in place with at least 19mm wide stainless steel bands
and seals.
PIPE SUPPORTS
1. Where the pipe is supported by spring hangers and hanger rods the pipe shall be
fully insulated, weatherproofed and placed in preformed cradle before being
supported.

MACHINERY
1. Rotating machinery such as pumps shall be insulated with removable metal box
that will allow removal without damaging the insulation in case of maintenance or
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shutdown.
2. Insulation shall be attached in the fabricated metal box and not on equipment.

Nozzles, Man-ways

1. Nozzles, man-ways, clean out holes, hand holes, and inspection holes, etc. shall
be insulated in accordance with attachment (PIP INIH0055)
2. Top nozzles on vertical vessels shall be insulated in accordance with attachment
(PIP INIH0055, 060)
Man-ways and side nozzles on vertical vessels shall be insulated in accordance
with attachment (PIP INIH060)

Piping
1. Secure single layer of insulation with 13mm wide x 0.5mm thick stainless steel
bands on 300 mm maximum centres.
2 Insulation support rings shall be installed for vertical run at every 6.4 meters of
Un-interrupted vertical piping.
3. Pipefittings, including valve bodies shall be insulated with prefabricated fitting
covers or mitred sectional pipe insulation securely taped or banded in place.

5 WEATHERPROOFING (METAL JACKETING)

5.1 Hot Vessels and Equipment

1. Metal jacketing for vessels equipment shall be in accordance with Spec.
2. All external surfaces of insulation, both indoors and outdoors, shall be provided
with weather protection.
3. Metal jacketing overlaps shall be arranged to shed water. Caulking compound
shall be applied at all possible sources of moisture penetration.
4. Circumferential overlap at the top tangent lines, transitions and stiffeners shall be
a minimum of 150 mm. All other circumferential overlap shall be at 75mm.
5. For vertical vessels and equipment, s-clips should be used to keep the jacket
sheets from sliding down. The length of the s-clip shall equal the overlap. They
shall be spaced at 600 mm centres maximum.
6. The strapping system for the insulation jacketing to be fastened to insulated shell
shall consist of 19 mm wide 0.5mm thick band held together with breather
springs, when required, and closed seals.
7. Breather springs shall be provided for all vessels in cyclic service and on all
vessels over 2.4 meters in diameter. At least 1 breather spring shall be installed
for every 9.1 metres length of banding strap.
8. Jacketing shall be secured with 19mm wide stainless steel banding spaced at
300 mm maximum centres. A band shall be installed over circumferential overlap
on horizontal vessels.
9. For vertical vessels, one strapping assembly shall be located on each
circumferential overlap, which shall pass through the s-clip. All other strapping
assembly shall be held in place by j-clips, fastened to the jacket with screws or
rivets, to prevent them from sliding down. The j-clips shall be spaced on 1.5
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meters maximum centres but not less than 4 per each strapping assembly. When
tensioning the strapping assembly, each breather spring unit, when required,
shall be expanded a total of 25% of its normal length.
10. Rain shields shall be installed at all protrusions and nozzles projecting upwards.
11. Metal flashing shall be installed at the bottom of insulation support of insulated
shells of vessels and equipment.
12. Longitudinal joints shall have the outer portion facing downwards to allow for
draining rainwater as per PIP INIH-1000.
13. Sheet metal screws with washers if required shall be installed on longitudinal
joints at 150mm centres to hold down jacketing. Metal screws shall not be
installed on circumferential laps.
14. Exposed edges of metal jacketing shall be machine bent or rolled to eliminate
sharp edges.

5.2 Hot Piping

1. All external surfaces of insulation, both indoors and outdoors, shall be provided
with weather protection. The metal jacketing to be used shall be as follows:

 All pipe insulation is to be protected with Aluminium smooth sheet as

per ASTM B209, alloy 3003-H14, of 0.5mm thickness up to 6” NPS,
0.6mm thickness from 6” to 20” NPS and 0.8mm thickness for greater
than 20” NPS, in accordance with Aramco Standard.

 Metal jacket circumferential and longitudinal sections shall be

overlapped a minimum of 50 mm arranged to shed water.

2. All longitudinal overlap shall be located at 4 o’clock or 8 o’clock position to shed

rainwater. Longitudinal overlap shall not be staggered.
3. Watertight metallic termination cover shall be installed where pipe insulation
terminates. Overlap of the cover over adjacent metal jacket shall be secured with
screws with washer installed on 150 mm centres.
4. At each overlap of metal sheets on horizontal pipe, the overlap must have
sealant to prevent water ingress into the insulation system. Also, flashing or
caulking compound shall be applied at all other possible sources of moisture
penetration.
5. On vertical pipes, “S” – clips on maximum 300mm centres, shall support upper
courses.
6. Removable Type cladding flange cover and Valve boxes shall be installed.

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QUALITY CONTROL
6.1 Quality Control of Materials
1. Only materials approved by the project owner shall be used on site.
2. If certain materials are not obtainable then the insulation contractor has the right
to recommend suitable alternatives and to propose suitable thickness and
methods of installation for the proposed alternative materials.
3. Verify materials received at site are the same as the specified or approved
materials. Such check shall include verification of labels, material safety data
sheets, delivery receipts and thickness. Unspecified, unapproved and damaged
insulation materials and accessories shall be removed from site.
4. Ensure that storage of materials will protect them from being damaged by
moisture, wind or any other atmospheric factors.
5. Ensure that insulation is dry, clean and fit for its purpose before weatherproofing
is applied.
6.2 Quality Control Before Applying Insulation
Prior to release for insulation, Ensure that the following had been checked as
required:
(a) Verify that pressure test have been completed
(b) Verify that painting of equipment; piping and protrusions have been
completed, if required.
(c) Verify surface to be insulated is dry, clean and free from dust, dirt, etc.
6.3 Quality Control During Insulation Application
1. Make sufficient check to verify that the materials being applied are the same as
the specified or approved materials.
2. Verify the insulated items, insulation code (applied versus the insulation code on
the isometric drawings), thickness and weatherproofing.
3. Verify that the insulation surface is uniform without gaps and voids.
4. Inspect tightness of joints and fasteners.
5. Inspect the location of bands.
6. Verify that the insulation on the expansion joints are properly installed.
7. Verify that insulation segments are properly staggered.
6.4 Quality Control Before and During Weatherproofing
1. Verify that the insulation is completely dry and free from gaps.
2. Inspect for proper overlap of metal flashing.
3. Verify the application of sealant at the circumferential overlaps of metal jacketing
on horizontal pipe and equipment.
4. Verify the location of bands, screws, s-clips, j-clips and breather springs are as
specified.
5. Final inspection shall be performed to check that no defects are existing. Defects
listed below shall be the cause of rejection.

 Concave and / or convex jacketing.

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 Torn jacketing
 Interstices and / or separation of jacketing
 Imperfection of water proof on cut out. (no caulking on cut out of
jacketing)

6.5 Quality control Records

Saudi Aramco Typical Inspection Plan (SATIP-N-001-02) and applicable SAIC-N-
2004, 2005, 2014, 2015, 2016 and 2017. Shall be followed for inspection Records.
For final inspection and mechanical completion SATR-A-2011 shall be used.

6.6 Repair Procedure

Any damage area insulation and cladding will be removed by cutting and clean the
Surface area dusting with cotton rags and reinstall with new insulation material, tie
with steel wire by lacing between joints, secure with banding belt with seals if
required for additional securement.

Fabricate new cladding materials for the cut out area with proper edge grooved
and fix with SS screw as per the distance mentioned in specification waterproof
method to be applied for cladding installation with enough overlap joints and apply
sealant in all cut out cladding joints to prevent water and moisture entry in to
cladded area.

6.7 Quality Control Manager (QCM) Responsibilities and authorities

Has the responsibility for the proper execution of the following;

- Report directly to the SKEC QC Manager

- Prepare the Quality Management System
- Conduct internal audits.
- Administer non-conformities and corrective actions.
- Check all procedures established by site staff
- Review, approve, issue and control specific Project Quality Control
Plans.
- Manage submission of QA documents to Samsung and represent the
company on quality matters towards the customer.
- Collect and evaluate Q.C. procedures provided by subcontractors
- Prepares a Testing Plan and ensure that all tests according to contract
are carried out.
- Check materials submission against specifications
- Assist in the preparation of technical submissions.
- Assist in the evaluation of suppliers and subcontractors

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 WASIT GAS
PROGRAM, INLET &
Method Statement for Hot Insulation Doc. No. : HOTC-DOC-0031

GAS PROCESSING
REV.NO 2
FACILITIES PROJECT
(WGC) for Package #1
(Piping and Equipment)
PAGE
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6.8 Duties and Responsibilities of QC Supervisor/QC Inspector:
- Report directly to QC Manager
- Over seeing through spot and routine inspection that the work under
execution complies with contract specification requirement, method
statements, approved drawings and that the site is utilizing material approved
by the Saudi Aramco. Deviations and non-conformities are reported to Quality Control
Manager for further action.
- Ensure that the set quality control procedures are adhered to, implemented
and perform training to employee in field where deficiencies are observed.
- Ensure that all equipments are properly working and calibrated.
- Receive material for permanent work and obtain Saudi Aramco approval for received
material.
- Assist site personnel in understanding and implementation of quality procedure set for
the project.
- Any other duty assigned by the Quality Control Manager.

7.0 SAFETY

7.1 Material Safety Data Sheets:

1. Preventive measure and precautions shall be implemented to reduce personal
exposure to hazardous dust and fibres.
2. All materials used on site shall be provided for with the material safety data
sheets, which will indicate the manufacturer’s recommendation for the safe use of
materials.
7.2 Personal Protective Equipment:
All personnel working with insulation shall wear the following personal protective
equipment as a minimum requirement:
(a) Safety coverall or long sleeved clothing
(b) Safety boots
(c) Hardhats or Helmets with chin straps (for working at heights)
(d) Dust Mask
(e) Safety glass with side shields
(f) Safety Goggles for overhead works
(g) Hand Gloves (leather palmed gloves or cotton gloves with rubber palm)
(h) Ear plugs (for noisy areas)
7.3 Working at Heights:
When work over 1.8 meters is required and no other means of fall protection is
provided the worker must wear a full body harness with double lanyard and
ensure 100% tie – up.
8.0 Attachments
A) Job safety analysis for Insulation activities
B) MSDS for Rockwool

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