1. PURPOSE
1.1 This global engineering specification defines the minimum requirements for the field installation of preinsulated piping systems.
2. scope
2.1 This specification applies to preinsulated piping that operates between -196oC and 38oC
(-320°F and +100°F).
2.2 This specification applies to systems that will be installed outdoors, aboveground, and subject to sunlight, temperature extremes, and other ambient weather conditions.
2.3 Fully described and detailed alternate methods of installation may be presented by the supplier for Air Products’ consideration and written approval.
3. related documents
3.1 Air Products Engineering Documents Å 3PI99002 Thermal and Acoustic Insulation Standard Å 4WCE-670200 Fabrication and Erection of Process Piping Å 4WPI-SW70002 Process Clean (Class B) Inspection and Acceptance Requirements Å 4WPI-SW70003 Oxygen Clean (Class AA) Inspection and Acceptance Requirements Å 4WPI-INS001 Cellular Glass Thermal Insulation System for Cold and Cryogenic Piping and Equipment Material Symbol C Å 4WPI-INS006 PIR (Polyisocyanurate Foam) Thermal Insulation System for Cold and Cryogenic Piping and Equipment Material Symbol P Å 4WPI-INS007Installation of Multi-Layer Thermal Insulation of Cryogenic Piping With PIR (Polyisocyanurate Foam) Symbol P1 4WPI-FWSI01 Preinsulated Pipe and Fittings – Material Symbol R1 Å 4WPI-EW44001 Pressure Testing of Piping and Equipment
3.2 American Society of Mechanical Engineers (ASME) Å B16.25 Buttwelding Ends Å B31.3 Process Piping Å Provided for background information only (not referenced in the text)
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 The insulation contractor who supplies and installs the insulation will be referred to herein as the contractor.
4.3 Approved equal in this specification means “approved in writing by Air Products.”
4.4 All temperatures and dimensions in the text of this document are given in metric units with US customary units in parentheses. 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 representative, who will obtain approval and written authorization from the relevant Air Products 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.
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 of the insulation installation’s completion to be agreed in writing prior to start of installation.
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 Air Products 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 then 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. GENERAL REQUIREMENTS
7.1 Air Products will provide piping drawings that define the project-specific pipe configurations as well as the locations of all field joints, pipe anchors, and external pipe supports.
7.1.1 Anchors shall be located only at field-joint locations as predetermined by Air Products.
7.1.2 The vapor barrier jacket shall rest directly on any pipe support, and the jacket shall be designed and used to carry the weight of the pipe and insulation system.
7.2 All prefabricated-pipe installation shall be performed in strict accordance with this specification together with all referenced specifications and/or standards.
7.3 Any evidence of moisture in the insulation or the system components, either before or after application, is unacceptable and shall be sufficient cause for rejection.
7.4 All insulation and accessories shall be stored in a dry place and shall be protected from contact with water from the time they are received until they are completely installed and accepted by the Air Products representative.
7.5 Insulation field joints shall be installed after testing of completed preinsulated piping system.
7.6 All surfaces of the carrier pipe shall be cleaned, be free of dirt and any foreign matter, and shall be dry and frost-free before the application of any insulation material.
7.7 All materials shall be installed or applied according to the manufacturer’s instructions and at or above ambient temperatures of 4°C (40°F).
8. FIELD JOINTS
8.1 Field joints shall be constructed as depicted in Figure 1 and to the manufacturer’s instructions. All material necessary to complete the installation of field joints shall be provided by the preinsulated piping system supplier. Each material shall meet the requirements specified and defined in 4WPI-FWSI01 Section 6.
8.2 Field joints kits shall consist of a combination of premolded insulation sections, formed in place insulation (froth pak), preformed vapor barrier jacket, epoxy mix, and banding material.
8.3 The vapor barrier jacket shall be of the same material as that used for the factory-applied jacket. It shall be supplied premolded in one piece with a longitudinal seam. This shall be prefitted in the shop before shipment. All longitudinal and circumferential seams shall be secured using compatible adhesive with any heating that might be required for the adhesive to set properly. The closure sleeve shall then be further secured in place using three stainless steel bands until adhesive is cured and then the bands removed.
8.4 All materials shall be suitable for proper installation at a minimum ambient temperature of 4oC (40°F).
9. SUPPLIER-FURNISHED INFORMATION
9.1 The prefabricated-pipe supplier will furnish a complete description of the pre-insulated system to be provided. Information shall include, but not be limited to, the following: Manufacturer and type of insulation. Manufacturer and type of glass mat. Manufacturer and type of expansion/contraction-joint insulation. Material used for vapor barrier jacket including thickness, resin or composition, and class. Method of field-joint installation including vapor barrier jacket installation. A Material Safety Data Sheet (MSDS) for each component associated with the equipment being assembled, sold, and furnished by the supplier and all subcontractors. All MSDS documentation shall be in the English language.
9.2 The contractor will furnish complete and detailed information regarding exceptions or proposed alternates to the specification requirements.
10. DOCUMENTATION
10.1 The contractor shall conform to all job-specific requirements.
11. SITE ESTABLISHMENT AND PREPARATION
11.1 All insulation installation shall be performed strictly according to this specification, the Insulation Summary, piping isometrics, and drawings provided by Air Products.
11.2 The contractor shall comply with all local and national regulations and safety rules.
11.3 The contractor shall comply with Air Products site and safety rules.
11.4 The contractor shall supply all tools, transport, and supervision required for satisfactory completion of the insulation contract. Materials for field joint are provided by the preinsulated pipe manufacturer.
11.5 All materials shall be new and shall be applied by competent personnel according to the manufacturer’s instructions, unless otherwise specified herein.
11.6 All materials and all installation of insulation shall be available for inspection by Air Products. Material having defects shall be replaced, and any defects found in the installation shall be corrected by the contractor at their expense.
11.7 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.
11.8 All pressure testing shall be satisfactorily completed before application of any insulating materials.
11.9 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.
11.10 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.
11.11 The contractor shall verify with the Air Products 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.
11.12 The contractor shall cover all openings in the equipment to prevent the ingress of insulation or foreign materials.
11.13 Welding or drilling on equipment, piping, and structures is prohibited.
11.14 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.
11.15 All insulation applied in one day shall be weatherproofed overnight or before rain by either the final coating or a temporary weatherproof covering.
11.16 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.
11.17 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.
11.18 Repair and/or replacement in kind of any existing insulation at tie-in points shall be considered as part of the insulation contract.
11.19 Insulation on piping and equipment specified as personal protection on the Insulation Summary and/or isometrics shall be installed only within the limits shown therein.
11.20 All moving parts shall be free of mastics and cements.
11.21 The contractor shall remove all waste or surplus material.
Figure 1 Preinsulated Piping System Field Joint 
| Glass Mat |
| Permanent Epoxy Bond – Typical All Joints and Seams |
| Field Installed Vapor Barrier |
| Field-Installed Premolded Insulation Sections (Froth Pack to be used for filling seams and voids) | Field Butt Weld, Socket- Weld Coupling, or Brazed Coupling for Small-Bore Pipe |
| SS Band (typ. 3 places) |
Appendix a Installation Quality Assurance Report
| Contract Reference | Report No. |
Description of work inspected to Air Products Engineering Specification 4WPI-INS017
| Area Location | Description of Equipment | Line Number | Insulation System Applied |
| 1. | Pre-application inspection | Erection and assembly complete | Yes/No |
| System successfully pressure tested | |||
| Painting complete, dry, and accepted | |||
| Surface clean and dry | |||
| 2. | Insulation materials | Correct premolded insulation sections supplied | |
| Correct accessory materials supplied | |||
| Preformed vapor barrier jacket and banding correct | |||
| No self-tapping screws supplied | |||
| 3. | Insulation application | Premolded insulation sections in position | |
| All voids filled with pour foam | |||
| Vapor barrier jacket complete and sealed | |||
| 5. | Finishing | Labels installed on outside of jackets | |
| Site cleaned and rubbish removed |
| Report by | Date |