a 7 La Insulation Inspector we ICorr Level 2 ~MTABLE OF CONTENTS INTRODUCTION INSULATION SYSTEME . CODING FOR INSULATION . INSULATION MATERIALS .. Insulation Protective coverings Fixing materials ‘Storage of materials APPLICATION OF INSULATION .. INSULATION INSPECTION REPORTING HEALTH & SAFETY (1) HEALTH & SAFETY (2) COSHH Regulations 1994 Occupational Exposure Limits (EH40) Volatile organic compounds Health & Safety datasheet QUALITY ASSURANCE, NORMATIVE DOCUMENTS NSS INS6 INST Pi Pint Pid Pine Pins eat Qasmean may also be sted retin eis, Tis ‘ype of icon ld Types of insulation Insulation is primarily used on piping and vessels to prevent excessive heat loss or to maintain temperatures at a low level. The insulation used for either of these purposes may be referred to as thermal insulation, ‘Thermal insulation may be required more specifically for the following: 1, Safety (personal protection), 2. Hot and cold conservation (precious resources) 9. Opetating costs (0 inaintal Cust effectiveness), ‘There are four main types of insulation commonly used in the power, oil, gas and chemical industries each having a specific function 1. Mineral wool 2. Calcium silicate, Rigid phenolic foame. 2 4. Cellular (foamed) gla. Inspection duties Ie is the duty of an insulation inspector to ensure all insulation and associated operations ate carried out in accordance with the specifications) forthe work to be undertaken Inspection is defined in BS 4778 : Part | (Quality Vocabulary) as, ‘activities such as ‘mewsuring, examining, testing, gauging one or more characteristics of a product or service and comparing these with specified requirements to determine conformity.” Inspectors should not deviate from the specification requirements unless the client or supervisor gives permission to do £0; this chould preferably be written permission. The following list gives an overview of duties applicable to an insulation inspector: 4. Obiain or gain access to the specfication(s) Learn the epesification(). © Getto know the plant 6. Get to know the personnel. Check that all concerned understand the specification, 1 Keep the engineer/supervisor informed at all umes ot any departure from the specification, 8 Conduct and/or atend site meetings. hh. Determine the days work programme with the contractors senior personnel. i. Check the materials J. Determine whether the work meets the specification requirements. k. Check for any application faults. Te Make wsitten xpos at a agioed frequency emma rr one INS1-1The hea expacty ofa ody fen bind dein a the temperature by 1K. Thermal insulation Thermal insulation is defined in BS 3533 as “a material or system that has the property of resisting the transfer of heat’ ‘The thickness of insulation required will be primarily governed by the type of insulating material used (especially its heat capacity) the heat capacity of the product, the heat capacity of the pipework etc., the Mow rate of the product in the system (vessels, pipework etc.) and the temperature requirement for the product. ‘There are two types of thermal insulation; (1) hot insulation and (2) cold insulation, Hot insulation Hot insulation, although not defined in BS 3533, is common terminology used for insolation tht wil tard the transfer of Beat energy from the isla system when the trmperaure in the system is higher than ambient temperate. ‘Therefore, hot insulation is sed to esp the product hor ina system Hot insulston may be used on external ura of pipework to keep te temperature of the produc inthe pipework high enoveh forthe product to flow, or flow ats higher rae than it would at ambient empertues for production cost reasons. Hot insulation may also be wed to protect personnel or plant from high temperatures CComnon materials used fr hot insulation systems include: a, Caleum silicate: < 100°C. b Mineral wool: 270°C. b. _Polyisocyanurate: > -145°C. © Polyurethane: > 100°C. Protection against condensation ‘The application of the insulation can prevent condensation at the surface of a containing vessel, pipework etc, but it will not necessarily prevent moisture being drawn through the insulation itself. The dew point may be reached within the insulation and it can become saturated if itis applied to a cold surface: tis will affect the heat insulation properties and its mechanical strength If the cold surface is ata temperature lower than the freezing point, the moisture will freeze and the insulation will tend to rupture and break away (ablate). Factory made pre-formed bends and other fitings will minimise gaps in the insulation to reduce the susceptibility to rupture, Vapour barriers are applied to these insulation systems to prevent or reduce the ingress of moisture. cote INS2-1PeoNell Posen nrd ect protcction | 1€the outside temperature remains low enough for long enough, and the movement of product through the pipe or vessel is slow, then freezing or excessive cooling may occur. Insulation may delay the onset of freezing or excessive cooling vo} The time taken for a liquid to reach freezing point under given conditions of temperature difference will depend on the heat capacity of the product, the heat capacity of the pipework, vessel ete. and the heat capacity ofthe insulation, INSULATION SYSTEMS ‘Small diameter pipes and other items are more vulnerable to freezing compared to larger items, therefore small diameter pipes etc. require a greater thickness of sa] iBsulation for protection against frost conditions than do larger diameter pipes etc /Acoustic insulation Acoustic insulation may be applied to piping, especially those pipes in which gases, fe} luids or particle solids are transported at high velocities. This may be applied for AV RE For Demdes | environmental reasons to reduce noise pollution or to protect personnel from eae prolonged exposure to high noise levels which can induce hearing los, Mleise Levers ‘The use of mineral wool of a high density in the form of pipe sections, lags or mattresses is commonly used to considerably reduce noise levels. ‘The thickness of insulation will dapend upon the dB rating. Lead vinyl sheeting may be used over the mineral wool, itis then protected by metal cladding. Lead vinyl sheeting consists of glass cloth impregnated with loaded viny! with an average thickness of ~ 1.4 mm. It is usually supplied in | mx I m sheets and usually operates within a service temperature of 50°C to +100°C. Other types of acoustic insulation may include perforated metal or plastic sheeting, | fabricated to form guards which can be fitted to machinery or compressors to reduce noise levels Insulation may be applied to ventilation ducts where quiet airconditioning is required. VeWeaw Less Trekwess \ a) Scrace Coven sation! RA. arvadees (RuusestTactets) 5 S\ Gees Cotten - Went Lass - W- Fie Grorected - Wotense Teles. ghee arnot INS2-2Fea E ll Heemouy Wfued UPT AmtdRescut 1 Yarn Wes eect,” ‘A coding system is normally used to identify the type of insulation, The coding rrormally consists of « simple abbreviation but may be used ay part of the. line ‘identification number, e.g. HC 40 P140361 The following abbreviations are shown to give an idea of what may be expected, but the system may change depending on specification used Hot insulation: A Acoustic Elect trace ED Electic wace 250 mm. diameter shall be secured with stainless steel banding at 250 mm intervals and within 50 mm. of each end joint. 4.6 Joint position On straight pipework, plain half sections or R&B lags/slabs shall be placed around the pipe/vessel with the circumferential joints staggered by half the length of the section/segment. Where insulation is applied in two or more layers all joints shall be staggered >75 mm in both circumferential and longitudinal directions on the outer layers. 4.7 Installation of jacketing A protective metal cladding will be applied. For piping and vessels >600 mm diameter the casing shall have 275 num citcumferential and longitudinal overlaps; below this diameter overlaps shall be >50 mm, The edge of the casing shall be swaged to allow for the application of a bead of mastic. 4.8. Fixing the jacketing Cladding shall be secured with self tapping screws at 150 mm centres. Apply a stainless steel band on each lap joint. 4.9 Sealing requirements for the jacketing The casing shall have a swaged edge to allow a bead of mastic to be applied both longitudinally and circumferentially. 4.10 Inspection ‘The Insulation Inspector must inspect the work by using check list F&C: indicates the activities in the application sequence which have to be inspected. Inspection reports shall be completed using proforma F&C-R-12, an information sheet provided with the proforma sheets identify information to be reported 5. Cold Work Insulation 222 whien 5.1 Surface inspection AS4I 5.2. Surtace preparation ASA2 5.3 Identification of Materials AS43 February 1997 Page 3 of S Revo© Ruane & THOMA Procedure No. P-B2-1 5.4 Method for installation for insulation Insulation <50 mm thick shall be applied in one layer. For insulation thicknesses >50 mm the insulation shall be applied in multi-layers. ‘The inner layer for multi-layer insulation shall be applied dry. To permit easy withdrawal, insulation shall be stopped short of studs or bolts by a minimum distance equal to the length of the studs plus 25 mm. Protrusions through the insulation shall be insulated for a distance of at least four times the insulation thickness, Lines which are not insulated which are connected to insulated lines or equipment shall be Insulated for a distance of 2 m from the insulated surtace. 5.5. Method of fixing insulation The inner layer of multi layer application shall be sceured by using glass reinforced polyester self adhesive tape and overlapped onto itself by at least 100 mm. Sections or segments shall be secured at 250 mm intervals and within 50 mm of each end joint. ‘The outer layer of multi-layer shall be secured using stainless steel banding at 250 mm intervals and within 50 mm of each end joint. 5.6 Joint position On straight pipework, plain half sections or lags, slabs shall be placed around the pipe/vessel with the circumferential joints staggered by half the length of the section/segment. Where insulation ic appliod in two or more layers, all joints to be staggered >75 mm in both circumferential and longitudinal directions. 5.7 Sealing requirements for insulation On single layer insulation all joints shall be sealed with joint sealer spread completely over the full mating joint faces and end faces. ‘On multi-layer application the outer layer shall be applied with joint sealer. 5.8 Vapour barrier To ensure banding seals do not puncture the vapour barrier. a 150 mm square patch of vapour seal mastic reinforced with glass cloth shall be applied over the banding seal before the application of the main vapour barrier. ‘The vapour barrier shall be applied on two coats having a | mm dry film thickness. The first shall completely seal the insulation surface. A glass cloth reinforcing membrane is to be applied immediately into the wet coating with a 75 mm overlap smoothed out prior to a second coat heing applied at least six hours after the first coat Terminations in insulation shall be completely sealed onto the metal surface for a distance of 75 mm. 5.9 Installation of jacketing A protective metal cladding will be applied. For piping and vessels 600 mm diameter the casing shall have 275 mm circumferential and longitudinal ovetlaps, below dis diameter ‘overlaps shall be >50 mm. The edge of the casing would be swaged to allow application of a bead of mastic. February 1997 Page 4 of 5 Rev© muane Fv UNeUt Procedure No. P-E2-1 5.10 Fixing the jacketing Cladding shall be secured with stainless steel bands on each circumferential joint at 250 mm centres on vertical pipes, vessels, columns etc... The cladding shall be supported at each ‘circumferential overlap by Z hooks to support both the cladding and the banding. 5.11 Sealing requirements for the jacketing ‘The casing shall be swaged along the edge to allow a bead of mastic to be applied both longitudinally and circumferentially. 5.12 Inspection Tue Insulation Inspector must inspect the work by using check list F&C-C-222 whieh indicates the activities in the application sequence which have to be inspected. Inspection reports shall be completed using proforma F&C-R-12, an information sheet provided with the proforma sheets identify information to be reported. February 1997 Page 5 of 5 RevoTECHNICAL QUERY FORM Project Number: 123 AGC _| Contract Number: G83 _ | TQNumber: ws /26t__ | Raiced Ry A. Maney Positions IWSULATION INSOCETOR Date: 6- 3-97 Company: A BC _INSULATIONS PROBLEM (please identify all relevant drawingvapecijications) 10" HC. TSmm 368804! PiPE RACK 6 AREA 2 Due T NodINceWT STRveTuRAL STCELNORR THe MULL THICKNESS OF MiWERAL WOOL INSULATICN CANNOT BE FITTED BETNEEN COLUMNS ll AND TiK- PROPOSED SOLUTION (if applicable). Reduce THE THckwas OF IWSEATON AT Corumms TH Awd Ty RT 25 mm Signed: Od [Position: Wwe slabaisn Lng. [Dae: 4/3/47 “APPROVED SOLUTION THE PRoPOSLD SoLUTION IS ACCEPTABLE. Signed: 4B yreceon | Position: gigi engimeee|Date: @)3)97 Signed (Client): D Jonon Position: PaoJECT énern€eR —_| Date: 08 /o3 97. DISTRIBUTION (as applicable) + Project Engineer | QC Engineer Z| ~ Chief Site Engineer 7 | Project QA Manager + Resident Construction Manager ~ Senior Inspector(____) + Project Controls Manager + Construction Superintendent FORML.SAMTECHNICAL QUERY FORM Project Number: (23 AGC | Contract Number: 688.3 — | TQNumber INS [262 Raised By: A MAW As Position’ INSULATION INSPECTOR Date: 63-97 Company: ABC INSULATION: PROBLEM (please identify all relevant drawing specifications): LATEST REVISION TO HOT INSULATION SPECIFICATION Az 3466 STATES THE HOT OM SYSTEM MINERAL Wool INSULATION IS TO CHANGE To FOAM GLASS . PLEASE CONFIRM IF THIS (8S COKRECH [Samet Qian [Poo rucaon (angio 6-597 | PROPOSED SOLUTION (applicable) Ba FID m RESON &D CF HST INSULATION ¢/ECEKATION TOM Gets WSLLATION 6 Te Peace mINRAL Hook Defwe ROVSION LE WEL BE Wys¥eh Acco IWLLY Signed: I Sp. Position: Ipolotivn Lagp__ | Date 6-3 IZ ‘APPROVED SOLUTION THE PlePSEP ScreTien 1S CORRECT, ENGINEERING To (S6eo REVISED DAAWAIGT Signed: Position: ep euo easineea| Date: 713 }a7 7 Signed (lien: J Broo Position: Aoséct Encik Date: 07/03/97 DISTRIBUTION (as applicable). Tox) rick + Project Engineer 7 [+ QCEngineer 4 + Chief Site Engineer ~ | Project QA Manager 7 ~ Resident Construction Manager = Senior Inspector ( ) + Project Controls Manager = Construction Superintendent [7] FORMISAMTECHNICAL QUERY FORM Project Number: {23 ABC | Contract Number: 6883 [TQNumber: WS (263 Raised Ry: A. MANN. Position: ¢WSURA TION INSPECTOR Dae: 6- 3-97 Company: AGC INSULATIONS PROBLEM (please identify all relevant drawings/specifications) 2h" AH (00mm 218823. HAS A DB RATING OF AZ FOR Anerh VIBRATION USINVQ LENO Vine SMELTING. Do VALVE AND FLANGE BOKES REQUIRE LEAD VINYL SHEETING 7 [Sienea: Offenn, Position: aautation larp| Date: 6-3-97. PROPOSED SOLUTION (if applicable}: NE SITUATED woitHw 4 PPwa Row dESGVATEN AS Pedi QWe NeGE CONTROL IWSLEATION ALE FLANGES AMD VALVES SHALL BE FULLY WYSURATED AND METAL CLADVED, AT TSE Pours riteKe PRE No REREemMENTS, FUR LERD MMR Seteetvts Fok PAT GS Raovz AS THRE wut Ae A REG men. Signed: Sp [ Position: (as steabon agp [Dates #/2/a7 [APPROVED SOLUTION - THe Peofosed SccveTienw is ACCEPTABLE. Signed: @ paevten [Poson: prec sucmeee [Dae €]3]47 Signed (Client): D Fneg | Position: Prajécr Ewcwieek [Date:_ 05/03/97 DISTRIBUTION (as applicable) + Project Engineer ~ QC Engineer Al + Chief Site Engineer 7H |+ Project QA Manager 7 Resident Consuucion Manager 7 Seo aspezor ~ Project Conuols Manager = Conscton Superintendent [7] FORMI.SAMTECHNICAL QUERY FORM Project Number: 123 ABC _| Contract Number: 6883 __]TQNumbec: INS/ 264 - Raised By: A WANAl Position Dae: 6-3-97 INSU) ATION INSPECTA Company: ABC INSYLATIONS — PROBLEM (please iderify all relevant drawtngiapecijcations) 2" CC. 180mm 48660 . COMPRESSOR HOUSE AREA 4 AT THE ETRE LOVER THE UNSULA TION THIERESS CAWNOT BE ACHIEVED DUE TO THE KENNEDY GRATING HAVING INSUPFILIENT CLERRANLE BEINEEN THE PYZE AND THE GRATING, CAN THE INSULATION BE REDUCED AT THIS PowwT? Signed: QMann_ Position: anulahon Insp | Pate: 6-3-97 | PROPOSED SOLUTION (applicable) INSULATION TAckMESs CAWMOT RE Reduced AT THES PROCES CACC = TS CE TICAL, KewmeDY GATING SHOE BE COT Ack AT mun Aaa Signed: Spa [ Position: (ng cbion Wnspecher| Date:_#/3/47 ‘APPROVED SOLUTION THE PROPOSED Socution iS ACCEPT HEE Signed. 8 Se gene | Position: FiEcy bag ween [PM &13)47 Signed (Client: Brg’ Position: ProSEcT_EweiweeR Date: 08 /o3/ 97 DISTRIBUTION (as applicable Lee Frick ; TE + Project Engineer = ~ [+ QC Engineer vw + Chief Site Engineer + Project QA Manager 4] Resident Couuucsivn Manager = Senior inspector ( Me + Project Controls Manager Construction Superintendent Pal FORMISAMTECHNICAL QUERY FORM Number: (683% TQNumber: ws /2ES Popa Nenbor 25 Ae [Conn Raised Ry: _T Spy Position’ iWSeATIR ENSPee OR Date: 6/3/47 Company: TRo JAW CONSTRUCTION el PROBLEM (please identify all relevant drawings/specifications): CORRDSIOM ENDER ISOLATION Cord DeVAOP ON CoLumAS E261, B262 AND B262 wane THT CH oY Aas LADD SUMeETS THROUGH THE IMGUER TION. IW) HIGH CaNSS THE METAL SERLALT CARS MAY DETACH ALD ALLOW BAW LATER TO ENTER THE WwSCLATION reve TO THE Cosma Signed: Se [Position wse-ariew wspecree| Date: L/4/47 PROPOSED SOLUTION (if applicable): APPLY MeTHL Boxes OVER THE CLEEIKG COUARS AT Tite SOPPORTS To Pho DE AdDIMowAL PROET ION Signed: Oe, [Postion lnswutren wepeeyos| Date: 6/3/47 [APPROVED SOLUTION Tae PRoPased Soetion 1S ACCEPTABLL . Signed @ we Position: ce eagunece [Dae | 5197 Signed (Client): ) Fron Position: (MIET EnGiNCER | Date: O7/o3/97 DISTRIBUTION (as applicable}: Trek] z 5 Prick + Project Engineer = QC Engineer 7 + Chief Site Engineer + Project QA Manager + Resident Construction Manager = Senior Inspector ( ) Project Controls Manager ‘Construction Superintendent FORMLSAM(PER SUPPLIERS oRAWING) 1.91 SE HEADS TOP AND BOTTOM 2 STDWALLLRE. / MANNING ) SEE SHEETS 2 TRUNKIONS SEE SHEETS. uu oRAN(ey | Ma. (i) INLET oIstRIBUTOR (BY BURGESS MANNING) SEE SHEETS 150 THK COLD INSUL. ON [SHELL & BOTH HEADS (BY oTHers 1 - MANHOLE & 1 GRAB RUNG TOSTO.Vs-2108 EL 750 any Sctoneets a) teem P= mo vias, e187 a gp i aise er, a ! 0" 2- INSULATION 8 Surronts nore 9 VORTEX SREAKER TO STOVS- 22915 TYPE I WELD BUILD-UP FLASHING RING (ore 4) BOSSES TOSTO.VS- 2508. ASSOCIATED SKIRT ‘STRENGTHENING TO SUPPLIERS DESIGN {| j|Lg_1880.00 120 THK SxsRT NUTS FOR INSULATION =< banning wore 4 EL - Gott + NOTE 4: INSULATION SUPPORTS REQ’D TO STD-VS-217/S DETAILS 1703 PLAN OF NAVI NOTE S\_Z SCH 160 PIPE & LR ELBOW s DEWPOINT SEPARATORS ‘SHEET OF SHEETS](CHECK OUT SCHEDULE AND ACCEPTANCE CERTIFICATE ] TDSULATION GENERAL, | Gis ODONOC [ARE GAS GATHERING |ConaNo: LA 4296 [lmaon Aaca 6 [wean Quire rtcxsnss) 8 8) Sal sy] ome REMARKS "pew | ‘Soncwisn’ |Seecnnen | 3¢ | £3) 88/22/22 32/8] 2 ” srrewme? | 22 | 34] 38/381 3E| 28/28) 3 4s He 120067 funeene woot! won [7 win| |v || vl”) [pg-47| cig? To View GMT 10082 |wmeene were SMM | iw lJ ix |v |v) x (02.977 | RE EEIED INSOPPICTERT G* PP 10001 res guneD [win [ain |nrm| mtn men] w/a eZ] ¥7 Line Meee PIED 10" E_woowo meen wor | 6Sun | [onl AL Hl“ | x |x 2.97 [SORES BE PIPED TER, ian HS 170860 roam geass | T5ny | Vinal [4 [| 7x [o NAL DocuNeNTATIEN Gwe 120081 Iuneune news | WUNM | A 7 Etat 1 | I | FORM SAM(CHECK OUT SCHEDULE AND ACCEPTANCE CERTIFICATE INSULATION GENERAL i Gee omanoc [one Pc acevenY [omnann: ua 4296 [imum aMEA TO [Smo EQUIPMENT tee | rmickyess) 8} [fal s] | ae REMARKS on oF oF | EE gle [46] | mogiume | mataren leottnon £4 se| Ba) Ef/E0|38| | » tore | “Ssts’ "Soci 2228) 2 822) 2) g Ac W6*100se foam cunss| woonn | v1 | o |wal “| > lela Line ace PED © 20" miaiz |fean Geass] Sam 17] x site PER REENS Te OMT ch 47 240332 fuser gunao | 0! i |ata lem [ne [sm | > tet be nee es 18" 1036 lean cunss| mm |v ly |v ||] x[ |] Suey APmRoWaL_TAC AAS eR SS Bere I f see FoRM2saMt( ay CnetaGarioy, 7 enecaring neon | [= bah PP e908 0/5aris2 0— ~ 77 a a t i SITE | MAST ER pct | __ en ne a ene wereee am i foas [Frc nxces) a9 racowtn Se 3a asec cba 7983-19/52/06/30/254/1464 | 0(CHAPTER V.3 LOUIO WATER ABSORPTION AND RETENTION NNSULATION Fig. V.11. The _most_likely spots for moisture entry, Teiention and subsequent corrosion Head nozzles top. . Davits . Large nozzle or manway. ‘Small gussetted connections Vessel support brackets. Fireproofing, vessel suppor. On-vessel pipe brackets, guides. 8. Stiffening or suppor ring, hidden Stiffening ting, exposed 10. Platform. ladder brackets Incpectian apenings warepaired 12, Lifting tugs 13. Top platform supports 14. Insulation thickness wsPeal fone 1 Ff tee Inculation Inepoctor Theory * Q-E2-1 1. What are the aims of quality assurance? 2. Name 4 types of normative document. 3. Which British Standard is entitled Glossary of thermal insulation terms? 4. How does the above standard define shermat insulation? 5. Name 6 types of insulation material. 6. Name 4 physical forms of insulation in adition to loose fill. 7. How many insulation layers are used for cryogenic insulation? 8. How does an inculation inspector know the minimum thicknece of insulation that ic to be applied? 9. What is « vapour barrier use fur? 10. What is scrim cloth used for? 11. What insulation related information can an insulation inspector find on piping and instrument diagrams? 12. Relatively speaking - and assuming other factors are constant - which diameter of pipe will require the thickest insulation: large diameter or small diameter? 13. Whats the difference between hard setting composition and self-setting cement? 14, Is itacceptable for the substrate to be damp when applying the first insulation layer? 15. Single layer insulation in section form is being applied to pipework. What should dhe insulation inspector be looking for? 16. What action should the inspector take if at the end of the working day there has been insufficient time to apply metal cladding over phenolic foam pipe sections, i. the insulation is exposed” (© Roane &T PON 2amane | Feb 97: Rev Oer 1 17. Is it necessary to insulate nozzles on pressure vessels assuming the rest of the vessel is being insulated with thermal insulation for temperatures up to 100°C? 1 What physically happens to calcium silicate when it ie exposed to high temperaturec? is invloved 19. List 8 items of information to be reported by an insulation inspector wh with the inspection of acoustic insulation on pipework. 20. Metal cladding has been delivered to site and is ready to be used. What should the ‘insulation inspector check before use? 21. What is the insulation inspector looking for at overlaps when using metal cladding? 22. How many coats are used to apply vapour seals? 23. What methods are used to reduce the occurence of insulation damage after application? 24, How should insulation materials be stored? 25. What safety precautions should be obfetved when vapour sealing? 26. Who is responsible for document control on site (related to insulation)? 27. Ist the insulation inspectors duty to raise non-conformity reports if any item of insulation material or insulation work undertaken does not conform to specified requirements? 28. Is it permissible to use self-tapping screws to secure metal cladding? 29. What does BS 5970 relate to? 30. What do you consider to be the dutics of an insulation inspector? (Less than 30 words) 31. What is vermiculite? 32. [sit permissible to apply polyisocyanate foam if thé relative humidity is 85%? 33. What action should the insulation inspector take if coating damage is found on the component immediately prior to the application of insulation? 34. For what type of application is loose fill insulation used for? (© Rsane & TPONI ams?) Geni 35. What are the following insulation codes likely to mean: aA b. PP. ice a HC! 36. What is the potential problem of aluminium metal cladding making contact with a steel component that is insulated? 37. Is it permissible to insulate over the top of nameplates? 38. Describe the reasons for corrosion problems which may be encountered on pipework, vessels ete tinder insulation 39. Is it permissible for the insulation inspector to allow banding to be spaced at 200 mm intervals? 40. What is an R&B slab? Ruane &TPONeit 20087Rarro.ousre wees Insulation Inspector Theory * Q-E2-3 Teoults, Name: Deve Wana. Signed WN Date: .S\E\N, £5 lo. ‘Multi-choice questions: Circle only one answer, i.e. a, b, ¢ or d. Trow many strokes of Ure puinp are sequined aol b 2 © 3. d. It depends on the tube type used. V7 using a Drager tube? Which of the following insulations requires wire netting to secure cement finishes? a. Isocyanurate. b. Calcium silicate. / Polyurethane. 4. Polystyrene, Under what conditions will foam glass will normally be applied in two layers? When the temperature of the system is over 100°C. When the temperature of the system is less than -50°C. When metal cladding isto be applied When self setting cement is to be used, Which size of open weave glass cloth is normally used with a vapour sealer? 8x8, 9x9. 10x 10% 12x 12. ‘Which standard is entitled Code of practice for thermal insulation of pipework and equipment (in the temperature range -100°C 10 +87/0°CJ! a BS 3533. b. BS 5750. © BS 5970. 10 9000.2, NN 10 u O23 ‘What is the usual minimum period which must pass by before a second layer of vapour sealer may be applied? a. 6 to 8 minutes. ho Kita Rhonrs 6 t08 days. 4.1 to 2 days. With which insulation is an anti-abrasive compound used to coat the inner layer? a. TIsocyanurate. b. Foam glass. Polyurethane. . Polystyrene, ‘What ts a typical minimum distance ror a staggered joint? 2. 50mm. b. 150mm. 250mm. 4 350mm. a Which of the following insulations require a vapour scaler? a. Polyurethane, phenolic foams and cellular glass.“ b. Mineral wool and polystyrene. ©. eritte ana polystyrene 4. Isocyanurate, polyurethane and mineral wool. Which of the following metal cladding fabrirations is typically made an site? a Domeends. b. Pipe cladding ©. Bends and tees. @. Any of the above. Why are S clips important on metal cladding joints in vertical runs? ‘They prevent the cladding from slipping. W~ ‘They prevent the securing band from slipping. ‘They prevent the insulation from slipping ‘The prevent expansion and contraction at the joint. On which of the following insulations would you not expect a joint sealer to be applied? a. Isocyanurate. b. Polyurethane. c. Calcium silicate. 4. Foam glass. ‘The specified minimum thickness of a vapour barrier is typically: a 05mm, bo 2mmv ce Simm. a. umm,RarPo-0697-8 a Personnel protection #7 / ‘What is the abbreviation PP representing a form of insulation on a drawing is likely to refer to? x / ue b. Perlite Polyisocyanurate 4. Polyurethane, 15. What is being measured when the unit Kelvin is used? 2. Vapour prs b. Relative humidity. © Temperature A Sound energy KH i Which of the following applies if a substance is designated a MEL of 350 ppm ? sxpased to concentrations abave this a Personnel shnnld nat by b. No danger exists because over 300 ppm is considered safe. gis designated as highly flammable ‘The oxygen concentration must not drop below 350 ppm. 17. Ana paint container there is a symbol which consists of a broad black cross with an orange background; what does this represent? Contents are toxic.” b. Contents are corrosive. Harmful or classed as an iritant. Highly flammable ® 18. Which of the following is not a normal duty for an insulation inspector performing inspection as, defined in EN and [50 standards? a. Ensuring the quality of the insulation system is assured to the requirements of ISO 9000. b. Supervision of insulation contractors. . Ensuring the right insulation system has been chosen from the outset of work. 4. Allthe above are not normal inspection duties. 7 19 vl hazardous to health ae defined by the COSHH Regulations which dose not have an OES will have what instead? a. ppm, & MCLs PPA. d. All substances hazardous to health have an OES. How many ym in 0.23 mm? 23, 7” 230,.0~ 23,000.RaTP0.0397-£ ws SBT Insulation Inspector General Theory * AS-E2-1 This GOWumIN 1S Tor OMmGe Use. Name DANO. MARTA... Results: at] 0 Signed: W) WK. ceed) Marker 1: QT cf Maree: Multi-choice questions: Circle only one answer, ie. a, b, ¢ or d. 1. Which of the following is a normative document? A Code of Practice. ‘An ISO standard. A painting specification. All of the above 2. How many strokes of the pump are required when using a Drager tube? al ee «5 Vd. It depends on the tube type used. 3. Calcium silicate displays permanent shrinkage after exposure to: a. Low temperatures. Vb. High tempecanices c. Moisture. 4. Any of the above. 4. Which of the following insulations requires wire netting to secure cement finishes? a. Isocyanurate Yb. Calcium silicate. ©. Polyurethane. 4. Polystyrene. 5. At what 11 temperature is foam glass insulation susceptible (thermal cracks? a. 130°C. b. 230°C. Ye. 430°C. 4d. 730°C. 6 Under what conditione will foam glace will normally be applied in two layers? a. When the temperature of the system is over 100°C, >. When the temperature of the system is less than -50°C, Wheat tal vlan io w be applic. 4d. When self setting cement isto be used.SEDI 7. Which corrosion inhibitor is usually used with perlite thermal insulation? Ya. Sodium silicate. b. Sodium carbonate, ©. Sodium chloride. 4. Sodium hydroxide. 8. Which metal cladding is usually used with vermiculite? V a. Stainless steel cladding. b. Galvanised steel cladding. ©. Aluminised steel cladding. 4. Aluminium ctaaaing. 9, Which ofthe following are fibrous insulations? &.Vermicutite, perite and isocyanurate. “ b. Mineral wool, calcium silicate and perlite. ©. Calcium silicate, foam glass and polyisocyanurate. 4. Foam glass, perlite and polyisocyanurate 10. In which of the following insulation systems is a vapour seal used? a. Hoteystem. “b. Cold system. ©. Acoustic system. 4. Cement finish system 11. Which size of open weave glass cloth is normally used with a vapour sealer? a RxR b. 9x9. Ve 10x10 a 12x12 12. Which standard is entitled Glossary of thermal insulation terms? a. BS 3533, b. BS 5750. cc. BS 5970. 4. 1S0 9000. 13. What is the usual minimum period which must pass by before a second layer of vapour sealer may be applied? a 6t0 8 minutes. Yb. 6to8hours. © 6t08 days 4. 1to 2 days. 14, With which insulation is an anti-abrasive compound used to coat the inner layer? Inve yanurate Foam glass. Polyurethane. Polystyrene.na770.0397-£ SEDI 15. What is a typical minimum distance for a staggered joint? a. 50mm, Yb. 150mm ce. 250mm. ©. 330mm. 16. Which of the following insulations require a vapour sealer? ¥ a. Polyurethane, phenolic foams and cellular glass. b. Mineral wool and polystyrene. Perlite and polystyrene. c. 4. Tbocyanurate, polyurcthans and mincral work 17. Which of the following metal cladding fabrications is typically made on site? Dome ends. Pipe cladding. Bends and tees. Any af the ahove v 18, Which of the following metal cladding materials would be best suited in the event of a fire? a Aluminium, b. Galvanised steel / c. Stainless steel: 4d. Aluzinc alloy. 19. According to BS 5970, hard setting composition should be applied in: a. one layer. 7b. two layers. three layers. 4. four layers. 20. According to BS 5970, self setting cement should be applied in: a a. one layer. B. two layers. c. three layers. 4. four layers. 21. What is the approximate thickness of self setting cement? a Imm, 4b. Smm. c 10mm 4. 20mm, finishing material based on which type of cement? 22. Self setting cement is defined as a. Blue Circle fe. Portland, c. Ribblesdale. d. Blue Stone.SER 23. Binding wire is used to secure which of the following insulations? a. Foam glass and isocyanurate, vb. Mineral wool and calcium silicate cc. Isocyanurate and polyurethane. Perlite and foam glass. 24, Why are S clips important on metal cladding joints in vertical runs? Va. They prevent the cladding from slipping. ‘They prevent the securing band from slipping. b c. They prevent the insulation from slipping. 4. The prevent expansion and contraction at the joint. 25. On which of the following insulations would you not expect a joint sealer to be applied? a. Isocyanurate. b. Polyurethane. ve. Calcium silicate. 4. Foam glass. 26. The specified minimum thickness of a vapour barrier is typically: a. 0S mm. vb, 2mm, ©. Smm, 410mm. 27. At what temperature should joint sealers and vapour sealers be stored? 28. Why isa vapour barrier important to protect foam glass insulation in a cold system? It prevents the insulation from becoming dehydrate. /b. _Itprevents the insulation from becoming saturated. €. It prevents the insulation from becoming contaminated with chlorides, sulphides and similar. 4d. It prevents the insulation from contracting. 29. “Activities such as measuring, examining, testing, gauging one or more characteristics of a product or service and comparing these with specified requirements to determine conformity.” ‘This is the definition for: a. quality contro b. testing. Yc. inspection. 4 Allthe above.nareo.aiere 30. All those planned or systematic actions necessary to provide adequate confidence that a product or service mill sutisfy xiven requirements for quality ~ B3 4778 Patt 1. This is a definition fox. a. inspection, b. quality control vc quaity assurance. a. Allof the above.TP ONell Onze Theory * Q-E2-4 1. _Isitacceptable for the substrate to be damp when applying the first insulation layer? 2. Single layer insulation in section form is being applied to pipework. What should the insulation inspector be looking for? 3. What action should the inspector take if at the end of the working day there has been insufficient time to apply metal cladding over phenolic foam pipe sections, i. the insulation is exposed? 4, Is it necessary to insulate nozzles on pressure vessels assuming the rest of the vessel is, ing insulated with thermal insulation for temperatures up to 100°C? 5. List 8 items of information to be reported by an insulation inspector who is invloved with the inspection of acoustic insulation on pipework. 6. Metal cladding has been delivered to site and is ready to be used. What should the insulation inspector check before use? J. What 1s the insulation inspector looking tor at overlaps when using metal cladding? 8. How many coats are used to apply vapour seals? 9. What methods are used to reduce the occurence of insulation damage after application? 10. What safety precautions should be observed when vapour sealing? 11. Who is responsible for document control on site (related to insulation)? 12. Is it the insulation inspectors duty to raise non-conformity reports if any insulation ‘material or insulation work undertaken does not conform to specified requirements? 13. Is it permissible to use self-tapping screws to secure metal cladding? 14. Is it permissible to apply polyisocyanate foam if the relative humidity is 85%? 15. What action should the insulation inspector take if coating damage is found on the component immediately prior to the application of insulation? 16. What is the potential problem of aluminium metal cladding making contact with a steel component that is insulated? 17. Isit permissible to insulate over the top of nameplates? 1's, Describe the reasons for corrosion problems which may be encountered on pipework, vessels etc. under insulation 19. 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