Insulation Systems for Hot Equipment 60 to 648 °C (140 to 1200 °F)

Insulation Systems for Hot Equipment 60 to 648 °C (140 to 1200 °F) (No Exposure to Water)

1. SCOPE………………………………………………………………………………..2. REFERENCES
3. GENERAL
4. MATERIALS …………………………………………………………………………5. CYLINDRICAL EQUIPMENT INSULATION PREPARATION
5.1 General
5.2 Guidelines for Insulation Supports ……………………………………..6. INSULATION APPLICATION
7. FINISH APPLICATION
FIGURE
1 Angle Iron Support Detail ………………………………………………………2 Vertical Tank on Foundation – Flat Bottom
3 Vertical Tanks – Top Head Flat, Conical, or Dished
4 Cylindrical Equipment – Single Layer ……………………………………….4A. Horizontal
4B. Vertical
5 Vertical Cylindrical Equipment – Leg Supported from Shell…………6 Vertical Cylindrical Equipment with Skirt Support
7 Vertical Equipment – Flanged
7A. Upper Head and Body Flanges ……………………………………7B. Lower Dished Head Where Straight Tangent is Bolt
Length Plus 25 mm or More
7C. Lower Dished Head Where Straight Tangent is Less Than
Bolt Length Plus 25 mm
8 Alternate Insulation Method……………………………………………………9 Block Pattern for Cylindrical Equipment – Inner Layer of Double
Layer Using 915 mm Long Blocks
10 Block Pattern for Cylindrical Equipment – Single Layer or Outer
Layer of Double Layer Using 915 mm Long Blocks
11 Horizontal Cylindrical Equipment – Double Layer……………………….
12 Deep Corrugated Metal Sheeting
13 Vertical Cylindrical Equipment – Leg Supported from Head or
Lug Supported
14 Beveled End Cap Application………………………………………………….15 Vertical Tank – Conical or Sloped Bottom
16 Use of Corner Angles
TABLE
I
Insulation and Finish Combinations …………………………………………
II Equipment Finish Systems
III Fasteners, Wire, or Bands for Insulation
IV Bands and Spacing for Metal Jacket……………………………………….

1. Scope
This standard describes the materials for and the application of thermal insulation systems for hot
equipment in the temperature range 60 to 648 °C (140 to 1200 °F).
2. References
Reference is made in this standard to the following documents. The latest issues, amendments, and
supplements to these documents shall apply unless otherwise indicated.
SABIC Engineering Standards (SES)
N01-F01 Insulation for Hot Equipment 60 to 648 °C (140 to 1200 °F) (Potential Water Exposure)
N01-F21 Beveled End Cap Fabrication
N01-F30 Cutting and Roll Forming Insulation Jacket
N01-F39 Insulation Anchor Details
N01-S01 Material Specification – Code Index
N01-S06 Insulation – Materials and Thickness
N01-S11 Insulation – Preformed Blocks
N01-S14 Insulation – Fluid and Plastic
N01-S15 Insulation – Coatings and Coverings
N01-S16 Insulation – Fasteners and Miscellaneous Items
N01-S19 Insulation – Adhesives and Sealers
American Society for Testing and Materials (ASTM)
E 84 Surface Burning Characteristics of Building Materials
3. General
3.1 The insulation systems in this standard are for indoor use where they are not exposed to an external
source of water. See SES N01-F01 for insulation in potential water exposure service.
3.2 Tables I and II list the insulation and finish materials in the combinations acceptable as the minimum
essential for normal conditions. Abnormal conditions require individual consideration.
3.3 Installations shall meet flame-spread rating limitations specified in ASTM E 84. A flame-spread rating
of 75 is the maximum installed rating for any combination of insulation and finish specified, except for FRP
and RTP finishes listed in Table II.
3.4 Thickness of insulation materials shall be stated in inches. See SES N01-S06.
3.5 Designation of materials and their application for a particular installation can be indicated by
identifying the work with a standard number, the insulation code, the insulation thickness in inches, and the
finish system numbers. (Example: N01-F02/102-2/C2/H50).
3.6 Preinsulated equipment shall not be stored outdoors without taking adequate precautions to prevent
moisture from entering the system.
3.6.1 Caution: When preinsulated items are stored outdoors, they shall be placed on supports of sufficient
height to keep them above flooding during rain. If preinsulated items are submerged, insulation on
austenitic stainless steel can lose its inhibitor. Severe corrosion can occur under the insulation on carbon
steel.
3.6.2 If a project delay appears likely, in-progress insulation work shall be checked to make sure that the
points of possible moisture penetration are adequately sealed before work is halted.
3.7 Insulation materials shall be handled as specified in manufacturer’s recommended safety procedures.
3.8 Insulation shall not be applied until equipment has been protected in conformance with the paint
specification.
3.9 Finish or jacket shall not be applied over wet insulation. Wet insulation shall be removed and replaced
with dry material.

3.10 Preengineered, preinsulated panel insulation systems shall be used when they suit the physical
shape, meet the thermal requirements of the equipment to be installed, and are economically justified.
4. Materials
4.1 Materials and temperature ranges are to be in accordance with applicable SES. See SES N01-S01.
4.2 Preformed Block and Pipe Insulation: SES N01-S11.
CODE DESIGNATION
102
Calcium silicate (Protects aluminum, austenitic stainless steel and carbon steel)
102.2 Perlite silicate – inhibited – water resistant
4.3 Fluid and Plastic Insulation: SES N01-S14.
CODE DESIGNATION
508
Heat transfer cement – water soluble (Protects aluminum, austenitic stainless
steel and carbon steel)
509
Heat transfer cement – waterproof
510
Heat transfer cement – nonhardening
4.4 Accessory Materials
4.4.1 Coatings and Coverings: SES N01-S15.
CODE DESIGNATION
716
Smooth aluminum jacket
716.5 Smooth aluminum jacket – coated
716.6 Deep-corrugated aluminum jacket
716.7 Deep-corrugated aluminum jacket – coated
717.6 Beveled end cap one-piece aluminum
717.8 Aluminum covers for vessel heads
720
Glass cloth with adhesive
734
Insulation mastic
743
Synthetic organic fiber cloth, open weave
4.4.2 Adhesives and Sealers: SES N01-S19.
CODE DESIGNATION
802.1
Lagging adhesive
803.2
Fibrous adhesive – asbestos free
803.4 High-temperature woven cloth adhesive
815
Anchor adhesive 107 °C (225 °F)
817
Anchor adhesive 93 °C (200 °F)
4.4.3 Fastenings and Miscellaneous: SES N01-S16.
CODE DESIGNATION
921
Stainless steel wire (18 gage)
926
Stainless steel bands and seals (10 mm)
927
Stainless steel bands and seals (20 mm)
929
Seals and racks
964.1 Spindle anchors (metal plate)
Corner beading
971.1 Sheet-metal screws (stainless steel)
Sheet-metal screws (aluminum)
979
Insulation pins (weldable)
979.1 Cupped-head insulation weld pins
980
All weather breather springs
997
S-clips (stainless steel)

5. Cylindrical Equipment Insulation Preparation
5.1 General
5.1.1 Insulation supports shall be checked prior to installing insulation and modified if necessary.
5.1.2 Written approval shall be obtained from SABIC before welding on tanks or vessels.
5.1.3 Where welding is prohibited, a segmented bolt-on angle shall be installed, as detailed in Figure 1.
5.2 Guidelines for Insulation Supports
5.2.1 Vertical Vessel / Tank – Flat Bottom on Foundation. The vessel tank bottom plate shall be extended
beyond the shell a distance equal to the insulation thickness plus 25 mm. For temperatures up to 149 °C
(300 °F), the extended plate and approximately 150 mm of the insulation (inside, bottom, and outside)
shall be coated with fibrated asphalt cutback (wet thickness 3 mm). See Figure 2.
5.2.2 Vertical Vessel / Tank – Top Head Flat, Conical, or Dished
5.2.2.1 Vertical vessels shall be designed to prevent moisture migration from the top head insulation to
the shell insulation.
5.2.2.2 The preferred method for vessels over 610 mm diameter is to install a 5 mm thick angle, with a
continuous seal weld at the top of the vertical wall of the vessel, with the horizontal leg of the angle 13 mm
longer than the insulation thickness. See Figure 3. For vessel temperatures over 149 °C (300 °F), head
insulation shall be extended down over the angle leg.
5.2.3 Vertical or Horizontal Vessels – Dished Head, Intermediate Bracket or Saddle Supported (1220 mm
or larger diameter). Dished head insulation shall be supported on both ends of horizontal vessel with a
continuous loop of 6 mm diameter rod. Loop shall be attached with 25 mm long x 6 mm diameter rods
welded on 305 mm centers to provide 6 mm clearance between loop and vessel, as in Figure 4A. For
vertical vessel, shell and bottom head insulation shall be supported with a continuous 5 mm flat bar, tack
welded at the knuckle. Support shall be equal to the insulation thickness and have a water shed with 6 mm
diameter rods, as in Figure 4B.
5.2.4 Vertical Vessel – Leg Supported from Shell
5.2.4.1 Short, slotted, flat bar clips shall be tack welded to the vessel legs for attaching segmented
support band, Figure 5. Clips shall project no more than is necessary to insert bands. Radial wires or
bands shall be attached to the segmented bands to support head insulation.
5.2.4.2 Bands or wires shall be fastened to the segmented bands to support the leg insulation and its
finish. Leg shall be insulated to same thickness as the tank insulation. Insulation shall be extended down
legs a minimum of 305 mm from outer surface of head insulation.
5.2.5 Vertical Vessel – Leg Supported from Head or Lug Supported. A 5 mm thick angle with a continuous
seal weld shall be installed near the knuckle radius of the lower head and install support rods. See
Figure 13.
5.2.6 Vertical Vessel – Dished Head, Skirt Supported
5.2.6.1 Vertical shell insulation shall be supported by a solid 5 mm thick flat bar, tack welded around the
skirt and located, as in Figure 6, below the top of the skirt. The bar shall be 13 mm wider than the
insulation thickness. When possible, bottom head shall be insulated while vessel is in horizontal position
prior to erection.
5.2.6.2 A continuous loop of 6 mm diameter rod shall be installed inside skirt to support dished head
insulation. See Figure 6. Loop shall be attached to skirt by 25 mm long x 6 mm diameter rods, welded on
305 mm centers to provide 6 mm clearance between skirt and loop.
5.2.7 Vertical Vessel – Intermediate or Top and Bottom Head Flanges
5.2.7.1 Insulation above flanges, other than top head, shall be supported with a 5 mm thick flat bar,
13 mm less than the shell insulation thickness, tack welded to the tank. Support shall be located one bolt length plus 25 mm from back of flanged, to permit bolt removal. For support, the flange insulation shall be
skewered to the insulation above the flange and secured with bands. See Figure 7.
5.2.7.2 For top head insulation preparations, 6 mm diameter rod loop shall be installed as in 5.2.3.1, one
bolt length plus 25 mm above back of upper head flange. See Figure 7A.
5.2.7.3 Bottom flanged dished head insulation shall be supported by radial wires or bands, anchored to
continuous loop of 6 mm diameter rod. See Figures 7B and 7C.
5.2.8 Vertical Vessel – Conical Bottom Section
5.2.8.1 The preferred method for supporting insulation on conical sections shall be to install the following
support mechanism when the vessel is being fabricated. A 5 mm thick angle shall be continuously seal
welded at the bottom of the cylindrical shell. The horizontal inside angle leg shall be 13 mm longer than the
insulation thickness. Support shall be provided for the conical section insulation by a 5 mm thick flat bar
continuously seal welded at the bottom of the conical section. The flat bar projection shall be 13 mm less
than the insulation thickness. A continuous loop of 6 mm diameter rod shall be installed on the angle and
flat bar. Loops shall be attached with 25 mm long, 6 mm diameter rods welded on 305 mm centers to
provide 6 mm long clearance for tie wires. At appropriate intervals along the conical section, as determined
by the length of the insulation to be used, continuous horizontal loops of 6 mm diameter rod shall be
installed. Loops shall be attached by 25 mm long, 6 mm rods welded on 305 mm centers to provide 6 mm
clearance between loops and the conical shell. See Figure 15.
5.2.8.2 As an alternative, when insulation supports are not installed during the vessel fabrication phase, a
5 mm thick angle shall be continuously seal welded at the bottom of the cylindrical shell, and also a 5 mm
thick flat bar at the bottom of the conical section, as outlined in 5.2.8.1. Instead of continuous horizontal
loops of 5 mm diameter rod and wire, cupped-head insulation weld pins shall be used to secure insulation
to conical surface. See Figure 15.
6. Insulation Application
6.1 Curved and shaped segments are available to fit most cylindrical tank walls. These preformed
segments shall be used when available. Cylindrical vessels 610 mm or less in diameter can be insulated
with preformed pipe insulation. The shell insulation shall be extended to permit installation of flat insulation
covers at each end. See Figure 8.
6.2 Crushed or damaged insulation shall not be used. It shall be returned to vendor or reworked to provide
square ends for a tight fit. Significant cracks and imperfections through single layer, or the outer layer of
double-layer insulation, shall be closed by tamping. If tamping will not close the opening without
significantly damaging the insulation surface, it shall be replaced.
6.3 Equipment Temperature Above 149 °C (300 °F). Metal in contact with the equipment, and that which
protrudes through the insulation, shall be insulated with the same thickness as the equipment insulation.
The protrusion shall be covered for a minimum of 305 mm from the equipment insulation surface.
6.4 Insulation Application to Cylindrical Sections. Double-layer insulation shall be banded. Joints shall be
staggered and tightly butted. See Figure 9. Single-layer insulation shall be installed and banded as in
Figure 10.
6.5 Insulation Application to Dished Heads. Before applying insulation to dished heads, supports shall be
checked to ensure their adequacy. Insulation can be laid in various patterns, pie-shaped or rectangular
segments. In double-layer construction, the outer layer joints shall be staggered with respect to those of the
inner layer. See Figure 11. Wires or bands shall be tightened firmly against the insulation. Wire twists shall
be bent over tight against the insulation. Radial wires or bands shall be positioned to not overlay at the
center of the head, with at least one wire or band crossing every block.
6.6 Insulation Support and Application to Flat or Square – Cornered Equipment
6.6.1 Duct sealant shall be applied before installing insulation.
6.6.2 Insulation pins, spot-welded to the metal surfaces of equipment or duct work, are preferred for
attaching insulation. Written approval shall be obtained from authorized personnel prior to welding.

6.6.3 Maximum temperature for cemented anchors is 162 °C (325 °F). Where temperature does not
exceed 106 °C (225 °F), spindle anchors may be cemented with anchor adhesive 106 °C (225 °F) or
anchor adhesive 93 °C (200 °F). Surfaces shall be dry and free of dust, rust, grease, and paint. See
SES N01-F39 for spacing.
6.6.4 Insulation shall be impaled over spindle anchors or insulation pins. Protruding nails shall be cut off
approximately 3 mm above washers.
6.6.5 Where adhesive, wires, or bands are used to support the insulation on ducts or breechings wider
than 457 mm, spindle anchors or insulation pins shall be installed on the underside for additional support.
6.6.6 Square corners of insulation on flat surfaces shall be protected with continuous corner angles
placed under wires or bands, as in Figure 16.
6.6.7 Block insulation shall be applied with joints staggered and tightly butted. Wires or bands shall be
placed over blocks approximately 50 to 100 mm from the end of each block, as in Figure 16.
6.6.8 4 x 4, 10 gage road mesh shall be tack welded to the stiffening angles on ducts or breechings having
either cross-section dimension over 1220 mm. Insulation support wires shall be attached to the road
mesh.
6.7 Insulation application to Conical Sections
6.7.1 When insulation supports are installed during vessel fabrication phase, fibrous adhesive shall be
spotted on the shell or insulation to hold insulation in place until secured. Insulation shall be positioned
with the joints butted tight. Tie wires shall be installed between continuous 6 mm diameter rod loops and
tightened to pull insulation tight against the shell. Tie wires shall form a diamond-shaped pattern with at
least 2 wires over each piece of insulation. If tamping does not close joints, the affected section of
insulation shall be replaced. If a metal jacket is to be applied, slotted 150 mm squares of 20 gage metal
shall be positioned behind the wires before tightening them. Squares shall be located where the jacket
corners overlap. These sheet-metal squares shall anchor the metal jacket against the insulation. The
number and location of the metal squares is determined by the size and configuration of the metal jacket.
See Figure 15.
6.7.2 When insulation supports are installed in the field, insulation shall be positioned with the joints
butted tight. Insulation shall be secured with cupped-head insulation weld pins on 406 mm centers
(maximum). Weld pins shall be selected of a length to pull the insulation tight against the shell. If a metal
jacket will be applied, the weld pin head shall be located where the corners of the jacket overlap. Screws
through the weld pin head shall anchor the metal jacket against the insulation. If tamping does not close
joints, the affected section of insulation shall be replaced.
7. Finish Application
7.1 Tables I and II of this standard list the acceptable combinations of insulation and finish materials.
Finishes are for outdoor use, and also indoors when they are exposed to an external source of water.
7.2 Metal
7.2.1 Deep-corrugated aluminum sheeting with 30 mm corrugations is preferred on vertical equipment
and vessels over 1830 mm in diameter. This may also be used on smaller diameter vessels.
Deep-corrugated aluminum sheeting shall be lapped with a minimum of 2.5 corrugations and shall require
breather springs. Laps shall be secured with sheet-metal screws on ridge of corrugation 152 mm centers.
Succeeding courses shall be supported with a minimum of 2 S-clips per sheet. See Figure 12.
7.2.2 Metal jacket and bands shall be cut and applied in a manner to avoid personal injuries from sharp
edges or burrs. For cutting and fastening instructions, see SES N01-F30.
7.2.3 Smooth metal jackets shall be overlapped by a minimum of 76 mm on tanks up to 7620 mm in
diameter and 100 mm on tanks over 7620 mm in diameter. Vertical seams on succeeding courses shall be
offset. Each course on vertical vessels shall be supported with S-clips on approximately 915 mm centers.

7.2.4 As each course of jacket is installed, bands shall be applied in as many sections as needed, with
each section not exceeding 9145 mm. Bands shall be tightened to pull evenly on all sections. See
Tables III and IV.
7.2.5 Metal bevel end caps, as in Figure 14, shall be installed at all exposed insulation terminations. For
end-cap fabrication, see SES N01-F21.
7.2.6 Where openings will be cut in the metal jacket to fit around nozzles and other fixtures, backup collars
or strips shall be used, secured by sheet-metal screws.
7.2.7 Metal jacketing for conical sections shall be cut to fit tight against the insulation. Sections of jacket
shall be overlapped 76 mm in a water shed fashion. Succeeding courses shall be supported with S-clips.
Jacket shall be secured with sheet-metal screws on 150 mm centers through the laps and the anchoring
squares or weld pin heads. Screw heads shall be covered with flashing compounds. See Figure 15.
7.3 Reinforced Mastics
7.3.1 This is the least durable finish system in this standard.
7.3.2 Prior to installing metal jacket on the cylindrical walls of horizontal vessels, the mastic finish on the
heads shall be extended over the tank wall insulation so the metal jacket, when applied, overlaps the
mastic finish by a minimum of 100 mm. A circumferential band shall be placed over the jacket, 38 mm from
the edge.

FIGURE 1
Angle Iron Support Detail