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 | |
| Cavities | 6 | |
| Vapor Barrier System | 6 | |
| Protective Metal Jackets | 7 | |
| Application of Insulation | 8 | |
| Straight Piping | 8 | |
| Insulation Support Rings | 9 | |
| Contraction Joints | 10 | |
| Fittings | 11 | |
| Flanges | 17 | |
| Valves and In-line Items | 19 | |
| Termination of Insulation | 22 | |
| Pipe Supports | 24 | |
| Cellular Glass/PIR Joints | 29 | |
| Straight Piping | 8 | |
| Insulation Support Rings | 9 | |
| Contraction Joints | 10 | |
| Elbows and Bends | 11 | |
| External View of Typical Elbow With Miter Segments | 12 | |
| Equal Tees | 13 | |
| External View of Tees or Branches | 13 | |
| Branches | 14 | |
| End Caps or Vessel Heads | 14 | |
| Reducers | 15 | |
| Flanges | 17 | |
| Valves (Preformed Insulation) | 19 | |
| Valves (Fabricated Insulation) | 20 | |
| Mechanical Flexible Joints or Bellows | 21 | |
| Termination of Insulation on Pipes | 22 | |
| Small Metal or Pipe Projections | 23 |
| Section | Title | Page |
| Pipe Support Saddles | 24 | |
| Pipe Support Rests | 24 | |
| Hanger Pipe Supports | 25 | |
| Shoe Pipe Support A | 26 | |
| Shoe Pipe Support B | 27 | |
| Trunnion or Duck-foot Pipe Supports | 28 | |
| Single Layer PIR/Cellular Glass Joints | 29 | |
| Horizontal Vessels | 30 | |
| Shell and Tube Heat Exchangers | 30 | |
| Vertical Vessels | 31 | |
| Horizontal Vessel Heads and Vertical Vessel Top Heads | 33 | |
| Vertical Vessel Bottom Heads | 34 | |
| Vertical Equipment – Contraction Joint Insulation | 35 | |
| Horizontal Equipment – Contraction Joint Insulation | 35 | |
| Single Layer PIR/Cellular Glass Joints | 36 | |
| Equipment Flange Insulation Detail | 37 | |
| Equipment Nozzle Insulation Detail | 38 | |
| Installation Quality Assurance Report | 40 | |
| Photographic Examples | 41 |
1. PURPOSE
1.1 This global engineering specification defines and describes the minimum requirements for the installation of single-layer thermal insulation using cellular glass for cold piping.
2. scope
2.1 This specification covers the installation of all preformed and slab cellular glass insulation materials including adhesives, sealers, mastics, and jackets.
2.2 This insulation material is identified on drawings with the symbol C4 (see 4WPI-INS001).
3. related documents
3.1 Air Products Engineering Documents Å 3PI99002 Thermal and Acoustic Insulation Standard 4WPI-INS001 Cellular Glass Thermal Insulation System for Cold and Cryogenic Piping and Equipment – Material Symbol C 4WPI-INS002 Installation of Multi-Layer Thermal Insulation of Cryogenic Piping With Cellular Glass Symbol C1 4WPI-INS007 Installation of Multi-Layer Thermal Insulation of Cryogenic Piping With PIR (Polyisocyanurate Foam) Symbol P1 4WPI-INS008 Installation of Single-Layer Thermal Insulation of Cold Piping and Equipment With PIR (Polyisocyanurate Foam) Symbol P4 Å Provided for background information only (not referenced in the text)
3.2 American Society for Testing and Materials (ASTM) C585 Standard Practice for Inner and Outer Diameters of Rigid Thermal Insulation for Nominal Sizes of Pipe and Tubing (NPS System)
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 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 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 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. MATERIALS
Note: No bituminous materials will be allowed.
7.1 All insulating materials and accessory materials to be used with this installation specification are defined in the Insulation System Specification 4WPI-INS001.
7.2 The contractor shall supply all insulating materials and accessory materials unless otherwise stated in the contract. The material shall be strictly according to the Insulation System Specification, which provides full names and addresses of suppliers.
8. MATERIAL REFERENCES
8.1 All materials are indicated in the text and figures of this specification by the numbers shown in square brackets, thus [0], that refer to the materials in Section 7, and are identified in the following list. [1] Pipe Insulating Material [2] Equipment Insulating Material [3] Cavity Fill Material [4] Vapor Barrier Jacket [5] Vapor Barrier Jacket Adhesive [6] Insulation Adhesive [7] Insulation Joint Sealer [8] Vapor Barrier Mastic [9] Insulation Banding Tape [10] Metal Jacket [11] Metal Bands [12] Pipe Clamp Insulation Support [13] Sheet Metal Insulation Support [14] Removable Insulation Boxes [15] Contraction Joint Cover [16] Contraction Joint Cover Adhesive [17] Sheet Metal [18] Bore Coating
9. INSULATION THICKNESS AND LIMITS
9.1 The insulation nominal thickness and the extent to which the insulation shall be provided and installed on piping and equipment shall be as stated on the Insulation Summary and/or isometrics and drawings provided by Air Products. Refer also to 4WPI-INS001. The actual insulation dimensions shall be according to ASTM C 585.
10. SITE ESTABLISHMENT AND PREPARATION
10.1 All insulation installation shall be performed strictly according to this specification, the Insulation Summary, piping isometrics, and drawings provided by Air Products.
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.
10.4 The contractor shall supply all materiel, 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. 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 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 applied in one day shall be weatherproofed overnight or before rain by either the final coating or a temporary weatherproof covering.
10.16 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.
10.17 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.
10.18 Repair and/or replacement in kind of any existing insulation at tie-in points shall be considered as part of the insulation contract.
10.19 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 Air Products. The contractor shall provide and install “electric traced” signs on the outside surface of the insulation over electric traced lines at 3 m (10 ft) intervals on both sides of the pipe. All gland plates on electrical tracing cables shall be banded to the metal jacket [10] and adequately sealed with [7].
10.20 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.
10.21 All moving parts shall be free of mastics and cements.
10.22 The contractor shall remove all waste or surplus material.
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 Vapor Barrier System
11.2.1 It is essential that all insulation to this specification shall be completely covered by the contractor as it is installed using a vapor barrier system that is totally watertight. The protective metal jacket shall not be considered as providing any sort of watertight vapor barrier.
11.2.2 It has been assumed in the text and drawings, that the contractor will choose to use a vapor barrier mastic with a reinforcement cloth [8]. However, as an acceptable alternative, the contractor may use a vapor barrier jacket [4] with a vapor barrier jacket adhesive [5], in which case, the insulation shall be secured in place after installing the vapor barrier jacket with insulation banding tape [9] instead of the metal bands [11] shown.
11.2.3 At flanges, valves, heat exchanger heads, and other bolted joints, there shall be insulation that is removable to allow maintenance of the equipment. The vapor barrier shall be installed over the outer layer of fixed insulation, on to the inner layers of 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 fixed insulation is fully sealed.
11.2.4 The vapor barrier mastic system shall be installed as follows:
11.2.4.1 All outer surfaces of all piping and equipment insulation shall be completely sealed with weather-resistant vapor barrier mastic reinforced with glass cloth [8] applied according to the manufacturer’s instructions. The glass cloth shall be embedded in the first coat of mastic while it is still wet; then the second (top coat) shall be applied.
11.2.4.2 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.
11.2.4.3 When the vapor barrier 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.
11.2.4.4 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 vapor barrier mastic only.
11.2.5 The vapor barrier jacket system shall be installed as follows:
11.2.5.1 All outer surfaces of all piping and equipment insulation shall be completely sealed with weather-resistant vapor barrier jacket [4]. The jacket and longitudinal flaps shall be sealed with vapor barrier jacket adhesive [5]. Circumferential butt joints shall be covered with a 75 mm (3 in) [or 100 mm (4 in) for equipment] wide strip of vapor barrier jacket material [4] and shall be sealed with adhesive [5] or self-adhesive tape [5] centered on the joint.
11.2.5.2 When installing insulation banding tape [9] to secure the outer layer, care shall be exercised in order not to damage or puncture the vapor barrier. Any damage or puncture shall be repaired with a piece of vapor barrier jacket [4] and adhesive [5] or self-adhesive tape [5].
11.2.5.3 When there is a slip joint provided in the insulation of equipment, the vapor barrier jacket shall be stopped short of the joint, and the joint shall be adequately sealed with vapor barrier mastic only.
11.2.5.4 On irregular surfaces, at the ends of insulation, at removable sections of insulation, or anywhere that it is not possible to use the vapor barrier jacket material [4], the vapor barrier mastic system shall be used according to paragraph 11.2.3. The mastic system shall extend a minimum of 75 mm (3 in) onto the vapor barrier jacket [4] of the adjacent pipe or equipment insulation.
11.3 Protective Metal Jackets
11.3.1 All insulation shall be protected with a metal jacket applied with minimum longitudinal and circumferential overlaps of 50 mm (2 in).
11.3.2 Longitudinal overlaps shall be located on or below 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.
11.3.3 Metal jackets shall be secured with metal bands [11] spaced at 250 mm (10 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. On vertical equipment, metal jackets shall be supported with ‘s’ clips on 300 mm (12 in) maximum centers and with a minimum of two per jacket section.
11.3.4 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.
11.3.5 All flanges, valves, expansion bellows, flexible hoses, strainers, pump casings, vessel manways, and other frequently maintained items shall be provided with prefabricated, proprietary or custom-made removable insulation boxes secured to allow easy access. 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.
11.3.6 Self-tapping screws or any other sharp-type fixing shall not be used under any circumstances. Any rivets used to fabricate metal jacketing shall have a smooth face on the insulation side of the jacket or shall be totally external to the insulation system. It must be demonstrated to Air Products’ satisfaction by the contractor before use, that the method proposed for using rivets or any other similar fixing cannot under any circumstances damage the vapor barrier.
11.3.7 All overlaps on metal jackets shall be installed to shed water and shall be sealed with insulation joint sealer [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.
11.3.8 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 insulation joint sealer [7].
12. APPLICATION OF INSULATION
12.1 Straight Piping
12.1.1 All insulation [1] shall be applied using single-layer construction and shall be secured with metal bands [11] spaced at 230 mm (9 in) maximum centers and at each end of the insulation section as indicated in Figure 1. Bore coating [18] shall be applied at site if the insulation [1] is not delivered with it already applied.
Figure 1 Straight Piping
12.1.2 Before application, insulation joint sealer [7] shall be applied to all joints of the insulation for the full depth of the thickness. Sealer shall be applied to both surfaces of mating insulation to provide a thin, 1 mm maximum (0.04 in), continuous seal for the full length and depth of each joint. Any sealer extruding from the mated joint due to compression during installation shall be leveled onto the joint and adjacent insulation surfaces to eliminate high spots. On nonvertical pipe or equipment, the longitudinal joints shall not be installed on the top of the pipe or equipment.
12.1.3 All insulation shall be provided with a vapor barrier according to paragraph 11.2.
12.1.4 The outer layer of all insulation shall be provided with a vapor barrier according to paragraph 11.2.
12.1.5 All insulation shall be completely covered with a protective metal jacket according to paragraph 11.3.
12.2 Insulation Support Rings
12.2.1 Insulation support rings are required on vertical piping at the maximum spacing of 5 m (16 ft) when there are no flanges, fittings, or valves. 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 2.
Figure 2 Insulation Support Rings
12.2.2 The contractor shall provide proprietary support rings or shall provide materials for and fabricate support rings as detailed in the Insulation System Specification for [12] or [13].
12.2.3 For piping DN150 (NPS 6) and smaller, a sheet metal support [13] shall be used. For piping larger than DN150, a pipe clamp support [12] shall be used.
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 outer layer of the insulation, an extra layer of insulation shall be installed over the clamp, notched to accommodate the ends of the clamp as necessary.
12.3 Contraction Joints
12.3.1 Contraction joints shall be installed in the insulation according to Figure 3. One contraction joint shall be installed and is required for any straight piping between 4 m (12 ft) and 6 m (20 ft) long, plus one additionally for every 6 m of length or fraction thereof over 6 m.
Figure 3 Contractor Joints
12.3.2 Insulation support ring locations on vertical piping that is insulated according to paragraph 12.2 may be considered as fulfilling the requirements of a contraction joint.
12.3.3 Flange, valve, and in-line equipment locations that are insulated according to paragraph 12.5 or 12.6 (for valves with fabricated insulation or for mechanical flexible joints or bellows) may be considered as fulfilling the requirements of a contraction joint.
12.4 Fittings
12.4.1 Fittings shall be insulated with prefabricated piping insulation [1] according to Figures 4, 5, 6, 7, 8, 9, and 10.
Figure 4 Elbows and Bends
Figure 5 External View of Typical Elbow With Miter Segments
Figure 6 Equal Tees
Figure 7 External View of Tees or Branches
Figure 8 Branches
Figure 9 End Caps or Vessel Heads
Figure 10 Reducers Concentric Reducer
12.4.2 The minimum thickness of insulation on fittings shall be equal to that required for adjacent straight piping.
12.4.3 Fitting insulation shall have insulation adhesive [6] applied to the longitudinal joints of the half sections of all fitting insulation. The butt ends that mate with the adjacent pipe insulation shall be coated with a thin layer of insulation joint sealer [7]. All joints and miters shall be completely sealed throughout the entire joint.
12.4.4 Small openings and voids shall be filled with cavity fill material [3].
12.4.5 The insulation shall be carefully fitted and secured in place with metal bands [11]. Although a minimum of three bands are mandatory on all fittings, it is the responsibility of the contractor to install as many as are required to ensure that the insulation is adequately secure.
12.4.6 A weather-resistant vapor barrier shall be applied over all fitting insulation according to paragraph 11.2.
12.4.7 All fitting insulation shall be completely covered with a protective metal jacket according to paragraph 11.3. When prefabricated, proprietary metal jackets are available, they are preferred; otherwise, jacketing shall be fabricated to suit.
12.5 Flanges
12.5.1 All flanges shall be insulated with the same thickness of insulation as the adjacent straight piping according to Figure 11, using the same methods as for straight piping. All voids shall be tightly packed with cavity fill material [3].
Figure 11 Flanges
12.5.2 The flange insulation shall overlap the pipe insulation by a minimum of 150 mm (6 in) and shall be installed in such a manner that it may be removed to provide access to the flanges and allow removal of the flange bolts without disturbing the adjacent piping insulation.
12.5.3 Flange insulation shall be fabricated in two halves from [1] using insulation adhesive [6]. The two halves shall be joined with insulation joint sealer [7], and the mating surfaces between the flange insulation and the adjacent pipe insulation shall also be sealed with [7].
12.5.4 Flange insulation shall be protected with a removable metal insulation box [14].
12.5.5 Spectacle blinds, blanks, or spacers shall be enclosed within the insulation box that shall have a label on the outside indicating their location.
12.6 Valves and In-line Items
12.6.1 All valves and in-line items shall be insulated with the same thickness of insulation as the adjacent straight piping according to Figures 12, 13, and 14. They shall be insulated with insulation fabricated in two halves with insulation adhesive [6] using the same methods as for fittings and straight piping. All voids shall be packed with cavity fill material [3].
Figure 12 Valves (Preformed Insulation)
Figure 13 Valves (Fabricated Insulation)
Figure 14 Mechanical Flexible Joints or Bellows
12.6.2 The valve or in-line item insulation shall be installed in such a manner that it may be removed to provide access to the valves or items for their removal, including the withdrawal of bolting, without disturbing the adjacent piping insulation.
12.6.3 Valve insulation shall have insulation joint sealer [7] applied to all joints of the valve insulation including the butt ends that mate with the adjacent pipe insulation.
12.6.4 The valve and in-line item insulation [1] shall be completely covered with a vapor barrier according to paragraph 11.2.
12.6.5 Valve and in-line item insulation shall be protected with a removable metal insulation box [14].
12.6.6 All valve packing glands shall be accessible for adjustment or repacking.
12.7 Termination of Insulation
12.7.1 When insulation terminates on a pipe, the insulation shall be installed according to Figure 15 and shall be adequately sealed with vapor barrier mastic [8] according to paragraph 11.2.
Figure 15 Termination of Insulation on Pipes
12.7.2 Small branch connections from cold lines such as pressure taps, safety valve connections, drains, and vents shall be insulated for a distance (when possible) of four times (minimum two times) the insulation thickness required for the piping according to Figure 16 and shall be adequately sealed with vapor barrier mastic [8] according to paragraph 11.2.
12.7.3 When insulation terminates on a small metal projection, the insulation shall be installed according to Figure 16 and shall be adequately sealed with vapor barrier mastic [8] according to paragraph 11.2.
Figure 16 Small Metal or Pipe Projections
12.8 Pipe Supports
12.8.1 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 insulation joint sealer [7] as shown in Figure 17.
Figure 17 Pipe Support Saddles
Figure 18 Pipe Support Rests
12.8.2 When insulation bears onto a pipe support or structural steel provided by others, the insulation shall be wrapped with sheet metal [18] 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 insulation joint sealer [7] and secured with metal bands [11], one at each end as shown in Figure 18.
12.8.3 When there are hanger supports provided by others, the insulation shall be wrapped with sheet metal [18] that is 300 mm (12 in) wide. The sheet shall be sealed to the outside of the metal jacket [10] with a liberal coating of insulation joint sealer [7] and secured with metal bands [11], one at each end as shown in Figure 19.
Figure 19 Hanger Pipe Supports
12.8.4 Shoe supports provided by others shall be insulated as shown in Figures 20 and 21.
Figure 20 Shoe Pipe Support A
Figure 21 Shoe Pipe Support B
12.8.5 Trunnion or duck-foot supports provided by others shall be insulated as shown in Figure 22.
Figure 22 Trunnion or Duck-foot Pipe Supports
12.8.6 All pipe supports, guides, and anchors shall be insulated in a manner generally according to Figure 17, 18, 19, 20, 21, or 22.
12.9 Cellular Glass/PIR Joints
12.9.1 When a pipe has an interface between insulation systems of cellular glass to this specification, and polyisocyanurate foam (PIR) to 4WPI-INS007 or 4WPI-INS008, the interface joint shall be insulated as shown in Figure 23.
Figure 23 Single Layer PIR/Cellular Glass Joints
12.10 Equipment
Figure 24 Horizontal Vessels
Figure 25 Shell and Tube Heat Exchangers
Figure 26 Vertical Vessels
12.10.1 All insulation shall be applied in a single layer. All blocks or slabs [2] shall be cut to follow the contours with as few joints as possible.
12.10.2 On irregular surfaces such as pumps and turbines, the insulation shall be cut and mitred as necessary to fit the shape and contour of the equipment and all cracks and voids shall be filled with cavity fill material [3].
12.10.3 All joints shall be tightly butted together and the long side of each block shall be parallel to the axis of the equipment. Prior to application, insulation joint sealer [7] shall be applied to all joints of the insulation for the full depth of the thickness. Sealer shall be applied to both surfaces of mating insulation to provide a thin, 1 mm (0.04 in) maximum, continuous seal for the full length and depth of each joint. Any sealer extruding from the mated joint due to compression during installation shall be levelled onto the joint and adjacent insulation surfaces to eliminate high spots. On nonvertical equipment, the longitudinal joints shall not be installed on the top of the equipment.
12.10.4 All insulation shall be secured with metal bands [11] at 230 mm (9 in) maximum centers as indicated in Figures 24, 25, and 26.
12.10.5 All insulation shall be provided with a vapor barrier according to paragraph 11.2.
12.10.6 All insulation shall be completely covered with a protective metal jacket according to paragraph 11.3.
12.11 Equipment Insulation Supports
Figure 27 Horizontal Vessel Heads and Vertical Vessel Top Heads
12.11.1 On vertical vessels, all insulation shall be supported on the insulation supports of 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 230 mm (9 in) centers.
12.11.2 On horizontal vessels, all insulation shall be supported in place with stainless steel metal jacket bands [11] at 230 mm (9 in) centers. Welding to the vessel is prohibited.
12.11.3 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 225 mm (9 in) round the circumference. Bands shall be fastened to insulation supports or circumferential bands and a floating ring in the center of the head according to Figure 27.
12.11.4 The floating ring shall be supplied and installed by the contractor. It shall be made from 10 mm (0.4 in) diameter (minimum) stainless steel rod welded shut. 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.
Figure 28 Vertical Vessel Bottom Heads
12.11.5 For the bottom head on vertical vessels, the insulation blocks shall be supported by metal bands [11] attached to the 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 metal bands [11] to the bottom insulation support ring. Installation shall be according to Figure 28.
12.12 Equipment Insulation Contraction Joints
Figure 29 Vertical Equipment – Contraction Joint Insulation
12.12.1 For vertical vessels, contraction joints shall be provided at each insulation support ring or shell stiffener except the bottom support.
Figure 30 Horizontal Equipment – Contraction Joint Insulation
12.12.2 For horizontal vessels, contraction joints shall be installed in the insulation at every 4.5 m (15 ft). There shall be at least one on equipment longer than 2.5 (8 ft) m between tangent lines, flanges, or stiffeners.
12.12.3 When only one contraction joint is required, it shall be located at the center of the equipment.
12.12.4 Contraction joints shall consist of a space 40 mm (1.5 in) minimum between insulation blocks filled with cavity fill material [3].
Figure 31 Vertical Equipment Shell Stiffeners Insulation Detail
12.12.5 Shell stiffeners shall be fully insulated with the same insulation thickness as the equipment.
12.13 Equipment Nozzles
Figure 32 Equipment Flange Insulation Detail
Figure 33 Equipment Nozzle Insulation Detail
12.13.1 All equipment flanges, bolted casings, nozzles, manholes, handholes, access flanges, and other bolted connections shall be insulated with the same thickness of insulation as the equipment. Any voids shall be tightly packed with cavity fill material [3].
12.13.2 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.
12.13.3 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 of 6 mm (1/4 in) minimum diameter rod, welded shut round the nozzle, manhole, or other bolted connections, and the bands shall be fastened to this ring as shown in Figure 33.
Appendix A Appendix a Installation Quality Assurance Report
| Contract Reference | Report No. |
Description of work inspected to Air Products Engineering Specification 4WPI-INS002
| 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 | |||
| Painting complete, dry, and accepted | |||
| Surface clean and dry | |||
| 2. | Insulation materials | Correct insulation supplied | |
| Correct accessory materials supplied | |||
| Metal jacket and banding correct | |||
| No 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 | |||
| No 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 | |
| Site cleaned and rubbish removed |
| Report by | Date |
Appendix B Photographic Examples Photograph 1
| DO provide removable valve and flange boxes.
DO allow for bolt removal within valve and flange boxes. DO NOT insulate valves, flanges, or other maintenance items in fixed insulation 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. Color copies of this appendix can also be obtained from Air Products, Engineering Standards upon request.
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 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. Color copies of this appendix can also be obtained from Air Products, Engineering Standards upon request.
Appendix B (continued) Photograph 5
| DO NOT use self-tapping screws to secure insulation. |
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. Color copies of this appendix can also be obtained from Air Products, Engineering Standards upon request.
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 that 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. Color copies of this appendix can also be obtained from Air Products, Engineering Standards upon request.