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) (Potential Exposure to Water)

1. SCOPE ………………………………………………………………………………………..2. REFERENCES
3. GENERAL
4. MATERIALS………………………………………………………………………………….5.
CYLINDRICAL EQUIPMENT INSULATION PREPARATION
5.1
Insulation Supports and Preparation
5.2
Guidelines for Insulation Supports …………………………………………….
6.
INSULATION APPLICATION – EQUIPMENT
7.
FINISH APPLICATION
8. CAULKING……………………………………………………………………………………
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. Cylindrical Equipment – Horizontal
4B. Cylindrical Equipment – Vertical ……………………………………………
5
Vertical Cylindrical Equipment (Leg Supported from Shell)
6 Cylindrical Equipment with Skirt Support – Vertical
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 Closure Strip Detail for Vertical Seam ………………………………………………14
Flashing at Nozzles
15
Use of Corner Angles
16 Beveled End Cap Application …………………………………………………………17 Vertical Tank – Conical or Sloped Bottom
18
Cylindrical Equipment – Vertical – Leg Supported from Head or
Lug Supported
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-F02 Insulation for Hot Equipment (No Water Exposure)
N01-F17 Metal Flashing for Critical Vertical Equipment
N01-F21 Beveled End Cap Fabrication
N01-F30 Cutting and Roll Forming Insulation Jacket
N01-F47 Rigid FRP Finish
N01-F48 Rigid RTP Finish Epoxy Resin
N01-S01 Material Specification – Code Index
N01-S06 Insulation – Materials and Thickness
N01-S11 Code Specification for Preformed Blocks
N01-S14 Fluid and Plastic Insulation
N01-S15 Code Specification for Coatings and Coverings
N01-S16 Code Specification for Fasteners and Miscellaneous Items
N01-S19 Code Specification for Adhesives and Sealers
3. General
3.1 The insulation systems in this standard are for outdoor use and for indoor use where they are exposed to an
external source of water. See SES N01-F02 for insulation in no water exposure service.
3.2 Under severe and critical conditions, see SES N01-F17. When additional protection from the entrance of water at
penetrations is required, for example: nozzles, brackets, clip angles, and support rings, see SES N01-F17.
3.3 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.
3.4 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.
3.5 Thickness of insulation materials shall be stated in inches. See SES N01-S06.
3.6 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).
3.7 Preinsulated equipment shall not be stored outdoors without taking adequate precautions to prevent moisture
from entering the system.
3.7.1 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.
3.7.2 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.
3.8 Insulation materials shall be handled as specified in manufacturer’s recommended safety procedures.
3.9 Insulation shall not be applied until equipment has been protected in conformance with the paint specification.
3.10 Austenitic stainless steel operating at 60 to 149°C (140 to 300°F) in areas that can get wet and which are
deemed to be in critical service shall be protected by a paint system. At 149 to 316°C (300 to 600°F) austenitic
stainless steel shall be protected with sodium silicate.
3.10.1 Noncritical austenitic stainless steel located in areas that can get wet and operating at 60 to 316°C (140 to
600°F) shall be protected with sodium silicate.

3.11 Finish or jacket shall not be applied over wet insulation. Wet insulation shall be removed and replaced with dry
material.
3.12 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
709
Fibrated asphalt cutback
717.6 Beveled end cap one-piece aluminum
718
Fire resistive fibrated asphalt cutback
720 Glass cloth with adhesive
751
32-Mil smooth aluminum jacket
751.1 32-Mil smooth aluminum jacket – coated
752
24-Mil smooth aluminum jacket
752.1 24-Mil smooth aluminum jacket – coated
752.2 24-Mil deep-corrugated aluminum jacket
752.3 24-Mil deep-corrugated aluminum jacket – coated
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
813
Caulking compound
815
Anchor adhesive 107°C (225°F)
817
Anchor adhesive 93°C (200°F)
4.4.3 Fastenings and Miscellaneous: SES N01-S16 (Table III).
CODE DESIGNATION
921
Stainless steel wire (18 gage)
926
Stainless steel bands and seals (10 mm)
927
Stainless steel bands and seals (10 mm)
929
Seals and racks
964.1 Spindle anchors (metal plate)
970
Corner beading
971.1 Sheet-metal screws (stainless steel)
979
Insulation pins (weldable)
979.1 Cupped-head insulation weld pins
980 All weather breather springs
980.1 Heavy duty expansion springs
997 S-clips (stainless steel)

5. Cylindrical Equipment Insulation Preparation
5.1 Insulation Supports and Preparation
5.1.1 Insulation supports shall be checked prior to installing insulation and modified if necessary.
5.1.2 Caution: Written approval shall be obtained from authorized personnel 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
5.2.1.1 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. Where temperature is 149°C (300°F) or less and the angle leg is exposed, it shall be coated
with fibrated asphalt cutback to a 3 mm wet thickness.
5.2.3 Vertical or Horizontal Vessels – Dished Head, Intermediate Bracket or Saddle Supported (1220 mm or larger
diameter).
5.2.3.1 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 bands;
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
5.2.5.1 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 15.
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 is 13 mm wider than the insulation thickness. Upper surface
of flat bar and 152 mm of insulation (inside, bottom, and outside) shall be coated with fibrated asphalt cutback [upper
limit 149°C (300°F)]. 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 skewed 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 road. 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 is 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 17.
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 17.
6. Insulation Application – Equipment
6.1 Curved and shaped segments are available to fit most cylindrical tank walls. These preformed segments shall be
used when available.
6.1.1 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 the double-layer
insulation shall be closed by tamping. If tamping will not close the opening without significantly damaging the insulation
surface, it shall be repaired as follows:
a. by filling with fibrous adhesive thickened with crumbled calcium silicate.
b. by replacing the affected section of insulation.
6.3 Equipment temperature above 149°C (300°F)
6.3.1 All 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
6.4.1 Double-layer insulation shall be banded. Joints shall be staggered and tightly butted. See Figure 9.
6.4.2 Single-layer insulation shall be installed and banded as in Figure 10.
6.5 Insulation Application to Dished Heads
6.5.1 Before applying insulation to dished heads, supports shall be checked to ensure 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.
6.5.1.1 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 so they do 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 18.
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 18.
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, before tightening
the wires, slotted 150 mm squares of 20 gage metal shall be positioned behind the wires. Squares shall be located
where the jacket corners overlap. These sheet-metal squares are used to 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 17.
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 is to be applied, head of weld pin shall
be located where the corners of the jacket overlap. Screws through the weld pin head are used to 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. Lap-deep-corrugated aluminum
sheeting with a minimum of 2.5 corrugations, requires 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 When using metal finish on dished heads, metal shall be cut into segments to conform to the head. Segments
shall be overlapped by a minimum of 76 mm. Flashing compound shall be applied in each lap and secured with
sheet-metal screws. Screw heads shall be covered with flashing compound.
7.2.3 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.
7.2.4 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.
7.2.4.1 Closure strips as in Figure 13, are required at longitudinal joints of vertical equipment to provide a stiffened
double joint for added wind resistance. The band spacing with closure strips is one band over each circumferential lap,
and one band at the middle of each sheet.

7.2.5 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 Table IV.
7.2.6 Metal bevel end caps, as in Figure 16, shall be installed at all exposed insulation terminations. For end-cap
fabrication. See SES N01-F21.
7.2.7 Where openings are cut in the metal jacket to fit around nozzles and other fixtures, backup collars or strips shall
be used, secured by sheet-metal screws. Openings and screw heads shall be sealed with flashing compound. See
Figure 14.
7.2.8 Metal jacketing for conical sections shall be cut to fit tight against the insulation. Sections of jacket shall be
overlapped 76 mm in a watershed 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 17.
7.2.9 On lug-supported vessels, a watershed cover over the supports or insulation, or both, shall be provided as
shown on Figure 15.
7.3 FRP
7.3.1 Shall be applied as detailed in SES N01-F47 or N01-F48.
7.3.2 This is the most durable finish system for dished heads.
7.3.3 Prior to installing metal jacket on the cylindrical walls of horizontal vessels, the FRP finish on the heads shall be
extended over the tank insulation so the metal jacket, when applied, overlaps the FRP finish by a minimum of 100 mm.
A 10 mm bead of flashing compound shall be applied on the FRP finish, positioned so it is under the metal and 38 mm
from the edge of the jacket. A circumferential band shall be placed over the jacket, 38 mm from the edge. On vertical
tanks, the FRP on the top head shall overlap the finish on the side walls by 76 mm.
8. Caulking
Systems shall be sealed with a 10 mm bead of caulking compound at all possible points of moisture penetration. Edges
shall not be feathered.

FIGURE 1
Angle Iron Support Detail