Table of Contents
| Section | Title | Page |
| Purpose | 3 | |
| Scope | 3 | |
| Related Documents | 3 | |
| Definitions | 3 | |
| Waivers | 3 | |
| Warranty | 4 | |
| Materials | 4 | |
| Material References | 4 | |
| Insulation Thickness and Limits | 4 | |
| Site Establishment and Preparation | 5 | |
| General Application | 6 | |
| Application of Insulation | 8 | |
| Straight Piping — Single Layer Construction | 9 | |
| Straight Piping — Double- or Multi-layer Construction | 10 | |
| Insulation Support Rings — Single Layer Construction | 11 | |
| Clamp-on Type Insulation Support | 12 | |
| Band-on Metal Insulation Support | 12 | |
| Insulation Support Rings — Double- or Multi-layer Construction | 13 | |
| Expansion Joints — Single Layer Construction | 14 | |
| Expansion Joints — Double- or Multi-layer Construction | 14 | |
| Elbows and Bends | 15 | |
| External View of Typical Elbow With Miter Segments | 16 | |
| Equal Tees | 16 | |
| External View of Tees or Branches | 17 | |
| Branches | 17 | |
| End Caps or Vessel Heads | 18 | |
| Reducers | 19 | |
| Termination of Insulation on Pipes and Metal Projections | 20 | |
| Hanger Pipe Supports | 21 | |
| Shoe Pipe Supports | 22 | |
| Trunnion or Duck-foot Pipe Supports | 23 | |
| Horizontal Vessels | 24 | |
| Termination of Insulation at Flanges | 26 | |
| Vertical Vessels | 26 | |
| Horizontal Vessel Heads and Vertical Vessel Top Heads | 27 | |
| Vertical Vessel Bottom Heads | 28 | |
| Vertical Equipment—Expansion Joint Insulation | 29 | |
| Horizontal Equipment—Expansion Joint Insulation | 29 | |
| Vertical Equipment Shell Stiffeners Insulation Detail | 30 | |
| Equipment Nozzle Insulation Detail | 31 |
Table of Contents
| Installation Quality Assurance Report | 33 |
| Photographic Examples | 34 |
| Information Sheet for Alternative Material Requests | 38 |
| Certificate of Conformity | 39 |
1. PURPOSE
1.1 This global engineering specification defines the minimum requirements for the installation of single-layer and multi-layer thermal insulation using fibreglass, calcium silicate, or mineral fiber.
1.2 This specification shall be used as a supplement to JSS-2210-001. If there is a conflict between these two specifications, Technip’s insulation spec shall govern.
2. scope
2.1 This specification applies to all piping and equipment on Air Products HYCO PST projects executed with Technip. However, this does not apply to reformer furnace piping.
3. related documents
3.1 Technip Engineering Documents JSS-2210-001 General Supply Rules for Hot Surface Insulation MTO-2212-001 Insulating and Painting Schedule
3.2 Air Products Engineering Documents 660.114 Removable Insulation Covers (+100° to +1200°F)
3.3 All standards and documents referred to herein shall be the latest issue, unless otherwise stated.
4. DEFINITIONS
4.1 Air Products and Chemicals, Inc. and its subsidiary and associated companies will be referred to herein as Air Products.
4.2 Technip is an alliance partner of Air Products that provides design expertise for Air Products HYCO projects and will be referred to herein as Technip.
4.3 The insulation contractor who supplies and installs the insulation will be referred to herein as the contractor.
4.4 Approved Equal in this specification means “approved in writing by Technip.”
4.5 All temperatures and dimensions in the text of this document are given in metric units with US customary units in parenthesis. In the figures, dimensions are only given in mm for clarity (divide by 25.4 to convert mm to inches).
5. WAIVERS
5.1 Applications for waivers of the requirements contained in this specification shall be made in writing to the Air Products field representative, who will obtain approval and written authorization from the relevant Technip manager prior to order, supply, or installation by the contractor.
5.2 In order that any request by the contractor may be evaluated, the contractor shall submit complete and full details of the recommended alternative. See Appendix C.
6. WARRANTY
6.1 The contractor shall provide a warranty guaranteeing the installation’s mechanical integrity against wind, weather, and normal operating conditions, and also the vapor barrier’s integrity against the ingress of moisture, all for a period after acceptance by Air Products field representative of the insulation installation’s completion to be agreed in writing prior to start of installation. See Appendixes A and D.
6.2 The contractor will be required to provide sample installations of insulation on the piping at the start of the contract. These will be inspected by the Air Products field representative and might be destroyed in the process of examination. The contractor will be judged on the quality of the workmanship and only if satisfactory will be allowed to start the contract. All work on the insulation shall be guaranteed by the contractor to be to the same quality of workmanship and will be judged to the same standard as the accepted sample. The contractor shall remove all damaged insulation and re-insulate as required.
7. MATERIALS
7.1 All insulating materials and accessory materials to be used with this installation specification are defined in JSS-2210-001.
7.2 The contractor shall supply all insulating materials and accessory materials unless otherwise stated in the contract.
8. MATERIAL REFERENCES
8.1 All materials are indicated in the text and figures of this specification by the numbers shown in square brackets that refer to the materials in Section 7 above and are identified in the following list. [1] Pipe Insulating Material [2] Equipment Insulating Material [3] Cavity Fill Material (unbonded, loose fibreglass or rockwool) [4] Covering [5] Covering Adhesive [6] Insulation Adhesive [7] Heat-Resistant Mastic (nonshrinking, nonhardening compound w/ low moisture vapour permeability) [8] Weather-Resistant Mastic [9] Tie Wires [10] Metal Jacket [11] Metal Bands [12] Pipe Clamp Insulation Support [13] Sheet Metal (Band-on) Insulation Support [17] Sheet Metal (Stainless Steel, minimum 0.8 mm (0.031 in) thick) [19] Rock Wool Blanket [20] Wire Mesh Reinforcement [21] Insulation Finishing Cement [22] Insulation Primer (required between [21] and [8]) [23] Self-tapping screws (see note below)
Note: Self-tapping screw: Contrary to Air Products standard practices, JSS-2210-001 spec allows the use of self-tapping screws to secure / attach metal coverings.
9. INSULATION THICKNESS AND LIMITS
9.1 The insulation nominal thickness and the extent to which the insulation shall be provided and installed shall be as outlined in MTO-2212-001 and JSS-2210-001. In addition, the following piping or components shall not be insulated: Piping and equipment flanges operating over 455°C (800°F), if special alloy bolting is not used to prevent bolt overstressing. All steam traps and trap inlet piping, including drip legs. Steam trap and liquid condensate discharge lines discharging to atmosphere. All vessel and equipment drains, unless heat tracing is required. Discharge lines should be continuously sloped to drain. Start-up bypass lines and valves. These lines are generally hot only during start-up and can be subject to unnoticed outside surface corrosion when insulated. Therefore, short runs of piping shall be provided with heat shields. Long, extensive runs of start-up lines shall be evaluated on a case-by-case basis. Vessel skirts and saddles, unless required for personnel or fire protection. All flanges in hydrogen or flammable gas service. All flanges operating under 455°C (800°F) and designated as having spectacle blinds shall not receive permanent insulation. Removable insulation covers shall be used. All equipment and piping for which heat loss is desired (such as compressor discharge piping), unless personnel protection is required. Internally insulated piping or equipment. All valve operators and glands. Nameplates on equipment. Cold inspection plates/stamps. Supports for piping. All relief devices and discharge lines. Strainers and unions. Refractory-lined piping or refractory-lined sections of certain vessels or equipment (i.e. transfer line, process gas boiler, prereformer, etc.)
10. SITE ESTABLISHMENT AND PREPARATION
10.1 All insulation installation shall be performed strictly according to this specification and
JSS-2210-001.
10.2 The contractor shall comply with all local and national regulations and safety rules.
10.3 The contractor shall comply with Air Products site and safety rules especially in the use of proper respirator and skin protection. Workers in the work area must be protected from loose flying particulates and manufacturer’s recommendations and MSDS with regards to safety shall also be followed.
10.4 The contractor shall supply all materials, tools, transport, and supervision required for satisfactory completion of the insulation contract.
10.5 All materials shall be new and shall be applied by competent personnel according to the manufacturer’s instructions, unless otherwise specified herein.
10.6 All materials and all installation of insulation shall be available for inspection by Air Products and Technip. Material having defects shall be replaced, and any defects found in the installation shall be corrected by the contractor at their expense.
10.7 Before starting work on site, the contractor shall prepare and obtain the agreement of the Air Products representative regarding their detailed program for the work. They shall also obtain agreement for the site establishment and for the location of working areas.
10.8 All pressure testing shall be satisfactorily completed before application of any insulating materials.
10.9 Insulating materials shall only be applied to a completely dry surface that might have been painted by others. All surfaces shall be free of dirt, rust, and any foreign matter.
10.10 Insulating and accessory materials shall only be applied to surfaces that are clean, dry, and frost-free, and when the ambient temperature is above +2°C (36°F). Great care shall be taken to prevent damage to the paint system, especially on stainless steel piping or equipment as this paint does not fully harden until it has reached the system’s operating temperature for the first time.
10.11 The contractor shall verify with the Air Products field representative, before commencing work on a pipe system or item of equipment, that the system is ready for insulation installation and shall also confirm the requirements for any special conditions such as cleanliness or internal purge.
10.12 The contractor shall cover all openings in the equipment to prevent the ingress of insulation or foreign materials.
10.13 Welding or drilling on equipment, piping, and structures is prohibited.
10.14 All insulating material shall be kept dry and shall be protected from inclement weather and contact with water at all times. Any evidence of moisture in the insulation or its accessories, either before or after application, shall be sufficient cause for rejection.
10.15 All insulation shall be fabricated using a minimum number of pieces, and all surfaces between adjacent pieces of insulation shall be tightly butted together so that no voids or gaps occur at any joint, except where specifically indicated. Allowable gap tolerance between edges of insulations is 0.8 mm (1/32 in).
10.16 Cutting and fitting of any insulation at tie-ins, valve handwheels, steel gratings, steelwork, conduit, cable tray, tubing, pipe supports, or other interference shall be considered part of the insulation contract.
10.17 Repair and/or replacement in kind of any existing insulation at tie-in points shall be considered as part of the insulation contract.
10.18 When piping or equipment is electrically or steam traced by others, insulation shall only be applied when the tracing has been completed and approved by the Air Products field representative. The contractor shall provide and install “electric traced” signs on the outside surface of the insulation over electric traced lines. For straight long runs, install the label at the middle and at the ends with a maximum spacing of 12 to 15 meters (40 to 50 ft) on both sides of the pipe. Where multiple elbows are involved, place the label at a maximum spacing of 6 meters (20 ft) unless closer than 6 meters (20 ft) to the power box where no label is required. All gland plates on electrical tracing cables shall be banded to the metal jacket [10] and adequately sealed with [7].
10.19 Insulation on piping and equipment specified as personnel protection in MTO-2212-001 and JSS-2210-001 shall be installed only within the limits shown therein.
10.20 All moving parts shall be free of mastics and cements.
10.21 The contractor shall remove all waste or surplus material and must enforce proper daily broom swept clean housekeeping.
10.22 The contractor mark the flow direction of all insulated check valves by wrapping the entire outer surface of the insulation jacket with a band of permanent, clearly visible, red or orange marking tape. Such banding shall be applied around the entire pipe diameter, both immediately upstream and downstream of the check valve. The contractor shall also indicate the direction of flow by taping an arrow to the most visible side of the insulated pipe between the upstream and downstream band markers.
11. GENERAL APPLICATION
11.1 Cavities
11.1.1 All cavities within the preformed insulation for pipes or equipment shall be completely filled by hand with cavity fill material [3] to a firm, resilient consistency.
11.2 Weatherproofing
11.2.1 It is essential that all insulation shall be completely covered as it is installed using metal jacket or a weatherproofing mastic system that is totally watertight. All insulation applied in one day shall be weatherproofed overnight or before rain by either the final coating or a temporary weatherproof covering. (See Appendix B, Photograph 3.)
11.2.2 Weatherproofing Mastic
11.2.2.1 When required, weatherproofing mastic shall be provided in accordance with JSS-2210-001 and the additional requirements in this specification as follows:
11.2.2.2 The coating shall be carefully examined after drying to ensure that there are no cracks, holes, thin spots, bare reinforcement, or open joints of any sort. If there are any defects of this type, an additional coating of mastic shall be applied at these locations until there are no further defects.
11.2.2.3 When the weatherproofing mastic [8] terminates onto a metal surface, the surface shall be cleaned of all dirt, grease, oil, and other foreign matter by wire brushing and solvent washing before the application of mastic.
11.2.2.4 When there is a slip joint provided in the insulation of equipment, the reinforcement cloth shall be stopped short of the joint and the joint adequately sealed with the mastic only.
11.2.2.5 For insulation that is removable, for example at flanges, valves, heat exchanger heads, and other bolted joints, the weatherproofing mastic shall also be installed over the underneath pipe or equipment insulation and on to the pipe or equipment. It shall be applied such that when the removable insulation is either taken off or is applied later, the pipe or equipment insulation is fully sealed.
11.3 Metal Jacket
11.3.1 In addition to the methods described in JSS-2210-001, metal jackets shall be applied as follows:
11.3.1.1 Longitudinal overlaps shall be located on the horizontal centerline, not on the top of piping or equipment, but installed to shed water. Adjacent longitudinal overlaps shall be installed at 180 degrees from one another to avoid double circumferential lap areas.
11.3.2 For piping, metal jackets shall be secured with metal bands [11] spaced at 300 mm (12 in) maximum and at each end of the jacket section as indicated in the drawings in Section 12, stretched and clamped under tension with seals. This shall not crush or crack the insulation. Any cracked or broken insulation shall be replaced.
11.3.3 All exposed edges and sharp corners of insulation jacketing shall be rounded off to prevent a safety hazard. Metal band ends shall be cut close to the seal [12 mm (0.5 in) minimum], folded under, and flattened.
11.3.4 All items that do not have their labels or tag numbers visible after completion of the insulation shall have labels provided and installed by the contractor on the outside of the insulation, especially flow direction labels for check valves.
11.3.5 All overlaps on metal jackets shall be installed to shed water and shall be sealed with heat-resistant mastic [7]. On straight seams, the metal joint sealing tape material is preferred and shall be installed continuously along the joint such that one edge is just visible.
11.3.6 All cut-outs in metal jackets shall be cut as close as possible to achieve a tight fit, shall be covered by a flashing of aluminum sheet, and shall be adequately sealed with heat-resistant mastic [7].
11.3.7 The use of self-tapping screws to secure metal jackets is allowed by this specification only. (See Appendix B, Photograph 5.)
11.4 Calcium Silicate System
11.4.1 In addition to the requirements stated in paragraph 11.2 and as detailed in the figures of this specification, when the piping and equipment are insulated with calcium silicate, the following shall also apply.
11.4.2 A layer of rock wool blanket [19], 25 mm (1 in) thick, shall be installed round pipe larger than DN900 (NPS 36) or equipment before the installation of the calcium silicate. The blocks of calcium silicate shall be cut and fitted to the outer dimensions of the rock wool and installed so that the rock wool is not compressed.
11.4.3 When the calcium silicate insulation is otherwise unsupported or not strapped in position or when block or blanket rock wool is without metal mesh, the wire mesh reinforcement [20] shall be tightly stretched over the insulation and securely laced into position with insulation tie wires [9]. This is also required over vessel heads and other rounded surfaces where the tie wires may be secured to the metal bands located on the head and on the shell.
11.4.4 After the insulation has been installed, the entire surface shall be given a 10 to 12 mm (3/8 to 1/2 in) thick (measured wet) coating of insulation finishing cement [21]. Sufficient material shall be applied to level off any surface depressions.
11.4.5 Before applying the weatherproofing mastic [8] system and after the insulation finishing cement [21] has dried, a coating of insulation primer [22] shall be applied according to the manufacturer’s instructions. The primer shall be allowed to dry for a minimum of eight hours before the weather‑resistant mastic may be applied.
11.5 Removable Insulation Cover
11.5.1 When required, removable insulation cover shall be provided in accordance with JSS-2210-001 and the additional requirements in this specification.
11.5.2 All frequently maintained items including valves, expansion bellows, flexible hoses, strainers, pump casings, and vessel manways shall be provided with removable insulation secured to allow easy access.
12. APPLICATION OF INSULATION
12.1 Straight Piping
12.1.1 All insulation shall be applied in a single layer. Multi-layer construction shall be used only when the piping conditions specified in JSS-2210-001 exist or when single layer is not available.
12.1.2 The insulation shall be applied dry and without sealer or adhesive, and all joints shall be tightly butted together.
12.1.3 When multi-layer construction is used, the longitudinal and circumferential joints shall be staggered between layers. Longitudinal joints shall be staggered midway between longitudinal joints on adjacent layers, and circumferential joints shall be staggered by half a section, but in no case closer than 150 mm (6 in) to the joint of the adjacent layer. There shall be no through joints.
12.1.4 The inner layers of multi-layer insulation shall be secured with tie wires [9] spaced as indicated in Figures 1 and 2. Ends shall be twisted together and pressed into the insulation.
Figure 1 Straight Piping —– Single Layer Construction
Note: All measurements expressed in mm.
Figure 2 Straight Piping — Double- or Multi-layer Construction
Note: All measurements expressed in mm.
Figure 3 Insulation Support Rings — Single-layer Construction
Note: All measurements expressed in mm.
12.1.5 The outer layer of multi-layer and single-layer insulation shall be secured with tie wires [9] or metal bands [11] spaced at 300 mm (12 in) maximum centers and at each end of the insulation section as indicated in Figures 1 and 2. On nonvertical pipe or equipment, the longitudinal joints shall not be installed on the top of the pipe or equipment.
12.1.6 The outer layer of all insulation shall be provided with a covering according to paragraph 11.2.
12.1.7 All insulation shall be completely covered with a protective metal jacket according to paragraph 11.3.
12.2 Insulation Supports
12.2.1 When required, insulation supports shall be provided in accordance with JSS-2210-001 and the additional requirements in this specification.
12.2.2 At flanges, fittings, or valve locations, support rings shall be installed as close as possible above these locations. These support rings shall be insulated as indicated in Figure 3.
12.2.3 The contractor shall provide materials for and fabricate support rings as detailed in Figures 3A and 3B for [12] or [13].
12.2.4 If in fabricating the pipe clamp insulation support it is not possible to cut off the arms of the clamp so that it does not extend past half of the insulation, then an extra layer of insulation shall be installed over the clamp, notched to accommodate the ends of the clamp if necessary.
12.2.5 Pipe Clamp Insulation Support [12]
12.2.6 When prefabricated, proprietary, pipe clamp insulation supports are available, they shall be used. Otherwise, clamp-on type supports shall be provided and fabricated according to Figure 3A from a pipe riser clamp with the arms cut back to extend no more than half the thickness of the outer layer of insulation and a flat plate tack-welded on to the top.
Figure 3A Clamp-on Type Insulation Support
Note: All measurements expressed in mm.
12.2.7 Sheet Metal (Band-on) Insulation Support [13]
12.2.8 Fabrication of sheet metal (band-on) insulation supports shall be according to Figure 3B.
Figure 3B Band-on Metal Insulation Support
Note: All measurements expressed in mm.
Figure 4 Insulation Support Rings — Double- or Multi-layer Construction
Note: All measurements expressed in mm.
12.3 Expansion Joints
12.3.1 When required, expansion joints shall be installed in the insulation in accordance with JSS-2210-001 and Figures 5 and 6.
12.3.2 Insulation support ring locations on vertical piping that are insulated according to paragraph 12.2 may be considered as fulfilling the requirements of an expansion joint. In addition, an expansion joint shall be installed just below the highest fitting in a vertical run of pipe. For horizontal pipe, when only one expansion joint is required, it shall be located midway between any two insulation anchor points such as pipe supports, branch connections, and elbows.
Figure 5 Expansion Joints — Single Layer Construction
Note: All measurements expressed in mm.
Figure 6 Expansion Joints — Double- or Multi-layer Construction
Note: All measurements expressed in mm.
12.4 Fittings
12.4.1 Fittings shall be insulated with prefabricated insulation when commercially available or with mitered piping insulation [1] according to Figures 7, 8, 9, 10, 11, 12, and 13.
12.4.2 The minimum thickness of insulation on fittings shall be equal to that required for adjacent straight piping.
12.4.3 The insulation shall be carefully fitted and secured in place with tie wires [9] for inner layers and with tie wires [9] or metal bands [11] for outer layer, single layer or premolded insulation. Although a minimum of three wires or bands are mandatory on all fittings, it is the responsibility of the contractor to use as many as are required to ensure that the insulation is adequately secure.
12.4.4 All voids shall be filled with cavity fill material [3]. Small openings, cracks, and joints shall be filled with insulation adhesive [6] to give a smooth, even, outer surface.
Figure 7 Elbows and Bends
Note 1: Single layer construction is shown for clarity.
Note 2: All measurements expressed in mm.
Figure 8 External View of Typical Elbow With Miter Segments
Note: All measurements expressed in mm.
Figure 9 Equal Tees
Note: All measurements expressed in mm.
Figure 10 External View of Tees or Branches
Note: All measurements expressed in mm.
Figure 11 Branches
Note: All measurements expressed in mm.
Figure 12 End Caps or Vessel Heads
Note: All measurements expressed in mm.
Figure 13 Reducers Concentric Reducer
Note 1: Single layer construction is shown for clarity.
Note 2: All measurements expressed in mm.
12.5 Termination of Insulation
12.5.1 When insulation terminates on a pipe or metal projection, the insulation shall be installed according to Figure 14.
Figure 14 Termination of Insulation on Pipes and Metal Projections
Note 1: Single layer construction is shown for clarity
Note 2: All measurements expressed in mm.
12.6 Pipe Supports
12.6.1 When insulation is supported by a saddle or cradle support provided by others, it shall be sealed to the outside of the metal jacket [10] with a liberal coating of Heat-Resistant Mastic [7].
12.6.2 When insulation bears onto a pipe support or structural steel provided by others, the insulation shall be wrapped with sheet metal [17] that is 200 mm (8 in) wider than the support steel. The sheet shall be sealed to the outside of the metal jacket [10] with a liberal coating of Heat-Resistant Mastic [7] and secured with metal bands [11], one at each end.
12.6.3 Hanger supports provided by others shall be insulated as shown in Figure 15 with removable insulation to allow the pipe support bolts to be checked and adjusted.
Figure 15 Hanger Pipe Supports
Note: All measurements expressed in mm.
12.6.4 Shoe supports provided by others shall be insulated as shown in Figure 16.
Figure 16 Shoe Pipe Supports
Note 1: Single layer construction is shown for clarity
Note 2: All measurements expressed in mm.
12.6.5 Trunnion or duck-foot supports provided by others shall be insulated as shown in Figure 17.
Figure 17 Trunnion or Duck-foot Pipe Supports
Note 1: Single layer construction is shown for clarity.
Note 2: All measurements expressed in mm.
12.6.6 At locations where pipe supports or small metal projections are attached directly to the pipe, the insulation shall be cut to fit neatly and shall be adequately sealed with heat-resistant mastic [7].
12.6.7 All pipe supports, guides, and anchors shall be insulated in a manner generally according to Figure 15, 16, or 17.
12.7 Equipment
12.7.1 When commercially available, all insulation shall be applied in a single layer. Multi-layer construction shall be used only when the equipment conditions specified in JSS-2210-001 exist or when single layer is not available. All blocks or slabs [2] shall be cut to follow the contours with as few joints as possible.
12.7.2 On irregular surfaces such as pumps and turbines, the insulation shall be cut and mitered as necessary to fit the shape and contour of the equipment, and all large voids shall be filled with cavity fill material [3].
12.7.3 The insulation shall be applied dry and without sealer or adhesive. All joints shall be tightly butted together, and the long side of each block shall be parallel to the axis of the equipment.
12.7.4 When multi-layer construction is used, the longitudinal and circumferential joints shall be staggered between layers so that there are no through joints.
12.7.5 All cracks and small openings shall be filled with insulation adhesive [6].
12.7.6 All layers of multi-layer insulation shall be secured with metal bands [11] at 300 mm (12 in) maximum centers as indicated in Figures 18, 19, and 20.
12.7.7 Single-layer insulation shall be secured with metal bands [11] at 300 mm (12 in) maximum centers as indicated in Figures 18, 19, and 20. On horizontal equipment, the longitudinal joints shall not be installed on the vertical centerline of the equipment.
12.7.8 All insulation shall be completely covered with a protective metal jacket according to paragraph 11.3.
12.7.9 When specified on the insulation Summary or the Isometric, equipment supports shall be personnel protected with insulation.
Figure 18 Horizontal Vessels
Note: All measurements expressed in mm.
Figure 19 Termination of Insulation at Flanges
Note 1: 100 mm minimum distance; distance is governed by stud/cap screw length.
Note 2: All measurements expressed in mm.
Note 3: Miter may be required due to dimensional constraints.
Figure 20 Vertical Vessels
Note 1: Single layer construction is shown for clarity.
Note 2: All measurements expressed in mm.
12.8 Equipment Insulation Supports
12.8.1 On vertical vessels, all layers of insulation shall be supported on the insulation supports off the vessel. These will be provided as part of the vessel by the vessel fabricator. Welding to the vessel is prohibited. The insulation shall be secured to the vessel with stainless steel metal jacket bands [11] at 300 mm (12 in) centers.
12.8.2 On horizontal vessels, all insulation shall be supported in place with stainless steel metal jacket bands [11] at 300 mm (12 in) centers. Welding to the vessel is prohibited.
12.8.3 For both heads on horizontal vessels and the top head of vertical vessels, all insulation shall be secured with stainless steel metal jacket bands [11] spaced at 300 mm (12 in) round the circumference. Bands shall be fastened to insulation supports or circumferential bands and a center ring in the center of the head according to Figure 21.
Figure 21 Horizontal Vessel Heads and Vertical Vessel Top Heads
Note 1: Lifting lugs and all projections shall be fully insulated.
Note 2: All measurements expressed in mm.
12.8.4 The center ring shall be supplied and installed by the contractor. It shall be made from two loops of No. 9 gauge stainless steel wire. The ring diameter shall be a minimum consistent with the number of insulation bands used. The bands shall be spaced to adequately secure all insulation blocks to the head.
12.8.5 For the bottom head on vertical vessels, the insulation blocks shall be supported by tie wires [9] attached to the square nuts supplied as part of the vessel by the vessel fabricator. For vessels without skirts, the insulation round the knuckle of the head shall be secured by tie wire to the bottom insulation, support ring. For multi-layer insulation, the outer layers may be attached to the tie wires supporting the inner layers. Installation shall be according to Figure 22.
Figure 22 Vertical Vessel Bottom Heads
Note 1: Single layer construction is shown for clarity.
Note 2: All measurements expressed in mm.
12.9 Equipment Insulation Expansion Joints
Figure 23 Vertical Equipment–Expansion Joint Insulation
Note 1: Single layer construction is shown for clarity.
Note 2: All measurements expressed in mm.
12.9.1 For vertical vessels, expansion joints shall be provided at each insulation support ring or shell stiffener except the bottom support.
Figure 24 Horizontal Equipment– Expansion Joint Insulation
Note 1: Single layer construction is shown for clarity.
Note 2: All measurements expressed in mm.
12.9.2 For horizontal vessels, expansion joints shall be installed in the insulation according to Figure 25 where required by the following rules:
| Operating Temperature | Expansion Joint Requirements |
| +21° to +300°C (+70° to +572°F) | One every 4.5 m (15 ft) |
| +301° to +650°C (+573° to +1202°F) | One every 2.1 m (7 ft) |
| Note: There shall be at least one on equipment longer than 2.5 m (8 ft) between tangent lines, flanges, or stiffeners. Operating temperatures are shown on the Insulation Summary and/or isometrics. | |
12.9.3 When only one expansion joint is required, it shall be located at the center of the equipment.
12.9.4 Expansion joints shall consist of a space 40 mm (1.5 in) minimum between insulation blocks filled with cavity fill material [3].
Figure 25 Vertical Equipment Shell Stiffeners Insulation Detail
Note 1: Single layer construction is shown for clarity.
Note 2: All measurements expressed in mm.
12.9.5 Shell stiffeners shall be fully insulated with the same insulation thickness as the equipment.
12.10 Equipment Nozzles
12.10.1 The insulation shall overlap the equipment insulation and shall be installed in such a manner that it may be removed to provide access to the flange and allow removal of the flange bolts without disturbing the adjacent equipment insulation.
12.10.2 When nozzles, manholes, or other bolted connections interfere with the spacing of metal bands used for insulation supports, the contractor shall supply and install a stainless steel ring, 6 mm (1/4 in) minimum diameter, welded shut round the nozzle, manhole, or other bolted connections. The bands shall be fastened to this ring as shown in Figure 26.
Figure 26 Equipment Nozzle Insulation Detail
Appendix a Installation Quality Assurance Report
| Contract Reference | Report No. |
Description of work inspected to Air Products Engineering Specification 4WPI-INS030 & Technip’s Insulation Specifications JSS-2210-001 & MTO-2212-001
| Area Location | Description of Equipment | Line Number | Insulation System Applied |
| 1. | Pre-application inspection | Pipe/equipment ready for insulation | Yes/No |
| Erection and assembly complete | |||
| System successfully pressure tested | |||
| Heat tracing installed (if applicable) | |||
| Painting complete, dry, and accepted | |||
| Surface clean and dry | |||
| 2. | Insulation materials | Correct insulation supplied | |
| Correct accessory materials supplied | |||
| Metal jacket and banding correct | |||
| Self-tapping screws supplied | |||
| 3. | Insulation application | Inner layer banded in position | |
| All voids filled | |||
| Outer layer banded in position | |||
| Vapor barrier jacket complete and sealed | |||
| All other areas sealed with vapor barrier mastic | |||
| All pipe supports and projections sealed | |||
| 4. | Metal jacket | All insulation covered with metal jacket | |
| All jackets banded securely in position | |||
| Self-tapping screws used | |||
| Overlaps installed to shed water | |||
| Horizontal overlaps staggered | |||
| All joints and openings sealed | |||
| 5. | Finishing | Labels installed on outside of jackets (i.e. heat traced lines, check valve flow direction, tags covered by insulation | |
| Site cleaned and rubbish removed |
| Report by | Date |
Appendix B Photographic Examples Photograph 1
| DO provide removable covers for required valves and flanges. |
| DO NOT insulate valves, flanges, or other maintenance items in fixedinsulation systems. |
Photograph 2
| DO install expansion/contraction joints at correct intervals. |
| DO support insulation adequately on vertical equipment or piping. |
Note: This specification when issued must contain this appendix. This appendix contains color images of photographs. Color printing or copying is preferred for paper distribution.
Appendix B (continued) Photograph 3
| DO protect insulation from rain during and after installation. |
| DO NOT install insulation during inclement weather. |
Photograph 4
| DO cover ALL insulation Contact Forms with metal jacketing. |
| DO NOT leave glass cloth reinforcement without mastic covering. |
| DO NOT leave sharp edges of jacket or banding protruding. |
Note: This specification when issued must contain this appendix. This appendix contains color images of photographs. Color printing or copying is preferred for paper distribution.
Appendix B (continued) Photograph 5
| The use of self-tapping screws [23] to secure metal covering is allowed |
| per this specification. (Note that this allowance is for high temperature |
| insulation applied to this specification only.) |
Photograph 6
| DO NOT leave ledges for water to collect. |
| DO NOT leave partially sealed areas. |
Note: This specification when issued must contain this appendix. This appendix contains color images of photographs. Color printing or copying is preferred for paper distribution.
Appendix B (continued) Photograph 7
| DO use bands to secure metal jacket. |
| DO arrange joints in jackets to shed water. |
| DO seal all surfaces of insulation and seal jacket joints. |
Photograph 8
| DO NOT leave gaps in the metal jacket or seams at the top which allow the ingress of water. |
Note: This specification when issued must contain this appendix. This appendix contains color images of photographs. Color printing or copying is preferred for paper distribution.
Appendix C Information Sheet for Alternative Material Requests
| Original Material Specified |
| Reference No. |
| Reason for Change Request |
Proposed Alternative Material (when appropriate, provide national standard, e.g., ASTM, BS, DIN)
| Name |
| Manufacturer/Supplier |
| General Description |
| Use or Application |
| Application Method (brush, trowel, or other) |
| Operating Temperature Limits +/-°C (or °F) |
| Physical Form (liquid, solid) |
| Color |
| Specific Gravity |
| Solids Content |
| Solvent |
| Water Vapor Permeance |
| Flash Point |
| Fire Rating |
| Health and Safety Precautions |
| Remarks |
REQUESTED BY
| Company | Date |
| For use on Project | Project No. |
APPROVED BY AIR PRODUCTS
| Signed | Date |
| Position |
Appendix d Certificate of Conformity
| Contract Reference | Air Products Project No. |
The following insulating materials according to Technip Engineering Specification JSS-2210-001 were supplied:
| Ref. No. | Description | Manufacturer | Mfg. Ref. No. |
| [1] | Pipe Insulating Material | ||
| [2] | Equipment Insulating Material | ||
| [3] | Expansion Joint and Cavity Fill Material | ||
| [6] | Insulation Adhesive | ||
| [7] | Heat-Resistant Mastic | ||
| [8] | Weather-Resistant Mastic | ||
| [9] | Tie Wires | ||
| [10] | Metal Jacket | ||
| [11] | Metal Bands | ||
| [12] | Pipe Clamp Insulation Support | ||
| [13] | Sheet Metal Insulation Support | ||
| [14] | Removable Insulation Boxes | ||
| [17] | Sheet Metal | ||
| [19] | Rock Wool Blanket | ||
| [20] | Wire Mesh Reinforcement | ||
| [21] | Insulation Finishing Cement | ||
| [22] | Insulation Primer |
| Contractor’s Name |
| Signed by | Date |