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Hengam Offshore Development Project EPCI For

Topsides and Infield Pipelines and Subsea Cables


Contract No. 4405-90-2FG
SPECIFICATION FOR INSULATION

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SPECIFICATION FOR INSULATION

B4

08.Feb.2014 Re-Issue as AFD

J. Patel/
S. Emamjomeh

Tushar

Arun

B3

12.Mar.2013 Re-Issue as AFD

J.W.Jung

Y.H. Park

Jitendra Patel

B2

17.Jan.2013

J.W.Jung

Y.H. Park

B1

12.Oct.2012

J.W.Jung

Y.H. Park

B0

16.Jun.2012

J.W.Jung

Y.H. Park

Rev.

Date

Prep.

Checked

Approved
for Design
Issued for
Approval
Issued for
Comment
Purpose of Issue

ISI / Ocean Development

Approve

H. Karimi

Approve
IOOC

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Document Number

INPUTS
Title

REVISONS & HOLDS


Revision

Description of Changes & Holds

Status

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TABULATION OF REVISED PAGES


Sheet

Revisions
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B1

B2

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B3

B4

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X

X
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X
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Sheet

Revisions
B0

B1

B2

B3

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Table of Contents
1.

GENERAL .................................................................................................................... 6
1.1

Definition ............................................................................................................................................... 6

1.2

Reference Documents ........................................................................................................................... 6

2.

INSULATION AND ACCESSORIES REQUIREMENTS ................................................ 8


2.1

General Application on Unmanned Platform .......................................................................................... 8

2.2

Insulation Material ................................................................................................................................. 8

2.3

Removable Insulation Covers ................................................................................................................ 8

3.

GENERAL APPLICATION REQUIREMENTS ............................................................... 9


3.1

General.................................................................................................................................................. 9

3.2

Un-insulated Surfaces ........................................................................................................................... 9

3.3

Pressure Testing Considerations ......................................................................................................... 10

3.4

Valves and Flanges ............................................................................................................................. 10

3.5

Insulation Supports .............................................................................................................................. 10

4.

INSULATION OF PIPING ........................................................................................... 10


4.1

Insulation Application ........................................................................................................................... 10

4.2

Weatherproofing Application ................................................................................................................ 11

5.

INSULATION OF VESSELS AND REQUIREMENT .................................................... 11


5.1

Insulation Application ........................................................................................................................... 11

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Weatherproofing Application ................................................................................................................ 12

6.

MOISTURE PROTECTION ......................................................................................... 13

7.

INSULATION TABLES ................................................................................................ 13


7.1

Schedule of Insulation and Accessory Materials .................................................................................. 13

7.2

Schedule of Insulation Materials Application........................................................................................ 15

7.3

Insulation Thickness ............................................................................................................................ 15

8.

INSULATION AND FITTINGS DETAILS ..................................................................... 18

9.

ENVIRONMENTAL CONDITIONS .............................................................................. 18


9.1

Ambient Conditions ............................................................................................................................. 18

9.2

Utility Supply Condition ........................................................................................................................ 18

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1. GENERAL
The Hengam Field is located in the Persian Gulf at approximately 45 km south of Qeshm Island. Iranian
Offshore Oil Company (IOOC) has awarded HENGAM offshore development EPCI project to Intelligent
Solutions Inc. and Ocean development LLC. Joint Venture to perform Basic & Detailed Engineering, as
well as procurement, fabrication, installation, pre-commissioning & commissioning for:

Topside facilities of three offshore wellhead platforms

Infield pipe lines

Submarine composite Cable (Power, Control, Fiber optic) from offshore to onshore facilities.

1.1

Definition

Wherever the word "shall" has been used, its meaning is to be understood as mandatory. Wherever the
word "should" has been used, its meaning is to be understood as strongly recommended or advised.
Wherever the wording "may be" has been used, its meaning is to be understood as a freedom of choice.
The following words and expressions shall have the meanings hereby assigned to them except where
the context of this document otherwise requires:

"Company"

"EPCI Contractor" means Company mentioned in the Contract as part of the "other part" and

means Iranian Offshore Oil Company (IOOC).

includes its successors and permitted assignees. (ISI/ODCO)

"Vendor"

means anyone who provides goods or services to a company. A vendor often

manufactures and/or sells their products to a customer.


Whenever terms appear in this document as capitalized terms, they shall have the meaning ascribed to
them here above.
1.2

Reference Documents
The standards that are listed here below forms an integral part of this specification, in the whole or only
the mentioned paragraphs, and with the modifications or additions indicated by the same
DESIGN CODES
ASME B 31.3

Process Piping.

ASME Section V

Non-destructive Examination.

REFERENCE DOCUMENTS
ASME

American Society of Mechanical Engineer

ASME B1.1

Unified Inch Screw threads (UN and UNR thread form)

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ASME B1.2

Gages and Gagging for Unified Screw Threads

ASME B1.20.1

Pipe Threads (except dry seal)

ASME B16.5
ASME B16.9

Pipe Flanges and Flanged Fittings


Factory-made Wrought Steel, Butt-welding Fittings

ASME B16.11

Forged Steel Fittings, Socket-welded and Threaded

ASME B18.2.1

C.S. and A.S. square and hex bolts and screws

ASME B18.2.2

A.S. and S.S. square and hex nuts

ASME B16.20

Metallic Gasket for Pipe Flanges- Ring Joint, Spiral wound and
Jacketed

ASME B16.21

Non-Metallic Flat Gaskets for Pipe Flanges

BS

British Standards Institute

BS 1133

Protection of Metal Surfaces against Corrosion during Transit


And Storage

BS 476 Part 4

Non-combustibility Test for Materials

ASTM

American Society of Testing and Material

ASTM A193

Alloy Steel and Stainless Steel Bolting Material for High


Temperature Service

ASTM A194

Carbon Steel and Alloy Steel Nuts for Bolts for High Pressure and High
Temperature Service

ASTM B209

Aluminium Alloy sheet and plate / Check

ASTM C195

Mineral Fiber Thermal Insulating Cement

ASTM C533

Calcium Silicate Block and Pipe Thermal Insulation

ASTM C547

Mineral Fiber Performed

ASTM C585

Inner and Outer diameters of Rigid Thermal Insulation for


Nominal Sizes of Pipes and Tubing (NPS System)

ASTM C612

Specification for Fiber Block 2 and board for Thermal Insulation

ASTM C795

Thermal Insulation for use in Contact with Austenitic Stainless Steel

ASTM C892

High-Temperature Fiber Blanket Thermal Insulation

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2. INSULATION AND ACCESSORIES REQUIREMENTS


2.1

General Application on Unmanned Platform


Insulation for process piping for process operation purpose is not required for un-manned platform.
Insulation for personal protection purpose shall be applied for process piping and process equipment
which maybe have hot surface with operating temperature more than 70C. No insulation shall be
installed around the bolts and flanges in hot oil service.
No insulation for utility system equipment and piping except emergency generator engine shall be
applied.

In case of emergency generator engine, the surface temperature of any exposed surface shall not
exceed 55C. The VENDOR shall identify areas likely to exceed this temperature. External personnel
protection facilities for exhaust hot gas piping system and hot surface of engine may be required.
Personal safety-wise, insulation maybe be considered on exhaust gas stack for emergency diesel
generator engine (2m above deck level) or warning plate shall be fitted.

In case of cold insulation, HEAGAM Well Head Platforms are not required except HVAC cold piping
system. For general principle of HVAC cold piping system, no pipes and duct pass through above
electrical equipment in LER shall be applied as far as practicable. When space and routing limitation is
not applicable this principle, minimum spot insulation above electrical equipment or drainage fittings
maybe utilized for preventing condensed moisture drop.

2.2

Insulation Material

Insulation materials, weatherproofing, and accessories shall be as specified in TABLE 1, Schedule of


Insulation and Accessories Materials.
Insulation materials shall be non-corrosive, whether wet or dry, and suitably inhibited for application to
steel surfaces. Insulation materials for austenitic stainless steel surfaces shall be in accordance with
ASTM C795, and transported, handled, stored, and applied in accordance with ASTM C929.

2.3

Removable Insulation Covers


Materials shall comply with the ASME B31.3, ASME B31.8 and Piping Specification and Removable
insulation covers shall be installed on flanges, flanged valves, pumps, instrumentation or similar
equipment and when so stated on pertinent drawings

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A removable cover insulation system shall be made of a minimum number of pieces. Joints shall be
arranged to eliminate any water penetration into the insulation. The weight of any single piece of the
cover shall not exceed 23 kilograms.
Insulation covers shall be constructed so that their natural seam is positioned on the gravitational
bottom of the fittings.
The various parts of covers shall be assembled using teflon-coated yarn or equivalent.
Insulation covers shall fit tightly over fittings and protrusions and shall be held in place with velcro
glassfabric straps (or equivalent) and stainless steel buckles. The insulation covers shall be of a
sufficient width to overlap the adjacent weatherproofing by a minimum of 125 mm on each side of the
fitting.

Each pipe of a removable cover shall have an embossed metal tag permanently attached with
applicable information such as equipment or pipe line number, size, rating and fitting type.

3. GENERAL APPLICATION REQUIREMENTS


3.1

General

Application of base insulation materials shall be as specified in TABLE 2, Schedule of Insulation


Materials Application.
Insulation materials shall not be applied if the moisture content is more than the stated amount given
in the SUPPLIERS application data.

Surfaces to be insulated shall be clean, free of oil, grease, dirt and moisture. All specified coatings
shall be applied and allowed to cure before proceeding with the application of insulation materials.
3.2

Un-insulated Surfaces

The following items shall not be insulated unless otherwise noted on the drawings or herein:
-

Drains

Dummy supports

Name plates

Stamping

Vents

Strainers

Gauges

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Pressure Testing Considerations


Vertical surfaces shall be insulated only after pressure testing.
Horizontal surfaces should be insulated after pressure testing. However, they may be insulated before
pressure testing upon Company approval provided the insulation is temporarily held back a minimum
distance of 150 mm on either side of welds, threaded, or bolted connections. After completion of
pressure testing, all missing insulation shall be installed and appropriately weatherproofed.

3.4

Valves and Flanges


In order to protect the flange mating faces, a removable flange protection made of AISI 316 stainless
steel shall be installed around the outer diameter of flanges. Tightness shall be reinforced with a
double Teflon band applied on the inner face of removable flange protection. Drainage outlets shall be
an integral part of the removable cover design so that leaks may be visually detected.

3.5

Insulation Supports
Insulation supports for vertical piping shall be of a bolted or clamp-on type. The width of the support
shall be one-half of the thickness of the insulation for single layer insulation.
All equipment insulation supports shall be installed by the equipment Manufacturer.

4. INSULATION OF PIPING
4.1

Insulation Application
Single layer pipe insulation shall be applied in a staggered circumferential joint arrangement. Multiple
layer pipe insulation shall be applied with all joints staggered. The following chart details when single
or multiple layer insulation shall be used.

NPS

Number of
insulation layers

Position of longitudinal joints (clock positions)

3 and 9

10

Inside layer : 4 and 10


Outside layer : 3 and 9

The circumferential joints of multiple layer insulation systems shall be staggered 150 mm from the
circumferential joints of any adjacent preceding or succeeding layer.

Insulation shall be secured with wire or bands (15 mm wide) up to 8 NPS, and with bands (20 mm
wide) for sizes 10 NPS and above. Wire and bands shall be spaced on 300 mm maximum centers.

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Securement of fittings shall be as required to hold the insulation segments together tightly, but a
minimum each extreme shall be secured.
4.2

Weatherproofing Application

All pipe fitting covers shall be banded on each extreme.


A watertight metal termination cover shall be installed where pipe insulation terminates. Insulation at
each termination shall be square cut. Band clips shall be equally spaced with one clip at the overlap.
Termination covers shall be with a band at each circumferential overlap and sheet metal screws
spaced on centers.

Irregularly shaped surfaces, which cannot be suitably weather proofed with metal jacketing, shall be
finished with a thick layer of finishing cement. A thick coat of weatherproofing mastic with reinforcing
fabric shall be applied over the cured cement. This finish shall extend at least 50 mm under the
adjacent metal jacketing. No porosity shall exist in the weatherproofing mastic when dry.
Sheet metal screws for fastening the metal weather proofing shall have a neoprene washer under its
head.

5. INSULATION OF VESSELS AND REQUIREMENT


5.1

Insulation Application
If needed, insulation on vessels and tubular equipment shall be applied in a staggered joint
arrangement to fit the contour so that no gaps are evident.
The insulation shall be secured in place with bands spaced on 450 mm centers
Banding of insulation over the head of horizontal equipment and top heads of vertical equipment shall
be as follows:

A floating ring, large enough to clear the center nozzle flange, if one exists, shall be made
from 6 mm diameter stainless steel rod. The ring shall be placed in the center of the head.
A girth ring, made from two bands shall be installed on the shell at approximately 150 mm
below the tangent line of the head.

Bands shall be run radially from the floating ring to the girth ring. The radial bands shall be
spaced at 300 mm maximum centers on the girth ring.

Unexposed bottom heads and cones on vertical vessels and tubular equipment shall have the blanket
insulation shaped so that all sections are tight and secured with wire to slotted weld pins or blanks
nuts.

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Vessel and tubular equipment transitions shall have the insulation applied with all edges securely
laced together with wire.
Vessels and tubular equipment stiffener rings shall be insulated. The insulation shall be applied with all
edges securely laced together with wire. The insulation shall also be secured in place with a band in
the center of each stiffener ring.
Insulation shall be applied behind the name plate mounting bracket, when possible.
5.2

Weatherproofing Application
Vessel and tubular equipment shells shall be weatherproofed with aluminum jacketing, (1.0 mm thick
by 35 mm corrugated).
Vertical overlaps of corrugated metal jacket sections shall be a minimum of one and one half
corrugations but not less than 75 mm. Vertical overlaps of non-corrugated metal jacket sections shall
be a minimum of 75 mm.

Circumferential overlaps at the top tangent lines, transitions and stiffeners shall be a minimum of 150
mm. All other circumferential overlaps shall be a minimum of 75 mm.

Metal jacketing overlaps and seams shall be arranged to shed water. Seams shall be water and
weather tight.

Insulation on the heads and transitions shall be weatherproofed with metal jacketing fabricated from
gores shaped to fit and lapped a minimum of 75 mm to ensure a weather tight construction. The gores
shall be secured with screw spaced on 75 mm maximum centers. All overlaps on the top head shall
have sealant.

On vertical vessels and equipment, S-clips shall be used to keep the jacket sheets from sliding down.
S-clips shall be fabricated from 20 mm wide bands. The length of the S-clip shall equal the overlap.
They shall be spaced on 300 mm maximum centers but not less than three per each metal sheet.

Metal jacketing over shells less than 4.60 meters in diameter shall be secured with bands spaced on
300 mm maximum centers. Band spacing shall be calculated on an individual basis for shells greater
than 4.60 meters in diameter. Each circumferential overlap shall have a band installed. J- clips,
fastened to the jacket with screws, shall be used to prevent bands from sliding down. Each band shall

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have J-clips on 1.80 meters maximum centers but not less than four J-clips per band. The band at the
overlap shall be installed over the S-clips.
Band shall be secured or fastened with closed seals. Wing type seals are not allowed on tank,
pressure vessel and equipment shells.

Insulated surfaces such as equipment bottom heads, which are not exposed to weather, may be
weatherproofed with mastic and scrim cloth in lieu of metal.

Heads of vessels and tubular equipment shall be weatherproofed with metal jacket. A minimum of 150
mm shall be turned down and overlap the shell jacketing. The jacketing shall be formed to fit the
contour of insulation. All seams shall be made up by lock-seam construction and secured with screws
spaced on 125 mm maximum centers. The head jacketing overlap shall be fastened to the jacketing
on the shell with sheet metal screws spaced on 125 mm centers. The head jacketing shall also be
secured in place at the circumferential overlap with a band.

6. MOISTURE PROTECTION
The cut surfaces of insulation segments at terminations and cut-outs shall be covered with 2 layers of
0.15 mm thick aluminium foil extending 300 mm on the underside and top of the insulation. The foil
shall be considered as a protective measure against rain water and not as a substitution for
weatherproofing.

A semi circular rain shield fabricated from 0.5 mm thick aluminium shall be installed immediately above
each uninsulated horizontal protrusion. The shield shall be at least 25 mm under the adjacent vertical
weatherproofing and project 25 mm to the side from the vertical surface.

7. INSULATION TABLES
7.1

Schedule of Insulation and Accessory Materials


TABLE 1
MATERIAL

MAXIMUM
OPERATING
TEMP. C

DESCRIPTION

Mineral fiber- blanket

650

ASTM C 592 Class 2 with metal mesh


both sides

Mineral fiber fitting covers

650

ASTM C 547 Class 2

Mineral fiber Pipe cover


Preformed

650

ASTM C 547 Class 2

COMMENTS

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MATERIAL

MAXIMUM
OPERATING
TEMP. C

Mineral fiber V Grooved

650

Ceramic fiber - Blanket

1260

DESCRIPTION
ASTM C592, Class 2, 128 kg/m3
Unfaced for fire protection
ASTM C892M, Type 3, Grade 8, 128
kg/m3
Unfaced for Fire protection
Type 3003-H14
or 5005-H14
Aluminium alloy with factory applied
moisture barrier
0.6 mm tick, smooth
Type 3003-H14
or
5005-H14 aluminium alloy
with factory applied
0.4 mm thick lead lining, 0.4 mm thick
flat, stucco embossed

Aluminium-Fitting covers

Acoustical jacketing

Aluminium jacketing

Type 3003-H14 or 5005-H14


aluminium alloy with factory applied
moisture barrier.
0.5 mm thick for 200 mm pipe
0.8 mm thick for 200 mm < 500
mm pipe
1.0 mm thick for > 500 mm pipe
and equipment

Stainless steel jacketing

Type 316 stainless steel with 2B mill


finish .4 mm thick smooth Fire
Protection Pipe and Equipment

Bands

Type SS 316L annealed temper, 15


mm by 0.38 mm for piping up to 8
NPS, 20 mm by 0.5 mm for equipment
and piping over 8 NPS

Seals

Type SS 316L, hard temper, wing and


closes types, 0.8 mm thick to match
the band
Shall be fabricated type SS 316L, 20
mm wide by 0.5 mm thick banding

B4

S Clips and band loops


Breather springs

SS 316L, 120 mm long

Screws

Type SS 316L, # 8 by 13 mm, Self


tapping slotted pan head with integral
neoprene washer

Wire

SS 316L annealed temper, 1.29 mm


diameter
Sodium silicate based fibrous
adhesive

Fibrous adhesive

454

COMMENTS

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MATERIAL

MAXIMUM
OPERATING
TEMP. C

Flashing
compound/Sealant
Insulation cement
Insulation boxes and
reusable insulation covers
Floating Ring

DESCRIPTION

93

Flexible non-shrinking type

650

ASTM C 195, mineral fiber insulating


cement

500

See Sections 8.2 and 8.3

COMMENTS

6mm diameter stainless steel rod

Note 1 : Mineral fiber pipe insulation shall be used for acoustic insulation except inside of cradles
where calcium silicate shall be used.
7.2

Schedule of Insulation Materials Application


TABLE 2
ITEMS TO BE
INSULATED
Pipe

Mineral fiber preformed pipe cover

Elbows & Tees

Mineral fiber preformed elbows

Flanges

Removable covers as required

Valves flanged

Insulation boxes/removable covers as required

Vessels
Top heads
Heads-other
Shells
24 diameter
> 24 diameter
Manhole covers

7.3

MATERIAL TYPE

Mineral fiber blanket


Mineral fiber blanket
Mineral fiber blanket
Mineral fiber blanket
Insulation boxes/removable covers

Insulation Thickness
The following insulation thicknesses are those used for engineering design and the production of
engineering drawings and documentation. The SUPPLIER shall be aware that a justified reduction in
insulation thickness is practicable but an increase in thickness may be problematical (support
standoffs, etc.)

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Refer to Table 3 for Heat Conservation insulation thicknesses.


Table- 3 Heat Conservation Insulation Thicknesses (mm)
(Mineral Wool Basis)
Maximum Metal Surface Temperature (C)
Pipe N.D. (in)

100

150

200

250

300

350

400

450

1/2
3/4
1
1 1/2
2
3
4
6
8
10
12
14
16
18
20
30+and Flat
Surface

20
20
30
30
30
40
40
40
40
50
50
50
50
50
50
80

30
30
40
40
40
50
50
50
50
60
60
60
60
60
60
80

40
40
50
50
50
60
60
60
60
80
80
80
80
80
80
100

40
40
50
60
60
80
80
80
80
80
100
100
100
100
100
100

50
50
60
60
80
80
100
100
100
100
100
120
120
120
120
120

50
50
60
60
80
80
100
100
100
100
100
120
120
120
120
140

50
50
60
60
80
80
100
100
100
100
120
120
120
140
140
160

50
50
60
60
80
80
100
100
100
120
120
140
140
160
160
180

500
plus
50
50
60
80
80
80
100
120
120
140
140
160
160
160
180
180

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Personnel protection as per table 4 is required for bare metal surface temperatures of:
-

-10C or below

+65C or greater

To avoid corrosion under insulation, insulation is not to be used for personnel protection. Expanded
metal or wire gauges are suitable and to be used.
However if insulation is to be used for personnel protection, mineral wool shall be used and thickness
shall not be less than 25mm.
Barrier system shall be consisting of perforated sheets or wire mesh. Barrier system used for
personnel protection shall be painted according to Specification for Painting, Coating and Corrosion
Protection
The distances between the perforated metal sheets/guards and bare surface and insulation thickness
for personnel protection shall be specified by the SUPPLIER.

Table - 4 Personnel Protection Insulation Thicknesses (mm)


(Mineral Wool Basis)
Maximum Metal Surface Temperature (C)
Pipe N.D. (in)
1/2
3/4
1
1 1/2
2
3
4
6
8
10
12
16
18
20
24
30+and Flat Surface

Upto250
25
25
25
25
25
25
25
25
25
25
25
25
30
30
30
30

300

350

400

450

500

550

600

650plus

25
25
25
25
25
25
25
25
30
30
30
30
30
30
30
30

25
25
30
30
30
30
30
30
30
30
30
30
30
30
30
30

30
30
30
30
30
30
40
40
40
40
40
40
40
40
40
40

30
30
30
30
40
40
40
40
40
40
50
50
50
50
50
50

40
40
40
40
40
50
50
50
50
50
60
60
60
60
60
60

40
40
40
50
50
60
60
60
60
60
75
75
75
75
75
75

50
50
50
50
60
60
60
75
75
75
75
75
75
75
75
75

50
50
60
60
60
75
75
75
75
75
100
100
100
100
100
100

SUPPLIER's Specification shall be approved by Company before placing any order.

Hengam Offshore Development Project EPCI For


Topsides and Infield Pipelines and Subsea Cables
Contract No. 4405-90-2FG
SPECIFICATION FOR INSULATION

Rev. B4

Proj.

Area.

Disc

Doc.

Seq.

Page

HEN

0000

ME

SP

0002

18 of 18

8. INSULATION AND FITTINGS DETAILS


Detail of Insulation and fittings shall be refer to other drawing and documents which will be issued
separately.

9. ENVIRONMENTAL CONDITIONS
9.1
B4

Ambient Conditions
For ambient condition refer to Process Design Basis HEN-0000-PR-DB-0001 and
Structural Design Basis HEN-0000-ST-DB-0001.

9.2

Utility Supply Condition


For utility supply condition refer to Process Design Basis HEN-0000-PR-DB-0001 and
Electrical Design Basis HEN-0000-EL-DB-0001