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OPTARA PROJECT SPECIFICATIONS

RAFFINADERIJ ANTWERPEN

AmendmenttoTotalgeneral
specificationGSRMISL001
thermalinsulationofpiping
vesselsandtanks

T4RA55GENA40008

REVISION1

ResponsibilityTOTAL/RC/IND

15February2013

OPTARA PROJECT
RAFFINADERIJ ANTWERPEN
REVISION1

AmendmenttoTotalgeneralspecificationGSRMISL
001thermalinsulationofpipingvesselsandtanks

15February2013

Revisiontracking

Revision
1

Revisiondate
15February2013

ScopeofRevision
ApprovedforOptaraProject

OPTARA PROJECT
RAFFINADERIJ ANTWERPEN
REVISION1

AmendmenttoTotalgeneralspecificationGSRMISL
001thermalinsulationofpipingvesselsandtanks

15February2013

Tableofcontents

Section

Contents
T4RA55GENA40008

Page

ISSUED FOR DESIGN


06 Sep 2012

Final
For Design Dossier
By Marcel Agterhof at 01 12 :21 Dec 2012

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 2 of 12

Table of Contents
1. INTRODUCTION ...........................................................................................................3
2. REFERENCES .............................................................................................................3
2.1. Client Specifications................................................................................................................3
2.2. Project Specifications..............................................................................................................3
2.3. Standards ................................................................................................................................3

3. AMENDMENTS TO TOTAL GENERAL SPECIFICATION ....................................................4


3.1. Section 1, Subject ...................................................................................................................4
3.2. Section 2, Reference documents, TOTAL General Specification...........................................4
3.3. Section 3, Applicability ............................................................................................................4
3.4. Section 5, paragraph 5.1.1 General ........................................................................................4
3.5. Section 5.1.4 Personnel Protection (PP) ................................................................................6
3.6. Section 5.2 Extent of the thermal insulation work ...................................................................6
3.7. Section 5, paragraph 5.3.1 Anti- Corrosion Protection ...........................................................7
3.8. Additional requirements for ACOUSTIC INSULATION...........................................................8
3.8.1. Classification of acoustic insulation ...........................................................................8
3.6.1.1. Class A .................................................................................................................8
3.6.1.2. Class B .................................................................................................................8
3.6.1.3. Class C .................................................................................................................9
3.8.2. Material requirements ................................................................................................9
3.8.3. Support of jacketing ................................................................................................ 10
3.8.4. Installation ............................................................................................................... 10

4. ATTACHMENTS.........................................................................................................12

Abbreviations
Abbreviation

Meaning

TRA

TOTAL Refinery Antwerp

ARDS

Atmospheric Residue DeSulphurisation

MHC

Mild Hydrocracker

SDA

Solvent DeAsphalting

SWS

Sour Water Stripper

U&O

Utilities and Offisites

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 3 of 12

1. Introduction
This document shall be considered as an amendment to referenced TOTAL General Specification and
has been specifically prepared for the OPTARA project scope covering the ARDS revamp, MHC, SDA,
SWS, Substation and related U&O scope.
This Amendment shall be read in conjunction with referenced OPTARA Project Specification Preamble
which contains information of the overall Project Specification approach and order of precedence.

2. References
2.1. Client Specifications
Document Number

Rev

Description

GS RM ISL 001

00

Specification Thermal insulation for piping, vessels and tanks

03

Specification Thermal and Acoustic Insulation

GS RM COR 003

00

Specification Wrapping of Aluminium foil

2.2. Project Specifications


Document Number

Rev

T4RA-00-GEN-A4-0002

00

Description
Design Dossier - OPTARA General - Preamble

2.3. Standards
Document Number

Description

ISO 15665

Acoustic insulation for pipes, valves and flanges

CINI 2012

C.I.N.I. Handbook for Insulation 2012

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 4 of 12

3. Amendments to TOTAL General Specification


This section describes the amendments to aforementioned TOTAL General Specification by making
direct references to its sections and paragraphs followed by a clear description of the amendment
using the following categories:
-

"addition" for any parts that need to be added to the General Specification

"deletion" for any parts that need to be deleted from the General Specification

"modification" for any parts that need to be changed in the General Specification

clarification for any parts that need to be clarified in the General Specification

3.1. Section 1, Subject


Addition:
The General Specification GS RM ISL 001 Thermal insulation for piping, vessels and tanks is
applicable for new units (MHC fractionation and SDA).
For revamped units and U & O, TRA specification P is applicable, GS RM ISL 001 shall not be used.
Modification:
C.I.N.I. handbook 2012 is applicable

3.2. Section 2, Reference documents, TOTAL General Specification


Modification:
TOTAL General Specification GS RM PVA 101, Refinery piping classes shall be replaced by T4RA50-GEN-A4-0003, Piping Material specification Process and Utility Piping.

3.3. Section 3, Applicability


Addition
The Requirements for Acoustical Insulation are provided per chapter 3.6.of this amendment.

3.4. Section 5, paragraph 5.1.1 General


Modification:
The insulation codes in section 5.1.1 shall be replaced by codes used on the OPTARA project.
An overview of the on the OPTARA Project used Insulation codes are given in table 3.4

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 5 of 12

Insulation and Tracing Codes


Type of Insulation

GS RM ISL 001

codes ARDS - MHC


P&ID

Line list

legend
Not Insulated

Codes SWS 99 +SDA +U&O


P&ID

Line List

legend
NI

NI

NI

Heat Conversation

HC

Ih

HC

HC

HC

Personnel
Protection

PP

Is

PP

PP

PP

Acoustical
Insulation

Ia

AC

AC

AC

Cold Insulation

Ic

CC

CC

CC

ST(H)

ST(H)

ST

ST

Steam traced with


spacers and
Insulated

STS(H)

STS(H)

ST1

ST1

Steam traced with


heat transfer
cement and
Insulated

STT(H)

Electrical Traced
and Insulated

ET(H)

Electrical Traced
with heat transfer
cement and
insulated

ETT(H)

Steam traced and


Insulated

Table 3.4

HC

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 6 of 12

Insulation and Tracing Codes (continued)


Type of Insulation

GS RM ISL 001

codes ARDS - MHC


P&ID

Codes SWS 99 +SDA +U&O

Line list

P&ID

legend
Electrical Traced
and Insulated

ET(W)

Electrical Traced
with heat transfer
cement and
insulated

ETT(W)

Steam traced and


insulated

Line List

legend

WT
ST(W)

ST(W)

Steam traced with


spacers and
insulated

STS(W)

STS(W)

Steam traced with


heat transfer
cement and
Insulated

STT(W)

Winterization

AF

AF

Anti Frosting

Anti Frosting

PS

PS

Process
Stabilization

Process
Stabilization

Table 3.4

3.5. Section 5.1.4 Personnel Protection (PP)


Modification
Personnel protection shall be applied where the hot surfaces are above 65C.

3.6. Section 5.2 Extent of the thermal insulation work


Addition
The following items shall receive insulation for heat conversation only when above 120C unless
specifically indicated otherwise on the relevant documents:
-

Process piping, except valves and flanges.

Steam piping 40 bar and lower, including valves and flanges.

Equipment, including vessels, steam turbines and steam engines.

Heat traced items including valves and flanges and tracer jumpers.
(Note: when in hazardous service or a service above self ignition temperature, e.g. hydrogen
service, valves and flanges shall be left free of insulation).

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 7 of 12

Piping with the following services shall have the valves and flanges insulated with removable
boxes: Pitch, hot oil (bitumen), sulphur and superheated steam, except where explicitly
indicated otherwise.

Hot oil valves will be insulated where possible to minimize heat loss.

Items NOT to be insulated for heat conversation, regardless of temperature, unless specifically
indicated otherwise on relevant documents
-

Piping and equipment where it is possible to lose heat and indicated as such on the relevant
documents.

Pumps and Compressors

Valves and flanges in steam service when above 40 bar and in process piping systems.

Valves and flanges in hydrogen and hazardous service, except valves, flanges and bellows in
H2S rich gas lines an sulphur plants (ARDS-jobs 57/98) (to prevent condensation).

Manholes, handholes (in view of leak detection).

Main flanges and bolts of heat exchangers and girth flanges of heat exchangers and other
equipment.

Piping and equipment operating intermittent, such as relief valves, vents, drains, steam-out,
snuffing steam and decoking systems, blow-down systems, flare systems and the by-pass of
heat exchangers.

Piping and equipment supports extending outside the insulation thickness of the item.

Expansion joints (e.g. bellows), hinge joints, line filters and line mixers.
(Note: This instruction does NOT include insulation expansion joints).

Fuel gas and pilot gas lines to individual burners (headers excluded).

Instrument air lines

Name Plates

3.7. Section 5, paragraph 5.3.1 Anti- Corrosion Protection


Addition
Stainless steel piping under Insulation and operating at evaluated temperature up to 150C shall be
protected against stress corrosion cracking by wrapping of Aluminium foil. The Aluminium wrapping
shall be applied according GS RM COR 003 Wrapping Aluminium Foil.

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 8 of 12

3.8. Additional requirements for ACOUSTIC INSULATION


This Specification includes the technical requirements for the design and application of acoustic
insulation to piping and equipment, in combination with or without thermal Insulation.
This Specification describes the set-up and application of sound pressure levels or required or
achievable noise reductions. Dealing with acoustic problems is the work of an acoustic
specialist, who will design and specify what items, shall be insulated, in what manner and to
what classification.
This Specification is related to ISO 15665, in terms of classification or acoustic insulation for
piping, valves and flanges.
These requirements substitute the requirements for specification P for all new equipment and
piping that shall be provided acoustical insulation.

3.8.1. Classification of acoustic insulation


Acoustic insulation is divided in 3 classes:
Class A

: Lightest noise reduction, most economic

Class B

: Medium noise reduction

Class C

: Heavy noise reduction

The thickness of the acoustic insulation and minimum jacketing mass for the four defined
classes is indicated in Table 2, unless specified otherwise.
Table 2 Classes of acoustic insulation
Class

Thickness of the porous layer(s)

Minimum jacketing mass

[mm]

[kg/m2]

50

st

1 layer
2nd layer

50
50

1st layer
2nd layer

50
50

10

Additional requirements for each class are specified below.

3.6.1.1.

Class A

Flanges and valves do not need to be insulated.

3.6.1.2.

Class B

The porous layers shall be applied in two 50 mm layers with staggered joints.

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 9 of 12

Pipe with a diameter 80 mm ( 3 inch) shall have maximum insulation thickness of 50 mm.
Distance and support rings shall be avoided whenever possible.
All flanges and valves shall be insulated to the same class as the pipe, except for valves and
flanges in hazardous service.
Pipe supports shall be insulated up to the concrete or steel base.

3.6.1.3.

Class C

The minimum jacketing mass shall be obtained by a combination of steel jacketing and mass
loaded thermoplastic sheet. Mass loaded thermoplastic sheet material is specified in paragraph
3.3.2.2.
Pipe supports, including guides, but not including anchors, shall be mounted on a vibrationisolating pad.
In addition all requirements of Class B apply.

3.8.2. Material requirements


The material requirements are equivalent with the material requirements for hot insulation with
the following exceptions:

Mass of jacketing

Use of mass loaded thermoplastic sheet

Minimum air flow resistance of insulation material of 25,000 - 75,000 Ns/m4

No rigid contact allowed between pipe and jacketing (use of anti-vibration seals and special
support of jacketing)

The drawings of ISO 15665 apply

3.8.2.1 Porous layer


The porous layer shall be mineral wool in accordance the requirements of thermal insulation.
The air flow resistance of the porous layer specified above is normally obtained by materials
with a density range of 65 - 125 kg/m3. The range may be extended to 50 kg/m3 for Class A
insulation.

3.8.2.2 Jacketing
Minimum jacketing mass per unit area shall be according Table 2 for the acoustic insulation
class considered.
Jacketing material shall be aluminium or stainless steel as per hot insulation specification
combined with mass-loaded thermoplastic sheet as required.
Approved thermoplastic sheet materials are:
a)

IDIKELL self-adhesive, 1.5 mm thickness, mass 3 kg/m or 2.5 mm thickness, mass


5 kg/m

b)

TERODEM 5500, 2.6 mm thickness, mass 5 kg/m

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 10 of 12

3.8.2.3 Anti-vibration seals


At locations where metal-to-metal contact occurs, anti-vibration seals shall be applied. Antivibration seals shall have a minimum thickness of 3 mm and a minimum width of 50 mm.
The edges of the jacketing or end cap shall be folded where they rest on the anti-vibration seal.
The anti-vibration seals shall be suitable and fully resistant to the specified operating
temperature
The following materials are suitable for use in anti-vibration seals:
(a)

Synthetic rubber

(b)

Natural rubber

(c)

Non-flammable felt

Where these materials are not compatible with the operating temperature, the seal shall be
made from compressed porous-layer material. Alternatively a clearance of about 10 mm may be
left where weather protection of the pipe is not a consideration. Note that, in many cases, antivibration seals may also be required to act as a watertight seal and the material shall be suitable
for this.

3.8.3. Support of jacketing


Where semi-rigid sections are used on horizontal pipe it will normally not be necessary to
support the jacketing; but where blankets are used it may be necessary to support the jacketing
through the porous layer. Semi-rigid sections, used at intervals, may be suitable for this provided
they are compatible with the operating temperature and the chemical environment.
Rigid spacers, as used in distance rings for thermal insulation, shall not be used in acoustic
insulation. Where it is necessary to use spacers, they shall contain a resilient element to reduce
the transmission of vibrations from the pipe. Where necessary the resilient element shall have a
built-in mechanical stop in the direction normal to the pipe axis in order to limit its mechanical
deflection.
With vertical pipes, any supports which carry the weight of the jacketing, shall contain resilient
elements to reduce the transmission of vibrations from the pipe. Where necessary, these
resilient elements shall contain mechanical stops to limit excess movement.
Resilient elements shall not be loaded to such an extent that their operational range of
deflections is exceeded.
Acceptable examples of additional jacketing support other than the use of semi rigid sections
are included in ISO 15665.
The required method for supporting the jacketing shall be agreed between the parties
responsible for the mechanical and acoustic design.
Additional supports shall not be welded without written approval from Companys
Representative.

3.8.4. Installation
3.8.4.1 General
The requirements of any relevant specification for thermal insulation shall apply, except where
excluded or superseded by this specification.

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 11 of 12

An essential feature of acoustic insulation is that the jacketing must not be in direct or indirect
metal-to-metal contact with the pipe, or the equipment. Any such contact will allow a
transmission of vibrations to the jacketing which will reduce or nullify the noise reduction of the
insulation; it may even enhance the noise radiation due to the greater surface area of the
jacketing. It is also important that there shall be no gaps in the insulation. Joints in the porous
layer shall therefore be staggered and the jacketing shall overlap at all joints.
If a multiple layer system is used, the joints of insulating materials of two consecutive layers
shall be staggered, generally single layer of insulation shall not exceed 75 mm.

3.8.4.2 Extent of insulation


The length of pipe to be insulated and the class of insulation shall be specified by Companys
Representative Noise Control Engineer responsible for the acoustic design.
Insulation of pipe supports, flanges and valves shall be in accordance with the requirements of
the Class (see paragraph 3.3.1.). Otherwise, the specified length of pipe shall be insulated to
cover the whole of the noise-radiating area, without gaps or voids.

3.8.4.3 End caps


At all exposed flanges the acoustic insulation shall be terminated with an end cap. This shall be
located as close to the flange as possible and shall not interfere with the requirements for bolt
removal. The end cap shall be isolated from the pipe by means of an anti-vibration seal.

3.8.4.4 Acoustic removable enclosures (not for class A)


The acoustic enclosure shall have an outer surface of metal sheet with a mass per unit area at
least equal to that of the jacketing. The porous layer shall be similar in material to that used on
the piping and shall be retained by an inner surface layer which is at least 10 mm away form the
flange or valve; for example, perforated-metal sheet with an open area of not less than 30%. In
general, a thickness of 100 mm will be sufficient for the porous layer of a valve enclosure.
Where acoustic enclosures are installed around flanged joints they shall be of sufficient length to
overlap the end caps on the pipe jacketing by at least 100mm for Class B and 200mm for Class
C.
Removable parts of acoustic enclosures heavier than 25 kg shall have lifting lugs.

3.8.4.5 Insulation of equipment (vessels, pumps, compressors)


Acoustic insulation of vessels shall comply with the above requirements for piping insulation. For
pumps and compressors, acoustic enclosures shall be considered.

T4RA OPTARA Project


TOTAL, Antwerp
AMENDMENT TO SPECIFICATION
GS RM ISL 001 Thermal Insulation for Piping, Vessels and Tanks
CONFIDENTIAL

T4RA-55-GEN-A4-0008
Rev. 1
5 Sep 2012
Page 12 of 12

4. Attachments
The following attachments form an integral part of this Amendment.

Document Number

Rev

Description

GS RM ISL 00

General Specification Thermal Insulation for piping, vessels and


tanks

Thermal and Acoustic Insulation

DR179E000Z00000001

Inspection hatch to provide access to Corrosion Monitoring points


under Insulation.

DR179E000Z00000002

Corrosion Monitoring locations

Refining

GENERAL SPECIFICATION
Insulation
GS RM ISL 001

Thermal insulation for piping, vessels and tanks

00

11/2009

Rev.

Date

Original issue
Subject of revision

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

This document is the translation of the official French version

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

Contents

Foreword ........................................................................................................................ 5
1. Subject ..................................................................................................................... 5
2. Reference documents............................................................................................. 5
2.1

Priority rules.......................................................................................................................6

2.2

Exemptions ........................................................................................................................7

3. Applicability............................................................................................................. 7
4. Definition of terms................................................................................................... 7
5. Thermal insulation design base............................................................................. 7
5.1

Function of thermal insulation............................................................................................7

5.2

Extent of the thermal insulation work.................................................................................8

5.3

Choice of thermal insulation system ..................................................................................9

5.4

Basic data ........................................................................................................................11

6. Thermal insulation thickness............................................................................... 13


6.1

Heat conservation............................................................................................................13

6.2

Protection against cold ....................................................................................................13

6.3

Protection of personnel....................................................................................................14

7. Extent of the Contractor's supply........................................................................ 14


7.1

General ............................................................................................................................14

7.2

Equipment to be thermally insulated................................................................................14

7.3

Studies.............................................................................................................................14

7.4

Equipment........................................................................................................................15

8. Thermal insulation ................................................................................................ 15


8.1

General characteristics ....................................................................................................15

8.2

Nature and form of the thermal insulation........................................................................16

9. Claddings............................................................................................................... 16
9.1

Preparation of the surfaces to be thermally insulated......................................................16

9.2

Fitting the thermal insulation............................................................................................16

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 2/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

9.3

Fitting the cladding...........................................................................................................16

9.4

Removable insulation ......................................................................................................17

9.5

Applying the cladding.......................................................................................................17

9.6

Accessibility .....................................................................................................................17

9.7

Covers without thermal insulation....................................................................................17

10. Thermally insulating piping.................................................................................. 18


10.1

Thermal insulation support ..............................................................................................18

10.2

Thermally insulating flanges and valving .........................................................................18

11. Thermally insulating sheet metal vessels........................................................... 18


11.1

Thermal insulation support structure ...............................................................................18

11.2

Removable items on manholes and hand holes..............................................................18

11.3

Wells ................................................................................................................................19

12. Thermally insulating tubular exchangers ........................................................... 19


12.1

General ............................................................................................................................19

12.2

Exchanger with a nominal diameter greater than 750 mm (30")......................................19

12.3

Exchanger with a nominal diameter less than or equal to 750 mm (30").........................19

13. Thermally insulating machinery .......................................................................... 20


14. Thermally insulating storage tanks ..................................................................... 20
14.1

General ............................................................................................................................20

14.2

Thermally insulating storage tanks ..................................................................................20

14.3

Application .......................................................................................................................22

15. Inspection and testing .......................................................................................... 24


16. Quality control....................................................................................................... 24
16.1

General ............................................................................................................................24

16.2

Material quality control.....................................................................................................24

16.3

Quality control before application of the insulation ..........................................................25

16.4

Quality control while the insulation is being applied ........................................................25

16.5

Quality control while the protective covering is being installed ........................................25

17. Acceptance of the works ...................................................................................... 25


17.1

Acceptance ......................................................................................................................25

17.2

Thermal performance inspections ...................................................................................26

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 3/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

18. Warranties.............................................................................................................. 26
Appendix 1

Thicknesses of the thermal insulation ............................................... 27

Appendix 2

FRANCE ................................................................................................ 30

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 4/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

Foreword
Engineering Companies and Design Offices that are contractually bound to TOTAL, are obliged
to always check that the applicable regulations, in particular regarding SAFETY, QUALITY and
protection of the ENVIRONMENT, do not impose more restrictive measures. If they do,
alternative solutions in accordance with the regulations shall be submitted in writing to TOTAL.
Except for when it is used internally, the application of this specification is systematically
covered by a contract.
Caution, for new equipment, this specification supersedes the following specifications:
DRE M 1100 revision R1 dated 06/06,
SGI 0001.ISL revision C dated 11/95,
RG ISL.B01 revision C dated 11/95,
STDI 0001.ISL.001 revision 04 dated 01/95,
STDI 0001.ISL.002 revision 03 (C) dated 12/95,
STDI 0001.ISL.003 revision C dated 03/95.

1. Subject
This general specification defines the hot operation thermal insulation rules for above ground
piping, valves, vessels and storage tanks.
This specification is based on the CINI document "Insulation for industries" (English version),
October 2008 revision, which should be considered to be an integral part of this specification.

2. Reference documents
The reference documents listed below form an integral part of this General Specification. Unless
otherwise stipulated, the applicable version of these documents, including relevant appendices
and supplements, is the latest revision published at the Effective Date of the Contract.
Standards
Reference

Title

NF EN 13501-1

Fire classification of construction products and building elements - Part 1 :


classification using data from reaction to fire tests

ASTM C795

Standard Specification for Thermal Insulation for Use in Contact with


Austenitic Stainless Steel

VDI 2055

Thermal insulation for heated and refrigerated industrial and domestic


installations Calculations, guarantees, measuring and testing methods,
quality assurance, supply conditions

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 5/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

Professional documents
Reference
CINI

Title
Commissie Isolatie Nederlandse Industrie (insulation for industries)

Regulations
Reference

Title

Not applicable
Codes
Reference

Title

Not applicable
TOTAL General Specifications
Reference

Title

GS RM COR 001

Equipment painting specification for external surfaces

GS RM GEN 001

Rules for creating Piping and Instrumentation Diagrams (P&ID)

GS RM INS 115

Protection of instrument against freezing and plugging

GS RM PVA 101

Refinery piping classes.

GS RM PVA 600

Steam tracing of equipment.

GS RM PVE 001

Unfired metallic pressure vessels.

Other documents
Reference

Title

Not applicable

2.1 Priority rules


The subject of this specification shall satisfy, in descending order of priority, the requirements of:
the local regulations, when applicable,
the projects job specification, when existing,
this specification,
other codes, specifications and standards to which this specification refers.
In the event of conflicting requirements between the selected construction code and these other
codes, specifications and standards (if they are stipulated by a particular contract), the most
restrictive requirements shall apply.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 6/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

2.2 Exemptions
Any exemption from the requirements of this specification may be suggested by the General
Contractor, Engineering Company, Manufacturer or Contractor, if he considers such exemption
beneficial for reducing the cost and/or completion time, provided that it does not compromise
the safety of personnel, service reliability, the cost effectiveness of the project in question or the
regulatory requirements (when such regulations apply).
Exemptions shall be submitted to TOTAL, as a variant with the necessary justifications, and
must receive the written approval of TOTAL.

3. Applicability
This specification applies to the design of new refining units or the remodelling of existing units
of TOTAL group refining units.
It does not apply:

to buried equipment,

to instruments,

to low temperature equipment,

to acoustic protection.

4. Definition of terms
Purchaser
Individual or legal entity responsible for drawing up the order documentation and
purchasing the equipment that is the subject of this specification. This specification shall
be an integral part of the order documentation.

5. Thermal insulation design base


5.1 Function of thermal insulation
5.1.1 General
Thermal insulation is intended mainly to provide at least one of the following functions:
heat conservation: coded HC (Heat Conservation),
protection against cold: coded WT (Winterisation),
protection of personnel: coded PP (Personnel Protection),
insulation with heat tracing: coded HC (Heat Conservation).
Note:
The reader is reminded that the symbols corresponding to the types of thermal insulation shall
be indicated alongside the identifiers of the lines included on the process and flow diagram (see
TOTAL specification GS RM GEN 001).
All thermal insulation shall be clearly and legibly marked with the name or code of the item to
which it is assigned.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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5.1.2 Heat conservation (HC)


The thermal insulation shall be applied to equipment for which the heat losses would lead
directly or indirectly to an additional consumption of fuel and to those items of equipment for
which thermal insulation is required by the process. The thermal insulation is limited to the parts
where it is economically justified.
5.1.3 Protection against cold (WT)
The thermal insulation shall be applied to the equipment containing or conveying fluids that can,
under the action of cold and in certain conditions:
solidify (heavy products, etc.),
crystallise (paraffins, etc.),
freeze (water),
give rise to the formation of condensates (fuel gas), circulating continuously or not.
It is therefore designed to delay the cooling of cold-sensitive fluids.
This protection against cold can be associated with equipment tracing. Other cold protection
means can be considered (see TOTAL specification GS RM PVA 600).
5.1.4 Personnel protection (PP)
This relates to the parts that can be accessed or are likely to be accessed during operation and
servicing procedures on any equipment with a surface temperature greater than 70C, for an
outdoor temperature of 20C, and not covered by the abovementioned section 5.1.2.
This relates to the areas situated less than:
2 metres above a platform,
0.6 metres from a traffic area.
To avoid any risk of burns to personnel, a protective grid shall be positioned around the relevant
equipment, so as to prevent any contact without prior dismantling. The use of thermal insulation
is allowed for equipment that operates continually and that has an actual operating temperature
greater than 150C.

5.2 Extent of the thermal insulation work


The process data sheet and the line list indicate the equipment that shall be thermally insulated
and the type of thermal insulation.
TOTAL specification GS RM PVA 101 indicates for each piping class whether or not the flanges
shall be thermally insulated. Generally, the flanges of equipment containing hydrocarbons or in
hydrogen operation are not thermally insulated.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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Flanged assemblies are thermally insulated in cases where there is an identified risk of gas
condensation that might cause corrosion, a risk of plugging or unacceptable thermal losses:
risk of formation of corrosive salts,
risk of product solidification (sulphur, bitumen, etc.),
flue gas condensation,
coking of FCC reactor effluents,
steam or heating fluid lines,
piping insulated against the cold (WT)...
These assemblies shall not have been calculated in application of a bolting temperature
reduction rule (for example, 20% reduction for the temperature of the bolting in accordance with
code B31.3).
The thermal insulation work for a flanged assembly shall be carried out in such a way that the
protective enclosure and the thermal insulation is easy to dismantle and reassemble. The boxes
shall include a drainage device (see drawing CINI 4.1.18).
The parts of equipment that are normally removable and that are to be insulated (such as
manholes, valves, removable domes), shall be equipped with removable insulation devices.
The following equipment shall not be covered with thermal insulation:
Manufacturers' plates when fixed to the wall of the equipment,
skirt and legs supporting vessels,
vessels or tanks with internal insulation,
traps, vent or drain nozzles to the open air, except in particular cases (equipment vents
conveying bitumen, sulphur, etc.),
valves and flanges in hydrogen service,
piping for vessels designed taking into account a reduced temperature because of the
dissipation of heat into the atmosphere.

5.3 Choice of thermal insulation system


The thermal insulation system comprises the following elements:

anti-corrosion protection for the support when necessary,

an insulating product,

a protective cladding against the ingress of water.

Choosing an insulator involves considering all the stresses to which it will be subjected, in order
to ensure its effectiveness over time:
the nature of the equipment (piping, vessel, tank, etc.),
the material of which the equipment is made,

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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the operating temperature,


the corrosivity of the environment,
the mechanical stresses,
fire resistance, etc.
The system (insulation and protective cladding) is defined using the CINI flow diagram 1.2.01,
supplemented with the following comments.
5.3.1 Anti-corrosion protection
Carbon steel equipment with an operating temperature less than 150C corrodes in the
presence of moisture. Such equipment shall be protected by a coating according to TOTAL
specification GS RM COR 001.
Equipment made of austenitic stainless steel with a temperature less than 150C and greater
than 50C can corrode under thermal insulation by pitting or by stress corrosion cracking. Such
equipment shall be protected by a coating compliant with TOTAL specification
GS RM COR 001.
5.3.2 Choice of insulation
The CINI table 1.2.01 uses temperature as input data. Other considerations shall be taken into
account such as:
fire resistance, on hydrocarbon processing units (light or hot), where the risks of fire are
significant, materials of a mineral origin (glass wool, rockwools, calcium silicate, perlite,
etc.) shall be employed, and not organic materials that have a low temperature resistance,
mechanical compression resistance may be a criterion of choice if there is a possibility of
passage,
in particularly humid sectors, an insulator will be selected that does not favour water
retention such as cellular glass.
5.3.3 Choice of protective cladding
The external cladding shall protect the insulation over time against the ingress of water and any
mechanical impacts. It also has an aesthetic function.
Location
Unit containing hydrocarbons

Offsite, utilities

Type of cladding

CINI specification

Aluminised plate

CINI 3.1.02

Stainless steel plate

CINI 3.1.05

Aluminised plate

CINI 3.1.02

Stainless plate

CINI 3.1.05

Aluminium plate

CINI 3.1.01

Tanks

Lacquered galvanised plate

Offsite or utility in humid area (pier,


proximity to cooling towers, etc.)

Fibre reinforced polyester

CINI 3.2.11

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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Fire resistance. On units processing hydrocarbons (light or hot), where the risks of fire are
significant, protective claddings made of aluminised plate (CINI 3.1.02) or stainless steel
(CINI 3.1.05), which has a better resistance over time, shall be employed.
In the absence of any fire risk, aluminium claddings (CINI 3.1.01) can be considered. They
offer good resistance over time to atmospheric corrosion, but their mechanical resistance
is lower. They offer low resistance to corrosion in the presence of acids or bases.
The use of galvanised steel is not recommended (lower resistance to corrosion). Its use in
galvanised and lacquered form is allowed on tanks.
Equipment made of austenitic stainless steel is sensitive to stress cracking by molten
metals, notably zinc. This affects equipment and instrumentation made of austenitic
stainless steel. For this reason, the use of galvanised plates or alu-zinc coated plates is
strictly prohibited on the units.
In sectors where humidity is high and/or the fire risk is not predominant, fibre reinforced
polyester type organic claddings (CINI 3.2.11), providing a good tightness, can be
employed if the temperatures remain moderate (jetty, proximity of cooling tower,
demineralisation unit, etc.).

5.4 Basic data


The data needed to study the thermal insulation of equipment shall be specified by TOTAL or
the Engineering Company.
5.4.1 Heat conservation (HC)
5.4.1.1 Thermal insulation-related data
To be specified by:
Cost of heat to be taken into account.

TOTAL

Characteristic of the fluid contained in the equipment (nature, normal and


maximum operating temperatures, specific gravity, specific heat, flow rates).

Engineering Company

Characteristics of the equipment to be thermally insulated (dimensions,


materials, weldability).

Engineering Company

Climatic conditions (annual average outdoor temperature, annual average wind


speed).

TOTAL

Economic criteria of choice.

TOTAL

Any environmental constraints (for example, aggressive atmosphere).

TOTAL

The normal operating temperature of the fluid is the temperature that shall be considered in
calculating the insulation, unless otherwise stipulated.
For double-walled equipment, it is the normal operating temperature of the double wall that shall
be considered in calculating the insulation.
For equipment including an internal refractory and for which thermal insulation is specified, it is
the metal temperature during normal operating conditions that shall be considered in calculating
the insulation.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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For heat traced piping, it is not the temperature of the tracer that shall be considered, unless
otherwise specified by Engineering.
For the exchangers, it is the average inlet/outlet temperature that shall be considered for each
part of the exchanger (shell and channel) except in the case of personnel protection where the
maximum operating temperature shall be taken into account.
For vertical equipment where the temperature of the fluid changes according to height, the
normaloperating temperature of the fluid on the insulated section shall be taken into account in
calculating the insulation. The insulation thickness may vary over the height of the equipment.
5.4.1.2 Particular data concerning storage tanks
To be specified by:
Tank dimensions (useful height, diameter).

Engineering Company

Description of accessories (manhole, nozzles, stairs, stiffeners, design of the


skirt-roof junction).

Engineering Company

Description of the heating installation (type of heating, heating fluid


characteristic, regulation mode).

Engineering Company

Part of the tank to be thermally insulated (shell or shell + roof).

TOTAL

Tank operating mode (frequency of fills and drains, quality of product passing
through annually).

TOTAL

5.4.2 Protection against cold (WT)


Thermally insulating an item of equipment (normally consisting of piping) shall be studied,
according to the fluid circulation conditions in the circuit during normal operation: continuous
circulation or intermittent or occasional circulation.
5.4.2.1 Data independent of fluid circulation conditions
To be specified by:
Minimum allowable fluid temperature (freezing, agglomeration).

Engineering Company

Characteristics of the item to be thermally insulated (dimensions, materials, Engineering Company


weldability).
Climatic conditions (minimum temperature and associated wind speed).

TOTAL

5.4.2.2 Data specific to continuous circulation


To be specified by:
Minimum fluid flow rate.

Engineering Company

5.4.2.3 Data specific to intermittent or occasional circulation


To be specified by:
Maximum duration of fluid circulation interruption.

Engineering Company

Maximum allowable temperature drop for the fluid corresponding to the


abovementioned duration.

Engineering Company

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In the case where the thickness of the thermal insulation is too great (case of small diameter
piping with circulation interrupted for a long period for example), the Engineering Company shall
consider other arrangements (see 5.1.3 above).
If tracing has to be provided to keep the fluid at a certain temperature, the thermal insulation
shall be designed for heat conservation.

6. Thermal insulation thickness


6.1 Heat conservation
6.1.1 General
The thermal insulation thicknesses can be determined:
either by calculation, taking into account the basic data that is the subject of 5.2 and the
method which is the subject of 6.1.2. This method shall be given preference for new unit
construction projects or major maintenance/upgraded works,
or based on the tables indicated in Appendix 1. These tables correspond to thicknesses
commonly used in Europe.
For each project, TOTAL shall specify the procedure to be used.
In all cases, the immediately higher standardised thicknesses shall be selected.
6.1.2 Determining thicknesses by calculation
Except in the case of personnel protection, the thermal insulation thicknesses shall be
determined by minimising the following function:
F = C x CC + OPEX
where:
C=

Cost of insulation per unit of surface area (m for flat surfaces and metre for piping).
The fixed costs of scaffolding and surface preparation shall not be included.

CC =

Capital charge (as a percentage according to the fixed return on investment time).

OPEX = Cost of thermal losses per unit of surface area or of piping length.
The thickness adopted shall be the standardised thickness immediately greater than the
calculated thickness.
The TICP ("Thermal Insulation Calculation Program") software is available from CINI. It can be
used to determine the optimum economic thickness and the thermal losses - See CINI 6.1.00.
Other programs may be approved with the agreement of TOTAL or its representative.

6.2 Protection against cold


The thermal insulation thicknesses shall be calculated by the Engineering Company, according
to the information contained in the CINI code, and according to the quantity of heat that may be
lost by the fluid.
The design notes shall be supplied to TOTAL.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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6.3 Protection of personnel


For protection arrangements for which the only justification is protection of personnel,
preference shall be given to expanded metal-type solutions. For temperatures below 150C
insulating paint coatings can also be used.
The use of thermal insulation is allowed only for equipment in continuous operation and with an
operating temperature greater than 150C.
The thicknesses of the thermal insulation shall be as given in the table in Appendix 1.

7. Extent of the Contractor's supply


7.1 General
The extent of the supply shall be defined by the Engineering Company taking into account the
provisions set out in 5 and 6. The qualities of the thermal insulations and coatings used shall
meet the requirements of this specification.

7.2 Equipment to be thermally insulated


It should be recalled that the equipment of an installation to be thermally insulated shall be
specified by the Engineering Company on the fluid circulation drawings (see TOTAL
specification GS RM GEN 001 and the "Comment" paragraph in 5.1.1).
Such equipment comprises in particular:
piping,
vessels (towers, drums, etc.),
exchangers,
machines,
storage tanks,
instruments (dealt with by TOTAL instrumentation specification GS RM INS 115).
The thermal insulation and the function of the thermal insulation shall be symbolically
represented on these drawings (see the abovementioned specification).
It should also be remembered that the types and thicknesses of the piping thermal insulations
shall be added by the Engineering Company to the list of installation lines.

7.3 Studies
At the request of the Purchaser, the Contractor shall indicate the guaranteed losses (for HC
type thermal insulation) or guaranteed temperatures (for WT and PP type thermal insulations),
in steady state operation, after insulation.
The losses shall be expressed in:
watts per square metre of external surface for vessels,
watts per linear metre for piping.
The use of kcal/h (instead of watts) is acceptable.
The guaranteed losses are valid with usage tolerances ( 10%).

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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Any check on the performance levels actually obtained will be carried out contradictorily
according to the usual methods, at the request of TOTAL and with costs borne by TOTAL (see
18).

7.4 Equipment
The equipment that is included in the Contractor's supply shall include everything that is needed
for the planned thermal insulation works, namely:
the thermal insulations,
the claddings,
ancillary equipment,
dismantleable items,
steel plate needed to form hot chambers on traced piping.

8. Thermal insulation
8.1 General characteristics
Choosing an insulator involves considering all the constraints to which it will be subjected, in
order to ensure its effectiveness over time:
the nature of the equipment (piping, vessel, tank, etc.),
the constituent material of the equipment,
the operating temperature,
the corrosivity of the ambient medium.
8.1.1 Thermal insulation designation
The only materials accepted are materials that meet the CINI specification, section 2 (see CINI
2.1.01 to 2.13.01). In addition to the CINI specification, the insulation products shall conform to
the specification ASTM C 795 (Karnes diagram).
The use of any other material shall be submitted for TOTAL's written agreement on presentation
of the following characteristics:
nature and chemical composition,
thermal conductivity coefficients in W/m.K as a function of temperature (nomogram with
points in a line or equivalent), perpendicularly to the direction of the fibres and, where
appropriate, in the direction of the fibres (see 8.1.2),
density in kg/m3,
fire resistance classification (categories A1 to F) according to the European classification
for the reaction to fire of construction products (Euroclasses) bearing classification of
materials and construction elements by categories according to their behaviour in
response to fire and definition of the test methods,
optimum usage temperature in continuous operation, that is to say the most efficient with
no loss of dimensional characteristics (optimum efficiency zone),
peak maximum usage temperature,

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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nature and percentage by weight of binder (batching oil and resin),


chloride and fluoride contents,
guarantee of harmlessness with respect to carbon steel and stainless steel, in particular
conformity to the Karnes diagram (ASTM C795),
fire loss,
maximum moisture take-up,
curves of sag under load at usage temperature,
percentage by weight of infibres (if relevant).
8.1.2 Quality control
On receipt of the materials on site, a sampling procedure may be carried out in order to check
their conformity to this specification.
8.1.3 Packaging
Fibrous insulating materials shall mandatorily be packaged in plastic packaging and labelled
(Manufacturer and material reference).
For prefab section, mention shall be made of the source block on the package label
(Manufacturer and material reference).

8.2 Nature and form of the insulation

9. Claddings
The claddings are intended to ensure:
tightness to water run-off (importance of the quality of the seal between mouldings),
mechanical protection of the insulator,
protection of the thermal insulation against fire,
good appearance and cleanliness.

9.1 Preparation of the surfaces to be thermally insulated


Before fitting the thermal insulation, the surface to be thermally insulated shall be cleaned and
dried and been successfully hydrostatically tested.
For installations in discontinuous operation or in continuous operation with an operating
temperature of less than 150C, the surfaces shall be painted. The painting shall be checked by
TOTAL or its representative before the thermal insulation is fitted.

9.2 Fitting the thermal insulation


See CINI 1.3.01 p 5 and 6

9.3 Fitting the cladding


See CINI 1.3.01 p 7

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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9.4 Removable insulation


Any thermal insulation for the following items shall be removable:
flanges with paddle blanks,
flanges receiving isolating blind seals on unit shutdowns,
flanges and valves on piping fitted to vessels provided with bypasses making it possible to
work on them while the installation is operating,
main accessories of the circuits that include tracing or jacketed piping.
All vessel manholes (towers, flasks, etc.) that are thermally insulated shall be provided with
removable covers.
Machine insulation shall be removable if possible.
For tubular exchangers, the thermal insulation for the channel box and for the shell cover shall
be removable.

9.5 Applying the cladding


The attention of the Contractor should focus on the need for maximum tightness of the
claddings to the ingress of water.
The cladding shall be fitted within a maximum period of 24 hours after the thermal insulation has
been fitted. If this period has to be exceeded, the thermal insulation shall be temporarily
covered with an impermeable plastic covering.
All the plates shall be arranged in such a way as to prevent the ingress of rainwater by run-off
(upstream plate shall overlap the downstream plate).
In exceptional circumstances, the use of a sealing mastic may be accepted to perfect this
tightness, when the skin temperature of the equipment is less than 120C.
All thermal bridges are proscribed (direct contact or contact via a metallic part between the
vessel or the piping and the metal cladding).

9.6 Accessibility
The thermal insulation shall not in any way hamper access to the valve or instrumentation for
process or maintenance operations.
When the thickness of the thermal insulation causes a problem, these thicknesses shall be
reduced locally.
Cutting of the thermal insulation to reveal a valve hand wheel or a dial is strictly prohibited.

9.7 Covers without thermal insulation


Covers without thermal insulation allow protection against run-off water or bad weather (case of
flanged seals on hydrogen operation).
They are made without a bottom or insulator and cover only the top half of the part to be
protected.
Such covers are fixed by screwed tabs (on the existing insulation when possible).

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10. Insulation of piping


The general drawings relating to the fitting of the thermal insulation on piping are contained in
the CINI code, 4.0.00.

10.1 Thermal insulation support


On-site welding of supports on the equipment is strictly prohibited without written agreement
from TOTAL.

10.2 Thermally insulating flanges and valving


10.2.1 Jackets made of padded fabric
Jackets made of padded fabric shall be preferred to removable covers when the removal frequency
is greater than once a year and the diameter is greater than 1 metre.
10.2.2 Recommendations
An orifice shall be provided at a low point, level with the valves or flanges (when they are
thermally insulated) to facilitate leak detection.

11. Insulation of vessels


The general drawings concerning the fitting of the thermal insulation on sheet metal vessels are
contained in the CINI code, sections 4.2.00, 4.3.00, 4.4.00.
If a suspended support structure is provided ("umbrella type"), the fitting standards shall be
approved by TOTAL.

11.1 insulation support


The support for the thermal insulation shall be made according to the CINI standards or the
Engineering Company's standards. In the latter case, these standards need to have been
approved in writing by TOTAL.
On-site welding of supports on the equipment is strictly prohibited.
It should be remembered that, for certain pressure vessels (see TOTAL specification
GS RM PVE 001), specific arrangements may be required to allow for the removal of the cladding
and of the thermal insulation only in the areas requiring inspections or checks (shell weld lines,
manholes, inspection holes, nozzles, taps, certain areas of small vessels).

11.2 Removable items on manholes and hand holes


Manholes on vessels shall be insulated by removable covers.
The design of the removable covers is identical to that defined in 10 above.
A cover shall be made in a single piece if it can be removed and refitted by no more than two
people.
It shall be fixed to the insulation secured by quick release toggle.
The tightness between the fixed insulation of the equipment and the removable cover shall be
provided by a flexible bead with a diameter of 10 mm.
Hand holes shall be insulated by semi-removable (screwed) covers.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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11.3 Wells
Wells shall be provided in the thermal insulation of vessels with a capacity of more than 2 m3 to
allow the thickness of the shell plate to be measured with an UTdevice.
The diameter of these wells shall be 150 mm.
There should be:
six wells on columns more than 20 m high, including one on each bottom,
four wells on other vessels of more than 10 m3, including one towards the bottom, one
towards the top and two in the middle of the shell,
three on vessels from 2 to 10 m3, situated towards the bottom.
The placement of the wells shall be indicated by the Engineering Company on the drawings of
the vessels and submitted for written agreement (see TOTAL specification GS RM PVE 001).
They shall be accessible from safety ladders or existing gangways.
For each well, a plug of thermal insulation of the same type as that covering the vessel shall be
provided, with a cover made of steel plate of the same type as the cladding employed for the
rest of the vessel.
These plugs shall be watertight.

12. Thermally insulation of tubular exchangers


The general drawings relating to the fitting of thermal insulation on tubular exchangers are
contained in the CINI code, 4.0.00.

12.1 General
The rules applicable to sheet metal vessels (see 11) are applicable to tubular exchangers,
subject to provisions contained in 12.2 and 12.3.

12.2 Exchanger with a nominal diameter greater than 750 mm (30")


The shell, the bottom and the channel shall have a fixed thermal insulation cladding leaving the
connecting flanges free to allow for bolting to be fitted and removed.
They shall be thermally insulated with separate removable covers in three or four parts with
internal thermal insulation. The thermal insulation shall be secured inside the removable items
by attachments riveted to the plate.
The parts of the covers shall be assembled by means of quick release toggle made of:
cadmium-plated steel for plates made of aluminium-coated steel,
A-G 3 M for plate made of aluminium and plate made of duralinox.

12.3 Exchanger with a nominal diameter less than or equal to 750 mm (30")
A cover shall be provided for the casing and the connecting seal of the shell, another for the
shell bottom and the connecting seal of the shell; the covers shall be in two parts.
If the frequency of removal of the covers from the casings and bottoms is greater than once a
year, jackets made of padded fabric shall be preferred to the covers. These jackets shall
include, at a low point, an eyelet for draining any leaks.

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13. Thermally insulating machinery


The general drawings relating to the fitting of thermal insulation on machinery are contained in
the CINI code, 4.6.00.
For heat conservation, the insulation shall be made removable either by covers, or by watertight and
fire-proof padding.
For machinery with irregular contours, the insulation may be provided by applying a thermal
insulating cement.

14. Thermally insulating storage tanks


The general drawings concerning the fitting of the thermal insulation on storage tanks are
contained in the CINI code, 4.5.00.

14.1 General
This specification covers the technical requirements for the design and application of thermal
insulation on the walls and the roof of storage tanks for working temperatures between ambient
temperature and 180C.
The maximum/minimum working temperatures shall be mentioned in the tank data sheets.
In the design of the insulation, the frequency of the occurrence of these extreme temperatures
shall be taken into consideration.

14.2 Thermally insulating storage tanks


14.2.1 General
The design of the thermal insulation for storage tanks may be divided into three parts:
tank walls: in accordance with section 6 of CINI, "thermal insulation calculations",
tank roof: the same approach shall be applied for the roof and the walls of the tank
although the heat lost via the roof is less than that lost via the walls of the tank in contact
with the product, and the maintenance and servicing of the insulation are much more
expensive for the roof than for the walls,
foot of tank.
The dimensions of the tank, the working temperatures and the loading due to wind shall be
included in the design of the construction of the insulation system for the walls and the roof of
the tanks.
The insulation systems for the roof are normally not practicable: an insulated tank roof on which
it is possible to walk has a special structure that is not described in this specification.
The measurements and dimensions indicated in the insulation/cladding details for the various
components shall be considered on the basis of minimum requirements; however, the exact
measurements and dimensions of systems not welded to large tanks shall always be
determined using calculation tables.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

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14.2.2 Insulation system


14.2.2.1 General
The insulation system shall be strong enough to withstand the wind loading and pressure for a
long period (approximately 20 years). Also, the insulation system shall be capable of absorbing
the deformations of the tank due to the temperature variations, the loading or unloading, etc., so
that the cladding retains its water-repellent properties.
14.2.2.2 Tank walls
Tanks with a diameter greater than 12 m:
A corrugated plate cladding shall always be applied.
If welding on the tanks is permitted, preference shall be given to the simplest and most
reliable system.
If welding is not permitted, a suspension system shall be applied:
preference shall be given to a wall-mounted suspension system in the case where a
steel bar reinforcement may be fixed around the walls of the tank and the
reinforcement can withstand thermal expansion due to the release of heat from the
tank and in the case where the tank is in continuous operation;
preference shall be given to an external suspension system in the case where the tank
is not frequently in operation since this system is more flexible given that the fixings
can be adjusted distance-wise, but for this reason the system is less resistant to high
wind loadings.
Tanks with a diameter less than 12 m:
A flat or corrugated plate cladding may be applied.
If welding on the tank is permitted, preference shall be given to a welded system covered
with a corrugated plate cladding.
If welding is not permitted, a suspension system shall be applied.
Small diameter tanks may be covered with a flat cladding:
tanks with a diameter less than 6 m: insulate like a vertical vessel, provided that it has
sufficient fixings available to secure the insulation system. In case of violent winds, a
securing strip may be installed on the back of the joint ring, in accordance with CINI
4.5.03 detail B.
tanks with a diameter from 6 m to 12 m and on which welding is permitted: the
insulation system described in CINI 4.5.03 may be applied.
tanks with a diameter from 6 m to 12 m and on which welding is not permitted: the
insulation system described in CINI 4.5.04 may be applied.
The walls of tanks may be insulated with one or more layers of mineral wool panels. In specific
cases, the application of different materials may be considered.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 21/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

14.2.2.3 Tank roof


The tank roofs shall be insulated with very rigid mineral wool panels in one or more layers. In
specific cases, the application of other materials may be considered. A certain degree of
ventilation shall be created in conjunction with a possible evacuation of condensation water.
For the covering of the insulations of miscellaneous roofs, cladding systems are available.
For tanks with a diameter less than 12 m radial segments with raised flanges shall be used to
cover the insulation panels. The segments and the insulation panels shall be anchored to the
roof of the tank by means of stainless steel clamps around the spiral welded to the roof.
CINI 1.3.04 page 5, CINI 4.5.07 to CINI 4.5.09.
14.2.2.4 Tank bottom
In certain conditions, the tank bottoms shall also be insulated.
This applies for:
tanks for which the working temperatures are high and which stand on a concrete
foundation,
tanks containing products with a low solidification temperature,
economic reasons.
The insulating materials used shall have a sufficiently high compression resistance to withstand
the load without undergoing deformation, such as, for example, foam glass.
Between the bottom of the tank and the insulating layer, a layer of bituminous sand (tar) shall be
applied for the distribution of pressure. In the case of large tanks, a ring of concrete shall be
arranged below the tanks so that they can be filled with insulating material.

14.3 Application
The thermal insulation is covered with cladding, which is fixed to securing strips with selftapping screws.
Corrugated plates are fitted with an overlap of at least one corrugation in the horizontal direction
and a vertical overlap of at least 50 mm.
System 2: With cladding made of flat plates, tank diameters less than 12 m
Rigid insulation panels shall be installed along the walls of the tank and fixed using stainless
steel straps; three per panel, two at 150 mm from the edges and one in the middle of the panel.
The securing strips shall be fitted around the thermal insulation and provided with safety
devices (springs).
The securing strips shall be installed with or without spacers and/or suspension strips. The
thermal insulation shall be covered with a cladding fixed to the securing strips using self-tapping
screws; horizontal and vertical overlap of 50 mm.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 22/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

14.3.1.1 Suspension system on the wall side with support spacers


The suspension strips are suspended against the walls of the tank and then the fixing strips are
fitted around the tank. After the spacers have been fitted, the fixing strips are secured using
clamping nuts. The aluminium ties are then closed on the clips of the spacers.
The flexible insulation panels are positioned from bottom to top on the tank and they are clad
over their entire length with corrugated plates, which are fixed to the attachment system using
self-tapping screws.
During installation, the insulation panels are placed behind the cladding plates. The corrugated
plates are fitted with an overlap of at least one corrugation in the horizontal direction and a
vertical overlap of at least 50 mm.
For tanks with a diameter less than 12 metres, but with a height greater than 12 metres and
working at elevated temperature, at least one expansion joint shall be placed every 10 metres,
depending on the design of the tank (see CINI 4.2.11).
In the case where reinforcing rings have to be installed, for suspended insulation systems, an
independent system shall be applied on both sides. The reinforcing rings are then separately
insulated, but this depends on the tank criterion.
The placement of the holes drilled for the plate screws shall be determined by trial and error,
depending on the thickness to be joined, the type of material, and so on. The self-tapping
screws shall be taken into account in the work.
The strips, made of 50 x 0.5 mm stainless steel, shall be placed on the outside of the cladding
plates, at least one for each plate level (see CINI 4.5.03). For safety, these strips are attached
to the cladding using "S" type ties. Springs shall be installed to absorb any expansion.
Around the relief and the connection nozzles of the tank, the cladding is cut to shape and then
made impermeable with a lining or an adhesive material. This material shall have mechanical
properties to enable it to absorb any movements.
The upper part of the insulation wall shall be correctly installed under a water repellent. Under
no circumstances should water be allowed to penetrate into the insulating wall.
After the storage tank has been started up, all the reliefs of the insulation system shall be
inspected. Similarly, when the installation is operating normally, the insulation system shall be
regularly inspected.
14.3.1.2 Tank roof
TOTAL shall specify in each case whether the roof has to be thermally insulated. If it does, the
Contractor shall submit the detailed thermal insulation procedure for TOTAL's written
agreement.
The insulation panels shall be attached to the roof of the tank.
Cladding with raised edges shall be installed in accordance with the design arrangements and
shall be anchored to the roof using stainless steel clamping strips.
A rainproof sheet shall then be installed on top of the flanges and fixed using stainless steel
screws.
The reliefs and/or vents passing through the insulation shall be protected against water and
ventilated, as indicated in CINI 4.5.11.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 23/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

After startup, all the protusions and vents passing through the insulation system shall be
inspected.

15. Inspection and testing


When the materials are received on site, TOTAL's representative may take samples from each
batch. These samples shall strictly conform to those indicated in the bid.
Any defective parts shall be scrapped.
The thickness of the thermal insulation shall be checked during the works.
TOTAL shall check that the fitting and the application quality of the thermal insulation and the
coating are in accordance with the requirements of this specification.

16. Quality control


16.1 General
The contractor is solely responsible for all the control and documentation activities.
The contractor shall have a quality plan that defines the people responsible and their
responsibilities within the framework of the quality system. People responsible for inspections
shall have sufficient authority to have the quality requirements applied, to initiate, identify,
recommend and advocate solutions to quality problems and to check the effectiveness of
corrective actions taken.
A copy of the quality plan shall be submitted to TOTAL or its representative for review and
approval before the start of the insulation works.
The insulation system shall be inspected at the following steps:
on receipt of the materials,
before application of the insulation,
while the insulation is being installed,
before and while the protective covering is being installed.

16.2 Material quality control


Check that the materials received on the site are indeed those specified or approved.
Such a check should include checking of the labelling, of the safety data sheet, of the
delivery advice notes and of the thicknesses. Non-approved materials and damaged
insulators, protections and accessories shall be removed from the site.
Check that the stored materials are protected from the weather and from any risk of
degradation.
Check that the covering is clean, dry and suitable for operating before application.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 24/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

16.3 Quality control before application of the insulation


Inform all the thermal insulation contractors that the welding of supports on the equipment
is prohibited without written authorisation from TOTAL or its representative.
Check that all the hydraulic tests have been completed.
Check that the surfaces to be insulated are clean and dry.
Check that the coating under insulation is achieved.
Check that the painting on protrusions extending through the thermal insulation has been
completed.
Inspect the thermal insulation supports to check their correct location, type, width and
length.

16.4 Quality control while the insulation is being applied


Quality control while the insulation is being applied shall include at least the following points:
check that the material installed is as planned,
check that the thermal insulation type is as planned (line list, or other applicable
document), check the thickness and the covering protection,
check that the expansion joints are properly installed,
check that the insulators are correctly fitted, in particular at the level of cradles and
changes of direction,
check that the thermowells, manufacturers' plates and other extending items have not
been covered by the insulation.

16.5 Quality control while the protective covering is being installed


Quality control while the protective cladding is being applied shall include at least the following
points:
check that the insulation is dry and correctly butt-jointed,
check that the plate overlaps are correct: adequate size and correctly oriented to avoid
any ingress of water,
check that the strips, screws, S-clips, J-clips and expansion springs are correctly
positioned,
inspect all the potential entry points for water, such as the ends, passages through the
thermal insulation and check that the protections are correctly applied,
finally, check that there is no degradation.

17. Acceptance of the works


17.1 Acceptance
The acceptance of the works shall be in accordance with the General Conditions of Execution
for Supplies to TOTAL.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 25/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00

17.2 Thermal performance inspections


These inspections of the installed thermal insulation may be carried out by a third party at the
request of TOTAL and with costs charged to TOTAL.
They shall be carried out when the installation are in steady state operation.
When TOTAL decides to carry out these inspections, the Purchaser shall draw up, or arrange to
have drawn up, preparation documentation for the corresponding tests, including:
the data used to calculate the thicknesses (see 5.3 above),
the physical organisation of these tests, bearing in mind that:
the inspections shall be carried out by a specialist organisation accepted by common
agreement by the Contractor and the Purchaser,
the inspection methods and means are proposed by the organisation which also has to
draft the final report,
the Purchaser shall define the identification on site and on the drawings of the
measurement points, and shall establish the means of accessing these points
(scaffolding, ladders, etc.),
thermal performance inspections shall be carried out for the first time no later than
6 months after provisional acceptance, a second time a little before the warranty period
expires,
the costs of these inspections continue to be borne by TOTAL,
excess loss is measured globally on all the points inspected.

18. Warranties
The warranty period for the thermal insulation is 5 years, from final acceptance.
The warranty includes materials, fitting works, thermal effectiveness and tightness of the
covering.
A reduction in the warranted thermal effectiveness caused by aging of 1% per year counted
from the date of provisional acceptance of the works is accepted.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 26/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00
Appendix 1

Appendix 1

Line diameter:
(inches)
(mm)
1/4"
1/2"
15
3/4"
20
1"
25
1 1/2"
40
2"
50
3"
80
4"
100
6"
150
8"
200
10"
250
12"
300
14"
350
16"
400
18"
450
20"
500
24"
600
30"
750
34"
850
36"
900
40"
1000
42"
1050
Flat surface

ti < 50
Th
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30

Thicknesses of the thermal insulation

Site references: Average temperature in France 20C


Hot thermal insulation: Classes HC heat conservation (0-40 Kcal at 0C)
Material: Mineral wool
ti < 100
ti < 150
ti < 200
ti < 250
ti < 300
ti < 350
ti < 400
ti < 450
Th
Th
Th
Th
Th
Th
Th
Th
30
40
40
50
50
60
60
70
30
40
50
50
60
60
70
70
30
40
50
50
60
60
70
80
40
40
50
60
60
70
70
80
40
50
50
60
70
70
80
90
40
50
60
60
70
80
80
90
40
50
60
70
70
80
90
100
40
50
60
70
80
90
100
110
50
60
70
80
80
90
100
110
50
60
70
80
90
100
110
120
50
60
70
80
90
100
110
120
50
60
70
80
90
100
110
130
50
60
70
80
90
100
120
130
50
60
70
80
90
110
120
130
50
60
80
90
100
110
120
130
50
70
80
90
100
110
120
140
50
70
80
90
100
110
120
140
50
70
80
90
100
110
130
140
50
70
80
90
100
110
130
140
50
70
80
90
100
120
130
150
50
70
80
90
100
120
130
150
50
70
80
90
100
120
130
150
50
70
80
90
100
120
130
150

ti < 500
Th
80
80
80
90
100
100
110
110
120
130
140
140
140
140
150
150
150
160
160
160
160
160
160

ti < 550
Th
80
90
90
100
100
110
120
130
140
140
150
150
160
160
160
160
170
170
180
180
180
180
180

ti < 600
Th
90
90
100
100
110
120
130
140
150
160
160
170
170
170
180
180
190
190
190
200
200
200
200

Thicknesses of the thermal insulation table 1


This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 27/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00
Appendix 1

Site references: Average temperature in France 20C


Hot thermal insulation: Classes HC heat conservation (0-40 Kcal at 0C)
Material: Foam glass
Line diameter:
(inches)
(mm)
1/4"
1/2"
15
3/4"
20
1"
25
1 1/2"
40
2"
50
3"
80
4"
100
6"
150
8"
200
10"
250
12"
300
14"
350
16"
400
18"
450
20"
500
24"
600
30"
750
34"
850
36"
900
40"
1000
42"
1050
Flat surface

ti < 50
Th
25
30
30
30
40
40
40
40
40
40
50
50
50
50
50
50
50
50
50
50
50
50
50

ti < 100
Th
40
40
50
50
50
50
60
60
60
70
70
70
70
70
70
70
70
80
80
80
80
80
80

ti < 150
Th
50
50
50
60
60
70
70
70
80
80
80
90
90
90
90
90
90
90
100
100
100
100
100

ti < 200
Th
60
60
60
60
70
70
80
80
90
90
100
100
100
100
100
100
110
110
110
110
110
110
110

ti < 250
Th
60
60
70
70
80
80
90
90
100
100
110
110
110
110
120
120
120
120
120
120
130
130
130

ti < 300
Th
70
70
70
80
80
90
90
100
110
110
120
120
120
120
130
130
130
130
140
140
140
140
140

ti < 350
Th
70
80
80
90
90
100
110
110
120
130
130
130
140
140
140
140
150
150
150
150
160
160
160

ti < 400
Th
80
90
90
90
100
110
120
120
130
140
150
150
150
160
160
160
170
170
170
170
180
180
180

ti < 450
Th
90
90
90
100
110
110
120
130
140
150
150
160
160
170
170
170
180
180
180
190
190
190
190

Thicknesses of the thermal insulation table 2


This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 28/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00
Appendix 1

Line diameter:
(inches)
(mm)
1/4"
1/2"
15
3/4"
20
1"
25
1 1/2"
40
2"
50
3"
80
4"
100
6"
150
8"
200
10"
250
12"
300
14"
350
16"
400
18"
450
20"
500
24"
600
30"
750
34"
850
36"
900
40"
1000
42"
1050
Flat surface

Site references: Average temperature in France 20C


Hot thermal insulation: Classes PP personnel protection 70C (0-40 Kcal at 0C)
Material: Mineral wool
ti < 100
ti < 150
ti < 200
ti < 250
ti < 300
ti < 350
ti < 400
ti < 450
ti < 500
Th
Th
Th
Th
Th
Th
Th
Th
Th
30
30
30
30
30
30
40
40
50
30
30
30
30
30
30
40
40
50
30
30
30
30
30
30
40
50
50
30
30
30
30
30
30
40
50
50
30
30
30
30
30
40
40
50
60
30
30
30
30
30
40
40
50
60
30
30
30
30
30
40
50
60
70
30
30
30
30
30
40
50
60
70
30
30
30
30
30
40
50
60
70
30
30
30
30
40
40
50
70
80
30
30
30
30
40
50
60
70
80
30
30
30
30
40
50
60
70
80
30
30
30
30
40
50
60
70
80
30
30
30
30
40
50
60
70
80
30
30
30
30
40
50
60
70
80
30
30
30
30
40
50
60
70
90
30
30
30
30
40
50
60
70
90
30
30
30
30
40
50
60
70
90
30
30
30
30
40
50
60
70
90
30
30
30
30
40
50
60
70
90
30
30
30
30
40
50
60
80
90
30
30
30
30
40
50
60
80
90
30
30
30
30
40
50
60
80
90

ti < 550
Th
60
60
60
60
70
70
80
80
90
90
90
100
100
100
100
100
100
110
110
110
110
110
110

ti < 600
Th
60
70
70
70
80
80
90
90
100
110
110
110
110
120
120
120
120
120
130
130
130
130
130

Thicknesses of the thermal insulation table 3

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 29/30

Refining
General Specification

Date: 11/2009

GS RM ISL 001

Rev: 00
Appendix 2

Appendix 2

FRANCE

Harmlessness of the insulation


The insulation manufacturer shall supply a certificate of harmlessness certifying that its product
is chemically neutral and presents no risk of corrosion to the support structures on which it is
applied, or to any protective coating.

This document is the property of TOTAL. It must not be stored, reproduced or disclosed to others without written authorisation from TOTAL.

Page 30/30

TOTAL Raffinaderij Antwerpen

Specification
-P-

Thermal and Acoustic


Insulation

Thermal and Acoustic Insulation


-P-

Rev. 3
29/04/2011
2/38

Total Raffinaderij Antwerpen


Revisie overzicht
Revisie
00
01
02
03

Opmerking

Weather proofing for equipment


Update for Cold Insulation

datum

gewijzigde paginas

10/03/1997
01/07/2004
06/10/2006
29/04/2011

5, 7, 9-13, 16-21, 22, 26


6,10,11,15,16

Revision coding:
Deleted items = strike trough.
New or changed text = background shaded grey.
Coding lasts only for present (one) revision.

Thermal and Acoustic Insulation


-P-

Rev. 3
29/04/2011
3/38

Total Raffinaderij Antwerpen

Inhoud

1.

SCOPE ...................................................................................................................................5
1.1.
1.2.
1.3.

2.

INSULATION MATERIALS....................................................................................................6
2.1.
2.2.
2.3.
2.4.

3.

GENERAL .........................................................................................................................6
BASE MATERIALS ..............................................................................................................7
W EATHER PROOFING MATERIALS ....................................................................................13
FASTENING MATERIALS AND ACCESSORY MATERIALS ........................................................13

TABLES FOR NOMINAL INSULATION THICKNESSES ...................................................16


3.1.
3.2.

4.

REFERENCES ...................................................................................................................5
DEFINITIONS.....................................................................................................................6
PIPING AND VESSELS ........................................................................................................6

HOT INSULATION ............................................................................................................16


COLD INSULATION...........................................................................................................18

EXTENT OF INSULATION AND DESIGN DETAILS ..........................................................20


4.1.
4.2.

FOR HEAT CONSERVATION (CODED ON DOCUMENTS AS HC). ...........................................20


ITEMS NOT TO BE INSULATED FOR HEAT CONSERVATION, REGARDLESS OF TEMPERATURE,
UNLESS SPECIFICALLY INDICATED OTHERWISE ON RELEVANT DOCUMENTS: ...................................20
4.3.
PERSONNEL PROTECTION (CODED PP)............................................................................20
4.4.
HEAT TRACED ITEMS ......................................................................................................21
4.5.
TELL TALE HOLES IN REINFORCEMENT RINGS OR SUPPORTS SHALL BE FITTED WITH A SMALL
WEEP LINE TO THE OUTSIDE AND PROJECTING CLEAR OF THE INSULATION JACKETING TO DISPOSE OF
POSSIBLE OIL LEAKAGE FROM BEHIND THE WELDS. .......................................................................21
4.6.
INSULATION AROUND PROTRUSIONS ................................................................................21
4.7.
INSULATION ON PIPING AND EQUIPMENT NEAR FLANGES SHALL STOP SHORT AT A DISTANCE
EQUAL TO THE BOLT LENGTH PLUS 25 MM. ...................................................................................21
4.8.
BARE AUSTENITIC STAINLESS STEEL SURFACES TO BE INSULATED SHALL FIRST BE WRAPPED
IN ALU-FOIL, ACTING AS BOTH BARRIER AND INHIBITOR AGAINST CORROSION. ................................22
4.9.
BUNDLING OF STEAM LINES TO BURNERS (HEADERS AS WELL AS INDIVIDUAL LINES)
TOGETHER WITH OTHER LINES IRRESPECTIVE OF SIZE IS NOT PERMITTED. .....................................22
4.10.
HEAT EXCHANGER INSULATION DETAILS .......................................................................22
4.11.
DETAILS VESSEL SUPPORTS ........................................................................................22
4.12.
ACOUSTIC INSULATION ................................................................................................22

5.

APPLICATION .....................................................................................................................23
5.1.
5.2.
5.3.
5.4.

6.

GENERAL .......................................................................................................................23
SURFACE PREPARATION..................................................................................................24
HOT INSULATION .............................................................................................................24
COLD INSULATION...........................................................................................................27

ACOUSTIC INSULATION....................................................................................................33
6.1.
6.2.
6.3.
6.4.

GENERAL .......................................................................................................................33
CATEGORY A..................................................................................................................33
CATEGORY B..................................................................................................................33
CATEGORY C .................................................................................................................33

Thermal and Acoustic Insulation


-P-

Total Raffinaderij Antwerpen


7.

Rev. 3
29/04/2011
4/38

QUALITY ASSURANCE AND INSPECTION ......................................................................34


1.
2.

LIST OF DRAWINGS .......................................................................................................35


INSULATION CHECKLIST ...............................................................................................36

Thermal and Acoustic Insulation


-P-

Total Raffinaderij Antwerpen

1.

Rev. 3
29/04/2011
5/38

Scope

This specification covers the minimum requirements for complete external insulation systems for
hot, cold and acoustic services on surfaces of piping, equipment, instruments, etc.
This specification does not cover underground systems, internal insulation and insulation of
buildings.
It is important to note that for new units this specification could be incomplete and does not
cover all services. In this case licenser, TOTAL group and engineering contractor specifications
(job specifications) shall be considered as well.
For revamp works original job specifications and licenser requirements shall be checked against
this specification. In case of conflict the most severe prevails.
In case there are items not covered by this specification, the engineering company shall check
the specifications of the TOTAL group, if the item is still not covered, the engineering company
shall spontaneously and at no cost submit its own specification for approval.
For deviations of the Total Raffinaderij Antwerpen (hereafter called TRA) Spec. "P" a waiver
request shall be issued for approval to TRA Engineering Department. Only the head of TRA
Engineering Department can approve deviations. Requests to change this specification shall be
made using the form DP-P003-F001.doc aanvraag tot specificatie of standard wijziging.
Remark:
This specification is not restrictive. Modifications or alterations can be done after approval of
Total Raffinaderij Antwerpen (TRA) Engineering Department.

1.1. References
Unless otherwise stated in the particular contractual conditions, all the referenced documents,
and their addenda, are applicable in their latest revision.
A.

B.

C.

Belgian Norms
NBN S-21-203

Non-combustibility of insulation materials (combustible class A0)

AISI Standards
AISI 304

Specification for Stainless Steel

ASTM Standards
ASTM A463
ASTM B209M
ASTM B221M
ASTM C167
ASTM C177
ASTM C302
ASTM C547
ASTM C552
ASTM C592
ASTM C795

D.

Specification for Aluminized Steel and Plate


Specification for Aluminum Alloy Sheet and Plate (METRIC)
Specification for Aluminum Alloy Shape
Determination of Density of Thermal Insulating Blankets
Test Method for Steady State Heat Flux Measurements and Thermal
Transmission Properties
Determination of Density of Preformed Pipe Insulation
Specification for Mineral Fibre Preformed Pipe Insulation
Specification for Cellular Glass Thermal Insulation
Specification for Mineral Fibre Blanket Insulation, and Blanket Type Pipe
Insulation (Metal Mesh Covered)
Thermal insulation for use in contact with austenitic Stainless Steel

AGI Standard (Arbeits Gemeinschaft fuer Industrie)

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AGI Q 132
AGI Q 136

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Determination of classification temperatures for fibrous insulation


Determination of water absorption

E.

Specification NWG 5 Acoustic Insulation of Pipes, Valves and Flanges, issued by


EEMUA.DIN Norms
DIN 7971 B
German specification for screws.
DIN 52612
Standard method for determination of heat transmission coefficient for
flat forms
DIN 52613
Standard method for determination of heat transmission coefficient for
cylindrical forms

F.

ISO Norms
ISO 8501 1
ISO 1182

Pictorial Standard For Surface Preparation


Non-combustibility of materials

1.2. Definitions

The temperatures in this specification are to be read as normal operating


temperatures unless specifically indicated otherwise.
Thermal conductivity of insulation base materials is expressed in W/mK at the given
mean temperature of the insulation.
Maximum permitted temperatures for fibrous insulation materials are meant to be the
classification temperatures as measured per AGI Q 132.
Nominal piping diameters including all appurtenances are stated as NPS, for
example a 12" line, as NPS12.
Vessels means process vessels.
Total Raffinaderij Antwerpen (TRA) and/or principal or its representative is further
referred to as OWNER.
Insulation contractor and/or any other performing insulation work is further referred to
as APPLICATOR.
c.t.c. means center to center.
VB means vapour barrier.
PP means personnel protection.
Jacketing means weather proofing metal sheeting constructed to a close fitting cover
of the base insulation.
HC means heat conservation.

1.3. Piping and vessels

2.

Piping above NPS 24 is to be insulated with same thickness and method as vessels.
Vessels and equipment having a diameter of 24 inch and smaller shall be insulated
with same thickness and method as piping of that size.

Insulation materials

2.1. General
1.

Asbestos and asbestos containing materials are not permitted.


- For Lump Sum Contracts and for skid-mounted units the applicator shall -at completioncertify in writing to owner that asbestos is not present in his work.
- For jobs initiated by work orders asbestos free must be certified separately.

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2.

Ceramic fibres may be hazardous to health.


Where application for high heat service (> 700C) is unavoidable, applicator is to request
for permission with submittal of his health procedures.
If permitted by owner, applicator shall duly register location and extent for future
reference. If permitted the fibres shall be have a > 6 microns.

3.

Zinc or zinc containing material shall not be used on or above stainless steel piping,
vessels and equipment.

4.

Insulation base material chloride content should meet de requirements of ASTM C795.

5.

The water absorption, measured according AGI Q 136 shall be lower than 10 % by
volume.

6.

Only one type wool is permitted on a job. Applicator shall indicate his choice already in his
bid.

7.

Properties of supplied material shall not deviate more than 2 % from those specified in
this specification.

8.

When economically attractive, applicator may propose in his quotation alternative


products, technically matching those specified here under, for acceptance by owner.

9.

Materials shall be non-combustible according ISO 1182 and NBN S-21-203.

10.

Insulation materials shall not produce smoke when materials are exposed to fire.

2.2. Base materials


2.2.1.

Rock wool

2.2.1.1.

Straight Pipe

Preformed rigid pipe sections made of resin bonded rock wool for services up till
700C and for max. NPS 24.
- Thermal conductivity: 0.037 at 50C; 0.043 at 100C; 0.060 at 200C; 0.083 at 300C;
2
2
0.100 W/m at 400 C and 0.180 W/m at 500 C.
3
- Density dependent on size and thickness: min. 100, max. 125 kg/m .
Density shall be conform ASTM C302.
(The split between use of preformed sections and blankets may lay at another size if
economically more attractive, to be agreed upon by owner.)
Supplier
Rock wool Lapinus
Roclaine
2.2.1.2.
-

Type
850
345

Vessels and equipment, horizontal and vertical (optional large pipe sizes)

Where horizontal insulation supports on vertical items are provided at each 2000 2200 mm or less (ref. drawing DR190E000Z00000031):
Blankets made of lightly resin-bonded rock wool stitched on galvanized or, for
application on austenitic stainless steel items stainless steel wire mesh, mesh 25
mm, suitable for services up to 700C.
o Thermal conductivity: 0.038 at 50C; 0.045 at 100C; 0.066 at 200C;
2
2
0.095 at 300C; 0.120 W/m at 400C; 0.180 W/m at 500C.

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o

Density: 70 - 80 kg/m, conform ASTM C167.

Supplier
Rock wool Lapinus
Roclaine Therminap
Isover
-

Where horizontal insulation supports on vertical items are provided at approximately


each 4000 mm or less (ref. drawing DR190E000Z00000031):
Resin impregnated rock wool semi - rigid board suitable for services up to 700C.
o Thermal conductivity: 0.039 at 50C; 0.046 at 100C; 0.065 at 200C;
0.077 at 300C.
o Density: 70-77 kg/m.
o Dimensions: 1000x600 mm.
Supplier
Rock wool Lapinus
Roclaine Thermipan

Type
160 ProRox WM 70
322
md 2

Where vertical insulation supports (as per 2.4.9.) on horizontal items are provided at
approximately each 4000 mm or less:
Resin impregnated rock wool semi - rigid board suitable for services up to 700C.
o Thermal conductivity: 0.039 at 50C; 0.046 at 100 C; 0.065 at 200C;
0.077 at 300C.
o Density: 70-77 kg/m.
o Dimensions: 1000 x 600 mm.
Supplier
Rock wool Lapinus
Roclaine Thermipan

2.2.1.3.
-

Type
590 HT600
333

Where vertical insulation supports (as per 2.4.9.) on horizontal items are provided at
each 2000 - 2200 mm or less:
Blankets made of lightly resin-bonded rock wool stitched on galvanized or for
application on austenitic stainless steel stainless steel wire mesh, mesh 25 mm,
suitable for services up to 700C.
o Thermal conductivity: 0.038 at 50C; 0.045 at 100C; 0.066 at 200C;
0.095 at 300C.
o Density: 70 - 80 kg/m.
Supplier
Rock wool Lapinus
Roclaine Therminap
Isover

Type
160 ProRox WM 70
322
md 2

Type
590 HT600
333

Storage Tanks

Roof:
Resin impregnated rock wool rigid board, extra water repellent, resistant to max.
250C.
o Thermal conductivity: 0.037 at 50C; 0.043 at 100C; 0.056 at 200C.
o Density: 155 kg/m.

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Supplier
Rock wool Lapinus
Isover Thermipan
-

Type
523 CRS
313

Shell:
Resin impregnated rock wool flexible board, resistant to max. 250C.
o Thermal conductivity: 0.044 at 50C; 0.055 at 100C; 0.080 at 200C.
o Density: 40 kg/m.
Supplier
Rock wool Lapinus
Thermipan

2.2.2.

Glass wool

2.2.2.1.

Straight pipe

Type
590 HT600
313

Preformed rigid pipe sections made of resin bonded glass fibre for services up till
400C and for max. NPS 24.
o Thermal conductivity: 0.035 at 50C; 0.041 at 100C; 0.059 at 200C.
o Density: 65 - 90 kg/m3 depending on NPS and thickness.
(Note: The split between use of preformed sections or blankets may lay at another size if
economic more attractive, to be agreed upon by owner.)
Supplier
Isover

2.2.2.2.
-

type IS-HI
type IS-I

Vessels and equipment, horizontal and vertical (optional large pipe sizes)

Where horizontal insulation supports on vertical items are provided at each 2000 2200 mm or less (ref. drawing DR190E000Z00000031):
Blankets made of non-bonded glass fibre stitched on galvanized or for
application on austenitic stainless steel items stainless steel wire mesh, mesh 25
mm, suitable for services up to 500C.
o Thermal conductivity: 0.036 at 50C; 0.044 at 100C; 0.063 at 200C;
0.075 at 250C
o Density: 55 kg/m
Supplier
Isover

Type
For bores up to 57 mm
For bores 61 mm and above

Type
Telisol 704

Where horizontal insulation supports are provided on vertical items at approximately


each 4000 mm or less (ref. drawing DR190E000Z00000031):
Resin impregnated glass fibre semi - rigid board suitable for services up to 350C.
o Thermal conductivity: 0.037 at 50C; 0.044 at 100C; 0.067 at 200C;
0.078 at 250C
o Density: 35 kg/m
o Dimensions: 1350 x 600 mm
Supplier

Type

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Isover
-

PSI350

Where vertical insulation supports (as per 2.4.9.) on horizontal items are provided at
each 2000 - 2200 mm or less:
Blankets made of non-bonded glass fibre stitched on galvanized or for
application on austenitic stainless steel items stainless steel wire mesh, mesh 25
mm, suitable for services up to 500C.
o Thermal conductivity: 0.036 at 50C; 0.044 at 100C; 0.063 at 200C;
0.075 at 250C
o Density: 55 kg/m
Supplier
Isover

Type
Telisol 704

Where vertical insulation supports (as per 2.4.9.) on horizontal items are provided at
approximately each 4000 mm or less:

Resin impregnated glass fibre semi - rigid board suitable for services up
to 350C.
o Thermal conductivity: 0.037 at 50C; 0.044 at 100C; 0.067 at
200C; 0.078 at 250C
o Density: 35 kg/m
o Dimensions: 1350x600 mm
Supplier
Isover
2.2.2.3.

Type
PSI 350
Glass wool rope crosswise wrapped in metal wire for steam tracers, small
bore bends and instrument tubing. Heat resistant up to 400C. In order to
waterproof the glass wool rope, Foster 35 01, together with glass fibre shall be
used. Weather proofing: self extinguishing and flame retardant PVC tape
temp. range -20/+70 C. Advance AT 7 or equal. Color: grey. When Foster
35.01 is used, this will be labeled with a stainless steel (150 x 40 mm) plate,
engraved Asbest vrij. The label will be attached with a stainless steel strap.

Supplier
Isover
2.2.2.4.
-

Type
"glaswolkoord"
Storage Tanks

Roof:
Resin impregnated compression resistant glass fibre rigid board, resistant to
max. 350C.
o Thermal conductivity: 0.035 at 50C; 0.043 at 100C; 0.064 at 200C
o Density: 45 kg/m
Supplier
Isover

Type
PSI450

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-

Shell:
Resin impregnated resilient glass fibre board, resistant to max. 250C.
o Thermal conductivity: 0.035 at 50C; 0.047 at 100C; 0.064 at 150C
o Density: 22 kg/m
Supplier
Isover

2.2.3.

Type
PSI A1

Multi Cellular Glass

Preformed sections and boards Alumino Silicated Glass with gas-filled cells, for cold
service and where specifically indicated for hot service up to 450C.
o Thermal conductivity: 0.039 at 0C
o Density: 115 kg/m
Supplier
Pittsburgh Corning
2.2.4.

Type
Foam glass T4

Anti Abrasive

The multi cellular glass shells in contact with pipe (first layer) will be provided with an antiabrasive coating.
1. Low temperature Anti-Abrasive (LTAA)
o Water based anti-abrasive based on modified polyurethane resins.
o Service temperature range: -196C to +93C
o Density: 1.60kg/dm
2. High temperature Anti-Abrasive (HTAA)
o Dry one-component mix of modified calcium sulphate with some inert
mineral fillers.
o Used where service temperature exceeds +120C or for temperatures
below -180C
Supplier
Pittsburgh Corning

2.2.5.

Type
LTAA: Low temperature AntiAbrasive.
HTAA: High Temperature AntiAbrasive

Bedding compound and joint filler for cold insulation

White impermeable elastomer.


o Density: 1.5 kg/I
Supplier
Foster
Pittsburgh Corning

Type
Flextra Sealant 95-50
Terostat PC joint sealant

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2.2.6.

Vapour barrier mastic for cold insulation

Elastomer on water basis.


First coat grey, second coat white.
o

Density: 1.4 kg/I

Supplier (Fabricate)
Foster

Type
30-91 81/91 vapor safe grey,
30-90 81/81 vapor safe white

Alternatively, the multi cellular glass shells may be bought with a factory applied Vapor
Barrier.
Supplier (Fabricate)
Pittsburgh Corning

2.2.7.
-

Type
Terostat PC Factory Applied on
Foam Glass T4

Armaflex

A closed cell, fibre-free elastomeric foam insulation.


o
o

Max operating temperature: -196C to +125C


Density 60-70 kg/m

Supplier (Fabricate)
Armacell
o
o

Max operating temperature: -50C to +105C


Density 40-60 kg/m

Supplier (Fabricate)
Armacell
2.2.8.

Type
Armaflex LTD

Type
AF/Armaflex and Armaflex LT

Vapour barrier reinforcing glass fibre cloth


2

Open weave glass cloth with acryl finish, mesh 3-4 mm, 250 gr/m .
2.2.9.

Insulation cement

Insulation cement shall be rock wool based heat resisting cement, for restricted use
after approval of owner and only where heat curing at the time of application is available.
2.2.10.

Anti-vibration seals

2.2.10.1.

Up to 120C Synthetic rubber.


Supplier: Hertel Belgium, Wijnegem.

2.2.10.2.

Above 120C Non-flammable high density felt. 5 mm thick.


Supplier for Benelux: Stokvis & Smits b.v. Umuiden, NL, Type VILTON 30

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2.3. Weather proofing materials
2.3.1.

Metal sheeting

2.3.1.1.

Acoustic insulation, categories B and C, and all thermal insulation of


equipment (on- and off-site) and on site piping:
Flat Aluminized Steel sheeting Type Armco 2, ASTM A463, type 2
Thickness: NPS 24 and smaller: 0.6 mm, above NPS 24, vessels and
equipment: 0.8 mm.

2.3.1.2.

Off-site piping (= outside unit Battery Limit) and off-site storage tanks:
Flat Aluminum sheeting, ASTM B209M alloy 3003, temper H 14 (half hard)
Thickness:

NPS 2 and smaller


NPS 3 thru 8
NPS 10 and above

0.6 mm
0.8 mm
1 mm

2.3.1.3.

If technical or economical justified: Stainless steel sheet, ASTM A-167 Type


304. Thickness NPS 24 and smaller: 0,6 mm, above NPS 24, vessels and
equipment: 0,8 mm.

2.3.2.

Perforated sheeting for personnel protection:


ASTM B209M, alloy 3003, temper H14, 1 mm thick, 60% open.

2.3.3.

Expanded metal lath for open cages for personnel protection shall be
galvanized or stainless steel, 1 mm thick, (see DR190E000Z000 00029) (in
Dutch language: "Strekmetaal").

2.4. Fastening materials and accessory materials


2.4.1.

General
For stainless steel items Only stainless steel fastening materials and
accessory materials are permitted to fasten the metal sheets.

2.4.2.

To fasten Insulation:
Hot Insulation
Type fastener
Galvanized or
< 24
SS Wire 1mm
SS Strapping
24 < 60 Band 12,5 x 0,5
mm
SS Strapping
60
Band 20 x 0,5 mm
Diam.

Diam.

Cold Insulation
Type fastener

< 6

Tape

6 - 24

SS Strapping Band
12,5 x 0,5 mm

> 24

SS Strapping Band
20 x 0,5 mm

2.4.2.

For NPS 24 or smaller, over base insulation for hot service, spaced at 300 mm
Galvanized binding wire, 1 mm,
Stainless steel AISI 304 wire 1 mm

2.4.3.

For NPS 12 or smaller over base insulation in cold service and for above NPS
24 and vessels and equipment with dia. up to 60 inch, over base insulation hot

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service, spaced at 300 mm and over weather proofing metal sheets where
required (e.g. at expansion joints and cold insulation) and for strapping
clamped supports as per drawing DR190E000Z00000021:
Galvanized strapping bands and seals 12.5 mm (1/2") x 0.5 mm*,
Stainless steel strapping bands and seals 12.5 mm x 0.5 mm*.
1
(* For cold service at outside dia. of insulation larger than 1m 0.6 or 0.8 mm
thickness)
2.4.4.

For sizes above 60 inch spaced at 300 mm over both base insulation and
metal sheeting, in combination with screws (cold service no screws) as per
item 2.C 4.7:
Galvanized strapping bands and seals 20 mm (3/4") x 0.5 mm*,
Stainless steel strapping bands and seals 20 mm x 0.5 mm*.
1
(* For cold service at outside dia. of insulation larger than 1m 0.6 or 0.8 mm
thickness)

2.4.3.

Breather springs for use in strapping bands vessels and equipment at


diameter's over 3000 mm and above 250C shall be made of stainless steel,
supplier Gerard. Note: Corrugated strips are not permitted.

2.4.4.

Blanket hooks
Galvanized wire 1.6 mm or Stainless steel wire 1.6 mm, at each 150 mm or at
shorter distances where required to prevent gaps.

2.4.5.

Screws
In hot insulation:
For aluminium sheeting: hard aluminium,
For stainless steel sheeting: only stainless steel fastening materials should be
used.

- For fastening of metal sheeting to supports, distance clips, etc.


Hard aluminium or stainless steel, hexagonal head with fixed ring lined at
the underside with vulcanized neoprene, 6.25 x 19 mm, type B, to be
applied at each 150 mm center to center.
- For fastening of metal sheeting to metal sheeting
Hard aluminium or stainless steel, cylindrical slotted head ST 4,8B (10 X
1/2) DIN 7971 B.
2.4.6

Pop Nails
Only stainless steel popnails will be used to fasten metal sheeting in cold
insulation.
Metal sheeting on horizontal/vertical pieces of pipe will be fastened with metal
strips. On bends they will be fastened with popnails. In order to do this, an
extra layer of bubble wrap (10mm) will be applied between sheeting and
vapour barrier to protect the vapour barrier.

2.4.7.

Quick release toggles


For removable covers NPS 12 and above and equipment:
Stainless steel, type CAMLOC V951I02-1-BP or approved equivalent.

2.4.8.

Steel Insulation Supports

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General
Steel insulation support rings/profiles and nuts/eyes for vessels and equipment
are normally welded-on at the fabricator's shop (for information see drawing
DR190E000Z00000034and DR190E000Z00000035).
Insulation support for insulated vertical piping shall be the responsibility of the
applicator as per drawing DR190E000Z00000021.
Also included in applicator's scope are:
Clamped carbon steel supports - for personnel protective open shields and
where required for (e.g. vertical supports on horizontal) vessels and
equipment.
Welding on-site by the applicator is not permitted. This activity is normally
done by the mechanical contractor. Where in case of urgent need the
application of e.g. welding pins is required, then for each case a written
approval from owner shall be obtained.
Steel support rings supplied by applicator shall be made of carbon steel strip 3
x 25 mm.
Angle profiles shall be made of carbon steel 3 x 20 x 20 mm.
The carbon steel supports destined for:
o use of clamped supports on all services stainless steel,
o for insulated carbons steel items under 150C
shall be blast cleaned to grade ISO Sa 2 and coated with at least 75 m Red
oxide Epoxy primer.
Support strips as per drawing DR190E000Z00000021 shall be stainless steel
2 x 30 mm.
Support plates as per drawing DR190E000Z00000021 shall be expanded
metal lath either made of aluminized steel sheet 2 mm thick or stainless steel
sheet 1.5 mm thick.
2.4.9.

Sealants
-

Silicone rubber compound:


Heat resistant silicone sealant
up to 300C:

Supplier: Dow Corning, Type: 781


Supplier: Dow Corning, Type: Q3-1566

2.4.10.

Inspection plugs (corrosion monitor hatches)


Removable and replaceable plugs for monitoring corrosion under insulation:
(Standard inspection plug: see drawing DR190E000Z00000002).
If required location shall be as indicated on drawings DR190E000Z00000004
up to DR190E000Z00000014.
(Note: Inspection plugs are not applicable at cold insulation)

2.4.11.

Aluminum Foil
Pure aluminium foil, approximately 30 micron thick, for austenitic stainless
steel protection.

2.4.12.

Flash band
Aluminium backing with bitumen - rubber compound adhesive.
Supplier: IMBEMA
Type: Jittra band

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3.

Tables for nominal insulation thicknesses


The thickness of insulating base material shall be selected with regard to:
- operating temperature
- size of equipment
- insulation purpose
and in accordance with the following tables.

3.1. Hot Insulation


A.

For heat conservation (HC) and steam tracing (ST)


Piping: Thickness of insulation in mm
OPERATING TEMPERATURE IN C
DIA

Up to
100

101-> 151-> 201-> 251-> 301-> 351-> 401 -> 451 ->
150 200 250 300 350 400 450 500

1"

25

40

40

50

50

50

50

50

70

1 1/2"

25

40

40

50

50

60

60

60

70

2"

25

40

40

50

50

60

60

60

80

3"

25

40

40

50

60

70

70

70

90

4"

40

50

50

60

60

80

80

90

100

6"

40

50

60

70

90

100

100

100

100

8"

40

50

70

80

90

100

100

100

110

10"
12"

40
40

50
50

70
70

80
90

100
100

110
110

110
110

110
110

110
110

14"

40

50

70

90

100

110

110

110

120

16"

50

60

70

90

100

110

110

110

120

18"
20"

50
50

60
60

70
80

90
90

110
110

110
110

110
110

120
120

120
120

22"

50

60

80

100

110

110

110

120

120

24"

50

60

100

100

110

110

120

120

140

30"

50

60

100

100

110

110

120

120

140

MATERIA
L

1 LAYER

2 LAYERS

ROCK WOOL / GLASS WOOL

Note:
Use preformed sections up to 12" nominal bore and slabs for 14" and larger nominal bore
pipe, utilising double layers for total thicknesses in excess of 100 mm.

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Equipment: vessels, exchangers, pumps.... and tanks
Operating temperature in C
Insulation thickness in mm

B.

50

100

150

200

250

300

350

400

450

500

50

60

75

90

90

100

110

125

140

150

For Process stabilisation (PS), personnel burn protection (PP) and anti frosting
INSULATION THICKNESSES REQUIRED FOR PERSONNEL PROTECTION
PIPE NOM.
BORE
1"
1 1/2"
2"

thickness of insulation (mm) at hot face temperature C


206-> 261-> 316-> 376-> 426-> 481-> 541 -> 591 ->
up to 205
260
315
375
425
480
540
590
650
25
25
25
25
38
38
50
50
63
25
25
25
38
38
50
50
63
63
25
25
38
38
50
50
63
63
75

3"
4"
6"
8"
10"
12"

25
25
25
25
25
25

25
25
25
25
25
25

38
38
38
38
38
38

38
38
50
50
50
50

50
50
50
50
50
63

50
63
63
63
63
63

63
63
63
75
75
75

75
75
75
100
100
100

75
100
100
100
100
100

14" OD
16" OD

25
25

25
25

38
38

50
50

63
63

63
63

75
75

100
100

100
100

18" OD

25

25

38

50

63

75

75

100

100

Note:
The above table is based on the same data as the previous table and on that basis the
above thicknesses will reduce insulation surface temperatures to 65 C or lower.

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3.2. Cold Insulation
A.

For cold conservation (CC) / Condensation Control

Thickness Foamglass
Temp.+18C to -110C
NORMAL OPERATING TEMPERATURE

NOMINAL

C THRU C

PIPE
SIZE
1
1
2
3
4
6
8
10
12
14
16
18
20
22
24
28
32
36

18
10
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
30
50

9
0
0
-10
30
30
30
30
30
30
30
30
30
40
30
40
30
40
30
40
30
40
30
40
30
40
30
40
30
40
30
40
30
40
30
40
30
40
50
50
1 LAYER

-11
-20
40
40
40
50
50
50
50
50
60
60
60
60
60
60
60
60
60
60

-21
-31
-30
-40
50
60
50
60
50
60
60
70
60
70
60
80
70
80
70
80
70
80
70
80
70
90
70
90
70
90
70
90
70
90
70
90
70
90
80
90
2 LAYERS

-41
-50
60
70
70
80
80
90
90
90
100
100
100
100
100
100
100
100
100
110

-51
-60
70
80
80
90
90
100
100
110
110
110
110
110
110
120
120
120
120
120

-61
-70
80
80
90
90
100
110
110
120
120
120
120
120
130
130
130
130
130
130

-71
-81
-80
-90
80
90
90
100
90
100
100
110
110
110
120
120
120
130
130
140
130
140
130
140
130
140
140
150
140
150
140
150
140
150
140
150
140
150
150
160
3 LAYERS

-91
-100
90
100
110
120
120
130
140
140
150
150
150
160
160
160
160
160
160
170

-101
-110
100
100
120
120
130
140
150
150
160
160
160
170
170
170
170
170
170
180

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Temp.-111C to -165C
NOMINAL

NORMAL OPERATING TEMPERATURE


C THRU C

PIPE

-111
-120
100

-121
-130
110

-131
-138
110

-141
-150
110

-151
-160
120

-161
-165
120

110

110

120

120

120

130

2
3
4
6
8
10
12
14
16
18
20
22
24
28
32
36

120
130
140
140
150
150
160
160
170
170
170
170
170
170
180
180

120
130
140
140
150
150
160
160
170
170
170
170
180
180
180
190

120
140
140
150
150
160
160
170
170
170
170
180
180
190
190
190

130
140
150
150
160
160
170
170
170
170
170
180
190
190
190
200

140
150
150
160
160
170
170
170
170
170
180
180
190
190
200
200

140
150
150
160
160
170
170
170
170
180
180
190
190
200
200
200

3 LAYERS

2
LAYE
RS

SIZE

Standard Thicknesses foamglass: 30, 40, 50, 60, 70, 80, 90, 100, 110, 120 mm

Dimensions in mm

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B.

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For heat/Cold conservation (HC) / Condensation Control (Normal operating temperature


from 18C thru -20C with high temperature cycles to 250C)

For Cyclic Serve application, the line expansion will have to be calculated in order to determine
which shells will be used, how the shells will be placed, and the location of joints.
In order to do this properly, the original jobspec must be consulted

4.

Extent of insulation and design details

4.1. For Heat Conservation (coded on documents as HC).


The following items shall receive insulation for heat conservation only when above 120C,
unless specifically indicated otherwise on the relevant documents:
- Process piping, except valves and flanges.
- Steam piping 40 bar and lower, including valves and flanges.
- Equipment, including vessels, steam turbines and steam engines.
- Heat traced items including valves and flanges and tracer jumpers.
(Note: when in hazardous service or a service above self ignition temperature, e.g.
hydrogen service, valves and flanges shall be left free of insulation.)
- Piping with the following services shall have the valves and flanges insulated with
removable boxes: Pitch, hot oil (bitumen), sulphur and superheated steam, except
where explicitly indicated otherwise.
Hot oil valves will be insulated where possible to minimize heatloss.

4.2. Items NOT to be insulated for heat conservation, regardless of temperature,


unless specifically indicated otherwise on relevant documents:
- Piping and equipment where it is desirable to lose heat and indicated as such on the
relevant documents.
- Pumps and compressors.
- Valves and flanges in steam service when above 40 bar and in process piping
systems.
- Valves and flanges in hydrogen and hazardous service, except valves, flanges and
bellows in H2S rich gas lines at sulphur plants (ARDS -jobs 57/58) (to prevent
condensation).
- Manholes, handholes (in view of leak detection).
- Main flanges and bolts of heat exchangers and girth flanges of heat exchangers and
other equipment.
- Piping and equipment operating intermittent, such as relief valves, vents, drains,
steam-out, snuffing steam and decoking systems, blow-down systems, flare system
and the by-pass of heat exchangers.
- Piping and equipment supports extending outside the insulation thickness of the item.
- Expansion joints (e.g. bellows), hinge joints, line filters and line mixers.
(Note: This instruction does NOT include insulation expansion joints).
- Fuel gas and pilot gas lines to individual burners (headers excluded).
- Instrument air lines.
- Name plates.

4.3. Personnel Protection (coded PP)


4.3.1.

General
Personnel protection shall normally be achieved by application of open shields
and/or cages (see drawing DR190E000Z00000029).
All surfaces indicated for PP shall be coated as for exposure to atmosphere by

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others.
Surfaces where PP is required by means of a thermal insulation system shall
be clearly indicated as such on the relevant documents. The outer surface of
the insulation shall not exceed 65 C.
4.3.2.

The distance of the open shields to the hot surface shall be as per the
thickness table for PP-insulation.

4.3.3.

PP shall be applied where the hot surfaces are above 65 C and when less
than 600 mm from normal working areas, walkways, etc., with risk to be
accidentally contacted by operating personnel, in every working area, walkway,
and on ground level.

4.3.4.

Extent shall be horizontally 600 mm to both sides and vertically 2000 mm


upwards from floor.

4.4. Heat Traced items

4.5.

4.4.1.

General
Traced surfaces with their tracers shall be insulated, inclusive valves and
flanges, except as outlined in item 4.1. of this chapter.
Jumpers shall also be insulated, unless specifically indicated otherwise. See
5.3.5. Selection of the insulation thickness shall be according the NPS or dia.
and the temperature of the traced item as per the insulation thickness table for
heat conservation.

4.4.2.

Jacketed lines and electrical traced items including drinking-water lines.


Application shall be same as for non-traced items.

4.4.3.

Steam traced lines shall be insulated according drawing


DR190E000Z00000025.

4.4.4.

Electrical traced lines shall be provided with stickers, size approximately 8 x 24


cm, yellow background, white lettering with legend: " ELECTRICAL TRACED",
each 10 m, facing walkways and personnel areas.

Tell tale holes in reinforcement rings or supports shall be fitted with a small weep line to
the outside and projecting clear of the insulation jacketing to dispose of possible oil
leakage from behind the welds.

4.6. Insulation around protrusions


The area around nozzles, man and handholes, vents and drains shall be kept free of
fibrous insulation to a distance of the outer circumference of the nozzle flange plus 25 mm
or when no flange to a distance of 25 mm, except at vertical protrusions with welded-on
shields, where fibrous insulation shall fit close to the protrusion. See also item 5.1.7. with
figure.

4.7. Insulation on piping and equipment near flanges shall stop short at a distance
equal to the bolt length plus 25 mm.
End caps and sealant are to be provided to prevent ingress of moisture.

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4.8. Bare Austenitic stainless steel surfaces to be insulated shall first be wrapped in
alu-foil, acting as both barrier and inhibitor against corrosion.

4.9. Bundling of steam lines to burners (headers as well as individual lines) together with other
lines irrespective of size is not permitted.
Fuel oil lines shall be steam traced and insulated separately.

4.10. Heat exchanger insulation details


4.10.1.

Shell and tube type


Shell and tubes up to and including 12" diameter, to be insulated with
preformed pipe sections, above 12" diameter with board type insulation.
Shell cover: Insulate the curved head but not the flange of the cover.
Channel: No insulation on channel flanges and bolts.
Channel cover: Insulate only the part within the bolts circle, leaving the
bolts and outer edge free of insulation.
Integral channel: Insulate as shell cover.
For frequently opened heat exchangers, removable parts will be foreseen:
see DR190E000Z0000061.

4.10.2.

Double pipe type


Preformed pipe sections to be applied on top of the upper tube and at the
underside of the lower tube.
Board of the same thickness as the pipe sections shall be placed in the space
between the upper and lower pipe sections and the entire assembly shall be
duly strapped without gaps or open joints.
Head and return bend shall be insulated with blankets, close fitting, with the
wire mesh laced and banded.

4.11. Details vessel supports


See drawings DR190E000Z00000031, DR190E000Z00000032 and
DR190E000Z00000035.

4.12. Acoustic insulation


4.12.1.

Noise reduction per category.


Acoustic insulation consists of 3 categories according specification NWG5,
viz.:
- Category A, light noise reduction
- Category B, medium noise reduction
- Category C, heavy noise reduction

The following table contains theoretical values for calculation purposes only.

CATEGORY

A
B

NOISE REDUCTION IN dB WITHIN THE OCTAVE BAND WITH THE MIDDLE


FREQUENCY (Hz)
63
-

125
-

250
5

500
5
15

1000
10
20

2000
15
25

4000
20
30

8000
25
35

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C

15

25

30

35

40

45

See further chapter 6.

5.

Application

5.1. General
5.1.1.

All insulation material shall be kept dry at storage, handling, during and after
application. Fibrous insulation material that has been wet shall be discarded.

5.1.2.

Where the required nominal insulation thickness cannot be reached with


commercial available standard thicknesses more layers shall have to be
applied with all joints staggered.

5.1.3.

Unavoidable gaps and voids at hot insulation shall be stuffed firmly with loose
wool. For this purpose cut-offs of blankets may be used.

5.1.4.

The insulation shall withstand the windload, inclusive the negative windload at
the off wind side as may occur on site. If so required by owner, applicator shall
submit his calculations for windload resistance to owner (for information only:
Prevailing wind direction: WSW, strength: permanent up to 90 km/h, peaks
135 km/h).

5.1.5.

Expansion joints shall be required at temperatures above 200C at lengths of


6 m, and further each 6 m both horizontally and vertically.

5.1.6.

Stiffener rings at vessels shall be kept free of insulation at the area between
flange and shell; if required the applicator shall provide an aluminum U profile, bottom up, on the stiffener ring. See drawing DR190E000Z00000030.

5.1.7.

Around nozzles, hand and manholes, etc. an area as per item 4.6. shall be
kept free of fibrous insulation. A removable ring of 2 or more sections of multi
cellular glass, thickness same as adjacent insulation, fitting the gap, shall be
installed. See figure below.

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Fibrous Insulation
Multi-cellular Glass

Diameter Flange
+ 50 mm

Vessel
Shield
Metal Sheeting

Removable insulation at nozzle


5.1.8.

Bottoms of vertical vessels, including those inside skirts shall be insulated as


per this specification and according drawing 13 "details of insulated vessel".

5.2. Surface preparation


All surfaces shall be dry prior to insulation. Piping and equipment to be insulated, and operating
below 150C, has been painted by others. If not painted or if coating has been damaged, then
applicator shall inform owner and postpone insulation work till instructions.
Painted and unpainted surfaces shall be thoroughly cleaned from all foreign matter. Oil and
grease shall be removed with solvents or degreasing agents.
The surface and the material used should be dry before and during application and should
remain so until startup. Hydrostatic, radiographic and other test should be completed before
starting the insulation.
Stainless steel piping and equipment or carbon steel piping and equipment above 150C have
not been painted. Good adhering temporary coats are not to be removed. Loose rust and mill
scale, where present, shall be removed.

5.3. Hot insulation


5.3.1.

Pipe insulation supports on vertical piping shall be installed by applicator as


per drawing DR190E000Z00000021.

5.3.2.

Preformed pipe sections


Sections shall be fitted snugly together and to the surface with no voids or gaps.
Longitudinal joints staggered. Elbows shall be mitered with binding wire or band
around each miter.
See drawing DR190E000Z00000020.

5.3.3.

Board
Board shall be bent to fit the curvature of the item, where required to avoid
open joints, the sides shall be bevelled. At large surfaces the boards shall be
applied in brick bond fashion. Strapping bands shall be applied at 300 mm
c.t.c.

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5.3.4.

Blanket
Blankets shall be applied with the wire mesh to the outside, except when used
around steam traced items and when applied to the inside of removable
covers, then the wire mesh shall face the hot side. Wire hooks shall be used
each 150 mm or less to draw the blankets tight around the item and to attach
the blankets to the insulation supports. All joints shall be laced together with
binding wire, 5 stitches every meter. At diameters of 30" and more, strapping
band shall be applied at 600 mm c.t.c.
See drawing DR190E000Z00000020.

5.3.5.

Glass wool cord


Jumpers at steam traced lines, bends in lines < NPS 1 shall be spiral wise
wrapped with glass wool cord.

5.3.6.

Weather proofing

5.3.6.1.

General
Metal weather proofing has to be installed immediately after application of the
base insulation.
When not feasible the base insulation shall be temporary and water tight
protected with duly taped plastic foil.
All joints in the weather proofing jacketing shall be arranged to shed water.
Vertical and circumferential joints in horizontal items shall have the overlap off
wind to prevent penetration of wind driven rain water.
Protrusions and transitions through the insulation jacketing, where no weldedon shields are present, shall be provided with a close fitting shield screwed on
top of the jacketing and sealed with heat resistant sealant.
Around nozzles, hand and manholes, etc., the metal jacketing shall stop short
at the multi cellular glass insulation.
The shield shall have a furrow at the edge and overlap with 100 mm and shall
be made easy removable for weld inspection.
Furrows at > 500 mm outer diameter insulation shall have a rounding radius of
15 mm, < 500 mm outside diameter min. 7 mm.

5.3.6.2.

Piping
Circumferential joints shall have an external furrow at the edge of overlap and
an internal furrow at 50 mm from the edge of the under lying jacket.
At the lowest part of each piping arrangement a 3 mm hole shall be drilled in
the external furrow for drainage and leak detection.
Circumferential joints shall not be screwed, but tightly banded.
In vertical piping S-clips shall be installed at each 400 mm but least 2 per joint.
Longitudinal joints shall be located as per drawing DR190E000Z00000022 and
have a furrow at the edge of the overlap. Furrow to terminate at 10 mm from
circumferential furrows.
Screw heads close against the furrow (for better locking) at 150 mm
c.t.c.Overlap on all joints 50 mm.
Expansion joints shall have an overlap of 100 mm with an external furrow at
the edge and another external furrow at 50 mm from the edge. The strapping
band shall lay in between and shall be tight but allow movement.
The underlying sheet shall not be furrowed at the expansion joint. See
drawing DR190E000Z00000023.
An expansion joint is required at straight length of pipe longer than 10 m and
further at each 10 m. For elbows see drawing DR190E000Z00000028.

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Termination of insulation (e.g. near flanges or at partial insulation) shall be


finished with a metal end cap, also when a flange or valve insulation cover is
to be applied.
All rope wrapped items shall be weatherproofed with flash band, starting and
ending at 100 mm over adjacent metal jacketing.
Flange and valve covers shall have the base insulation attached to the inside
of the covers. For details see drawings DR190E000Z00000026 and
DR190E000Z00000027.
Rain caps shall be installed above the insulation at pipe hangers and above
slots for moving valve handles.
Metal weather proofing at pipe shoes shall have a water deflector according to
drawing DR190E000Z00000024.
5.3.6.3.

Vessels and equipment


All joints shall overlap with min. 50 mm. Only the overlapping part of the sheet
shall have a furrow at the edge. At cross points the underlying furrow shall be
flattened. All joints, with exception of expansion joints shall be screwed at
max. 150 mm c.t.c. Jackets shall be screwed to support rings as per item
2.4.7.1.
Bands shall be strapped at each 300 mm. Horizontal bands, where not close
above a furrow, shall be prevented to slip by screws at 2000 mm c.t.c, but at
least 2 per band. Breather springs each 6000 mm.
Expansion joints shall have an overlap of 100 mm. Horizontal expansion
joints shall have two strapping bands with approximately 30 mm in between
and no screws but S-clips. One clip each 600 mm and at least 4 per joint.
Spherical heads on top of vertical vessels shall be weather roofed with
aluminum orange peel segments with standing seams. See figures A and B
below.

A
B
figures standing seams
Korbogen heads (disk heads) with diameters up to and including 3000 mm
shall preferably be weather roofed with conical covers (hood caps) else with
aluminum sections following the curve of the head. See figure below.

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Termination of insulation (e.g. near flanges or at partial insulation) shall be


finished with a metal end cap, also when a flange cover or other type insulation
cover is to be applied. A 3 mm hole shall be drilled at each lowest point for
drainage and leak detection.
Pumps, turbines, compressors, etc., only when specifically indicated for
insulation, shall be insulated with a removable box without bottom resting on
the base plate. The insulation shall be attached to the inside of the box.
Openings for in- and outgoing lines and leads shall be closed with screwed
shields and sealant.
5.3.7.

Storage tanks

5.3.7.1.

The applicator shall prepare his design and procedures in accordance with this
specification and in view of the insulation supports provided on the storage
tank. See drawings DR190E000Z00000036.
Bottom 300 mm of tank shell shall be kept free of insulation and lowest course
of insulation shall be made of water repellant insulation (multi-cellular
glass/foam glass).
Installation of insulation plates shall be done according a stretcher bond
arrangement.
When a multiple layer arrangement is required, the joints shall be staggered.
Installation of insulation blankets on the tank shell, make ISOVER type PSI A1,
shall be done by pressing these blankets over weld-bolts.
The M8 weld-bolts shall be installed every 600 mm horizontally and every 1500
to 2000 mm vertically. The lowest weld-bolt row shall be located 320 mm from
the tank bottom. Neoprene cladded nuts, fastened to the M8 weld-bolts, shall
be covered by special aluminum profiles (thickness = 3 mm). These aluminum
jacket shall be fixed with 18/8 screws on those ALU-profiles.

5.3.7.2.

5.3.7.3.

Aluminum jacket
The aluminum jacket shall be aluminum corrugated plates minimum thickness
0.8 mm. The plate length will relate to the tank diameter. Plate lengths of
minimum 4 m shall be used. The corrugated plates shall be fastened
horizontally every 150 mm. The overlap between plates shall be minimum one
complete corrugation. The corrugated plates shall be fastened vertically every
250 mm.
Corrugated plates shall be fixed to each other with self tapping screws with
EPDM washer.
Alternative systems, such as prefab storage tank insulation systems or free
hanging systems, may be submitted for approval to owner, together with full
information and data about technical and economical benefits.

5.4. Cold Insulation


General.
-

The temperature limits of the adhesives and accessory products should be respected
during both storage and application. Avoid applying foamglas insulation on pipes and
equipment in service.
Metal wire to fix foamglas should be avoided due to the wire cutting of the foamglas
surface. Two stainless steel straps per standard length should be used. In case of

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several layers, the layers underneath can be fixed by means of a fibre-reinforced selfadhering tape. The outer layers should always be fixed with stainless steel straps.
An anti-abrasive coating is applied onto the inner side of the foamglas elements, which
will be in contact with the metal pipe.
All joints will be sealed with joint sealer. Joints must be as tight as possible.
In order to determine the correct accessories (e.g. bedding compound to assemble the
sections and shells), the design temperature of the system will always be given to the
Insulation Contractor.
5.4.1.

Pipe Insulation:

Single layer application


All shells will be applied dry, they will not be joined using adhesive (except specific approval of
TRA engineering). The shells are applied onto the pipes with staggered joints.
All joints will be sealed with joint filler. Joint filler that has been squeezed out is to be spread
over the outer surface of the insulation.
A first layer of 1.4 to 2 mm thick GRAY Vapor Barrier is to be applied over the insulation and at
termination's (incl. expansion joints) onto approximately 25 mm of the steel surface. Glass cloth
is to be embedded in the still sticky VB, without wrinkles or voids, edges overlapping 25 mm. A
second layer 1.4-2 mm thick WHITE VB shall be applied on top, covering all surfaces onto 25
mm of the item steel surface.
After full curing the metal weather proofing jacketing can be applied. Care shall be taken that no
sharp edges or corners of the metal sheeting shall pierce through the VB.
The shells kept in place with stainless steel straps, 3 straps per standard length (1000mm).

Double or Multi-layer application


Start as with the single layer application.
Each section of inner layer shall be tightly fixed in place with two self-adhesive, glass-fibre
reinforced tapes, applied with a minimum overlap of 150mm.
Joints shall be staggered between the different insulation layers (in 2 directions). All joints will
be sealed with joint filler. Joint filler that has been squeezed out is to be spread over the outer
surface of the insulation.
A first layer of 1.4 to 2 mm thick GRAY Vapor Barrier is to be applied over the insulation and at
termination's (incl. expansion joints) onto approximately 25 mm of the steel surface. Glass cloth
is to be embedded in the still sticky VB, without wrinkles or voids, edges overlapping 25 mm. A

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second layer 1.4-2 mm thick WHITE VB shall be applied on top, covering all surfaces onto 25
mm of the item steel surface.

After full curing the metal weather proofing jacketing can be applied. Care shall be taken that no
sharp edges or corners of the metal sheeting shall pierce through the VB.
The shells kept in place with stainless steel straps, 3 straps per standard length (1000mm).

In case of Terostat PC coating:


Single layer application and outer layer of multiple layer applications will have Terostat PC
applied to all longitudinal and circumferential joints. The Terostat PC is applied by cartridge to
one of the mating surfaces, to the outmost outer side of the joint to give a bead of 7 mm
diameter, at outer layer thickness of 50 mm or less; for outer layer thicknesses of 60 mm and
above, a second bead will be applied in the inner half of the joint.
The shells wil be firmly tensioned using tensioning band system. Terostat PC squeezed out of
the joint is to be smoothed flush with the factory applied Terostat PC surface.
Insulation fixing straps will be applied after having smoothed the joints. Tensioning straps will be
removed.

Single layer terostat pc coating


1. Anti-abrasive layer
2. Foamglass
3. Terostat PC joint sealant
4. Metal fixing strap
5. Terostat PC factory applied
6. Metal sheeting if specified.

Double or Multi Layer terostat pc coating


1. Anti-abrasive layer
2. Foamglass

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3. Tape or metal fixing straps
4. Terostat PC sealant in all joints
5. Metal fixing straps
6. Terostat PC factory applied
7. metal sheeting if specified

Contraction joints of 20mm shall be installed in each insulation layer. They will be filled with
Armaflex.
Distances between these contraction joints
Operating Temperature
C
Below
Thru
19
-18
-18
-46
-46
-73
-73
-101
-101
-129
-129
-157
-157
-165

Joint
Spacing
(mm)
18300
9150
6100
5490
4270
3660
2440

The maximum expansion joint / insulation support spacing for vertical piping shall be 3.6
meters regardless of the operating temperature.
Contraction joints shall be provided beneath all insulation support rings.

5.4.2.

Flanges:

1. Flange diameter < outside diameter of insulation:


The flange is insulated with a shell having the same inner diameter as the outside diameter of
the pipe insulation

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2. Flange diameter > outside diameter of insulation:


In the case the flange diameter is more than the pipe insulation outside diameter, the insulation
at both ends has to be increased in thickness.

After installation all joints shall be sealed with sealant.


5.4.3.

Valves

Valves shall be insulated, using prefabricated boxes (fitting covers). These boxes are not
reusable. They will be filled with Armaflex.
The insulation of valves is applied in the same way as flanges with regard to overdimensioning
of the insulation shells.
Prefabricated valve insulation

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Filled with Armaflex


After installation all joints shall be sealed with sealant.
Pipe supports, vessel and equipment supports, and other protrusions shall be insulated to the
extent of 4 X the insulation thickness, reckoned from the outer surface of the insulation. See
also drawing DR190E000Z00000034.Valves boxes on LPG vessels shall be removable as per
drawing DR190E000Z00000026 with the multi cellular glass glued to the inside of the box and all
joints filled.
All joints in metal sheeting of box and between box and adjacent jacketing shall be sealed from
the outside.

5.4.4.

Metal sheeting:

For Cold Insulation, metal sheeting should be provided where needed to protect the vapor
barrier, up to a height of 2 m from walkway.
This is in all areas next to walkways, maintenance roads, .

Piping
Weather proofing as for hot insulation. , but strapping bands instead of screws and no internal
furrows. For straight pipes SS straps will be used to fasten metal sheeting. Metal sheeting on

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bends will be fastened with popnails. In this case an extra layer (10mm) of bubble wrap will be
applied underneath the metal sheeting.
Valves and flanges shall have the insulation fitted and glued to the inside of the box. And the VB
shall be applied over the cold side of the insulation.
After installation all joints shall be sealed with sealant.

Vessels and equipment


Weather proofing as for hot insulation, but without screws. Popnails can be used, if an extra
layer (10mm) of bubble wrap is applied underneath the metal sheeting
Horizontal joints on vertical items shall be provided with S-clips.
Slippage of horizontal strapping bands shall be prevented by clips riveted to the metal sheeting
before application. One clip each 2 m and at least 2 clips per joint. Hand Inspection holes and
manholes and flange covers to be insulated and sealed as outlined for piping/valves/flanges.

6.

Acoustic insulation

6.1. General
6.1.1.

Acoustic insulation is only effective when there is no metal to metal contact


between insulated surface and metal jacketing.
Supports and attachment points shall be acoustically separated by anti
vibration seals. Contact points shall be avoided.

6.1.2.

Application is generally same as for hot insulation.

6.1.3.

Combined hot and acoustic insulation shall be according the most severe
requirements of each class.

6.1.4.

Combined cold and acoustic insulation shall have the acoustic base insulation
on top of the cold base insulation., the vapour barrier and metal jacketing shall
be applied over the acoustic insulation.
Each case of acoustic/cold insulation will be reviewed separately to find the
best solution for that specific case.
If the total thickness meets construction restraints, then locally the thickness of
each layer shall be equally reduced in agreement with owner.

6.2. Category A
Base insulation 50 mm preformed pipe sections or board. Aluminum weather proof
jacketing, minimum thickness 0.8 mm.
Flange and valves, hand and manholes, etc., shall not be insulated.

6.3. Category B
Base insulation 100 mm preformed pipe sections or board.
Aluminized steel weather proof jacketing, minimum thickness 0.8 mm.
Flange and valves, hand and manholes, etc., shall be insulated.

6.4. Category C

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Base insulation 100 mm preformed pipe sections or board.


Aluminized steel weather proof jacketing, min. thickness 1 mm, with 1.3 mm thick
2
barium filled PVC - foil glued to the inside of the jacketing, total mass 10 kg per m .
Flange and valves, hand and manholes, etc., shall be insulated.
Pipe supports attached to pipe shall be insulated unto an acoustical break.

7.

Quality assurance and inspection

1.

Applicator is responsible for his own quality assurance and inspection procedures.
He shall submit these procedures for review to owner before start of work.

2.

Each part of the work shall be subject to acceptance by owner and shall not be covered
prior to acceptance.
Work not in accordance with this specification, or with written approval for deviation
from owner, shall be rejected, and at instruction of owner be completely replaced or
ameliorated.

3.

For information purposes a checklist has been attached to this specification.

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LIST OF TRA STANDARDS


1. LIST OF DRAWINGS
Drawing DR190E000Z00000002
Drawing DR190E000Z00000003
Drawing DR190E000Z00000004
Drawing DR190E000Z00000005
Drawing DR190E000Z00000006
Drawing DR190E000Z00000007
Drawing DR190E000Z00000008
Drawing DR190E000Z00000009
Drawing DR190E000Z00000010
Drawing DR190E000Z00000011
Drawing DR190E000Z00000012
Drawing DR190E000Z00000013
Drawing DR190E000Z00000014
Drawing DR190E000Z00000019
Drawing DR190E000Z00000020
Drawing DR190E000Z00000021
Drawing DR190E000Z00000022
Drawing DR190E000Z00000023
Drawing DR190E000Z00000024
Drawing DR190E000Z00000025
Drawing DR190E000Z00000026
Drawing DR190E000Z00000027
Drawing DR190E000Z00000028
Drawing DR190E000Z00000029
Drawing DR190E000Z00000030
Drawing DR190E000Z00000031
Drawing DR190E000Z00000032
Drawing DR190E000Z00000033
Drawing DR190E000Z00000034
Drawing DR190E000Z00000035
Drawing DR190E000Z00000036
Drawing DR190E000Z00000061

Inspection hatch to provide access to corrosion


monitoring points under insulation
Standard for corrosion monitoring points
Location corrosion monitoring points on towers and
vertical drums
Location corrosion monitoring points on horizontal
drums
Location corrosion monitoring points on heat
exchangers type 1
Location corrosion monitoring points on heat
exchangers type 2
Location corrosion monitoring points on heat
exchangers type 3
Location corrosion monitoring points on heat
exchangers type 4
Location corrosion monitoring points on heat
exchangers type 5
Location corrosion monitoring points on heat
exchangers type 6
Location corrosion monitoring points on heat
exchangers type 7
Location corrosion monitoring points on heat
exchangers type S1-S4
Location corrosion monitoring points on heat
exchangers type S5-S8
Standard location measurement points for corrosion
monitoring points
Pipe insulation
Insulation clamp supports vertical piping
Details Jackets for pipe
Expansion joints pipe
Insulation at pipe shoe
Insulation of traced pipes
Removable flange/valve insulation box
Construction details enclosures
Metal weather proofing of insulated piping (Ells)
Personnel protective shields/cages
Detail mounting ring caps
Vessel insulation
Details of insulated vessels bottom/skirt
Removable enclosure for level gauge
Detail cold insulation vessel at bottom and skirt
Insulation attachments for hot vessels
Tank insulation
Hot insulation for frequently opened Heat Exchangers

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2. INSULATION CHECKLIST
2.1.

Purpose
This checklist belongs to TRA. Insulation specification "P" and is for the sole purpose of
quality control by owner.

2.2.

Limitations
This checklist does not cover overall inspection items, such as good workmanship,
cosmetic appearance, calculations, etc.
It shall in no way be used instead of said specification or replace the quality procedures
of the applicator

2.2.1.

Instructions
Read the specification and consult it constantly.
General contains items relevant to all parts and procedures of the work and is to be read in
conjunction with the applicable additional sheets stated hereunder.
2.3.2. Piping
2.3.3. Vessels and equipment
2.3.4. Acoustic
2.3.5. Cold

2.3.1.

General
Before application
Safety and health procedures observed
Weather conditions favourable
Coating integer
Surface clean
Stainless steel wrapped with alu foil no exposed parts
Welded supports provided
Correct material handling and storage
Required documentation (e.g. contracts, specification, SA, certificates) available at
site
Base material
Correct type and thickness
Fibrous insulation kept dry at all procedures
Applied with staggered joints where required
No open joints, close snugly fitting
No galvanised wire/bands or accessories near stainless steel items
Cuttings, scrap material and waste removed same day
Weather proofing
Immediately after application base insulation, else temporary plastic protection
Correct material (steel sheet for acoustic C & D, and fire proofing insulation)
No sharp edges, bent corners, dents
Correct furrowing

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Close fitting
Joints water shedding, off wind (from WSW)
Shields at protrusions
Screws correct material, size and heads for:

- sheet to sheet
- sheet to supports

Drain holes at lowest points


Sealant where required
2.3.2. Piping
Vertical piping clamped supports as per drawing 2
Internal and external furrows at circumferential joints
Circumferential joints banded
Longitudinal joints staggered, external furrow
Longitudinal joints screwed, 150 mm c.t.c. heads against furrow
Expansion joints as per drawing 4 at > 10 m and each 10 m
Circumferential joints in vertical piping S - clips each 400 mm, min. 2
Rain caps above hangers and slots
Metal end caps duly sealed
Valves and flanges:
Check if bodies of flanged valves are to be insulated for special cases, where
normally no valve insulation is required.
Removable boxes for following services:
Pitch, hot oil (bitumen) sulphur, superheated steam
Check absence of flange covers at hydrogen service and services indicated as
hazardous
Jumpers of heat tracing to be wrapped with cord without voids and water tight with
flash band
Steam traced lines, when blanket type insulation wire mesh to the inside
2.3.3. Vessels and equipment
Check support rings on drainage and prevention of liquid retention
Stiffener ring free of base insulation
Strapping bands each 300 mm
Strapping bands at > 250 C and at length > 6 m and on each 6 m a breather spring,
both over base insulation and jacketing
Expansion joints at > 200 C and each 6 m, both base insulation and jacketing
Horizontal expansion joints jacketing 2 bands, with S - clips each 600 mm, min. 4
Horizontal bands when not close to furrow provided with screws to prevent slipping,
each 2 m but min. 2
Removable multi cellular glass insulation and metal sheet at nozzles, hand- and
manholes
Terminations with metal end caps
Underlying furrows at cross points flattened

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2.3.4. Acoustic
Check carefully on absence of metal to metal contact between jacketing- and the
insulated item
Check carefully on noise leaks through open joints, etc.
Category B to be provided with steel jacketing 0.8 mm thick
Category C to be provided with steel jacketing 1 mm thick with the heavy filled foil
glued to the inside
2.3.5. Cold
Bedding compound equally distributed over the surface
Sections / block perfectly aligned
Joints completely filled
Squeezed out filler spread out
Expansion joints < minus 10 c and each 6 m stuffed with wool
Gray VB completely covering multi cellular glass and expansion joints -1.4 to 2 mm
thick onto 5 mm of steel surface of insulated item
Glass cloth smooth applied without wrinkles, overlap 5 mm at edges onto 5 mm of
item
White VB completely hiding glass cloth and gray VB -1.4 to 2 mm thick
Check curing; after fully cured
Jacketing no internal furrows
- to be provided where required, before application, with riveted clips to
prevent slippage of horizontal bands
- to be checked on sharp edges, corners, and anything that can endanger
the integrity of the VB
All joints sealed.

INSPECTION HATCH TO PROVIDE ACCESS TO CORROSION MONITORING POINTS UNDER INSULATION - DR179E000Z00000001 (Revision 0)
- (Revision 0) (1/1)
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Database : GEDEON

CORROSION MONITORING LOCATIONS - DR179E000Z00000002 (Revision 1)


- (Revision 1) (1/1)
Printed on: 08/08/2012 at 16:44, GUEST GUEST

Database : GEDEON