Piping Insulation Practise

8/19/2019 Piping Insulation Practise

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TENDER FOR ANNUAL RATE CONTRACT FOR HOT & COLD INSULATION AND

REFRACTORY LINING & COATING WRAPPING OF UNDER-GROUND PIPING.

Documents consist o t!e o""o#in$% -

1. Letter inviting tender.

2. Tender form.

3. Definition of terms.

4. Scope of work with detailed material specifications for hot & cold insulation !"# $!ol%"rethane #oam' (% )nSitu method and spra% insulation on drive tur(ine casing of

compressor as per *nne+ure)

,. Scope of work with detailed material specifications for refractor% lining as per

*nne+ure )

-. Scope of work with detailed material specifications for coating & wrapping of piping as

per *nne+ure )

. Schedule of rates as per *nne+ure ))

/. 0eneral terms & conditions.

NOTE%

1. T )S"L*T) ot )nsulation will (e done with L56 $Lightl% 5esin 6ond'

5ock #i(res 7attress with 8ire 7esh 7achine stitched on one side with Densit% of 129

:g;73. ot )nsulation of 6oiler essel Tank ?himne%


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DEFINITIONS OF TERS

)n the contract documents herein defined where the conte+t so admits the following words and

e+pression will have the meanings assigned to them respectivel%

1. CThe wnerC means the ational #ertiliEers Ltd. incorporated in )ndia. having its

registered office at S?!< ?7!L


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Anne/ue - I

HOT & COLD INSULATION

SCOPE OF WOR0

)t includes (ut not limited to the following

1.1 Suppl% of complete raw material re=uired for 7aintenance of ot & ?old )nsulation

including Transportation Loading unloading etc. Strictl% in accordance with detailed

specifications of materials and Jo( specification.

1.2 5emoval of ot & ?old )nsulation strictl% as per instructions of essels


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2.2. The material should (e relativel% free from shot content $unfinished material' which

should not e+ceed 19K (% weight when sieved through )S sieve $Spec. )S 4-91A-2' of

,99 microns. o shot shall (e larger than ,mm in siEe $*s per )S 3-1A--'

2.2./ Sulphur content should not e+ceed .-K $)S 3-1A--'

2.2.A 8ater a(sorption should not e+ceed 2K (% weight $)S 3-1A--'

2.2.19 ?hloride content shall (e limited to 3, ppm.

2.2.11 The material shall (e chemicall% inert rot and vermin proof and shall not cause corrosion

when applied to steel surfaces under conditions of limiting operating temperatures.

2.2.12 The a(ove properties should (e tested as per )S 31441A-, 7ethod of Test for 7ineral

8ool;L56 Thermal >isulating properties.

2.2.13 The mineral wool fi(res shall (e made into mattresses prefera(l% machine stitched at the

factor% itself and should retain their form under ordinar% handling conditions. The

metal facing used for (acking the (lankets should consists of the specified galvaniEed

iron wire netting. #or use on piping upto 12G dia the (lanket should (e (acked on onl%

one side with wire netting where as for piping a(ove 12C dia and for vessels and

e=uipment the (lanket should (e (acked on (oth sides with wire netting. #or dou(le and

multi la%er insulation the second and the su(se=uent la%er (lankets should have onl% one

side wire netting.

2.3.9 ANCILLARY ATERIALS%2.3.1 WIRE NETTING4 LACING AND STITCHING WIRE%

8ire netting shall (e galvaniEed 29mm chicken mesh and not less then 29 S80 as

metal facing for the mineral wool fi(res e+cept in case of machine stitched mineral wool

mattresses where 3;4 + 21 S80 0) wire netting shall (e accepta(le. Lacing & stitching

wire shall (e 29;19 S80 0L wire respectivel%.

2.3.2 2ANDS%

6ands for securing insulation material on Large >essel and


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2.-.9 SEALANTS AND ASTICS

2.-.1 onconductive hard setting content to *ST7?1A49 or other e=uivalent standard.

2.-.2 6itumeniEed roofing felt to )S 13221A9 T%pe2 0r)

2.-.3 7astic Sealer to (e given (% ?ontractor to withstand a temperature of -99o ? $7in'

2.-.4 *luminium foil 9.1 mm thick

2.-., 8eather !roofing 7astic shall (e (itumeniEed as(estos insulkote or e=uivalent.

2..9 REO7AL AND APPLICATION%

The insulation areas to (e removed will (e shown (% the


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TA2LE-I

9RECOENDED THIC0NESS IN FOR INERAL WOOL INSULATION:

Pi5e )i'

Tem5e'tue in De$ee Ce"sius

U5to

;<

;,

to,8<

,8,

to8<

8,

to38<

38,

to68<

68,

to88<

88,

to=8<

=8,

to>8<

>8,

to?8<

I II III I7 7 7I 7II 7III I@

,&,

96< mm:

2, 2, 2, 49 ,9 -, , 199 12,

B-3B

98


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COLD INSULATION

3.1.9 The )nsulation thickness for piping e=uipment etc. shall (e calculated (ased on normal

operating temperature and shall (e got approved (% the


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3.4.2 INSULATION THCI0NESS AND LIITS%

)nsulation thickness shall (e in accordance with the attached Ta(les) & )). The

thickness limits of the applied insulation shall (e ,K to 29K. )nsulation thickness

e+cludes the additional thickness resulting from outside finish and >apour 6arrier.

7ultila%er construction can (e used for an insulation thickness ,9 mm and a(ove or

where operating temperature is 49o ? and (elow. There shall (e no through Boints. *

guide line for multi la%er insulation is given in the Ta(le )))*.

3.4.3 7APOUR 2ARRIER%

* vapour (arrier meant to prevent moisture penetration into the insulation shall (e

applied over the insulation as per the following steps

a' ne coat of (itumen emulsion $2., mm thick when dr%' shall (e applied on the

pol%st%rene half sections;sla(s.

(' 0lass fa(ric or 5.!. tissue shall (e applied with minimum overlap of ,9 mm over

the first coat of (itumen emulsion when the later not full% dried.

c' *n other coat of (itumen emulsion $1.,mm thick when dried' shall (e applied

over the glass fa(ric.

3.4.4. 7APOUR 2ARRIER & WEATHER PROTECTION%

a. !roviding ot 6lown 6itumen /,;2, M 1., :g;72

(. 8rapping #i(re 0lass or 5.!. Tissues. c. !roviding ot 6lown 6itumen /,;2, 1., :g;72

d. !roviding one la%er 0.). wire netting 29mm F 24 0

e. !roviding one la%er of 6itumen


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TA2LE-,A

?old )nsulation of >essels and


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4.9.9 TEST CERTIFICATE%

The ?ontractor have to su(mit test certificate for the material used from recogniEed

La(oratories whenever these are asked (%


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,.2.4 Steam traced and nonsteam traced pipelines shall (e normall% specified and measured

separatel%. Steamtraced pipelines with single or multiple tracers shall also (e normall%

specified and measured separatel% according to the num(er of traces.

,.2., *nticorrosive painting or wrapping with aluminium foil over stainless steel;allo% steel

piping and e=uivalent prior to application of insulation shall (e measured separatel%.

,.2.- )nsulation of )nstruments shall (e measured separatel% and length covered (% such

instruments which are not a+ial with the pipe line shall not (e considered in the

measurement of the connected piping insulation.

,.3.9 )nsulation of steam tracing line is to (e carried out in following steps

i' Steam traced line should (e tied to the pipe with the help of SS 29 gauge lacing

wire.

ii' !roviding *luminium foil over the steam traced line.

iii' !roviding lagging over *luminium foil after providing wire netting on (oth side

of wool (lanket.

iv' !roviding *luminium sheeting over the Lagging.

REFRACTORY LINING

-.9.9 SCOPE OF WOR0 -.1.9 6oiler Steam Super eater Start up eater eat


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.1.4 *llowa(le wastage for refractor% concrete;mortar;(ricks and casta(le should not (e more

than 3K

.1., 8henever casta(le are used the surface should (e painted with (itumastic paint or

covered with paper which will (urn out during operation for creating gap for e+pansion

(etween casta(le refractor% and the surface.

.1.- The installation of material in the reactor should (e so perfect that ).D. of lining shall (e

uniform level and centre should (e maintained.

.1. Specific procedure for carr%ing out each Bo( will (e given to the contractor (efore hand

(%


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A.9 COLD INSULATION WITH POLYURETHANE FOA 9PUF: 2Y IN-SITU

ETHOD

SCOPE o WOR0%

A.1 The ?ontractor will arrange all Tools & Tackles #oam Spra% 7achine alongwith

au+iliaries Scaffolding 7aterial and ?onsuma(le re=uired for the e+ecution of 8ork.

A.2 ?ontractor should (e a(le to mo(iliEe the sufficient manpower during the short otice.

A.3 The ?ontractor shall adhere to all safe working practices as per #actories *ct during the

e+ecution of Bo(. #L is ?hemical #actor% and contractor will educate his workers

a(out the dangers in the !lant and not smoke in NO SO0ING AREA. 7oreover

the Bo( will (e e+ecuted during Shutdown proper care has to (e taken to avoid an%

*ccident in the (us% area.

A.4 7easurement of the )nsulation work will (e taken on the #inish Surface as per the

relevant )S.

A., ?ontractor must ensure his 8orkers should (e provided with a Safet% elmet and Safet%

6elt while working at Site.

A.- The ?ontractor will arrange all the skilled;semiskilled manpower and supervisor re=uired

for e+ecution of work.A. The work ma% (e re=uired to carr% out on round the clock (asis as per re=uirement of the

Bo(;plant or as directed (% essels;Tower & !iping containing fluids or

vapours which is necessar% to

a' 7aintain low temperature for process control.

(' *void surface condensation and fire proofing.

19.2 *ll application of spra% insulation shall (e made in accordance with this specifications

detailed in the tender document. The contractor shall su(mit with his proposal the

following information

a' The Test ?ertificate of material offered as descri(ed.

(' The C:C value curve chart alongwith the literature and name of supplier;

service of procurement.c' The design calculations for Thickness & heat gain etc.

,3


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19.3 PROTECTION OF ATERIAL DURING STORAGE%

)nsulation materials must (e protected against an% damage from deliver% to finish

coating;cladding !ol%urethane chemicals shall (e stored in a flat surface in a horiEontal

position. )nsulation material shall never (e stocked directl% on the ground.

19.4 PROTECTION OF PARTIALLY COPLETED 1O2S%

*ll precautions shall (e taken to ensure that each da%Is work is vapour sealed as weather

proofed during erection and (efore (eing left over night to prevent seepage of water into

the material and getting trapped. The s%stem shall (e protected (% Tarpaulin water shed

and other protective means.

19., HYDROSTATIC TEST%

)nsulation shall (e applied on Tower after successful completion of h%drostatic test all

welded and mechanical Boints shall (e left e+posed for testing and su(se=uentl%

insulated after successful completion of h%drostatic test. prior approval of