Sample Specification for Insulation

October 1997

SAMPLE

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COMMERCIAL USE

Process Industry PracticesInsulation

PIP INSH2000Installation of Hot Service

Insulation Systems

1/8/97 INEG1000Draft 3 Insulation Design and Type Codes

Process Industry Practices Page 2 of 10

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice hasbeen prepared from the technical requirements in the existing standards of majorindustrial users, contractors, or standards organizations. By harmonizing these technicalrequirements into a single set of Practices, administrative, application, and engineeringcosts to both the purchaser and the manufacturer should be reduced. While this Practiceis expected to incorporate the majority of requirements of most users, individualapplications may involve requirements that will be appended to and take precedenceover this Practice. Determinations concerning fitness for purpose and particular mattersor application of the Practice to particular project or engineering situations should notbe made solely on information contained in these materials. The use of trade namesfrom time to time should not be viewed as an expression of preference but ratherrecognized as normal usage in the trade. Other brands having the same specificationsare equally correct and may be substituted for those named. All practices or guidelinesare intended to be consistent with applicable laws and regulations including OSHArequirements. To the extent these practices or guidelines should conflict with OSHA orother applicable laws or regulations, such laws or regulations must be followed.Consult an appropriate professional before applying or acting on any materialcontained in or suggested by the Practice.

©Process Industry Practices (PIP), Construction Industry Institute, TheUniversity of Texas at Austin, 3208 Red River Street, Suite 300, Austin,Texas 78705. PIP member companies may copy this practice for theirinternal use.

Not printed with state funds.

October 1997


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Process Industry PracticesInsulation

PIP INSH2000Installation of Hot Service

Insulation Systems

Table of Contents

1. Introduction..................................21.1 Purpose ............................................. 21.2 Scope................................................. 21.3 Insulation Systems ............................ 21.4 Supporting Documents ...................... 2

2. References ...................................22.1 Process Industry Practices (PIP)....... 22.2 Industry Code and Standards............ 2

3. Definitions ....................................3

4. Storage and Handling ofInsulation Materials .....................3

5. Application of Insulation .............35.1 General .............................................. 35.2 Securement ....................................... 45.3 Metal Jacketing.................................. 45.4 Screws ............................................... 55.5 Expansion Bands............................... 55.6 Insulation Expansion Joints ............... 65.7 Supports for Vertical Piping ............... 65.8 Fitting, Flange and Valve Insulation .. 65.9 Mastic (PVA or Acrylic) Weather-

proofing.............................................. 6

5.10 Protection of Installed Insulation........ 7

5.11 Damage Considerations .................... 75.12 General Housekeeping...................... 7

6. Extent of Insulation ..................... 8

7. Documentation ............................ 8

Data Sheets

INSH2001 Extent of InsulationINSH2002 Documentation Requirements

PIP INSH2000October 1997 Installation of Hot Service Insulation Systems


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1. Introduction

1.1 Purpose

The purpose of this Practice is to provide requirements for installation of hot serviceinsulation systems, ambient to 1200°F (649°C).

1.2 Scope

This Practice covers requirements for storage and handling of insulation materials,application of insulation, extent of insulation, and documentation.

1.3 Insulation Systems

Systems requiring additional insulation specifications beyond PIP Practices shall becovered by Purchaser’s documentation.

1.4 Supporting Documents

Use of this Practice for contractual purposes requires the Purchaser make specificchoices and assemble additional supporting documents. Listing of or reference tosupporting documents within this Practice does not imply suitability for specificdesigns.

2. References

When adopted in this specification or in the contract document, the latest edition of thefollowing codes, standards, specifications and references in effect on the date of contractaward shall be used, except as otherwise specified. Short titles will be used herein whenappropriate.

2.1 Process Industry Practices (PIP)

– PIP INSH2001 - Extent of Insulation

– PIP INSH2002 - Documentation Requirements

2.2 Industry Code and Standards

• American Society of Testing and Materials (ASTM)

– ASTM C450 - Standard Practice for Prefabrication and Field Fabrication ofThermal Insulating Fitting Covers for NPS Piping, Vessel Lagging andDished Head Segments

• American Petroleum Institute (API)

– API 521 - Guide for Pressure-Relieving and Depressuring Systems



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3. Definitions

For the purposes of this Practice, the following definitions apply:

Contractor: Party responsible for furnishing and/or installing the insulation system

Owner: Principal end user

Purchaser: Owner or the owner’s authorized agent

4. Storage and Handling of Insulation Materials

4.1 From delivery to installed finished product, insulation materials shall at all times beprotected from the elements and have adequate drainage.

4.2 Insulation materials shall be handled and stored per manufacturer’s printedrecommendations.

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

4.4 Materials with expired shelf life and dates shall be removed from the site andreplaced with new material.

5. Application of Insulation

5.1 General

5.1.1 All materials shall be stored, mixed, thinned, and applied in accordance withthe manufacturer’s printed instructions. All conflicts between thisspecification and the manufacturer’s instructions shall be brought to theattention of the Purchaser for resolution.

5.1.2 Authorization to proceed with application of insulation shall be obtained inwriting from the Purchaser.

5.1.3 Unless otherwise specified, insulation shall not be applied until completionof the following has been verified:

a. Required hydrostatic and/or pneumatic pressure testing

b. Application of required substrate protective coating systems, includingtouch-up of previously applied coatings

c. Installation and testing of required tracing systems

d. Cleaning of surfaces that are to receive insulation

5.1.4 If required by the Purchaser, application of insulation may proceed beforepressure testing is complete, provided that all welds and flanged and threadedconnections are left exposed until the pressure testing is complete.Temporary terminations of installed insulation shall be adequately protectedat all times.



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5.1.5 Where insulation has been specified on piping or equipment flanges that areto be hot bolted, the insulation shall not be installed until hot bolting has beenaccomplished and the flange determined to be leak-free.

5.1.6 Unless otherwise specified, all insulation materials shall be installed in asingle layer when the total thickness does not exceed 3 in. (75 mm).

5.1.7 When applying single layer insulation, other then hinged pipe covering, thecircumferential butt joints of each half section shall be staggered.

5.1.8 Thicknesses 3-1/2 in. (90 mm) and greater shall be applied in multi-layerswith staggered joints. Consideration shall be given to multi-layer insulationfor operating temperatures over 600°F (316°C).

5.1.9 When applying double or multi-layer insulation, each succeeding layer shallbe staggered to the longitudinal and circumferential joint of the layerbeneath. All joints of all layers shall be staggered.

5.1.10 Each layer of double layer or multi-layer insulation shall be held in placeseparately.

5.1.11 All insulation shall be smooth and free from cracks, voids, gaps anddepressions greater than 1/8 in. (3 mm). All cracks, voids, gaps anddepressions in the insulation greater than 1/8 in. (3 mm) shall be refitted notfilled.

5.2 Securement

5.2.1 Insulation up to 12 in. (300 mm) outside diameter (O.D.) shall be held inplace with 16 gauge Type 304 stainless steel tie wire, except cellular glassand polyisocyanurate foam insulation, which may be held in place withfiberglass reinforced pressure-sensitive tape or stainless steel tie wiresapplied over the tape.

5.2.2 Insulation 12 in. (300 mm) O.D. to 24 in. (610 mm) O.D. shall be held inplace with 1/2 in. (13 mm) wide by 0.020 in. (0.51 mm) thick Type 304stainless steel bands and wing seals. Above 24 in. (610 mm) O.D., use 3/4in. (19 mm) wide by 0.020 in. (0.51 mm) thick bands and wing seals.

5.2.3 Metal jacketing 12 in. (300 mm) O.D. to 24 in. (610 mm) O.D. shall be heldin place with 1/2 in. (13 mm) wide by 0.020 in. (0.51 mm) thick Type 304stainless steel bands and wing seals. Above 24 in. (610 mm) O.D., use 3/4in. (19 mm) wide by 0.020 in. (0.51 mm) thick bands and wing seals.

5.2.4 All cut ends of wire shall be embedded into the insulation.

5.3 Metal Jacketing

5.3.1 Metal jacketing on vertical equipment 48 in. (1219 mm) and larger indiameter shall be aluminum sheets, 0.024 in. (0.61 mm) thick with 1-1/4 in.(32 mm) pitch corrugations, measuring approximately 33 to 48 in. (838 to1219 mm) wide by 10 ft (3 m) long. The length of corrugated jacketing maybe modified to minimize waste and cutting.

5.3.2 Metal jacketing on horizontal equipment 48 in. (1219 mm) and larger indiameter shall be aluminum 0.024 in. (0.61 mm) thick. Finish shall be



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specified by purchaser, (i.e., smooth, corrugated, cross-crimped, embossed,coated, etc.)

5.3.3 Metal jacketing on all vessels, and piping, less than 48 in. (1219 mm) indiameter shall be aluminum, 0.016 in. (0.406 mm) thick and machine-rolledfor circumferential fit. Finish shall be specified by the Purchaser, (i.e., smooth,corrugated, crossed crimped, embossed, coated, etc.).

5.3.4 Vessel head segments, fittings, valves, etc., shall be fabricated from smoothmetal.

5.3.5 Stainless steel jacketing 0.010 in. (0.254 mm) or zinc-aluminum alloy coatedsteel 0.016 in. (0.406 mm) thick shall be used on equipment and piping whenfire protection is required, to comply with API 521.

5.3.6 When aluminum jacket is used on lines with an operating temperatureexceeding 750°F (400°C), 0.010 in. (0.254 mm) thick stainless steel shall beused at points of contact.

5.3.7 Exposed edges of metal jacketing shall be machine-bent or rolled toeliminate sharp edges.

5.4 Screws

Screws shall be self-drilling No. 8 by 1/2 in. (13 mm) stainless steel, withelastromeric washer. Heads may be hex, Phillips recessed round, round, or hex-slotted or pan type.

5.5 Expansion Bands

Banding on vessels over 8 ft (2.4 m) in diameter shall have 4 in. (100 mm) stainlesssteel springs. Springs shall be located every 30 ft (9.1 m) of band length. Each springshall be installed and loaded in accordance with the manufacturer’s printedinstructions. Expansion springs on external jacketing shall be compression type.



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5.6 Insulation Expansion Joints

5.6.1 Insulation expansion joints for rigid insulation materials shall be installed inuninterrupted straight pipe insulation, spaced at the following intervals:

Pipe MaximumOperating Temperature

Insulation ExpansionJoint Spacing, Maximum

°F (°C) Feet (meters)

200 (93) 60 (18.2)

400 (204) 30 (9.1)

500 (260) 12 (3.6)

700 (370) 9 (2.7)

Above 700 (>370) 6 (1.8)

5.6.2 Insulation expansion joints shall be a minimum of 1 in. (25 mm) wide,packed tightly with mineral fiber blanket insulation compressed a minimumof 50%.

5.6.3 Insulation expansion joints shall be installed in all layers of multiple layerinsulation. Joints shall be staggered between layers.

5.6.4 Insulation expansion joints shall also be installed below insulation supportclips or rings on equipment and piping

5.7 Supports for Vertical Piping

Vertical pipe insulation shall be supported by a pipe insulation support locateddirectly above all elbows, flanges or flanged valves. Additional supports are requiredat a maximum of every 21 ft 1 in. (6425 mm) of uninterrupted length.

5.8 Fitting, Flange and Valve Insulation

5.8.1 Molded insulation fittings shall be used when commercially available.

5.8.2 Insulation for all fittings shall be fitted and assembled with tight joints.Cementing of prefabricated assemblies shall be done with fabricatingcement.

5.8.3 Insulation for fittings, flanges and valves shall be fabricated in accordancewith ASTM C450 and the Adjunct. Pre-fabricated items may be used in lieuof field fabricated items.

5.9 Mastic (PVA or Acrylic) Weatherproofing

5.9.1 On flat, larger curved and irregular insulation surfaces, when masticweatherproofing is specified, the surface shall be covered with a tack coat ofmastic sufficient to embed reinforcing. The reinforcing shall be overlapped aminimum of 2 in. (50 mm). An application of insulation finishing cementmay be required to obtain adhesion on fibrous materials.

5.9.2 The weatherproofing mastic shall then be installed in accordance with themanufacturer’s printed instructions over the reinforcing, pressing it through



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the mesh to obtain a good bond. Care shall be taken to completely fill andseal the mesh openings.

5.9.3 The combined thickness of the weatherproofing mastic and reinforcing shallbe in accordance with the manufacturer’s recommendation.

5.9.4 Mastic weatherproofing shall overlap adjoining metal surfaces to provide aweather-tight joint.

5.10 Protection of Installed Insulation

5.10.1 Insulation systems must be caulked and/or sealed at all possible points ofmoisture entry. Do not feather edge of caulk.

5.10.2 Installed insulation shall have the required permanent protection ortemporary protection applied before the conclusion of that day’s work.

5.10.3 Installed insulation shall have temporary protection applied if the insulationcan be damaged by rain or other forms of atmospheric moisture.

5.11 Damage Considerations

5.11.1 Unless otherwise specified, insulation that becomes wet shall be removedand replaced with dry insulation, and the wet insulation shall be discarded.

5.11.2 Damaged insulation shall be replaced if the nature of the damage willadversely affect the thermal performance of the system. Any disputesregarding the need for replacement of insulation shall be referred to thePurchaser for resolution.

5.12 General Housekeeping

5.12.1 Insulation materials shall be handled and disposed of in accordance withapplicable federal, state, and local laws and regulations.

5.12.2 Insulation-related materials, such as mastics, shall be handled and appliedwith care to prevent splattering on adjacent facilities, such as concretefoundations, paving, structural steel, equipment, piping, gauge glasses,instruments, machined surfaces, valve stems, and packing.

5.12.3 All mastic over-spray and splatter shall be cleaned up as soon as it occurs.

5.12.4 Flammable materials shall be stored away from ignition sources such aswelding operations.

5.12.5 Debris resulting from insulation application work shall be removed from thework area on a regular basis and placed in containers at the end of the workday.



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6. Extent of Insulation

For extent of insulation see Data Sheet PIP INSH2001.

7. Documentation

Documents required to define the scope of the work shall be listed on Data Sheet PIPINSH2002.

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Installation of Hot ServiceInsulation Systems

Data Sheet for Extent of Insulation

PIPINSH2001

PAGE 1 OF 2JAN 97

PROJECT _________________________________________ DATE ___________________________

INSULATION REQUIREMENTS FOR PIPING AND EQUIPMENT(Note: Project piping and equipment insulation specifications may modify these requirements.)

INSULATION CODES: HC - Heat ConservationPS - Process StabilityET - Electric TracedST - Steam Traced

SJ - Steam JacketedHT - Hot Fluid TracedHJ - Hot Fluid Jacketed

PF - Prevention From FreezingPP - Personnel ProtectionFP - Fire Protection Insulation

ITEMS HC [1]AMB - 1200°°°°F

(649°°°°C)

PSAMB - 1200°°°°F

(649°°°°C)

ET, ST, SJ,HT, HJ, & PF

FP(As Required bythe Purchaser)

Straight or bent pipe, socketweld, threaded or buttweld pipefittings.

Socketweld, threaded or buttweld valves.YES YES YES

Pipe unions NO [4] NO [4] NO [2]Steam traps, related strainers NO [4] NO [4] NO [2]Flanged pipe fittings, flanged valves (excluding relief and

control valves), flange orifice sets, piping flanges connectedto equipment nozzles and flanged special items (i.e.strainers)

YES [5] NO [2, 5] YES [5]

Primary piping for instrument connections, sample piping,vent and drain piping. NO NO YES

Expansion or rotation joints, slide valves, etc. NO [4] NO [4] YES [5]Instruments and associated tube NO NO YESRelief valves NO NO NOControl valves NO [2, 5] NO [2, 5] YES [5]Tee and inline strainers NO [2, 5] NO [2, 5] YES [5]Vessels, shell and head surfaces YES [4] YES [4] YESVessel handholes NO [2, 5] NO [2, 5] N/AVessel manways NO [2, 5] NO [2, 5] N/AVessel instrument trim NO NO YESShell and tube heat exchangers, excluding flanged joints

YES YES N/AHeat exchanger flanged joints NO [2, 5] NO [2, 5] N/APump casings NO [2, 5] NO [2, 5] YES [5]

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Data Sheet for Extent of Insulation

PIP INSH2001PAGE 2 OF 2

JAN 97

PROJECT _________________________________________ DATE ___________________________

INSULATION REQUIREMENTS FOR PIPING AND EQUIPMENT(Note: Project piping and equipment insulation specifications may modify these requirements.)

INSULATION CODES: HC - Heat ConservationPS - Process StabilityET - Electric TracedST - Steam Traced

SJ - Steam JacketedHT - Hot Fluid TracedHJ - Hot Fluid Jacketed

PF - Prevention From FreezingPP - Personnel ProtectionFP - Fire Protection Insulation

ITEMS HC [1]AMB - 1200°°°°F

(649°°°°C)

PSAMB - 1200°°°°F

(649°°°°C)

ET, ST, SJ,HT, HJ, & PF

FP(As Required bythe Purchaser)

Steam turbines YES [3] [5] N/ACompressors [5] NO [2] N/ABlowers, fans [5] YES [4] N/AInternally insulated items NO [4] NO [4] N/A[1] Economics of insulating these items will vary dependent on climate, fuel cost, labor and material cost, and cost of money.[2] Insulate or guard only where required for personal protection.[3] Insulation shall be furnished by the equipment supplier.[4] Provide removable metal guards or suitable personnel barriers where required for personnel protection.[5] Removable/reusable covers should be considered.

Personnel Protection (PP) shall be provided to 7 feet (2.13 meters) above grade or platforms and 3 feet (0.91 meters) horizontally from the peripheryof platforms, walkways, or ladders.

Comments:

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Data Sheet forDocumentation Requirements

PIP INSH2002

PAGE 1 OF 3JAN 97

PROJECT _________________________________________ DATE ___________________________

NUMBER TITLE REV DATE NOTES

INEG1000 Insulation and Type CodesINGG1000 Document Use GuidelinesINSH1000 Requirements for Hot Service Insulation MaterialsINSH2000 Installation of Hot Service Insulation SystemsINSH2001 Extent of Insulation Data Sheet

SELECTED INSULATION THICKNESS TABLESINEG1001 YES ! NO ! Thickness of Calcium Silicate

Insulation for HCINEG1002 YES ! NO ! Thickness of Calcium Silicate

Insulation for PPINEG1003 YES ! NO ! Thickness of Calcium Silicate

Insulation - Combined TableINEG1004 YES ! NO ! Thickness of Cellular Glass Insulation

for HCINEG1005 YES ! NO ! Thickness of Cellular Glass Insulation

for PPINEG1006 YES ! NO ! Thickness of Cellular Glass Insulation

- Combined TableINEG1007 YES ! NO ! Thickness of Fiberglass Insulation for

HCINEG1008 YES ! NO ! Thickness of Fiberglass Insulation for

PPINEG1009 YES ! NO ! Thickness of Fiberglass Insulation -

Combined TableINEG1010 YES ! NO ! Thickness of Mineral Wool Fiber

Insulation for HCINEG1011 YES ! NO ! Thickness of Mineral Wool Fiber

Insulation for PPINEG1012 YES ! NO ! Thickness of Mineral Wool Fiber

Insulation - Combined TableINEG1013 YES ! NO ! Thickness of Expanded Perlite

Insulation for HCINEG1014 YES ! NO ! Thickness of Expanded Perlite

Insulation for PPINEG1015 YES ! NO ! Thickness of Expanded Perlite

Insulation - Combined TableINEG1016 YES ! NO ! Thickness of Polyisocyanurate

Insulation for HCINEG1017 YES ! NO ! Thickness of Polyisocyanurate

Insulation for PP

HOT INSULATION INSTALLATION DETAILSINIH0001 YES ! NO ! Piping - General ArrangementINIH0002 YES ! NO ! Piping - Layered InsulationINIH0003 YES ! NO ! Piping - Vertical Insulation Support

Single LayerINIH0004 YES ! NO ! Piping - Vertical Insulation Support

Multi-LayerINIH0006 YES ! NO ! Piping - Flange InsulationINIH0007 YES ! NO ! Piping - Insulation ConnectionsINIH0008 YES ! NO ! Piping - Expansion Joint

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PIP INSH2002

PAGE 2 OF 3JAN 97

PROJECT____________________________________________________ DATE______________________


INIH0009 YES ! NO ! Removable and Reusable Insulation -Flexible

INIH0010 YES ! NO ! Valve CoverINIH0011 YES ! NO ! Pipe SupportsINIH0012 YES ! NO ! Hanger Rod Rain ShieldINIH0013 YES ! NO ! Spacer Blocks for Typical Tracer

ArrangementsINIH0050 YES ! NO ! Vertical Vessels with Outside

Diameters over 36" (915)INIH0051 YES ! NO ! Vertical Vessels with Outside

Diameters 36" (915) and LessINIH0052 YES ! NO ! Vessel Composite Type 1INIH0053 YES ! NO ! Vessel Composite Type 2INIH0054 YES ! NO ! Vertical Vessel Bottom Head InsulationINIH0055 YES ! NO ! Top/Horizontal Head NozzlesINIH0056 YES ! NO ! Vessel Stiffener Insulation DetailINIH0057 YES ! NO ! Insulated Manhole CoverINIH0058 YES ! NO ! Rigid, Removable and Reusable

Insulated Manhole CoverINIH0059 YES ! NO ! Typical Clip DetailsINIH0060 YES ! NO ! Nozzle FlashingINIH0061 YES ! NO ! Lap Seam DetailsINIH0062 YES ! NO ! Horizontal VesselsINIH0063 YES ! NO ! Application of Metal Gores on

Horizontal Vessel HeadsINIH0064 YES ! NO ! Horizontal Heat Exchangers

SELECTED MATERIALS SYSTEM DATA SHEETSINSH1001 YES ! NO ! Hot Service Insulation System for

Project Specific RequirementsINSH1002 YES ! NO ! Calcium Silicate Insulation System for

Pipe and EquipmentINSH1003 YES ! NO ! Expanded Perlite Insulation System

for Pipe and EquipmentINSH1004 YES ! NO ! Mineral Wool Performed Pipe

Sections Insulation SystemINSH1005 YES ! NO ! Mineral Wool Board Insulation System

for EquipmentINSH1006 YES ! NO ! Mineral Wool Blanket Insulation

System for Pipe and EquipmentINSH1007 YES ! NO ! Glass Fiber Performed Pipe Sections

Insulation SystemINSH1008 YES ! NO ! Glass Fiber Block and Board

Insulation SystemINSH1009 YES ! NO ! Glass Fiber Blanket Insulation SystemINSH1010 YES ! NO ! Cellular Glass Block and Fabricated

Sections Insulation System

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PIP INSH2002

PAGE 3 OF 3JAN 97

PROJECT____________________________________________________ DATE______________________


INSH1011 YES ! NO ! Polyisocyanurate Insulation SystemINSH1012 YES ! NO ! Ceramic Fiber Blanket Insulation

SystemINSH1013 YES ! NO ! Glass Fiber Needled Blanket

Insulation SystemOTHER